FAKULTI TEKNOLOGI KEJURUTERAAN

ELEKRIK DAN ELEKTRONIK

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

INDUSTRIAL PROCESS CONTROL

BEEA 4813 SEMESTER 1 SESSION 2019/2020

LAB: GAD-101 Level Process Control Trainer

DATE 25TH OCTOBER 2019

1. DEN ROKO BIN KASDI B071610708

NAME OF GROUP MEMBERS
2. AHMAD BASHIR BIN MOHD NIZAM B071610537
&

MATRIX NUMBER 3. AMIN BIN AHMAT B071610947

1. AHMAD MUZAFFAR BIN ABDUL KADIR

NAME OF INSTRUCTOR

EXIMINAR’S COMMENT VERIFICATION STAMP

TOTAL MARKS

Document Number Issue Number

N/A

Revision Number Total Page

181019 10
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

MODULE 1A & 1B:

• Process Control Module

OBJECTIVES:

• Familiar the Model GAD-101 Process Control Trainer

• Operate the Model GAD-101 at Manual Control mode using the SCADA system for
Flow Control and Level Control
PLANT START-UP CHECK LIST

• Refer to ‘’MAINTENANCE MANUAL START-UP CHECK LIST’’.

PROCEDURE EXPERIMENT 1A
1. Please refer ‘’MAINTENANCE MANUAL START-UP CHECK LIST’’. It is assumed that
students have already performed all the procedures to start-up the process control
trainer before start the experiment exercise.
2. Open the manual valve MV-102, and MV-104.
3. Closed the manual valve MV-103 & MV-105.
4. Ensure the selection button at local panel position.

5. On the SCADA view, click main menu and please select FIC-101 button until green
indicator will be light on at that button.
6. Click the FIC-101 Tuning Panel
7. Click the MANUAL mode button until green indicator will be light on.
8. Click on the Manipulated Variable (MV) value to set the output value.

9. Change the output value 30% and start the pump (P-101).
10. Make sure the manual valve MV-101 at marking point.

11. Wait for about 2 to 3 minutes, and observe the flow response in PID controller process
variable display and the SCADA trending display.
12. Record down the flow in L/min engineering unit in the Table 1.
13. Change the Output Value (MV) as per Table 1.

1
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

Table 1A: Output Value and flow rate

No Output Value, MV (%) Flow Rate (L/M)

1
30 2.1
2
45 3.4
3
60 5.7
4
80 7.1

5 100 7.5

MANUAL MODE CONTROL

14. Manipulate the Output Value (MV) to maintain the liquid flow at 4.0 L/M
15. Observe the liquid flow response on the SCADA trending display and the PID
controller display.
16. Record down the PID controller output value.
17. Perform the print screen of the SCADA historical trending for record and report
purposes.
Manual Mode Control
Trial 1A:
Liquid Flow Rate : 4.0 L/M
Output Value (MV) : 50 %

Redraw the level process response taken from trending snapshot from the SCADA:

50%

Figure 1A: Liquid flow rate process response

2
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

PROCEDURE EXPERIMENT 1B
1. On the SCADA view, click main menu and please select LIC-101 button until green
indicator will be light on at that button.
5. Click the LIC-101 Tuning Panel
6. Click the MANUAL mode button until green indicator will be light on.
7. Click on the Manipulated Variable (MV) value to set the output value.
8. Change the output value 25% and start the pump (P-101).
9. Make sure the manual valve MV-101 at marking point.
10. Wait for about 2 to 3 minutes, and observe the level response in PID controller
process variable display and the SCADA trending display.
11. Record down the level in percentage (%) engineering unit in the Table 2.
12. Change the Output Value (MV) as per Table 2.
Table 2: Output Value and percentage of level

No Output Value, MV (%) Level (%)

1 25 18.6

2 30 55.6

3 40 100

4 50 100

5 60 100

MANUAL MODE CONTROL

13. Manipulate the Output Value (MV) to maintain the liquid level at 35%
14. Observe the liquid level response on the SCADA trending display and the PID
controller display.
15. Record down the PID controller output value.
16. Perform the print screen of the SCADA historical trending for record and report
purposes.

3
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

Manual Mode Control

Trial 1B:
Liquid Level : 35 %
Output Value (MV) : 28 %

Redraw the level process response taken from trending snapshot from the SCADA:

28%

Figure 1B: Liquid Level rate process response

4
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

MODULE 2A & 2B:

• Liquid Level Process Control Module

OBJECTIVES:
• Process Control PID tuning for Liquid Level Feedback single loop PID control
with Load Disturbances and with set-point Disturbances.
PLANT START-UP CHECK LIST
Please ensure the following plant condition shall be meet before perform this experiment:
• Make sure the drain valve MV-105 is fully CLOSED

• Make sure the manual valve MV-101 at marking point.

