Process Control & Instrumentation Laboratory BKF4791

Faculty of Chemical & Natural Resources Engineering

BKF4791
Process Control & Instumentation Laboratory

Name
Matric No.
Group
Program
Section
Date

Sem. I - Session 2010/2011

Process Control & Instrumentation Laboratory BKF4791
Vision
To be a center in producing professionals in the area of chemical and natural resources engineering,
with emphasis on industrial practices and applications.

Mission
To provide for the study of chemical and natural resources engineering in an industrial context
through outstanding education, research, and development.

Program Educational Objective (PEO)

PEO 1: Our graduates will demonstrate effective communications, leadership and teaming skills
PEO 2: Our graduates will demonstrate the foundation and breadth to obtain, apply, and transfer
knowledge across disciplines and into emerging areas of chemical engineering and
related fields
PEO3: Our graduates will demonstrate the foundation and depth for successful chemical
engineering careers in industry, academia, or government
PEO 4: Our graduates will demonstrate that they have a sense of responsibility are ethical in the
conduct of their profession, and have an appreciation for the impact of their profession on
society.

Program Outcomes (PO) for Laboratory

The students are expected to attain the following;
• PO 2: ability to communicate effectively, in verbal and written forms, with both technical
and non-technical groups. (S)
• PO 3: acquired in-depth technical competence in chemical engineering and related
disciplines (K)
• PO 8: ability to function effectively as an individual and in a group with the capacity to be
a leader or manager (A)
Process Control & Instrumentation Laboratory BKF4791
CONTENTS
A. Teaching Plan

B. Laboratory Report Format & Evaluation

B1. Laboratory Report Format
B2. Report Evaluation
B3. Laboratory Front page

C. Occupational Safety & Health (OSH)

C1. FKKSA Occupational Safety & Health
C2. General Laboratory Procedures
C3. Emergency Notification & Response

D. Experiment
Exp 1: Density Measurement
Exp 2: Measurement and Analysis of Liquid Flow System
Exp 3: Measurement and Control of Air Flow System
Exp 4: Study on Dynamics of First Order and Second Order Systems
Exp 5: Study on Dynamics of First Order System using Furnace
Exp 6: Steady State and Dynamic Studies of Distillation Column
Exp 7: Gas Temperature Control Using PID Controller
Exp 8: Single Loop PID Level Control Using DCS
Exp 9: Gas Pressure Control Using PID Controller
Exp 10: Dynamic Studies of Simulated Gas Mass Flow Process
IPBL 1: Open Loop Studies of Simulated Gas Mass Flow Process
IPBL 2: PID controller Tuning of Simulated Gas Mass Flow Process
Process Control & Instrumentation Laboratory BKF4791
TEACHING PLAN

1 Course Code and Name BKF4791 Process Control & Instrumentation Laboratory
Semester and Year
2 Semester 1 Year 4
Taught
Program
3 Degree/Process Control & Instrumentation
Level/Category
4 Unit 1 Credit

5 Prerequisite Course

Lecture: 0 unit (0 hours X 14 weeks)

6 Contact Hours Tutorial: 0 unit (0 hours X 14 weeks)
Laboratory: 3 units (3 hour X 14 weeks)
This laboratory have been developed to address the key engineering
educational challenge of realistic problem solving within the constraints of
a typical lecture-style course in process dynamics and control. Students
will conduct experiments based on two major process operations which are
based on computer simulation and plant experimental works. In computer
7 Course Synopsis simulation, students will simulate a case study using Matlab environment
software and also operate a system on Distributed Control System (DCS).
While the students also run the experiment using pilot plant available in
this laboratory. This application will encourage students to apply their
process control theories into practical term and inculcate the critical
thinking among the group members.
By the end of semester, students should be able to:
CO1 To apply the process instrumentation and control hardware of the
control system
CO2
To implement control strategies manually and automatically using
software packages and plant
CO3
8 Course Outcomes To perform scan, control, alarm and data acquisition (SCADA)
functions and operate a system using DCS
CO4
To develop convenient graphical interface for students that allowed
them to interact in real-time with the evolving virtual experiment
CO5
Function effectively as an individual and in a group throughout the
semester based on tasks/modules assigned
Distribution (%) CO1 CO2 CO3 CO4 CO5
Report 50 % X
Industrial Problem
Based Learning 10 % X X X X X
(IPBL)
9 Assessment Methods
Test 20 % X
Mentor Mentee 15 % X
Peer Evaluation 5% X
100
Total
%
1. Syntech Process Control Module
2. Marlin, T.E., Process Control: Designing Processes
and Control Systems for Dynamic Performance, 2nd Edition, Mc
Graw Hill, USA, 2000.
3. F.J. Doyle III Process Control Modules, Prentice Hall
10 Learning References 4. Seborg, D.E., Edgar, T.F. and Mellichamp., Process
Dynamic and Control, John Wiley 2004.
5. Stephanopoulos, G., Chemical Process Control: An
Introduction to Theory and Practice, Prentice-Hall 1984.
6. D.R. Coughnowr, S.LeBlance., Process Systems,
Analysis and Control, Mc-Graw Hill, 2008.
Process Control & Instrumentation Laboratory BKF4791
B. LABORATORY REPORT FORMAT & EVALUATION

B1. Laboratory Report Format

1. Front page
2. Abstract
3. Introduction
4. Literature Review
5. Experiment Objective
6. Methodology
7. Result and Discussion/Questions
8. Conclusions & Recommendations
9. References
10. Appendices

B2. Report Evaluation:

Part A : 55%
(Inclusive of Front Page/Format; Abstract; Introduction; Literature Review; Experiment
Objective; Methodology; Conclusions & Recommendations; References; Appendices; Grammar
& Spelling; Timeliness)

Part B : 45%
(Inclusive of Result and Discussion/Questions)
Process Control & Instrumentation Laboratory BKF4791
Report Evaluation for Part A

Instruction: Please assess each item using the given scales. Fractional marks will be given for each category.

Unacceptable Acceptable Good Very Good Excellent

Item Assessed Score
(1) (2) (3) (4) (5)
Organization and Not follow FKKSA Partially follow FKKSA Follow FKKSA Follow FKKSA Follow FKKSA
Format laboratory report laboratory report laboratory report laboratory format of laboratory report
format. Not well format. Contents show format of writing; all writing; all needed format of writing; all
organized. Contents enough of knowledge needed sections sections present. Well needed sections
show lack of but still a few concept present. Well organized and easily present. Tables and
knowledge. and ideas are loosely organized. Contents followed. Contents figures are correctly
connected. show enough show full knowledge drawn and numbered.
knowledge of subject. of subject. Excellent organized
and easily followed.
Contents show full
excellent knowledge
of subject.
Keywords: Front page, Content, Page No., Total page >8, Arrangement
Abstract Several major aspects Abstract misses one Abstract contains Abstract contains all Abstract contains
of laboratory report or more major aspects most major aspects of major aspects of references to all major
are missing. of laboratory report. laboratory report. laboratory report i.e. aspects of laboratory
Incomplete description Abstract may be too main purpose of the report i.e. main
of experiment. technical and only experiment, its purpose of the
Student displays a understood by importance, experiment, its
lack of understanding specialist in the methodology/ importance,
about how to write an discipline. approach, most methodology/
abstract. significant results or approach, most
findings, main significant results or
conclusions and/or findings, main
recommendation. conclusions and/or
recommendation.
General audience
easily understands
abstract.
Keywords: Introduction, Objective, Method, Result, Conclusion, Suggestion, 1 page
Process Control & Instrumentation Laboratory BKF4791
Unacceptable Acceptable Good Very Good Excellent
Item Assessed Score
(1) (2) (3) (4) (5)
Introduction Very little background Some introductory Introduction is nearly Introduction is Introduction is
information or information, but still complete, missing complete and well complete and well
information is missing some major some minor points. written but theory may written; provides all
incorrect OR, does not points. OR, gives little not be backed up to necessary
give any information information concise lead-in to the background principles
about what to expect laboratory experiment. and theory for the
in the laboratory experiment. Present a
report concise lead-in to the
laboratory experiment.

Keywords: Related Theory, Principles, Process Background

Literature Review Poor understanding of Acceptable Good understanding Good understanding Complete
topic experiment, understanding of of topic, adequate of topic, adequate understanding of
inadequate topic, adequate information evident, information evident, topic, topic extensively
information or very information evident, sources cited. sources cited. well-informed and
little information sources cited. Sufficient literature Sufficient and relevant variety of sources are
regarding experiment Insufficient literature review. literature review. cited.
topic. review or may contain Literature review
No external literature unrelated materials. contains information
review. relevant and directly
related to experiment
topic.

Keywords: Experiment Topic Information

Experiment No objective or Objective is partially Objective is relevant Objective is clear, Objective is precise,
Objective objective missing the defined. but not elaborated. relevant and clear, relevant and
important points. elaborated but well elaborated with
missing some point on relevant explanation.
relevant explanation.

Keywords: Objective Elaboration

Methodology Missing several Materials and Materials and Materials and Materials and
important methodology nearly methodology are methodology are methodology are
Process Control & Instrumentation Laboratory BKF4791
Unacceptable Acceptable Good Very Good Excellent
Item Assessed Score
(1) (2) (3) (4) (5)
explanations of complete but still explained with complete. Mostly easy complete and
materials and/or missing some sufficient detail; some to follow. Description adequately detailed.
methodology. Not important lack detail or are of procedure can be Logical and easily
sequential. Most steps experimental details. confusing. Mostly replicated. followed. Description
are missing or are Others may have easy to follow. of procedure is
confusing. Some difficulties following Description of complete, ensuring
procedural procedures; some procedure makes it that it can be
components generally steps are likely that the work replicated.
described but are not understandable; but can be reliably
replicable. most are confusing replicated.
and lack detail. Can
replicate experiment if
reader makes some
inferences.

Keywords: Experiment Procedure, List of Equipment

Conclusions and No conclusions or Conclusions regarding All the important All the important All the important
recommendations conclusion missing major points are conclusions are drawn conclusions have conclusions have
the important points. drawn, but many are could be better stated. been made. been clearly made.
No recommendation misstated, indicating a Conclusion is related Conclusion is Conclusion is
given to improve the lack of understanding. to general interest. precisely stated. precisely stated and
experiment. Conclusion is too Several Conclusion and relates the study to
general. Several recommendations recommendation general interest, other
recommendations have been stated and relates the study to studies that have
have been given but they are partially general interest and been conducted.
they are too general contributed to the other studies that Recommendations
and not contributing to experiment’s have been conducted. given are significantly
the experiment’s improvement. contribute to the
improvement. experiment’s
improvement.
Keywords: Experiment Summary, Recommendation
Process Control & Instrumentation Laboratory BKF4791
Unacceptable Acceptable Good Very Good Excellent
Item Assessed Score
(1) (2) (3) (4) (5)
References Some citations in text A few citations in text All citations in text are All citations in text are All citations in text are
are not available in list are not available in list available in list of available in list of available in list of
of reference. of reference. reference but list of reference and list of reference. List of
reference is less than reference is more than reference is more than
3. 3. 3 and variety source.
Keywords: Book Reference, Journal Reference, Website Reference
Appendices Appendices not Only a few Appendices available Appendices available Appendices available
available in laboratory appendices available in laboratory report in laboratory report in in laboratory report in
report. in laboratory report. but poorly constructed structured manners structured manners,
clearly and precise
Keywords: List of Formulas, Tables, Figures, Calculation
Grammar and Numerous spelling Still many spelling Occasional Occasional Minimal to no spelling
Spelling and/or grammar and/or grammar grammar/spelling grammar/spelling mistakes. Spell
errors. Transitions errors. Few or weak errors. May have a mistakes. Spell checked and proofed
confusing and transitions, often few unclear checked and proofed throughout. Good
unclear. wanders and jumps transitions. throughout. Good sentence and
around. sentence and paragraph structure
paragraph structure and transitions.
and transitions.

Keywords: Language
Timeliness Laboratory report Up to one week late Up to three days late Handed in one day Laboratory report
handed in more than late handed in on time
one week late

Keywords: Punctuality

Total Assessment Marks (55%)

Process Control & Instrumentation Laboratory BKF4791
B3. LABORATORY REPORT FRONTPAGE

PROCESS CONTROL & INSTRUMENTATION LABORATORY

(BKF4791)
2010/2011 Semester I

Title of Experiment :
Date of Experiment :
Date of Submission :
Instructor’s Name :
Group of Member :
Name ID
1.
2.
3.
4.
5.
Group No. :
Section :

Marks :

Part A 55
Part B 45
TOTAL 100

FACULTY OF CHEMICAL AND NATURAL RESOURCES ENGINEERING

Process Control & Instrumentation Laboratory BKF4791

UNIVERSITI MALAYSIA PAHANG

C. OCCUPATIONAL SAFETY & HEALTH (OSH)

C1. FKKSA OCCUPATIONAL SAFETY AND HEALTH POLICY

In our mission to disseminate knowledge, stimulate teaching and learning,

and inculcate soft-skill, FACULTY OF CHEMICAL AND NATURAL
RESOURCES ENGINEERING is fully committed in practising safety and
health with the aim of achieving the highest standards of Occupational
Safety and Health (OSH).

In line with UMP OSH policy, FKKSA will preserve the safety and health of its
associates, students, and related parties in accordance with safe system of
work and best practice.

