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SECTION OF CHEMICAL PROCESS

MALAYSIAN INTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

PROCESS CONTROL LABORATORY

LABORATORY INSTRUCTION SHEETS

COURSE CODE
EXPERIMENT NO. EXPERIMENT 4

EXPERIMENT TITLE Gas Pressure Process Control

DATE
GROUP NO.
1)
LECTURER/INSTRUCTOR/TUTOR
2)
DATE OF REPORT SUBMISSION
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%

INTRODUCTION: /5%

PROCEDURE: /5%
RESULTS& CALCULATIONS /15%
ANALYSIS /15%
DISTRIBUTION OF MARKS FOR DISCUSSIONS: /20%
LABORATORY REPORT: ADDITIONAL QUESTIONS /15%
CONCLUSION /10%
SUGGESTIONS& RECOMENDATIONS /5%

REFERENCES: /5%

TOTAL: /100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

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STUDENT CODE OF ETHICS

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit to

not accept or provide any assistance in preparing this report and anything

that is in it is true.

1) Group Leader: ………………………………………….. (Signature)

Name : __________________________________
Matrix No. : __________________________________

2) Group Member 1: ………………………………………. (Signature)

Name : __________________________________
Matrix No : __________________________________

3) Group Member 2:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________
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1.0 OBJECTIVES
a) To identify the important components of the air pressure control system and
to mark them in the P&I Diagram To study single loop flow control using PID
controller
b) To control the pressure in single capacity and two capacity processes using
PID controller.
c) To tune the PID controller using Ziegler Nichols closed-loop method.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:
2.1 To be familiar with the basic steps of machine from start-up to shut-
down with proper handling and setting.
2.2 To identify the major component of the Gas Pressure process control
training system

3.0 INTRODUCTION
Pressure vessels play an important role in chemical industries as storage
vessels for gas phase components, reaction vessels to carry out a gas phase
reaction, etc. Precise control of pressure in the pressure vessels is necessary in
order to:
(i) Maintain a constant concentration of components in the vessel,
(ii) Maintain the number of moles in the vessel, and
(iii) Protect the vessel from being damaged due to very high pressures.

4.0 INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

The control system consists of a microprocessor based PID controller with an
inbuilt ON/OFF controller. It is equipped with the necessary instrumentation and
signal transmission system.
Identify and mark the following major components of the syst em in the P&I block
diagram provided in the schematic diagram is shown in Figure 1.
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Figure 1: Schematic diagram of Gas Pressure Process Control Training