• Make sure the water level tank T-102 is empty by switching the outlet valve MV-
104 at fully OPEN status
• Make sure the water level tank T-102 is operated as an open tank, therefore
manual valve MV-102 and MV-104 must be OPENED at all time during the
liquid level process control experiment is running.
• The water storage tank T-101 shall be filled up to the overflow water level

• Make sure the air regulator for pneumatic control valve is set at approx. 4 barg,
and make sure that the manual valve of air regulator is always at OPEN
position
PROCEDURE EXPERIMENT 2A
1. Selection switch select to local selection on the Local Control Panel
2. Make sure the following manual valves at the normal operating position as follow:
MV-102 & MV-104 : OPEN
MV-103 & MV-105 : CLOSE

3. On SCADA view, click main menu and please select LIC-101 button until green
indicator will be light on at that button
4. Click the LIC-101 tuning panel
5. Click the MANUAL mode button until green indicator will be light on.
6. Click on the output value (MV) to set the output value 25%
7. Start the feed-water pump P-101 by pushing the START pushbutton (Green color) on
the local control panel.
8. Observe the feed-water flowrate from the field instrument flowmeter (LT-101) and
PID controller LIC-101 at the local control panel. Record the both flowrate below

5
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

Field Level Transmitter:

LT-101 local display : 21.3 %

PID Controller:
LIC-101 Process variable : 21.4 %

9. Change the LIC-101 Tuning Panel to AUTO mode. Set the Level PID Tuning Panel LIC-
101 set-point to the 50%.

10. Change the PID parameters to the following:

PID Parameters trial [I]:
P = 1.0
I = 10 s
D =0s

11. Observe the liquid level response from the SCADA trending display. Wait for three
(3) cycles of liquid level response before proceeding to the next step.
12. Apply the Load Disturbance by fully OPEN the manual valve MV-101 for about 10
seconds and make sure the manual valve MV-101 returned to marking point.
13. Observe the liquid level response from the SCADA trending display.
14. Comment the liquid level response after three (3) cycles of level responses.
15. Repeat procedures 11 ~ 14 for different trial of PID parameters setting as follow:
PID Parameters trial [II]:
Set-point = 50%
P = 1.0
I = 15 s
D =0s
Applying the Load Disturbance as described in step 12 after applying the new
PID parameters setting

PID Parameters trial [III]:

Set-point = 50%
P = 1.0
I = 25 s
D =0s
Applying the Load Disturbance as described in step 12 after applying the new
PID parameters setting

16. Record the level response from the SCADA historical trending and comment the level
response for the above different set of PID parameters settings.

6
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

OBSERVATION RECORD
Applying the Load Disturbance as described in step 12 after applying the new PID
parameters setting. Record the level responses from the SCADA historical trending after
the Load Disturbance. Redraw the level process response taken from trending snapshot
from the SCADA.

PID Parameters trial [I] with Disturbance Response

PID Parameters trial [II and III] with Disturbance Response

7
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

Please comment the level response for the above PID parameter setting.

In this part, there are 3 values of PID control implemented. During trial I, the
disturbance was added by opening the valve for 10 seconds. Here, the process
value (PV) changed its reading but then the system tried to remove the error back to
setpoint (SP). The PV eventually went back to SP but it took a long time to reach
because of the PID setting placed.

In trial II, the integral value is set higher that before. When disturbance occurred,
the SP was achieved faster with the same amount of disturbance added. The
disturbance was kept constant with the same interval of valve opening to observed
the effect of PID control.

Trial III gave the fastest response of correction from the effect of disturbance. The
steady state condition was achieved in no time compared to the two previous trial I
and II.

8
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

PROCEDURE EXPERIMENT 2B
1. Repeat steps 1 to 8 from Experiment 2A, but follow steps onwards as below.
** (You may skip to step 2, if the experiment is done continuously from 2A to 2B).
2. Set the Level PID Tuning Panel LIC-101 to AUTO mode and set-point to the 50%.
3. Change the PID parameters to the following:
PID Parameters trial [I]:
P = 1.0
I = 10 s
D =0s

4. Observe the liquid level response from the SCADA trending display. Wait for three
(3) cycles of liquid level response before proceeding to the next step.
5. Apply the set-point Disturbance by changing the set-point from 50% to 70%.
6. Observe the liquid level response from the SCADA trending display.
7. Comment the liquid level response after three (3) cycles of level responses.
8. Continue task for different trial of PID parameters setting as follow:

PID Parameters trial [II]:

Applying the set-point Disturbance change the set-point from 70% to 50%
P = 1.0
I = 5s
D =0s

PID Parameters trial [III]:

Applying the set-point Disturbance change the set-point from 50% to 70%
P = 1.0
I = 5s
D =0s

9. Record the level response from the SCADA historical trending and comment the level
response for the above different set of PID parameters settings.

OBSERVATION RECORD
Record the level response from the SCADA historical trending after the Set-point
Disturbance. Redraw the level process response taken from trending snapshot from the
SCADA.

9
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

**Step 2 was skipped because the task was continuously done.

PID Parameters trial [II] 70% to 50%

PID Parameters trial [II] 50% to 70%

10
 BEEA4813 (INDUSTRIAL PROCESS CONTROL)

Please comment the level response for the above PID parameter setting.

In this part, the setpoint was changed to see the response of the system from the
setpoint disturbance. At first, the 50% level setpoint was changed to 70%. The at
trial II the setpoint was changed from 70% to 50%. The response of this trial II was
a bit slower compared to the previous trial. The PID value was kept constant
because the response of higher level to lower level and vice versa was yet to be
observed.

11