It is our policy to:

1. Facilitate our associates and related parties with sufficient information

and effective training related to Safety and Health.
2. Comply with all the relevant legislations, regulations and procedures in
the conduct of the operation.
3. Achieve zero lost time injury record by having a competent Safety and
Health Management Team and a self-motivated trained workforce.
4. Nourish OSH as our highest core values in organisational goal.
5. Review safety management systems periodically or continuously in
order to achieve safe system of work and best practice.
6. Establish systems and procedures to maintain the laboratory and pilot
plant facilities as scheduled and to implement safe system of work.

The OSH policy shall be subjected to periodical review to cater for likely
variations in the course of the operations and shall be made available to all
interested parties.

“STRIVE TOWARDS ZERO LOST TIME INJURY”

______________________________
Assoc. Prof Zulkafli B. Hassan
Dean of FKKSA

Dated: AUGUST 2008

Process Control & Instrumentation Laboratory BKF4791

C2. General Laboratory Procedures

DO
 Know the potential hazards of the materials used in the laboratory. Review the Chemical Safety
Data Sheet (CSDS) and container label prior to using a chemical.
 Know the location of safety equipment such as emergency showers, eyewashes, fire
extinguishers, fire alarms, spill kits and first aid kits.
 Review emergency procedures to ensure that necessary supplies and equipment for spill response
and other accidents are available.
 Practice 5S to minimize unsafe work conditions such as obstructed exits and safety equipment,
cluttered benches and hoods, and accumulated chemical waste.
 Wear personal protective equipment when working with chemicals. This includes eye protection,
lab coat, gloves, and appropriate foot protection (no sandals). Gloves should be made of a material
known to be resistant to permeation by the chemical in use.
 Wash skin promptly if contacted by any chemical, regardless of corrosivity or toxicity at least 15
minutes.
 Label and store chemicals properly. All chemical containers should be labeled to identify the
container contents (no abbreviations or formulas) and hazard information. Chemicals should be stored
by hazard groups and chemical compatibilities.
 Use fume hoods when processes or experiments may result in the release of toxic or flammable
vapors, fumes, or dusts.
DON’T
 Eat, drink, chew gum, or apply cosmetics in areas where chemicals are used and stored.
 Perform unauthorized experiment.
 Store food in laboratory freezer or ovens.
 Drink water from laboratory water sources.
 Use laboratory glassware to prepare or consume food.
 Smell or taste chemicals.
 Pipette by mouth.
 Leave potentially hazardous experiments or operations unattended without prior approval
from the lab instructor.
 Use chipped, cracked or dirty glassware.
 Work alone in the laboratory after office hour.
 Dispose chemical waste into sink drains.
 Immerse hot glassware in cold water. The glassware may shatter.
Process Control & Instrumentation Laboratory BKF4791

 Look into a container that is being heated.

Process Control & Instrumentation Laboratory BKF4791

C3. Emergency Notification & Response

UNI V E R SI T I M A L AY SI A P A H AN G
F A C U L T Y O F C H E M IC A L& N A T U R A L R E S O U R C E S
E N G IN E E R IN G

C H E M I C A L S P I L L A G E N O T I F I C A T I O&
N R E SP ON SE
BY WHOM PROCESS FLOW INFORMATION

START

W IT NESS FOU N D C HEM IC AL SPILLAGE

W IT N ESS ALER T PER SON N EL IN AD JAC EN T

AR EA & EVACU AT E N ON ESSENT IAL
PERSON FR OM SPILL AR EA

Poin t T o R emember :
1. Pleas e do not handle spillage unless
W IT N ESS NO TR AIN ED FOR H AN D LE you w ear a com plete Personal
SPILLAGE Protective Equipm ent(PPE).
2. If flam m able vapors are involved , do
not operate electrical s witches unless
to turn off electric equipm ent .
YES 3. If s pilled m aterial is flam m able
,
extinguish flam es and all other sources
of ignition.
W IT N ESS F IND SAFE EN VIRONM EN T
LOC ATION SPILL ON

PEOPLE
REFER T O C SD S F OR
W IT N ESS R EFER T O C SD S FOR AC TION
AC T ION
(FIR ST AID M EASU RES PAR)T
(AC C ID EN TAL R ELEASE
M EASU R ES PART )
SH E Co ntact N:o
09-549 2430 / 2387 / 2419 / 2640

W IT N ESS IN FOR M SHE UN IT IN FORM SH E U NIT

/ FIR ST AID ER F irst Aid er Co ntact N: o
En. Anuar : 013- 6986946
En. H isham : 012- 3058524
Pn H afizah: 012- 9848565
SITE C OM M AND ER
/ AC T IVATE EM ER GEN CY
EM ER GENC Y C OORD INATOR R ESPON SE T EAM(ER T)
IF EM ERGENC Y OC CU R A FT ER
OFF ICE HOUR ; C ON TA C T U M P
SEC UR ITY A T09 – 549 1121
EM ER GENC Y R ESPONSE T EAM C LEAN TH E SPILL FIR ST AID T R EAT M ENT
(ER T)

EM ER GENC Y R ESPONSE T EAM SEN D VIC TIM T O C LIN IC T OGET HER U M P Stud ent Health U n it C o ntact: N o
(ERT) / W IT NESS W IT H C SD S 09- 549 2539

EM ER GENC Y R ESPONSE T EAM NO

SPILL SECU R ED
(ER T)

YES

SITE C OM MAN D ER
/ EM ERGEN CY CALL F IR E& RESC U E F IRE & RESCU E D EPT CONT A C T N
.O
COOR D INATOR D EPT GEN ER AL: 999
T AM AN TAS : 09-538 3704
KU ANT AN: 09-513 5544
U PON T HE AR R IVAL FIR E
EM ERGEN CY RESPON SE T EAM (ERT)
& R ESC U E D EPT
,
AND FIR E& R ESCU E D EPT
H AN D OVER ALL D U TIES
TO TH EM

SPILL SEC UR E AND FIR E

F IR E& RESC UE DEPT
& R ESC U E D EPT
C ON FIR M COND ITION IS
SAF E
SITE C OM MAN D ER
/ EM ERGEN CY
DEC LARE EM ERGENC Y OVER
COOR D INATOR

END
Process Control & Instrumentation Laboratory BKF4791

UNI VE R SI T I M A L A Y SI A P A H A NG

F A C U L T Y O F C H E M IC A &
L N A TURA L RE SOURC ES
E N G IN E E R IN G
F IR E N O T I F I C A T I O N& R E S P O N S E
BY WHOM PROCESS FLOW INFORMATION

ST AR T

W IT N ESS F OU N D F IR E

BIG F IR E/
UN CON TR OLLABLE
W I TN ESS ASSESS SIT U AT ION

SM ALL F IR E/ C ON T ROLLABLE

NO KN OW H OW T O
W IT N ESS F IGHT F IRE?

YES

LOOKIN G F OR F IR E FIGH TIN G

W I TN ESS
EQU IPM EN T

HA N D L IN G OF FI RE EXT IN GU ISHER
P Pull the safety pin
W I TN ESS YES A Aim dis charge noz z le to fire base
PU T OU T F IRE
S Squeez e t he lev er
S Sweep bac k and forth as you m ov e
c los er to the f ire
NO

W I TN ESS SHOU T F IR !EF I RE!, BR EAK

EM ER GEN CY GLASS

W I TN ESS F IND SAF E LOC AT ION

& IN F OR M SH E IN F OR M SH E SH E CON T A CT N.O
U N IT UN IT 09-549 2430 / 2387 / 2419 / 2640
IF EM ERGENC Y OC CU R AF T ER
OF F ICE H OU ;RC ON T A C T UM P
SIT E COM M AN DER/ EM ER GEN C Y AC T IVAT E EM ER GENC Y RESPONSE
SEC U R IT Y A T09 – 549 1121
C OOR DI NATOR T EAM (ER T)

EM ERGEN C Y R ESPON SE T EAM YES

PU T OU T F I RE
(ERT)

NO
F I RE & RESCU E DEPT C ON T AC T .NO
SIT E COM M AN DER/ EM ER GEN C Y GEN ER AL: 999
C OOR DI NATOR C ALL F IR E& R ESC UE D EPT
T AM AN T AS : 09-538 3704
KU AN T AN: 09-513 5544

EM ER GEN C Y RESPON SE T EAM (ER T) U PON T H E AR R IVAL F IR&ERESCU E

AN D F IR E& RESC U E D EPT DEPT, H AN D OVER ALL D UT IES T O
T H EM

F IRE PU LL OU T AN D F IR&ERESC U E
F IR E& RESC U E D EPT
D EPT C ON F IR M BUILD ING IS SAF E

SIT E COM M AN DER/ EM ER GEN C Y

D EC LAR E EM ER GEN C Y OVER
C OOR DI NATOR

END
Process Control & Instrumentation Laboratory BKF4791

UNI V E R SI T I M A L A Y SI A P A H A NG
F A C U L T Y O F C H E M IC A &
L N ATURA L RESOUR CES
E N G IN E E R IN G
H U M A N I N J U R Y N O T I F I C A T I O&N
R E SP O N SE
BY WHOM PROCESS FLOW INFORMAT ION

ST AR T

W ITN ESS H U M AN IN JU R Y

Po in t T o R ememb:er
NO T R AIN ED IN F IR ST AID 1. D o not m ove victim unless to
W IT N ESS
T R EAT M EN T prev ent further injury
.
2. D o not rem ove any evidence

YES

W ITN ESS F IR ST AID TR EAT M EN T

SH E C o ntact N:o
09-549 2430 / 2387 / 2419 / 2640
F irst A id er C o n tact :N o
W ITN ESS IN F OR M SH E U N IT
/ F IR ST AID ER En. Anuar : 013-6986946
En. H isham : 012-3058524
Pn. H afiz ah: 012-9848565

IF EM ER GEN C Y OC C U R A F T ER
NO N EED FU R TH ER OF F IC E H OU;RC ON T A C T U M P
EM ER GEN C Y R ESPON SE T EAM SEC U R IT Y A T09 – 549 1121
T R EAT M EN T
(ER T)

YES U M P Stu d en t H ealth U n it C o n tact: N o

09- 549 2539
EM ER GEN C Y R ESPON SE T EAM SEN D VIC T IM T O C LIN/IC
H OSPIT AL
(ER T) / W IT N ESS
H T A A C o ntact N: o
09-557 2222

SITE C OM M AN D ER
/ EM ER GEN C Y
EM ER GEN C Y OVER
C OOR D IN AT OR

END
Process Control & Instrumentation Laboratory BKF4791

UNI V E R SI T I M AL AY SI A P AH ANG
F A C U L T Y O F C H E M IC A L& N A T U R A L R E S O U R C E S
E N G IN E E R IN G

G A S L E A K A G E N O T I F I C A T I O N& R E S P O N S E
BY WHOM PROCESS FLOW INFORMATION

ST AR T

W IT N ESS D ET EC T GAS LEAKAGE

ALER T PER SON N EL IN AD JAC EN T

W ITN ESS AR EA

Po in t T o R ememb er :
W ITN ESS C U T OFF GAS SU PPLY F R OM
1 . Please do not handle gas leakage
SOU R C E
unless y ou w ear a com plete Personal
Protectiv e Equipm ent(PPE).
2 . If flam m able gas involv, edo not
operate electrical s w itc hes unles s to
NO T R AIN ED T O NO turn off electric equipm ent.
W ITN ESS H AN D LE GAS IN VOLVE IN JU R Y 3 . If gas leak ge is flam m able,
LEAKAGE extinguis h flam es and all other s ourc es
of ignition.
YES YES

R EF ER T O C SD S F OR R EF ER TO C SD S F OR AC TION
W ITN ESS AC T ION (F IR ST AID M EASU R ES PAR
)T
(AC C ID EN T AL R ELEASE
M EASU R ES PAR )T
SH E C o ntact N o
:
09-549 2430 / 2387 / 2419 / 2640
W ITN ESS IN FOR M SH E U N IT IN F OR M SH E U N IT
/ F IR ST AID ER
Fir st A i der C o ntact N: o
En. Anuar : 013-6986946
En. H is ham : 012-3058524
SIT E C OM M AN D ER/ AC TIVAT E EM ER GEN C Y Pn. H afizah: 012-9848565
EM ER GENC Y C OOR D I N AT OR R ESPON SE T EAM(ER T)
IF EM ER GEN C Y OC C U R A F T ER
OF FIC E H OU R; C ON T A C T U M P
EM ER GENC Y R ESPON SE TEAM SEC U R IT Y A T09 – 549 1121
F IR ST AID TR EAT M EN T
(ER T)

EM ER GENC Y R ESPON SE TEAM SEN D VIC T IM TO C LIN IC TOGET H ER

U M P Stu d en t H ealth U n it C on tact :N o
(ER T) / W IT N ESS W ITH C SD S
09- 549 2539

EM ER GENC Y R ESPON SE TEAM YES GAS LEAKAGE

(ER T) SEC U R ED

NO

SIT E C OM M AN D ER/ EM ER GEN C Y C ALL F IRE& R ESC U E FIR E & R ESC U E D EPT C ON TA C T N. O
D EPT GENER AL: 999
C OOR D IN ATOR
TAM AN T AS: 09-538 3704
KU AN T AN: 09- 513 5544
U PON T H E AR R IVAL F IR E
EM ER GENC Y R ESPON SE TEAM (ER T) & R ESC U E D EPT,
AN D FIR E& R ESC U E D EPT H AN D OVER ALL D U T IES
T O TH EM