System
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5.0 PROCEDURE
5.1 STARTUP PROCEDURES
Go through these steps before starting any experiment.
1) Switch the "PANEL, SCADA/DDC" selector switch at the front of
the cubicle to the "PANEL, SCADA" position.
2) Switch ON the main power supply at the front of the cubicle. All
the panel instruments will lit up.
If the recorder chart drive is running, STOP it by pressing the
`RCD' pushbutton.
3) If any annunciator gets activated, press the ACKNOWLEDGE
button to silence the buzzer.
4) Set the instrument air supply regulator to the pressure indicated at
the air regulators at the pneumatic control valves PCV91 and
PCV92. Purge if there is any condensed water in the air regulators
by opening the bottom drain valves.
5) Make sure that the by-pass valves around the control valves PCV91
and PCV92 are shut fully and the pair of manual valves
upstream/downstream of these control valves are opened.
6) Check that the control valve positioner (PP) of PCV91 is connected
(ON) (i.e., not by-passed).
7) Make sure the compressed air is available at the pressure inlet air
regulator AR91.
8) Check that the vent valve (V) and bottom drain valve (D) of vessel
T91 are shut.
9) SHUT fully the manual valves MV91B and MVIII.
10) SHUT fully the process inlet manual valve MV91.
11) Place the panel controller PIC91 in manual (M) mode and adjust its
MV = - 6.3% to open the control valve PCV91 fully.
12) Open fully the final discharge manual valve (VP). This valve is at
downstream of pressure control valve PCV91.
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13) From the process air supply, trace the two pipe lines PLI and PLII
as follows: Pipeline PLI: Single capacity process:
AR91-MV91-T91-PLI-B92- FI92 -P CV9 1 –VP
Two-capacity process
AR9 1 -MV9 1 -T91 -PLI-MVI-T92-MV92-FI92 -PCV 9 1 –VP
Pipeline II (PLII):
AR9 1 -MV9 1 -T91-PLII-MVII-PCV92-MV92A/MV92B-V
14) Open fully the pipelines PLI (Single capacity process) and PLII at
their various manual valves.
15) Make sure the manual by-pass valve B92 around vessel T92 is
opened and the manual valves at the inlet MVI and outlet MV92 of
T92 are shut.
16) The pipeline PLII has two discharge manual valves, MV92A (globe
valve) and MV92B (gate valve). SHUT both the valves MV92A and
MV92B.
17) Check and adjust the pressure at AR91 is approximately at the
pressure indicated at AR91. Check MV91 is fully shut.
18) Slowly open MV91 and regulate it until the flow rate at the variable
area flow meter FI92 reads 35 Nm3/Hr
19) Check the pressure and flow rate setting:
a. Shut fully PCV91 from PIC91 in manual (M) mode with
MV=106.3%. Read the pressure at vessel T91 at the PV
reading of PIC91. If the pressure is about 22 – 27 psig, the
pressure is correctly set.
b. Open fully PCV91 from PIC91 in manual (M) mode with
MV=-6.3%. Read the pressure at vessel T91 at the PV
reading of PIC91. If the pressure is below 10 psig and the
flow rate at FI92 also reads 35 Nm3/Hr, the air flow rate is
correctly set.
c. Now the process air supply pressure and flow rate are set.
DO NOT readjust AR91 and MV91 hereafter.
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5.2 ON/OFF PRESSURE CONTROL
It uses the ON/OFF pressure controller PIC92 to control at the High
pressure limit of PIC91.
1) Make sure that you have gone through the START-UP
procedures very carefully.
2) Start the chart drive of the recorder by pressing the `RCD'
pushbutton at the front of the recorder.
3) Shut fully PCV91 from PIC91 in manual (M) mode with
MV=106.3%. Read PV at PIC91, the pressure at vessel T91. The
pressure should be in the range of 22-27 psig.
4) Note the response of PT91 at the recorder PR91.
PCV92 opens when PT91 exceeds 21 psig and closes when PT91
drops below a fixed Dead Band (0.5 psig), i.e., 20.5 psig.
5) Try to repeat the ON/OFF action by opening and closing
PCV 91. This is done from PIC91 in manual (M) mode by
reducing the MV such that pressure PV drops below 20 psig.
Then shut PCV91 fully again with MV = 106.3%.

5.3 PID CONTROL OF PRESSURE IN SINGLE CAPACITY PROCESS

1) Make sure that you have gone through the START-UP
procedures very carefully.
2) Start the chart drive of the recorder by pressing the `RCD'
pushbutton at the front of the recorder.
3) Make sure that pipelines PLI are opened throughout.
4) Open only the manual discharge globe valve MV92A at the
common vent of PLII.
5) Close the gate valve MV92B at the common outlet of PLII
6) For single capacity operation, only vessel T91 is used. Vessel
T92 is by-passed
a. Open by-pass valve B92 around T92
b. Shut the manual valves at the inlet, MVI, and at the
outlet, MV92, of T92.
c. Make sure the air flow path T91-PLI-FI92-PCV91-VP is
opened through B92.
7) Set the set point of PIC91 as SV = 15 psig.
8) Set the PID controller with the first (I) trial values:
PB1 = 70%, T11 = 40 secs, TD1 = 0 sec.

9) Transfer the controller to Auto (A) mode and wait for the
response to become almost stable.
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10) Switch PIC91 to Manual (M) mode, decrease MV about 10%,
switch back to Auto (A) mode and observe the response for a
few minutes.
DO NOT FORGET TO MARK THE PID VALUES AND THE
SETPOINT ON THE CHART PAPER WHENEVER THE
VALUES ARE CHANGED. ALSO MARK ON THE CHART THE
BEGINNING OF EACH PART OF THE EXPERIMENT
11) If the response is slow to return to the set point SV = 15 psig,
reduce TI1 to 20 secs. and repeat the step (10) again.
12) Now set the PID controller with the second (II) trial values:
PB1 = 45%, TI1 = 30 secs, TD1 = 0 sec.

13) Switch PIC91 to Manual (M) mode, decrease MV about 10%,

switch back to Auto (A) mode and observe the response for a
few minutes.
If the response is not oscillatory, proceed to step (15). If the
response is oscillatory, go to the next step, step (14).
14) Increase PB1 by 10% and repeat the step (13).
15) Try the third (III) trial values for the PID controller: --
PB 1 = 20%, TI1 = 10 secs, TD1 = 2 sec.
16) Introduce the disturbance in MV as in step (13) and observe
the response.