GAS LEAKAGE SEC U R E

AN D F IR E& R ESC U E
F IR E& R ESC U E D EPT D EPT C ON FI R M
C ON D IT ION IS SAF E

SIT E C OM M AN D ER/ EM ER GEN C Y D EC LAR E EM ER GEN C Y OVER

C OOR D IN ATOR

END
Process Control & Instrumentation Laboratory BKF4791

UNI VE R SI T I M AL AY SI A P AH ANG

F A C U L TY O F C H E M IC A L& N A T U R A L R E S O U R C E S
E N G IN E E R IN G
E X P L O S I O N N O T I F I C A T I O N& R E S P O N S E
BY WHOM PROCESS FLOW INFORMATION

ST AR T

W IT N ESS
F OUN D EXPLOSION

SH OU T EXPLOSION!, EXPLOSION !,
W IT N ESS
BR EAK EM ER GEN C Y GLASS

F IN D SAF E LOC ATION& IN F OR M SH E SH E C ON T A CT N.O

W IT N ESS
U N IT 09-549 2430 / 2387 / 2419 / 2640
IF EM ERGEN C Y OC C U R A F TER
SIT E COM M AND ER/ EM ER GEN C Y AC T IVAT E EM ER GEN C Y R ESPON SE OF FIC E H OU R C ON TA C T U M P
C OOR D IN ATOR T EAM (ER T) SEC U R IT Y AT09 – 549 1121

U N D ER C ON T R OL
EM ER GENC Y R ESPON SE T EAM
ASSESS SIT U AT ION
(ER T)

EM ER GENC Y R ESPON SE T EAM NO BEYON D C ON TR OL

PU T OU T EXPLOSION
(ER T)

YES
F IR E & R ESC U E D EPT C ON TA C T N
. O
SIT E COM M AND ER/ EM ER GEN C Y
C ALL F IR E& R ESC U E D EPT GEN ER AL: 999
C OOR D IN ATOR
T AM AN T AS : 09-538 3704
KU AN T AN: 09-513 5544
EM ER GEN C Y R ESPON SE TEAM (ER T) U PON T H E AR R IVAL F IR&ER ESCU E
AN D F IR E& R ESC U E D EPT D EPT, H AN D OVER ALL D U T IES TO
T H EM

F IR E & R ESC U E D EPT EXPLOSION OVER AN D F IR&E

R ESC U E D EPT C ON FIR M BU ILD IN G IS
SAFE

SIT E COM M AND ER/ EM ER GEN C Y

C OOR D IN ATOR D EC LAR E EM ER GEN C Y OVER

END
Process Control & Instrumentation Laboratory BKF4791

UNI V E R SI T I M A L AY SI A P A H AN G
F A C U L T Y O F C H E M IC A L& N A T U R A L R E S O U R C E S
E N G IN E E R IN G

C H E M I C A L S P I L L A G E N O T I F I C A T I O&
N R E SP ON SE
BY WHOM PROCESS FLOW INFORMATION

START

W IT NESS FOU N D C HEM IC AL SPILLAGE

W IT N ESS ALER T PER SON N EL IN AD JAC EN T

AR EA & EVACU AT E N ON ESSENT IAL
PERSON FR OM SPILL AR EA

Poin t T o R emember :
1. Pleas e do not handle spillage unless
W IT N ESS NO TR AIN ED FOR H AN D LE you w ear a com plete Personal
SPILLAGE Protective Equipm ent(PPE).
2. If flam m able vapors are involved , do
not operate electrical s witches unless
to turn off electric equipm ent .
YES 3. If s pilled m aterial is flam m able
,
extinguish flam es and all other sources
of ignition.
W IT N ESS F IND SAFE EN VIRONM EN T
LOC ATION SPILL ON

PEOPLE
REFER T O C SD S F OR
W IT N ESS R EFER T O C SD S FOR AC TION
AC T ION
(FIR ST AID M EASU RES PAR)T
(AC C ID EN TAL R ELEASE
M EASU R ES PART )
SH E Co ntact N:o
09-549 2430 / 2387 / 2419 / 2640

W IT N ESS IN FOR M SHE UN IT IN FORM SH E U NIT

/ FIR ST AID ER F irst Aid er Co ntact N: o
En. Anuar : 013- 6986946
En. H isham : 012- 3058524
Pn H afizah: 012- 9848565
SITE C OM M AND ER
/ AC T IVATE EM ER GEN CY
EM ER GENC Y C OORD INATOR R ESPON SE T EAM(ER T)
IF EM ERGENC Y OC CU R A FT ER
OFF ICE HOUR ; C ON TA C T U M P
SEC UR ITY A T09 – 549 1121
EM ER GENC Y R ESPONSE T EAM C LEAN TH E SPILL FIR ST AID T R EAT M ENT
(ER T)

EM ER GENC Y R ESPONSE T EAM SEN D VIC TIM T O C LIN IC T OGET HER U M P Stud ent Health U n it C o ntact: N o
(ERT) / W IT NESS W IT H C SD S 09- 549 2539

EM ER GENC Y R ESPONSE T EAM NO

SPILL SECU R ED
(ER T)

YES

SITE C OM MAN D ER
/ EM ERGEN CY CALL F IR E& RESC U E F IRE & RESCU E D EPT CONT A C T N
.O
COOR D INATOR D EPT GEN ER AL: 999
T AM AN TAS : 09-538 3704
KU ANT AN: 09-513 5544
U PON T HE AR R IVAL FIR E
EM ERGEN CY RESPON SE T EAM (ERT)
& R ESC U E D EPT
,
AND FIR E& R ESCU E D EPT
H AN D OVER ALL D U TIES
TO TH EM

SPILL SEC UR E AND FIR E

F IR E& RESC UE DEPT
& R ESC U E D EPT
C ON FIR M COND ITION IS
SAF E
SITE C OM MAN D ER
/ EM ERGEN CY
DEC LARE EM ERGENC Y OVER
COOR D INATOR

END
Process Control & Instrumentation Laboratory BKF4791

UNI VE R SI T I M A L A Y SI A P A H A NG

F A C U L T Y O F C H E M IC A &
L N A TURA L RE SOURC ES
E N G IN E E R IN G
F IR E N O T I F I C A T I O N& R E S P O N S E
BY WHOM PROCESS FLOW INFORMATION

ST AR T

W IT N ESS F OU N D F IR E

BIG F IR E/
UN CON TR OLLABLE
W I TN ESS ASSESS SIT U AT ION

SM ALL F IR E/ C ON T ROLLABLE

NO KN OW H OW T O
W IT N ESS F IGHT F IRE?

YES

LOOKIN G F OR F IR E FIGH TIN G

W I TN ESS
EQU IPM EN T

HA N D L IN G OF FI RE EXT IN GU ISHER
P Pull the safety pin
W I TN ESS YES A Aim dis charge noz z le to fire base
PU T OU T F IRE
S Squeez e t he lev er
S Sweep bac k and forth as you m ov e
c los er to the f ire
NO

W I TN ESS SHOU T F IR !EF I RE!, BR EAK

EM ER GEN CY GLASS

W I TN ESS F IND SAF E LOC AT ION

& IN F OR M SH E IN F OR M SH E SH E CON T A CT N.O
U N IT UN IT 09-549 2430 / 2387 / 2419 / 2640
IF EM ERGENC Y OC CU R AF T ER
OF F ICE H OU ;RC ON T A C T UM P
SIT E COM M AN DER/ EM ER GEN C Y AC T IVAT E EM ER GENC Y RESPONSE
SEC U R IT Y A T09 – 549 1121
C OOR DI NATOR T EAM (ER T)

EM ERGEN C Y R ESPON SE T EAM YES

PU T OU T F I RE
(ERT)

NO
F I RE & RESCU E DEPT C ON T AC T .NO
SIT E COM M AN DER/ EM ER GEN C Y GEN ER AL: 999
C OOR DI NATOR C ALL F IR E& R ESC UE D EPT
T AM AN T AS : 09-538 3704
KU AN T AN: 09-513 5544

EM ER GEN C Y RESPON SE T EAM (ER T) U PON T H E AR R IVAL F IR&ERESCU E

AN D F IR E& RESC U E D EPT DEPT, H AN D OVER ALL D UT IES T O
T H EM

F IRE PU LL OU T AN D F IR&ERESC U E
F IR E& RESC U E D EPT
D EPT C ON F IR M BUILD ING IS SAF E

SIT E COM M AN DER/ EM ER GEN C Y

D EC LAR E EM ER GEN C Y OVER
C OOR DI NATOR

END
Process Control & Instrumentation Laboratory BKF4791

UNI V E R SI T I M A L A Y SI A P A H A NG
F A C U L T Y O F C H E M IC A &
L N ATURA L RESOUR CES
E N G IN E E R IN G
H U M A N I N J U R Y N O T I F I C A T I O&N
R E SP O N SE
BY WHOM PROCESS FLOW INFORMAT ION

ST AR T

W ITN ESS H U M AN IN JU R Y

Po in t T o R ememb:er
NO T R AIN ED IN F IR ST AID 1. D o not m ove victim unless to
W IT N ESS
T R EAT M EN T prev ent further injury
.
2. D o not rem ove any evidence

YES

W ITN ESS F IR ST AID TR EAT M EN T

SH E C o ntact N:o
09-549 2430 / 2387 / 2419 / 2640
F irst A id er C o n tact :N o
W ITN ESS IN F OR M SH E U N IT
/ F IR ST AID ER En. Anuar : 013-6986946
En. H isham : 012-3058524
Pn. H afiz ah: 012-9848565

IF EM ER GEN C Y OC C U R A F T ER
NO N EED FU R TH ER OF F IC E H OU;RC ON T A C T U M P
EM ER GEN C Y R ESPON SE T EAM SEC U R IT Y A T09 – 549 1121
T R EAT M EN T
(ER T)

YES U M P Stu d en t H ealth U n it C o n tact: N o

09- 549 2539
EM ER GEN C Y R ESPON SE T EAM SEN D VIC T IM T O C LIN/IC
H OSPIT AL
(ER T) / W IT N ESS
H T A A C o ntact N: o
09-557 2222

SITE C OM M AN D ER
/ EM ER GEN C Y
EM ER GEN C Y OVER
C OOR D IN AT OR

END
Process Control & Instrumentation Laboratory BKF4791

UNI V E R SI T I M AL AY SI A P AH ANG
F A C U L T Y O F C H E M IC A L& N A T U R A L R E S O U R C E S
E N G IN E E R IN G

G A S L E A K A G E N O T I F I C A T I O N& R E S P O N S E
BY WHOM PROCESS FLOW INFORMATION

ST AR T

W IT N ESS D ET EC T GAS LEAKAGE

ALER T PER SON N EL IN AD JAC EN T

W ITN ESS AR EA

Po in t T o R ememb er :
W ITN ESS C U T OFF GAS SU PPLY F R OM
1 . Please do not handle gas leakage
SOU R C E
unless y ou w ear a com plete Personal
Protectiv e Equipm ent(PPE).
2 . If flam m able gas involv, edo not
operate electrical s w itc hes unles s to
NO T R AIN ED T O NO turn off electric equipm ent.
W ITN ESS H AN D LE GAS IN VOLVE IN JU R Y 3 . If gas leak ge is flam m able,
LEAKAGE extinguis h flam es and all other s ourc es
of ignition.
YES YES

R EF ER T O C SD S F OR R EF ER TO C SD S F OR AC TION
W ITN ESS AC T ION (F IR ST AID M EASU R ES PAR
)T
(AC C ID EN T AL R ELEASE
M EASU R ES PAR )T
SH E C o ntact N o
:
09-549 2430 / 2387 / 2419 / 2640
W ITN ESS IN FOR M SH E U N IT IN F OR M SH E U N IT
/ F IR ST AID ER
Fir st A i der C o ntact N: o
En. Anuar : 013-6986946
En. H is ham : 012-3058524
SIT E C OM M AN D ER/ AC TIVAT E EM ER GEN C Y Pn. H afizah: 012-9848565
EM ER GENC Y C OOR D I N AT OR R ESPON SE T EAM(ER T)
IF EM ER GEN C Y OC C U R A F T ER
OF FIC E H OU R; C ON T A C T U M P
EM ER GENC Y R ESPON SE TEAM SEC U R IT Y A T09 – 549 1121
F IR ST AID TR EAT M EN T
(ER T)

EM ER GENC Y R ESPON SE TEAM SEN D VIC T IM TO C LIN IC TOGET H ER

U M P Stu d en t H ealth U n it C on tact :N o
(ER T) / W IT N ESS W ITH C SD S
09- 549 2539

EM ER GENC Y R ESPON SE TEAM YES GAS LEAKAGE

(ER T) SEC U R ED

NO

SIT E C OM M AN D ER/ EM ER GEN C Y C ALL F IRE& R ESC U E FIR E & R ESC U E D EPT C ON TA C T N. O
D EPT GENER AL: 999
C OOR D IN ATOR
TAM AN T AS: 09-538 3704
KU AN T AN: 09- 513 5544
U PON T H E AR R IVAL F IR E
EM ER GENC Y R ESPON SE TEAM (ER T) & R ESC U E D EPT,
AN D FIR E& R ESC U E D EPT H AN D OVER ALL D U T IES
T O TH EM

GAS LEAKAGE SEC U R E

AN D F IR E& R ESC U E
F IR E& R ESC U E D EPT D EPT C ON FI R M
C ON D IT ION IS SAF E

SIT E C OM M AN D ER/ EM ER GEN C Y D EC LAR E EM ER GEN C Y OVER

C OOR D IN ATOR

END
Process Control & Instrumentation Laboratory BKF4791

UNI VE R SI T I M AL AY SI A P AH ANG

F A C U L TY O F C H E M IC A L& N A T U R A L R E S O U R C E S
E N G IN E E R IN G
E X P L O S I O N N O T I F I C A T I O N& R E S P O N S E
BY WHOM PROCESS FLOW INFORMATION

ST AR T

W IT N ESS
F OUN D EXPLOSION

SH OU T EXPLOSION!, EXPLOSION !,
W IT N ESS
BR EAK EM ER GEN C Y GLASS

F IN D SAF E LOC ATION& IN F OR M SH E SH E C ON T A CT N.O

W IT N ESS
U N IT 09-549 2430 / 2387 / 2419 / 2640
IF EM ERGEN C Y OC C U R A F TER
SIT E COM M AND ER/ EM ER GEN C Y AC T IVAT E EM ER GEN C Y R ESPON SE OF FIC E H OU R C ON TA C T U M P
C OOR D IN ATOR T EAM (ER T) SEC U R IT Y AT09 – 549 1121

U N D ER C ON T R OL
EM ER GENC Y R ESPON SE T EAM
ASSESS SIT U AT ION
(ER T)

EM ER GENC Y R ESPON SE T EAM NO BEYON D C ON TR OL

PU T OU T EXPLOSION
(ER T)

YES
F IR E & R ESC U E D EPT C ON TA C T N
. O
SIT E COM M AND ER/ EM ER GEN C Y
C ALL F IR E& R ESC U E D EPT GEN ER AL: 999
C OOR D IN ATOR
T AM AN T AS : 09-538 3704
KU AN T AN: 09-513 5544
EM ER GEN C Y R ESPON SE TEAM (ER T) U PON T H E AR R IVAL F IR&ER ESCU E
AN D F IR E& R ESC U E D EPT D EPT, H AN D OVER ALL D U T IES TO
T H EM

F IR E & R ESC U E D EPT EXPLOSION OVER AN D F IR&E

R ESC U E D EPT C ON FIR M BU ILD IN G IS
SAFE

SIT E COM M AND ER/ EM ER GEN C Y

C OOR D IN ATOR D EC LAR E EM ER GEN C Y OVER

END
 Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 1: DENSITY MEASUREMENT

OBJECTIVES

1. To study the fundamental principles (hydrostatic) of density measurement

2. To compare the density measurements by two different density transmitters of different
process applications and measurement techniques
3. To study the effect of pressure on the density measurement.

INTRODUCTION

Model DMS 212 is carried out in Model DLT912 Density Level Temperature Measurement / Site
Calibration Plant. Model DLT912 plant is a scale-down real INDUSTRIAL PROCESS PLANT
built on 5ft x 5ft steel platform, complete with its own dedicated control panel. The process
equipment and process instrumentation are real INDUSTRIAL PROCESS type. The plant is
constructed in accordance to industrial process plant standards and practices, with fail-safe
features. For example , the pump (P1) will be automatically switched off unless the liquid level is
above a predetermined low level limit detected by a level switch LS. The process flowrates are at
COMMERCIAL PRODUCTION flowrates, using pipes and not tubings.

PLANT DESCRIPTION

PART A: PLANT INSTRUMENTATION

1. Tank T1
It is a stainless steel cylindrical vessel with a pressure relief valve (PRV), vent (V), overflow and
manual discharge valves i.e. gate valve and globe valve located at the bottom of tank T1. A
pressure gauge (PG) and temperature gauge (TG1) are also mounted at tank T1. Tank T1 can be
operated as an open or closed tank by pressuring with compressed air. A Different Pressure /
Density / Level Transmitter (DT1/LT1) is mounted to measure the density of the liquid or level
in tank T1. A sight glass with millimeter scale (LG1) is also provided to observe the tank level.
Process Control & Instrumentation Laboratory BKF4791

2. Tank T2
It is a rectangular tank made of plastic transparent material for internal visibility. A Differential
Pressure / Density / Level Transmitter (DT2/LT2) of bubble tube arrangement is mounted to
measure the density of the liquid or level in tank T2. A temperature gauge (TG2) is also mounted
at tank T2.

3. Tank T3
It is a stainless steel rectangular tank mounted at the platform (below tank T1) with bottom drain
and overflow drain. The water in tank T3 is pumped to tank T1 or T2 using a pump (P1),
complete with its pump suction valve, pump discharge valves (including MV1), pump by-pass
valve (BV1) and pressure relief valve (PRV1). The water in the tank can be heated but the water
temperature is controlled using a RTD element (TE1), a temperature digital indicator TIC1 with
an ON/OFF alarm, set at say 60°C maximum. If the water temperature in the tank exceeds its
high temperature limit, set at temperature ON/OFF controller TIC2, the annunciator TAH will be
activated. A level switch (LS) will automatically switch off the pump P1 if the water is below the
predetermined low-level limit. A stirrer is provided for better mixing in tank T3. The experiment
can also be conducted using sugar water instead of water.

PART B: FIELD INSTRUMENTATION

At Tank T1:
• PG : Pressure Gauge
• TG1 : Temperature Gauge, bimetal, 0-100°C.
• LG1 : Sight Glass with millimeter scale.
• DT1 : Differential Pressure / Density transmitter.
• PRV : Pressure Relief Valve
• AR1 :Air supply regulator to pressurize tank T1.

At Tank T2:
• TG2 : Temperature Gauge bimetal 0-100°C
• LG2 : Level millimeter scale
• DT2 : Differential Pressure / Density transmitter
Process Control & Instrumentation Laboratory BKF4791

Immersed in the tank T3 are the following:

• TE1 : RTD (PT100) element.
• TE2 : Type K Thermocouple element.
• TG : Temperature Gauge, bimetal, 0-100°C
• LS : Level Switch
• - : Stirrer

PART C: PANEL INSTRUMENTATION

Mounted at the control panel are the following:

• DIA1 : Digital Density Indicator, from DT1, with ON/OFF alarm to Annunciator
DAL.
Actual density (S.G.) reading = Reading in DIA1, % x its maximum
calibrated density (S.G.)
• DI2 : Digital Density Indicator, from DT2.
: Actual density (S.G.) reading = Reading in DI2, % x its maximum
calibrated density (S.G.)
• TIC1 : Digital Temperature Indicator, RTD (PT100) input with ON/OFF alarm
to control the tank Heaters ON/OFF
• TIC2 : Digital Temperature Indicator, Type K Thermocouple input, from TE2,
with ON/OFF alarm to Annuncator TAH
• DLTR : Recorder with four analog pen/bar graph display, as well as display in
engineering units. The ANALOG displays are in % of their maximum upper
range values.
*Red pen (Channel 1) :DT1, 0-100%
*Green pen (Channel 2) :DT2, 0-100%
*Blue pen(Channel 3) :TE1/TIC1, 0-100°C
*Purple pen (Channel 4) :TE2/TIC2, 0-100°C

* An external selector switch is provided to select either LT1/DT1 and LT2/DT2

or TIT3 and TIT4 to be recorded by the Red and Green pens or displayed at
channel 1 and 2, in % of their respective upper range values.
Process Control & Instrumentation Laboratory BKF4791

: ANALOG display in the form of horizontal cloured bar or pen-chart

paper are to be read as follows:-
: Analog display x Maximum (calibrated) = Actual reading,
in % range values, engineering, engineering units
units
:Digital display in engineering units are 0-100°C for Channels 1 and 2, and 0-
100°C for Channels 3 and 4.
: The chart drive is set for fast speed (500mm/h).
The recorder chart drive is started or stopped by pressing the RCD button
with the front swing cover opened

• Annunciators (TAH, DAL/LAL) with Test and Acknowledge buttons.

TAH : The liquid temperature in tank T3, as measured by the temperature
element TE2 (thermocouple type-K) exceeds the preset High Limit of say 60°C,
set at TIC2
DAL : The density of liquid in tank T1, as measured by the Density Transmitter
DT1 is below its Low limit, set at DIA1

A buzzer will come on and the respective alarm window will lit up when the above abnormal
or alarm conditions occur. Pressing the Acknowledge button will silence the buzzer sound. The
dedicated alarm window remains lit as long as its process variable is still in the alarm condition.
The alarm window light will go off when the process variable is restored to normal.
The Test button is to test if the Annunciator alarm window light is working.

PART D: MEASUREMENT / INSTRUMENTATION:

DT1 : Differential Pressure / Density transmitter, diaphragm-seals

DT2 : Differential Pressure / Density transmitter , bubble tube arrangement
 Process Control & Instrumentation Laboratory BKF4791

PROCEDURES

1. Fill up water in tank T3 to the marked level. Make sure its drain valve is fully shut.
2. Make sure there is air supply connected and available in the Lab. Do not adjust the air
regulators.
3. At the front panel, switch ON the main power supply. The panel instruments are all lit up.
Make sure the heaters, Pump (P1) and stirrer are switch OFF, from the front panel.
4. Check that the pump suction valve is fully open. The pump discharge valve (MV1) is one
turn open.
5. Open one turn pump by-pass valve (BV1). Let this BV1 open throughout the experiment
for better mixing. If BV1 has a hose connected to it, make sure it is discharge back to the tank.
6. Decide on which tank (T1 or T2) to be operated for the density measurement, say tank
T1. Thus shut fully MV2 and the interconnecting manual valve MV4. Open one turn MV3.
7. At tank T1, make sure its top vent (V) and overflow valve are fully open. Also check that
its manual discharge valve i.e. bottom GLOBE valve is fully open but its gate valve is fully close.
8. Locate the air inlet manual isolation valve located next to AR located at the top tank of
tank T1 and make sure its valve handle is 90° to the air supply inlet tubing. The top space of tank
T1 is at atmospheric pressure as monitored by the pressure gauge (PG).
9. During the experiment, if the water level in Tank T3 is below the preset low level limit,
the level switch (LS) will automatically switch off the Pump (P1). In this case, top up more water
into tank T3 from the external water supply.

EXPERIMENT: DENSITY MEASUREMENT (AMBIENT WATER)

1-9. Please refer to the above Start -Up Procedures.
10. Start Pump (P1) by pressing the green pushbutton at the front panel.
11. Switch ON the stirrer from the front panel. Check that it is turning, otherwise turn
clockwise the knob at air speed controller located next to the stirrer.
12. Do not switch on the Heaters yet.
13. At the sight glass with millimeter scale (LG1), observe the level in tank T1 rising until it
overflows. Let the water circulate throughout tank T1 and tank T3 until the temperature
gauge (TG1) reading is close to the reading at the temperature indicator (T1C1) at the
front panel.
14. Shut the manual discharge GLOBE valve at tank T1.
15. At the front panel, switch off the pump (P1)
 Process Control & Instrumentation Laboratory BKF4791

RUN I
16. RUN I is done as follows:
a) Scoop out about 500ml of water from T3 and pour into measuring cylinder. Read
the Specific Gravity of water from tank T3 using the hydrometer provided. Pour
the water back into T3.
b) Note that, three consecutive (3) sets of readings are taken for every RUN.
Each set of density readings consists of two readings to be taken simultaneously:
• Actual Density (S.G) read from density indicator (DIA1) i.e. Reading in DIA1, % x
its max calibrated S.G.
• Actual temperature in tank T1 read from temperature gauge (TG1).
Take down the readings in TABLE 1A, RUN I.

RUN II
17. Continue with RUN II as follows:
a) Set tank T1 to close tank i.e. top space of tank T1 is pressurized.
b) Shut fully the overflow valve and vent (V) valve.
c) Shut fully the bottom gate and globe valves.
d) Let air flow into the top space of tank T1 by turning the air inlet manual
isolation valve handle parallel to the air supply inlet tubing.
Take down readings in RUN II. Three consecutive (3) sets of readings are taken.
18. Set tank T1 back to open tank.
a) Shut the air inlet manual isolation valve. Its handle should be 90° to the air supply
inlet tubing.
b) Then open fully the overflow valve and vent (V) valve.
19. The next test is to use DT1 to verify the density Hydrostatic principle that the density
is proportional to the pressure difference between two elevations in a tank i.e.
Density, ρ = DP where DP is the pressure difference
g H
a) Take the density (S.G) and pressure difference (DP) readings as follows:
- Density (S.G) read from density indicator (DIA1) i.e:
Reading in DIA1, % x its max calibrated density (S.G)

- Pressure difference reading in mmH2O read at the density transmitter DT1.