5.4 PID CONTROL OF PRESSURE IN TWO CAPACITY PROCESS

1) Make sure that pipelines PLI and PLII are opened throughout.

2) Open only the manual discharge globe valve MV92A at the

common vent of PLII.

3) Close the gate valve MV92B at the common outlet of PLII

4) For two- capacity operation, vessels T91 and T92 are used.
• Shut the by-pass valve B92 around T92
• Open the manual valves at the inlet, MVI, and at the
outlet, MV92, of T92.
• Make sure the air flow path T91-PLI-T92-F192-PCV91-VP is
opened through MVI and MV92.
5) Switch P1C91 to Manual (M) mode.
6) Open PCV9I about 50% from PIC91 with MV = 50%.
7) Set the set point of P1C91 as SV = 18 psig.
8) Set the PID controller with the first (I) trial values:
PB1 = 70%, TI1 = 40 secs, TD1 = 0 sec.

9) Transfer the controller to Auto (A) mode and wait for the response
to become almost steady or continues to oscillate even after 3
cycles.
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10) Switch PIC91 to Manual (M) mode, decrease its MV by about
10%, switch back to Auto (A) mode and observe the response till
it becomes almost steady or continues to oscillate even after 3
cycles.
DO NOT FORGET TO MARK THE PID VALUES AND THE
SETPOINT ON THE CHART PAPER WHENEVER THE VALUES
ARE CHANGED. ALSO MARK ON THE CHART THE BEGINNING
OF EACH PART OF THE EXPERIMENT.

11) If the response is slow to return to the set point SV = 18 psig,

reduce TI1 to 20 secs. and repeat the step (10) again.
PB1 = 45%, T11 = 30 secs, TD1 = 0 sec.

12) Now set the PID controller with the second (II) trial values:

13) Switch PIC91 to Manual (M) mode, decrease MV by about

10%, switch back to Auto (A) mode and observe the
response for a few minutes.

14) If the response is not oscillatory, proceed to step (17). If the

response is oscillatory, go to the next step, step (16).

15) Increase PB1 by 5% and repeat the step (1 4).

16) Try the third (III) trial values for the PID controller:
PB1 = 20%, TI1 = 30 secs, TD1 = 2 sec.

17) Introduce the disturbance in MV as in step (13) and

observe the response.

18) Switch PIC91 to Manual (M) mode, decrease set-point to 9

psig, switch back to Auto (A) mode and observe the
response till it becomes steady.

19) STOP the chart drive and retrieve the relevant portions of the
chart paper. Attach the chart paper along with the result
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6.0 SHUTDOWN PROCEDURE
1. Switch the controller PIC91 to Manual(M) mode, and set the MV=100%
2. Stop Recording by push the recorder “RCD” button
3. Switch Off the main power supply

7.0 RESULTS & CALCULATIONS

The recorder PR91 records the results of the experiments. Suitable

portions of the recorder chart paper should be submitted as RESULTS
of the experiment.

The report should contain

1. The P&I diagram with all major components marked clearly.
2. A detailed report of the start-up procedure.
3. The response curves of the ON/OFF controller with all particulars
such as Setpoint and Dead Band.
4. Response curves for single capacity and two-capacity processes
with different PID controller values. Include all the details such as
setpoint, PID controller values.
5. Discussion on the response characteristics.

8.0 ANALYSIS OF THE RESULTS

Analysed critically each results obtain in section 7.0 by referring to the

theory/introduction parts. Find reasons (suggested reasons) on each
occurrence shown in the results

9.0 DISCUSSIONS

Based on your observation, comment/discuss on the following:

1. The choice of Air-to-Open or Air-to-Close control valve is determined by
safety consideration.
2. ON/OFF control is a two position control. Use of dead band is
recommended in ON/OFF controllers. Why?
3. Difference between single capacity and two-capacity processes.

10.0 CONCLUSION
Conclusion is merely a summary of the important findings already reported in
the discussion section. It also relates to the objectives stated earlier.
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11.0 SUGGESTIONS & RECOMMENDATIONS
Your ideas of suggestion & recommendation to improve the learning process for
this experiment or anything related to the experimental procedure etc.

12.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter(base)
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