 Process Control & Instrumentation Laboratory BKF4791

As this pressure difference reading (DP) has not been processed or filtered yet by
the DP transmitter, it is noisy (fluctuating). Take a nominal mean or average value
for DP.
b) Refer to the RESULT section for a simple calculation to verify that
DP
ρ=
gh

RUN III

20. Verify the density measured from DT1 with another density measurement from DT2
located at tank T2. Note that both DT1 and DT2 are of different measurement application.
a) Open the connecting manual valve MV4.
b) Starts pump (P1). Note that the stirrer is still on.
c) Let the water circulate throughout tank T1, T2 and tank T3 until the temperature
gauge (TG2) reading is close to the reading at the temperature indicator (TIC 1) at the front
panel.
d) Stop pump (P1)
Notice the bubbles flowing out from the copper tube. Otherwise quickly check that the air
supply is connected and adjusts AR2 until bubbles is flowing. To measure density
accurately, always allow the liquid to reach its overflow pipe but not more.
e) Note that, three consecutive (3) sets of readings are taken for every RUN.
Each set of density readings consists of two readings to be taken simultaneously:
• Density (S.G) read from density indicator (DI2) i.e. Reading in DI2, % x
its max calibrated density (S.G)
• Actual temperature in tank T2 read from temperature gauge (TG2)
f) Take down the readings in TABLE 1A, RUN III.
g) Drain out all the water in tank T2 by opening its bottom drain valve. Shut the
connecting manual valve MV4. Drain out all the water in tank T1 by opening its bottom GLOBE
valve
21. Repeat the experiment procedure for sugar.
RESULT

TABLE 1A:DENSITY MEASUREMENT (AMBIENT WATER)

MEDIUM : WATER
HEATER :OFF
Process Control & Instrumentation Laboratory BKF4791

SPECIFIC GRAVITTY (S.G) read from hydrometer : _________(use hydrometer with scale
0.900-1.000)
RUN I: OPEN TANK T1 Set 1 Set 2 Set 3 Average
A Temperature (TG1),°C
B Actual Density (DIA1),%
Actual Density (S.G)
C Deviation with hydrometer
D Calculated Density,kg/m3
E Density from table, kg/m3
F Deviation D from E, kg/m3

RUN II: CLOSE TANK T1 Set 1 Set 2 Set 3 Average

A Temperature (TG1),°C
B Actual Density (DIA1),%
Actual Density (S.G)
C Deviation with hydrometer
D Calculated Density,kg/m3
E Density from table, kg/m3
F Deviation D from E, kg/m3

RUN III: OPEN TANK T2 Set 1 Set 2 Set 3 Average

A Temperature (TG2),°C
B Actual Density (DI2),%
Actual Density (S.G)
C Deviation with hydrometer
D Calculated Density,kg/m3
E Density from table, kg/m3
F Deviation D from E, kg/m3

TABLE 1B:DENSITY MEASUREMENT (SUGAR)

MEDIUM : SUGAR
HEATER :OFF
SPECIFIC GRAVITTY (S.G) read from hydrometer : _________(use hydrometer with scale
0.900-1.000)

RUN I: OPEN TANK T1 Set 1 Set 2 Set 3 Average

A Temperature (TG1),°C
B Actual Density (DIA1),%
Actual Density (S.G)
C Deviation with hydrometer
D Calculated Density,kg/m3
E Density from table, kg/m3
F Deviation D from E, kg/m3
 Process Control & Instrumentation Laboratory BKF4791

RUN II: CLOSE TANK T1 Set 1 Set 2 Set 3 Average

A Temperature (TG1),°C
B Actual Density (DIA1),%
Actual Density (S.G)
C Deviation with hydrometer
D Calculated Density,kg/m3
E Density from table, kg/m3
F Deviation D from E, kg/m3

RUN III: OPEN TANK T2 Set 1 Set 2 Set 3 Average

A Temperature (TG2),°C
B Actual Density (DI2),%
Actual Density (S.G)
C Deviation with hydrometer
D Calculated Density,kg/m3
E Density from table, kg/m3
F Deviation D from E, kg/m3

Remarks:
A: Read from the Temperature Gauge (TG1,TG2) mounted at tank T1 or T2. Take the average
value for further calculation.
B: Read from the Digital Density Indicator (DIA1 or DI2). Take the average value for further
calculation.
Actual Measured Density (S.G) at T1 = Reading in DIA1,% x 1.182
Actual Measured Density (S.G) at T2 = Reading in DI2,% x 1.182
C: Calculate from equation Deviation = | (B-hydrometer) |
D: Calculate from equation
ρw at operating temperature TG1 or TG2 = S.G. x ρw at reference temperature 15.6°C
Note: Density of water at 15.6°C i.e. ρw,ref =999.007 kg/m3
E: Read from the Table 2-28, Perry’s VII at temperature (TG1, TG2)
F: Calculate from equation Deviation = | (D-E) |

QUESTIONS

DP
1. VERIFICATION OF THE LEVEL/HYDROSTATIC PRINCIPLE, ρ = gh

• The following are the test readings taken at Procedure 19, Experiment 1A and 1B:

a) Density (S.G.), at DIA1 : __________ % x 1.182 = __________(S.G.)

Process Control & Instrumentation Laboratory BKF4791

100 = __________kg/m3
b) Pressure difference, DP at the density transmitter DT1 : ____________mmH2O.
Note that the pressure difference DP displayed at DT1 is the pressure difference between
the top and bottom tapping points and has NOT been processed yet (i.e. has not been
filtered yet). The display may be fluctuating due to the turbulence inside the pipeline, thus
take a nominal mean or average reading for DP.

These two readings shall be used to verify the density hydrostatic principle,
DP
ρ= as follows:
gh

The Density Transmitter DT1 has been calibrated as follows:

Pressure Difference (DP) Output Transmission Signal
-557mmH2O 4mA, equivalent to density (S.G.) 0
148.6 mmH2O 20mA, equivalent to the full-scale density (S.G.) of
1.182

DP
Since ρ = gh

Say at maximum SG= 1.182, i.e. ρ = 1.182 x 999.007kg/m3 = 1180.826 kg/m3

Ρref at 15.6°C = 999.007 kg/m3
1180.826 kg/m3 = (148.6 +557) mmH2O
gh
gh = 0.59755
SG = _________DP ________
0.59755(999.007)
∴SG = (Measured DP + 557), mmH2O “the density equation for DT1”
596.95

2. Use the pressure difference (DP) reading question 1(b) and substitute into “density
equation for DTI”. Calculate ρ or S.G., based on this pressure difference (DP) reading. Is
Process Control & Instrumentation Laboratory BKF4791

the calculated S.G. equal to the S.G. reading taken at the above (a)? Is the calculated ρ in
kg/m3 equal to the density (ρ) reading taken at the above 1(a)?
3. Explain the function of globe valve and gate valve located at the bottom of tank T1? What
is the significant both of the valves compared to other type of valve?
4. The calculated density is based on pressure difference (DP) reading. In your opinion, how
far the accuracy of calculated density? Suggest the way to improve the accuracy?
5. Describe the important of density measurement compared to temperature or flowrate
measurement in term of chemical process?
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 2: MEASUREMENT AND ANALYSIS OF LIQUID FLOW

SYSTEM

Objective: To study the volumetric Flow Measurement using the Variable Area (FI31),
Orifice / DP (FE31/FT31) and Electromagnetic flow meters (FT32)

Flow PATH :T32 FI31 FT31 LCV31 T31 FT32 T32

Special Remark: Theoretically, FI31 = FE31/FT31 = FT32, if the Level at T31 is controlled.

START-UP CHECK LIST AND PRELIMINARY EXERCISE

Get familiar with the equipment, instrumentation, piping system and various manual valves. The
following preliminary procedures are recommended for familiarization.
1) The tank T32 should be filled with water up to almost the level of its overflow drain pipe.
Excess water will overflow into the common drain. Check that the Instrument Air Supply
(IAS) is connected (32psi).
2) Locate the pump :
Suction Valve fully OPEN
At P32 Discharge valve fully OPEN
By-pass valve BV32 fully OPEN
Suction Valve fully OPEN
At P31
Both Discharge valve fully OPEN
At T31 Both Gate and Globe valve fully SHUT

Check that the two adjacent manual valves at the control valve LCV31 are fully open
while the by-pass valve fully shut.
Make sure the T32 Drain valve is fully shut.
3) Turn ON the power supply at the front of the cubicle, to provide power to the pumps,
Recorder and Controller.
4) Get the RECORDER (LFR31) ready as follows but do not start the pump yet.
• The Recorder (LFR31) is ON (open it front swing cover and locate its ON/OFF push –
in type switch at the bottom right side below the push button keyboard. Press in to
switch ON )
• When the ‘RCD’ display is lit up at the Recorder, its chart drive is running. The
Recorder chart drive can be switched ON/OFF from the ‘RCD’ pushbutton at the front
of the Recorder (with its front swing cover opened).
Process Control & Instrumentation Laboratory BKF4791

• Learn how to access data from the Recorder (LFR31). In particular, note the digital
indication of the various flow rates.
- the pen trend record is analog 0-100% of 3m³/h
- the indicator is in engineering units, 0 to 3.0m³/h for flow rates. Flow
rates (in m³/h) are displayed at Channels 2 &3. Channel 1 is for Level
(0 to 800mm)
5) Get the Controller (LIC31) ready as follows:
• The Controller (LIC31) should be in MANUAL (M) mode with its control output
MV=100%. Check at LCV31 that it is fully open.
• Access its PID1 page and set PB1 = 10%, TI1 = 15 sec, TD1 = 0 sec, set point
SV1 = 400mm
• Make sure the Controller selector switch is at Position 1: LIC31.
6) Always make sure the pump P32 suction valve and by-pass valve BV32 are always
opened before starting the pump.
7) Start the pump P32. When the pump is started ad flow is verified (check return water
discharge back into the tank via the appropriate pipelines), shut gradually the pump
manual by-pass valve BV32 until FI31 reads about 2 m³/h.
8) When the Level at T31 is near its Set point 400mm (see at PV), start pump P31 and
switch the controller LIC31 to Auto (A) mode.
9) To vary the flow rate, regulate one of the discharge valve at P31 and note the flow rates at
the Recorder display at Channel 2 & 3 and FI31 as per TABLE 1A
Is FI31 = FT31 = FT32 approximately (when the level in tank T31 is controlled)?
Otherwise there is flow ‘leakage’ or ‘by-pass’, OR the instrumentation in inaccurate and
requires calibration check.
10) Stop the pumps P32 and P31.

EXPERIMENT PROCEDURE
1) Please refer to the Section ‘Start-up Check List and Preliminary Exercise’ and follow
the procedures from 1 to 10.
2) Locate the various flow meters and learn how to read the volumetric flow rates as
follows:
FI31 :Variable area flow meter: Read directly at the flow meter FI31 (m³/h) near the
pump discharge.
Process Control & Instrumentation Laboratory BKF4791

FE31 / FT31 : Orifice-Differential Pressure: Read LFR31,Green Pen (%) (DP) flow
meter and Channel 2 (m³/h)
FT32 : Electromagnetic flow meter :Read at LFR31, Blue Pen (%) & Channel 3(m³/h).
Note the result in TABLE 1A (see RESULT SECTION). Also read the flow rate
indicator LOCALLY at the flow meter FT32 and compare it with Channel 3 at the
Recorder LFR31. They should be similar.
3) The next test is to use FE31/FT31 to verify the Orifice/DP flow meter principle that the
flow rate is proportional to the square root of the pressure drop i.e.
Volumetric Flowrate, Fv = k¹√h, where h is the pressure drop across the Orifice plate
FE31 measured by FT31
- Open the pump P31 manual discharge valve fully.
- Take the flowrate and pressure drop reading as follows:
a) Flowrate (Fv) in m³/h at the Recorder Channel 2.
b) Orifice plate (FE31) pressure drop, h, in mmH2O at the DP transmitter FT31.
As this pressure drop reading (h) has not been processed or filtered yet by the DP
transmitter, it is noisy (fluctuating). Take a nominal mean or average value for h.
- Refer to IV at the RESULT section for a simple calculation to verify that;
Fv = k¹√h.
4) Reduce the flow rate by gradually shutting the pump P31 manual discharge valve (locate
before the strainer) so that the flow rate (read FT32) is reduced. Note the results in
TABLE 1A.
5) Repeat Procedure 4 at two (2) other flow rates at approximately 1.0 m³/h (33.3%) and
0.8 m³/h (26.71%) of the full scale flow rate of 3 m³/h.
See Procedure 2, 3 and 4. Record the reading in TABLE 1A similarly.
Repeat procedures with increasing flow rates and record the reading in TABLE 1A.
6) Experiment completed. SHUT DOWN the plant:
• Switch off the pump P31, P32 at the front panel/Cubicle.
• Switch off the Recorder (LFR31) chart drive by pressing its RCD pushbutton with its
swing cover opened.
• Switch the Controller LIC31 to Manual (M) mode with its output MV = 0%. Make
sure the Selector Switch is at position 1:LIC31.
• Open fully the pump manual by-pass valve BV32.
• Switch off the main power supply switch at the front of the cubicle.
 Process Control & Instrumentation Laboratory BKF4791

• Shut fully the manual valve for instrument air supply (IAS). No need to regulate its air
regulator.
RESULT
I. Note the volumetric flow rate readings in TABLE 1A below at four (4) decreasing and four (4)
increasing flow rates.
Regulate the manual discharge valves at P31 to desired flow rate. Shut one of the pump manual
discharge valve (P31) to reduce flow further.
II. Reading in % and Engineering Units at Recorder LFR31 (Channel 2, 3)
% Reading x Max. Calibrated Range value = Reading in engineering units
% Reading x 3 m³/h = reading in m³/h
III. Theoretically, FI31 = FE31/FT31 = FT32, if Level is kept constant
Using FT31 as the reference, note down the various flow rate reading deviations from FI31,
FT32 using the last Column in TABLE 1A.
For FI31 Deviation % = FI31 – FT31 x 100%
FT31
For FT32 Deviation % = FT32 – FT31 x 100%
FT31
IV. Verification of the Orifice / DP flowmeter principle, Fv = k¹√h.
• The following are the test readings taken at Procedure 5:
a) Flow rate, Fv at the Recorder Channel 2:____________m³/h.
b) Pressure drop, h at the orifice/DP flowmeter FT31 : ___________mmH2O.
Note that the pressure drop, h displayed at FT31 is the pressure drop across the orifice
plate FE31 and has NOT been processed yet. As the display is fluctuating due to the
turbulence inside the pipeline, take a nominal mean or average reading for h.
There for:

Fv (m³/Hr) = 0.03√h (mmH2O)

the flowrate equation for FE31/FT31

Use the pressure drop (h) reading mentioned at the above IV (b) and substitute into the
flowrate equation for Fe31/FT31. Calculate Fv in m³/h, based on this pressure drop (h)
reading.
* Is the calculated Fv in m³/h equal to the Flowrate Fv reading taken at above IV (a)?
Process Control & Instrumentation Laboratory BKF4791

TABLE 1A
VOLUMECTRIC FLOW RATE READING Calculate the %
At FI31 At the Recorder LFR31, panel
At FT31 local indicator Deviation from
FE31/FT31 FT32
FI31
Flow Green Pen Channel 2 Blue Pen Channel 3 H Fv = k¹√h Compare PT31
Reading
rate with
no.
m³/h Channel 2
m³/h % m³/h % m³/h mmH2O m³/h For FI31 For FT32
SAME
OR NOT
1 1.2
2 1.0
3 0.8
4 0.5
5 1.5
6
7
8

QUESTIONS
1. Based on volumetric flow rate reading, discuss comparison data Channel 2 FE31/FT31 and at FT31 local indicator? Explain why
the data is different?
2. Based on % deviation data FI31 and FT32, what is your observation? Suggest a solution to minimize the deviation?
Give a brief conclusion for overall volumetric flow rate reading.
 Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 3: MEASUREMENT AND CONTROL OF AIR FLOW SYSTEM

PLANT MODEL : AFPT921 Air Flow Pressure Temperature Process

Control Training System

OBJECTIVE
Part 1
1. To study gas volumetric flow rate (Fv) measurement using the orifice plate-pressure drop (h)
method, assuming the gas pressure/temperature (i.e. density) remain unchanged and at the
values used in the sizing of the orifice.
2. To study gas mass flow rate (Fm) measurement using the orifice plate-pressure drop (h)
method, using the Perfect Gas Law to compute the gas density from the flowing pressure
and temperature.

Part 2
1. To study gas mass flow rate (Fm) control using PID control mode.

INTRODUCTION
Experiment system AFMS211 is carried out in Model AFPT921 Gas Flow Pressure Temperature
Process Control Training System. This Model AFPT921 plant is a scale-down Real Industrial
Process Plant built on 5ft X 10ft steel platform, complete with its own dedicated control panel. The
process equipment and process instrumentation are real Industrial Process type. The plant is
constructed in accordance to industrial process plant standard and practices, with fail-safe features.
For example, the air heater cannot be turned ON unless there is enough air flow in the pipeline. The
process flow rates are at COMMERCIAL PRODUCTION flow rates, using pipes and not tubings.

PLANT DESCRIPTION
PART 1: INSTRUMENTATION
1. Pipelines PL1
a. This is the ½” process pipeline connecting the air heater and the cooling vessel C90
in Model AFPT921. Pipeline is also lagged.
2. Field Instrumentation
At the process pipeline PL1 are:
a. FT91 : multivariable air mass flow transmitter, with
i. Integral orifice plate FE91
Process Control & Instrumentation Laboratory BKF4791

ii. Differential Pressure transmitter DPT911

iii. Absolute pressure transmitter PT911
iv. RTD/Temperature Transmitter (TE911/TT911)
b. FI911 : Variable Area Flow meter (or Rotameter)
The calibration Temperature and Pressure is tagged at the flow meter.
Panel instrumentation
Mounted at the control panel are the following:
Air heater ON/OFF switch
TIC91 : Microprocessor-based Panel Controller (Multifunction) for Temperature Controls.
FIC91 : Microprocessor-based Panel Controller (Programmable) for Flow Control
FPTR91: Recorder with four analog pen/bar graph display, as well as display in engineering units.
However, only the green pen/Channel 2 and purple pen/Channel 4 shall be used for this experiment.
The analog displays are in % of their maximum upper range values.
Green pen (Channel 2) : Fm, 0-50 kg/h
Purple pen (Channel 4) : ρ f, % of 0-6.165 kg/m3

: ANALOG display in the form of horizontal coloured bar or pen-chart paper is to be

read as follows:-
Analog display X Maximum (calibrated) = Actual reading
in % range values, engineering engineering
units units

: Digital display in engineering unit is 0-50 kg/h for Channels 2

: The chart drive is set for fast speed (500mm/h).
The recorder chart drive is started or stopped by pressing the RCD button
with the front swing cover opened
e. Annunciators (TAH911, FAL90, FAL91) with Test and Acknowledge buttons.
TAH911 : The process air temperature in pipeline PL1, as measured by the
RTD sensor/transmitter TE911/TT911exceeds the preset High Limit
of say 200 oC.
FAL90 : The flow rates as detected by FS90 are below its Low limit.
FAL91 : The mass flow rate is below its Low limit.
A buzzer will come on and the respective alarm window will lit up when the above
abnormal or alarm condition occur. Pressing the Acknowledge button will silence
the buzzer sound. The dedicated alarm window remains lit as long as its process
variable is still in the alarm condition. The alarm window light will go off when the
Process Control & Instrumentation Laboratory BKF4791

process variable is restored to normal. The test button is to test if the Annunciator
alarm window light is working.

INSTRUMENTATION SYSTEM
1. FIC91/PIC911/FIC90: Microprocessor-based Panel Controller (Programmable).
Display h measurement input in % at the I/O as X4.
X4 : h, from DPT911, % of 0-10,000mm H2O
: compute Fv = k1 √ h and display at PT Register as P15, in m3/h
2. FIC91/PIC911/FIC90: Microprocessor-based Panel Controller (Programmable).
Display measurement inputs in % at the I/O Data as follows:
X1 : Computed Fm, from FT91, % of 0-50 kg/h
X2 : Temperature (T), from TT911, % of 0-200 oC.
X3 : Absolute pressure (P), from PT911, % of 0-70 psia
X4 : Differential Pressure (h), from DPT911, % of 0-10,000mm H2O
PV1 : Computed Fm, from FT91, kg/h

PROCESS VARIABLES
1. : Volumetric flow rate, Fv, m3/h = 0.237 √ h (mmH2O), P and T uncompensated
: Volumetric flow rate at actual flowing condition
Fvf, m3/h = 0.0703 √h (mmH2O) √T(K) , P and T uncompensated
√P (psia)

: Volumetric flow rate at Normal condition (1 atm, 0 oC)

Fvb, Nm3/h = 1.305 √h (mmH2O) √P (psia) , P and T uncompensated
√T(K)

2. Mass Flow rate, Fm, kg/h = 1.68 √h (mmH2O) √P (psia)

8
√T(K)

PART 2: CONTROL SYSTEM

The PID mass flow control system consists of the following in feedback:
Fm-FIC91-FCY91/PP/FCV91

Where
 Process Control & Instrumentation Laboratory BKF4791

Fm, kg/h = km √(hP) Computed in Multivariable Flow Transmitter FT91

√T

FIC91 : Flow PID Controller

FCY91: Current-to-Air Converter
PP : Pneumatic Positioner, with By-pass
FCV91: Flow Control Valve, Air-to-Close (ATC)
FPTR91: 4-pen Recorder
• Green pen (Channel 2) : Fm, Range: 0 to 50 kg/h

PROCESS VARIABLES
Mass flow rate Fm under PID control by FIC91.
Display at recorder: Green pen (Channel 2)

SPECIAL REMARK
The 1-2 Position Selector Switch for controller FIC91/PIC911/FIC90 must be in Position 1, for
FIC91 controller output MV1 to throttle FCV91.

EXPERIMENTAL PROCEDURES
PART 1
1. Switch ON the main power supply. Check that the Process Air and Instrument Air Supply
(IAS) are available at the lab.
2. Make sure the ‘Process Air Inlet’ switch is at its ‘OPEN’ position, and ‘Air Heater’ switch is
at its ‘OFF’ position, at this instance.
3. Shut pipeline PLII by shutting the manual valve (MVII) just before FCV90 so that the air
can only flow via the mass flow meter FT91, in PLI. Remember to re-open it after this experiment
1.
4. Check that the Pneumatic Positioner (PP) of the control valve FCV91 is connected and not
by-passed. With the PID flow controller FIC91 in manual (M) mode, set FCV91 at 100% open
with its controller output MV=-6.3%. For confirmation, check the stem indicator of control valve
FCV91. Note that FCV91 is Air-To-Close (ATC)
5. Check that the Pneumatic Positioner (PP) of the control valve PCV91 is connected and not
by-passed. With the PID flow controller FIC91 in manual (M) mode, set PCV91 at 100% open
with its controller output MV=-6.3%. For confirmation, check the stem indicator of control valve
PCV91. Note that PCV91 is Air-To-Close (ATC)
 Process Control & Instrumentation Laboratory BKF4791

6. Set-up the maximum Pressure and Flow rate of the Model Plant. Please follow these
procedures.
a. Set the maximum process pressure.
Check that compressed air is available as process air and is connected to the Model
Plant at the Air Regulator AR90 (Check that it is upstream process air supply manual
valve (PASV) is fully opened). With the manual downstream valve MV90A fully
shut, set the pressure at AR90 to the pressure indicated. Then open MV90A by 1
turn and shut again. Recheck that the pressure at AR90 is correctly set. Once AR90
is set, it need no further adjustment.

b. Set the maximum process air flow rate

To set the maximum process flow rate, adjust MV90A at the process inlet so that
PVI (i.e. Fm) at FIC91 reads from 40 to 50 kg/h. Note that AR90 is used to set the
maximum pressure and MV90A is used to set the maximum flow rate. Once AR90
and MV90A are set, they need no further adjustment.
7. Concentrate on the flow PID controller FIC91 and the recorder FPTR91 and learn to access
and read the following data shown in the table. Also note the variable area flow meter FI911.

CONTROLLER: FIC911/PIC911/FIC90 RECORDER

FIC91: PT REMARKS
FIC91: I/O DATA FPTR91
REGISTER
Case 1 h is from FE91/DPT911
- Fv=K1√h is computed in
X4: h, % of 0-10,000 mmH2O P15:Fv FIC91
Case 11
Fm=Km √(hP)
√T
X1: Air Mass Flow (Fm), % of - -
Computed in FT91
0-50 kg/h
From TE911/TT911

X2: Air Temperature (T), % of - -

O
From PT911
0-200 C

From DPT911
X3: Air Absolute Pressure (P), - -
% of 0-70 psia

X4: h, 0-10,000 mmH2O - -

Others

See above X1,X2,X3,X4 P16: Fvf Fvf = Kvf √(hT)

 Process Control & Instrumentation Laboratory BKF4791

√P
P17: Fvb Fvf = Kvf √(hP)
√T
P18: ρ f ρ f=Fm/Fvf

P15,P16,P17,P18 are
computed in FIC91
FIC91: main face plate
PV1: Fm (kg/h) Green Pen Fm is computed in FT91
-
Channel 2

Note: X1,X2,X3,X4 are in % and are at the I/O Data of FIC91/PIC91/FIC90

P15,P16,P17,P18 are at the PT register of FIC91/PIC91/FIC90

8. Both the following temperature and pressure are to be changed as the experiment progresses,
to get various air flow rates, flowing air temperature (TT911) and pressure (PT911). Refer
to the result section to see the datas required of this experiment. Get ready to collect the
reading for column I, II and III.

PART 2
1. Please refer to the section “START-UP CHECK LIST AND PRELIMINARY
EXERCISES”. (1-14)
2. Please refer to Experiment No. 1 and follow the Procedure 1-6.
3. Concentrate on the unit panel controller FIC91/PIC911/FIC90 in particular FIC91.
4. With FIC91 still in Manual (M) mode, adjust its set point SV1 to 30 kg/h. Access the PID
parameters of FIC91 and set the following first (I) trial PID values:

First (I) trial PID values for FIC91

PB1= 200%
TI1 = 6 secs
TD1 = 0 secs
5. Check that recorder FPTR91 is at fast chart speed (i.e. 500 mm/h) on the occasional print-
out on the recorder chart. If the recorder chart drive has been preset at 500 mm/h but has
been stopped temporarily, press the “RCD” button at the front of the recorder with its swing
cover opened.
6. Transfer FIC91 to Auto (A) mode and watch the recorder response until the flow Fm (Green
Pen) is fairly steady at its set point SV1 to within ± 0.1 kg/h. Introduce a sharp pulse load
disturbance by quickly opening by one turn and then shutting fully the manual by-pass
valve around FCV91. Remember that this by-pass valve must be always shut.
Process Control & Instrumentation Laboratory BKF4791

7. Repeat with a second (II) and third (III) set of trial values, using the same sharp pulse load
disturbance as in procedure 6. Flow process is generally high gain and oscillatory and will
require a higher PB% (low gain) controller for damping. Too large PB% however slow
down the response and its recovery to the set point SV.

First (II) trial PID values for FIC91 First (III) trial PID values for FIC91
PB1= 100% PB1= 150%
TI1 = 6 sec TI1 = 10 sec
TD1 = 0 sec TD1 = 0 sec

The recorder Green pen records the flow (Fm) in %, for example 30 kg/h is 60% of 50 kg/h.
Note down the corresponding PID values and set point on the chart paper beside its chart
trend response.
8. The air mass flow control experiment is now completed. Transfer FIC91 to manual (M)
mode with its MV1=-6.3% for maximum air mass flow.

RESULT

Table 1
INSTRUMENT CONTROLLER
READINGS FIC911/PIC911/FIC90 I** II** III**
At the PANEL I/O Data
FT91, Fm X1*, % of 0-50 kg/h kg/h kg/h kg/h

TT911, T X2*, % of 0-200 OC o

C o
C o
C
K K K
PT911, P X3*, % of 0-70 psia psia psia psia

DPT911, h X4*, % of 0- mmH2O mmH2O mmH2O

10,000mmH2O

PT Register
Fv P15*, m3/h m3/h m3/h m3/h
Fvf P16*, m3/h m3/h m3/h m3/h
Fvb P17*, Nm3/h Nm3/h Nm3/h Nm3/h
ρ f P18*, kg/m3 kg/m3 kg/m3 kg/m3
 Process Control & Instrumentation Laboratory BKF4791

Main Face Plate

Fm PV1*, kg/h kg/h kg/h kg/h

Recorder FPTR91
Recorder Fm, kg/h kg/h kg/h kg/h
Channel 2
Recorder Density, ρ f, % of 0- kg/m3 kg/m3 kg/m3
Channel 4 6.165 kg/m3

At the PLANT

FI911, Nm3/h Nm3/h Nm3/h Nm3/h

PG911A, psig psig psig psig

*Note: X1, X2, X3, X4 are in % and are at the I/O Data of FIC91/PIC91/FIC90
P15, P16, P17, P18 are at the PT register, Fv, m3/h
PV1 is at the main face plate display of FIC91, Fm, kg/h
X1: % of 0 to 50 kg/h or % of 50 kg/h
X2: % of 0 to 200 oC or % of 200 oC
X3: % of 0 to 70 psia or % of 70 psia
X4: % of 0 to 10,000 mmH2O or % of 10,000 mmH2O
The Fm value at the Recorder FPTR91 is computed at the multivariable air mass flow transmitter FT91 then
retransmitted to the Recorder.

**Column I: Maximum air flow rate: FIC91, MV=-6.3%, TIC91, MV1=-6.3%, Switch OFF Heater, PIC91,
MV=-6.3
Column II: Higher Air Temperature: FIC91, MV1=-6.3%, TT911 at least 100 oC, TIC91 Auto (A) mode
with SV1= 150 oC, PB1=10%, TI1=100 sec, TD1=25 sec, Switch ON Heater, PIC91=-6.3%.
Column III: Different Pressure/Flowrate/Temperature: FIC91, MV1=70%, TT911 at least 100 oC, TIC91
Auto (A) mode with SV1= 150 oC, PB1=10%, TI1=100 sec, TD1=25 sec, Switch ON Heater, PIC91=-6.3%.

QUESTIONS
1. What is your observation based on data I, II and III? What is the relationship between these three
data?
2. What is the significant the introduction a sharp pulse load disturbance?
3. Why PI controller is used instead of PID controller in this process? From your own understanding,
how far the performance of the process if PID controller is applies on the process?
 Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 4: STUDY ON DYNAMICS OF FIRST ORDER AND SECOND ORDER

SYSTEMS

OBJECTIVE
1. To demonstrate the properties of a first order system for various values of the system gain
and time constant and also to demonstrate the dynamic properties of a second order system
for various values of the system gain, natural period and damping coefficient.
2. To illustrate the dynamic response of a first order and second order system to different input
signals.

EXPERIMENT PROCEDURES
PART A: FIRST ORDER SYSTEM
1. To start the first order system, click once on the First and Second Order Systems button
from the Main Menu then select the First Order System button. The two windows will be display;
the first is the system window and the second is the input/output window.
2. First, set the system gain Kp (numerator coefficient) and the system time constant τP
(denominator coefficient) both to 10.0 by clicking once on the first order system block. Now set the
step time to 10.0, initial value of the step function to 0.0 and the final value of the step function to
1.0 by clicking once on the step function block. Click OK after you have done.
3. To start the simulation, select Start from the Simulation menu. Record the new steady state
value and the length of time it takes for the output to reach the new steady state (sec). Use the
Pointer button to take several points along the response curve in your analysis.
4. Now increase the value of Kp to 40.0 and repeat step 3. How does this response differ from
the response in step 3?
5. Set Kp back to 10.0 and now try increasing the value τP of to 20.0. Repeat the simulation.
How does this response differ from the response in step 3?
6. Now decrease the value of the Kp to 5.0 and decrease the value of τP to 5.0. Repeat the
simulation. Record the new steady state value and the length of time it takes for the output to reach
the new steady state (sec) in Table 1.

Table 1
Process Control & Instrumentation Laboratory BKF4791

Kp τP Time Output
10 10
40 10
10 20
5 5

SYSTEM IDENTIFICATION PROBLEM

From the Main Menu, select the System Identification Problem 1 button. Using a step input, run the
simulation to generate output data that can be used to determine the system gain (Kp) and the system
time constant (τP). Remember to use the Pointer button and to take several points along the response
curve in your analysis of the system output.

QUESTION

1. What is the slope of initial response?

2. Calculate the final output value minus the initial output value.
3. Fill in the following table with the parameter values you calculated:
Table 2
Kp
τP

4. Give the first order transfer function of this unknown system.

EXERCISE
1. What effect does increasing the gain have on the system output?
2. What is meant physically by a system with a large gain?
3. What effect does decreasing the time constant have on the system output?
4. What is meant physically by a system with a small time constant?
5. Is it possible for a system to have a negative gain? What is the expected behavior?
6. Is it possible for a system to have a negative time constant? What is the expected
behavior?
7. What is the expected response from a first order system driven by a sinusoidal input?

PART B: SECOND ORDER SYSTEM

 Process Control & Instrumentation Laboratory BKF4791

1. To start the second order system, click once on the First and Second Order Systems button
from the Main Menu then select the Second Order Systems button. The two windows will be
display; the first is the system window and the second is the input/output window.
2. The system under consideration is described by the following transfer function:
KP
y (s) =
As + Bs + 1
2

3. Set the system gain (Kp) to 10.0 (numerator coefficient), the value of A to 40.0 and the value
of B to 14.0 (denominator coefficient) by clicking Second Order System block.
4. Now set the initial value of the Step Function to 0.0 and the final value of the Step Function
to 1.0 by clicking once on the Step Function block.
5. To start the simulation, select Start from the Simulation menu. Is the system overdamped,
underdamped or critically damped? If the system is underdamped, what is the overshoot, decay
ratio, rise time, settling time and the period of oscillation?
6. Change the value of A to 18 and the value of B to 2. Repeat the simulation. Is the system
overdamped, underdamped or critically damped? If the system is underdamped, what is the
overshoot, decay ratio, rise time, settling time and the period of oscillation?
7. Change the value of A to 42.25 and the value of B to 13. Repeat the simulation. Is the
system overdamped, underdamped or critically damped? If the system is underdamped, what is the
overshoot, decay ratio, rise time, settling time and the period of oscillation?

Table 3
Kp A B Type Overshoot Decay Rise Settling Period
Ratio Time Time
10 40 14
10 18 2
10 42.25 13

SYSTEM IDENTIFICATION PROBLEM

1. Close the two windows by clicking the left mouse button on the upper left hand box of both
windows and selecting Close. From the First and Second Order Systems Menu, select the
System Identification Problem 2 button.
2. Using a step input, run the simulation to generate data that can be used to determine the
system gain (), the system time constant () and the damping coefficient ().
QUESTION
1. What is the overshoot in the response?
 Process Control & Instrumentation Laboratory BKF4791

1. What is the period of the oscillatory response?

2. Calculate the final output value minus the initial output value.
3. Fill in the following table with the parameter values you calculated:
Table 4
Kp
τP
Ξ

4. Derive the second order transfer function for this unknown system.

EXERCISE
Consider the following values for the damping coefficient for a second order dynamic system.

Region I Region II Region III

Ξ<1 Ξ=1 Ξ>1

1. What types of poles does this system have? What types of response would be expected for a
system with a damping coefficient in Region I, II and III?
2. Sketch the corresponding response of the output variable to a step input in Region I, II and
III.
3. How does a decrease in the damping coefficient affect the speed of response?
4. Which of the three responses would be expected to have a shorter response time and
sluggish?
5. What is the trade-offs from a control perspective of the different responses?
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 5: STUDY ON DYNAMICS OF FIRST ORDER SYSTEM USING

FURNACE

OBJECTIVE
The purpose of this module is to demonstrate the properties of a first order system for various
values of the system gain and time constant. This module also illustrates the dynamic response of a
first order to different input signals.

INTRODUCTION
The unit operation in this module represents a furnace fueled by natural gas which is used to preheat
a high molecular weight hydrocarbon feed (C16 – C26) to a cracking unit at a petroleum refinery. The
furnace model consists of energy and component mass balances which result in coupled nonlinear
differential equations. The furnace model has seven inputs and four outputs as listed below:

Inputs Outputs
Hydrocarbon Flow Rate Hydrocarbon Outlet Temperature
Hydrocarbon Inlet Temperature Furnace Temperature
Air Flow Rate Exhaust Gas Flow Rate
Air Temperature Oxygen Exit Concentration
Fuel Gas Flow Rate
Fuel Gas Temperature
Fuel Gas Purity

The combustion of the fuel is assumed to occur via the following reaction mechanism:

3
CH 4 + O2 → CO + 2 H 2 O
2
1
CO + O2 → CO 2
2

There are two major objectives for operation of the furnace. First, in order to minimize fuel costs,
the furnace must be operated with proper oxygen composition to ensure complete combustion of the
fuel (carbon monoxide is an undesired product). Second, the hydrocarbon feed stream must be
delivered to the cracking unit at the desired temperature.
The furnace has the following manipulated and controlled variables:
Manipulated Variables Controlled Variables
Air Flow Rate Hydrocarbon Outlet Temperature
Fuel Gas Flow Rate Oxygen Exit Concentration
Process Control & Instrumentation Laboratory BKF4791

The system also has the following load (or disturbance) variables:

Load Variables
Hydrocarbon Flow Rate
Fuel Gas Purity

PROCEDURE
1. Start by selecting the Furnace from the Main Menu. This is done by clicking the left mouse
button once on the Furnace button. This opens the menu window for the furnace modules.
Click the left mouse button on the Furnace button. Two additional windows should open,
one for the input and output graphs and one for the furnace process flowsheet.
2. Under the Simulation menu, select Start. This command should be executed once during a
lab session. It is the simulated equivalent to a perfect process startup. The process output
graphs are located on the window labeled Furnace Process Monitor. Notice how the outputs
remain unchanged with time.
3. Next, try decreasing the fuel gas purity. This will act as a disturbance to the system. By
double clicking on the Fuel Gas Purity box, change the value from 1.0 to 0.95 by clicking on
the value box and using the backspace key to erase the old value. When you have entered a
new value, click on the Close button. Again, notice how the outputs on the process monitor
are changing with time. Now return the Fuel Gas Purity to 1.0 by double clicking on Fuel
Gas Purity box and adjusting the value as done before.
4. Start the furnace. Record the initial steady state values for each of the inputs and outputs of
the furnace:

Inputs
Hydrocarbon Flow Rate m3/min
Hydrocarbon Inlet Temperature K
Air Flow Rate m3/min
Air Temperature K
Fuel Gas Flow Rate m3/min
Fuel Gas Temperature K
Fuel Gas Purity mol CH4/mol total

Outputs
Hydrocarbon Outlet Temperature K
Furnace Temperature K
Exhaust Gas Flow Rate m3/min
Oxygen Exit Concentration mol O2/min
Process Control & Instrumentation Laboratory BKF4791

5. Make the following sequence of increases in the air flow rate by double clicking the left
mouse button on the Air Flow Rate box. The remaining inputs (the six other inputs) should
be kept at their initial steady state values. After each change in the air flow rate, allow the
system to reach a new steady state (approximately 40 simulation minutes) and then record
the values of the output variables obtained using the pointers on the output graphs. Record
the steady state values:

Air Flow Rate Hydrocarbon Outlet Oxygen Exit Concentration

Temperature
17.9 (nominal)
18.1
18.3
18.5
18.7

Return the Air Flow Rate to its initial value allows the furnace to reach steady state.
6. Make the following sequence of increases in the fuel gas flow rate by double clicking the
left mouse button on the Fuel Gas Flow Rate box. The remaining inputs (the six other
inputs) should be kept at their initial steady state values. After each change in the fuel gas
flow rate, allow the system to reach a new steady state (approximately 40 simulation
minutes) and then record the values of the output variables obtained using the pointers on
the output graphs. Record the steady state values:

Fuel Gas Flow Hydrocarbon Outlet Oxygen Exit Concentration

Rate Temperature
1.21 (nominal)
1.22
1.23
1.24
1.25

Return the Fuel Gas Flow Rate to its initial value allows the furnace to reach steady state.

7. Make the following sequence of increases in the hydrocarbon flow rate by double clicking
the left mouse button on the Hydrocarbon Flow Rate box. The remaining inputs (the six
other inputs) should be kept at their initial steady state values. After each change in the
hydrocarbon flow rate, allow the system to reach a new steady state (approximately 40
Process Control & Instrumentation Laboratory BKF4791

simulation minutes) and then record the values of the output variables obtained using the
pointers on the output graphs. Record the steady state values:

Hydrocarbon Flow Hydrocarbon Outlet Oxygen Exit Concentration

Rate Temperature
0.0350 (nominal)
0.0355
0.0360
0.0365
0.0370

Return the Hydrocarbon Flow Rate to its initial value allows the furnace to reach steady
state.

8. Make the following sequence of increases in the fuel gas purity by double clicking the left
mouse button on the Fuel Gas Purity box. The remaining inputs (the six other inputs) should
be kept at their initial steady state values. After each change in the fuel gas purity, allow the
system to reach a new steady state (approximately 40 simulation minutes) and then record
the values of the output variables obtained using the pointers on the output graphs. Record
the steady state values:

Fuel Gas Purity Hydrocarbon Outlet Oxygen Exit Concentration

Temperature
1.00 (nominal)
0.99
0.98
0.97
0.95

Return the Fuel Gas Purity to its initial value allows the furnace to reach steady state.
9. Increase the nominal Air Flow Rate by 20% and repeat Procedure 4-8.
10. To end the session, stop the simulation by selecting Stop under the Simulation menu, then
select Yes under the Quit menu from the Main Menu window. This will return you to the
MATLAB prompt. At this prompt, type quit to exit MATLAB.

QUESTIONS
Process Control & Instrumentation Laboratory BKF4791

1. Using the information from Procedure 5-8, calculate the steady state gain for each of the
following input-output pairings. This can be accomplished by graphically by plotting the
output versus input values from the tables and calculating the best linear fit to the data.
*Hint: There are 8 steady state gain
2. Compared with results from (1), is the nonlinear behavior of the furnace apparent? How this
behavior manifested?
3. Using the gains obtained in (1), determine the values of the Air Flow Rate and Fuel Gas
Flow Rate that are necessary to increase the Hydrocarbon Outlet Temperature by 7 ºC and
decrease the Oxygen Exit Concentration by 0.05 mol O2/m3 by assuming the load variables
remain constant. Calculate the new value of the Fuel Gas Flow Rate and Air Flow Rate.
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 6: STEADY STATE AND DYNAMIC STUDIES OF DISTILLATION

COLUMN

OBJECTIVE
The purpose of this module is to demonstrate the properties of a first order system for various
values of the system gain and time constant and also to demonstrate the dynamic properties of a
second order system for various values of the system gain, natural period and damping coefficient.
This module also illustrates the dynamic response of a first order and second order system to
different input signals.

INTRODUCTION
The process under consideration in this unit is a binary distillation column which separates a
mixture of methanol and ethanol. Distillation is a very important unit operation in the chemical and
petroleum industries. Increasing demand for high quality products coupled with the demand for
more efficient energy utilization has highlighted the role of the process control for distillation
columns.

The particular column studied in this unit has 27 trays, a reboiler on the bottom tray and a total
condenser on the overhead stream. A 50%-50% mixture of methanol and ethanol is fed at the
fourteenth tray. This column was originally modeled by K. Weischedel and T.J. McAvoy in 1980. It
represents a benchmark that has been studied by a number of researchers for the purpose of
controller design. The specific control objective is to achieve an 85% methanol stream at the top
and an 85% ethanol stream at the bottom of the column. This is referred to as dual composition
control.

This column is modeled with component mass balances and steady state energy balances which
result in coupled nonlinear differential algebraic equations. The column model has four inputs and
four outputs as listed below.

Inputs Outputs
Reflux Ratio Overhead Methanol Composition
Vapor Flow Rate Overhead Flow Rate
Feed Methanol Composition Bottom Methanol Composition
Feed Flow Rate Bottom Flow Rate
Process Control & Instrumentation Laboratory BKF4791

The column has the following manipulated and controlled variables:

Manipulated Variables Controlled Variables
Reflux Ratio Overhead Methanol Composition
Vapor Flow Rate Bottom Methanol Composition

The system also has the following load (or disturbance) variables:
Load Variables
Feed Flow Rate
Feed Methanol Composition

PROCEDURE
1. Start by selecting the distillation column from the Main Menu. This is done by clicking the
left mouse button once on the Distillation Column button. This opens the menu window for
the distillation column modules. Click the left mouse button on the Distillation Column
button. Two additional windows should open, one for the distillation column process
monitor and one for the distillation column flowsheet.
2. Double click on the box Vapor Flow Rate. Use the backspace key to delete the existing
value and enter 0.045 m3/sec. Close the box and start the simulation. Click on the window
showing the monitor to bring it to the front of your screen. It gives information about the
system outputs. These graphs give both the current and the nominal process values.
3. Changes in the values of Reflux Ratio, Feed Flow Rate and Feed Methanol Composition can
be given in a similar manner. Increase the value of Reflux Ratio to 3.0. Observe the effect
on the outputs. Once the system has reached a new steady state, increases the Feed Methanol
Composition to 0.55. Again, observe the effect on the outputs.
4. When the column has reached the new steady state, return all of the input values to their
nominal values and allow the system to return to its initial steady state.
5. Start the column. Record the initial steady state values for the inputs and outputs.

Inputs
Reflux Ratio
Vapor Flow Rate mol/sec
Feed Methanol Composition mol MeOH/mol total
Feed Flow Rate mol/sec

Outputs
Overhead Methanol mol MeOH/mol total
Composition
Bottom Methanol mol MeOH/mol total
Composition
Process Control & Instrumentation Laboratory BKF4791

6. Make the following sequence of moves in the reflux ratio by double clicking the left mouse
button on the Reflux Ratio box. The remaining inputs (the three other inputs) should be kept
at their initial steady state values. After each change in the reflux ratio, allow the system to
reach a new steady state (approximately 40 simulation minutes) and then record the values
of the output variables obtained using the pointers on the output graphs. Record the steady
state values:
Reflux Ratio Overhead Methanol Bottom Methanol
Composition Composition
1.75 (nominal)
1.85
1.95
1.65
1.55

Return the Reflux Ratio to its initial value allows the column to reach steady state.

7. Make the following sequence of changes in the vapor flow rate by double clicking the left
mouse button on the Vapor Flow Rate box. The remaining inputs (the three other inputs)
should be kept at their initial steady state values. After each change in the vapor flow rate,
allow the system to reach a new steady state (approximately 40 simulation minutes) and then
record the values of the output variables obtained using the pointers on the output graphs.
Record the steady state values:

Vapor Flow Rate Overhead Methanol Bottom Methanol

Composition Composition
0.033 (nominal)
0.040
0.036
0.034
0.032

Return the Vapor Flow Rate to its initial value allows the column to reach steady state.

8. Make the following sequence of moves in the feed flow rate by double clicking the left
mouse button on the Feed Flow Rate box. The remaining inputs (the three other inputs)
should be kept at their initial steady state values. After each change in the feed flow rate,
allow the system to reach a new steady state (approximately 40 simulation minutes) and then
record the values of the output variables obtained using the pointers on the output graphs.
Record the steady state values:
Process Control & Instrumentation Laboratory BKF4791

Feed Flow Rate Overhead Methanol Bottom Methanol

Composition Composition
0.025 (nominal)
0.026
0.024

Return the Feed Flow Rate to its initial value allows the column to reach steady state.

9. Make the following sequence of moves in the feed composition by double clicking the left
mouse button on the Feed Composition box. The remaining inputs (the three other inputs)
should be kept at their initial steady state values. After each change in the feed composition,
allow the system to reach a new steady state (approximately 40 simulation minutes) and then
record the values of the output variables obtained using the pointers on the output graphs.
Record the steady state values:

Feed Composition Overhead Methanol Bottom Methanol

Composition Composition
0.50 (nominal)
0.53
0.47

Return the Feed Composition to its initial value allows the column to reach steady state.
10. To end the session, stop the simulation by selecting Stop under the Simulation menu, then
select Yes under the Quit menu from the Main Menu window. This will return you to the
MATLAB prompt. At this prompt, type quit to exit MATLAB.

QUESTION
1. Using the information from Procedure 6-9, calculate the steady state gain for each of the
following input-output pairings. This can be accomplished by graphically by plotting the
output versus input values from the tables and calculating the best linear fit to the data.
*Hint: There are 8 steady state gain
2. Using the gains obtained in (1), determine the values of the Reflux Ratio and Vapor Flow
Rate that are necessary to increase the Overhead Methanol Composition to 0.88 and the
Bottom Methanol Composition to 0.17. Assume that the load variables remain constant.
Calculate the new value of the Reflux Ratio and Vapor Flow Rate.
Process Control & Instrumentation Laboratory BKF4791

3. Implement this manipulated variable change in the column and record the values of the
output variables. How close do the outputs come to the desired values? Record the actual
values. Return the Reflux Ratio and Vapor Flow Rate to their initial values and allow the
column to reach steady state.
 Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 7: GAS TEMPERATURE CONTROL USING PID CONTROLLER

OBJECTIVE

To study the Gas temperature control using PID control.

INTRODUCTION

Model AFPT921 is a process control training system (PCTS) that uses only air to simulate gas,
vapour or steam. Air is readily available from a compressor. (It is deemed unsafe for students
without any industrial experience and safety training to deal with steam or gas). It provides the
simple gas physical processes where the measurement and control of their important variables of
flow, temperature and pressure can be studied.

The inlet air is heated at the electric heater and the heated air flows into pipeline PLI (or
automatically into pipeline PLII if the air flowrate through PLI is too low). Heated air from the
heater can flow into pipeline PLI (or pipeline PLII) via two flow paths:-

1. Via the Flow control valve (FCV91), cooling vessel C90, vessel T91 and vessel T92A.
2. Via a parallel pipeline (pipeline PLII) from the heater directly into pipeline PLI, by-passing
flow control valve (FCV91), cooling vessel C90, vessel T91 and vessel T92A.

There are three basic process control systems found in this plant for air temperature control:

1. Single Loop PID Temperature Control: TE91/TT91 - TIC91 - TCY90/Heater

2. Single Loop PID Temperature Control: TE92/TT92 - TIC92 - TCY90/Heater
3. ON/OFF Temperature Control: TE92/TT92 - TIC910 – Power Supply to Heater
4. Temperature Auto-Selector Control:TE91/TT91 - TIC91 - TCY90/Heater
TE92/TT92 - TIC92 - TCY90/Heater

PROCEDURE

1. Switch ON the operator workstation. (Press the Acknowledge button to silence the alarm
buzzer sound).
2. Select the Gas Temperature Process.
3. Make sure the TIC91A and TIC92A are set to “PID” control mode throughout this
experiment.
 Process Control & Instrumentation Laboratory BKF4791

4. Call up the TIC91 faceplate. Set the TIC91 to Manual mode and make sure its Output is 0%.
5. Call up the TIC92 faceplate. Set the TIC92 to Manual mode and make sure its Output is 0
%.
6. Call up the TIC92 faceplate. Set the TIC92 to Auto mode and set its Setpoint (SP) to
200°C . Set the subsequent PID trials of

Gain (100/P) = 10
Reset (I) = 22 s
Rate (D) = 5s

7. Call up the TIC91 faceplate. Set the TIC91 to Auto mode and set its Setpoint (SP) to 80°C .
Set the first PID trials values:

Gain (100/P) = 10
Reset (I) = 100 s
Rate (D) = 25 s

8. Observe patiently the control response in Process View History. Wait till the response is
steady at its set point SV1 to within ±0.2 to ±0.3 OC or shows oscillatory response even after 3
cycles of oscillation.
9. When the response is steady or shows oscillatory response even after 3 cycles of oscillation,
apply Load Step Disturbance. Switch the controller TIC91faceplate to Manual (M) mode and step
increase the control output MV by about 20%. Quickly switch TIC91 back to Auto (A) mode. The
set point SV1 remains unchanged at the previous SV1 value.
10. When the response is steady or shows oscillatory response even after 3 cycles of oscillation,
apply Set Point Disturbance. Step-increase the temperature set point SV1 at TIC91 to 100 OC.
Wait till the response is steady at its set point SV1 to within ±0.2 to ±0.3 OC or shows oscillatory
response even after 3 cycles of oscillation.
11. Repeat procedure no. 4 and 5.
 Process Control & Instrumentation Laboratory BKF4791

12. Make sure both temperature on TIC91 and TIC92 are cooling down to room temperature.
This process will take about 30-40 minutes.
13. Repeat procedure no 6.
14. Call up the TIC91 faceplate. Set the TIC91 to Auto mode and set its Setpoint (SP) to 80°C .
Set the second PID trials values:

Gain (100/P) = 5
Reset (I) = 70 s
Rate (D) = 18 s

15. Repeat procedure no 8-10.

16. Before shutdown the process, please ensure controller TIC91 and TIC92 are switched to the
manual mode and MV are reset to 0%.

RESULTS

PID TIC91 Gain Reset Rate (D) Observation

Setpoint (100/P (I)
)
Sec Sec
I

II

III

DISCUSSION

1. Discus on your observation based on the temperature response at Process History View and the
overshoot value of the temperature response for each PID setting?
2. From the experiment, which is the best PID for this process? Why?
3. Why controller TIC92 didn’t achieve their set point? Explain the factors that influence the
process.
4. What do you learn from this experiment?
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 8: SINGLE LOOP PID LEVEL CONTROL USING DCS

Plant Model : WLF922 / DCS (Distributed Control System)

Objective : To study Single Loop PID Level Control (LIC31)

PLANT START-UP CHECK LIST

1) Tank T32 should be filled with water up to and just below the level of the shortest level
probe of the Level Switch LS32 which is slightly below the tank T32 overflow pipe outlet.
Top up the water later whenever necessary.
2) Pump P33 in Auto/Manual control mode. Leave it in Manual mode.
3) Quickly check the various manual valve as follows:
• Locate the Inflow pump P32. Manual suction, discharge and by-pass valve are fully
Opened.

• Pump P31: Manual suction valve = Open Fully

Two (2) manual parallel discharge valve = Shut Fully
Process Control & Instrumentation Laboratory BKF4791

• Pump P33: Manual suction & by-pass valve = Open Fully

Manual discharge valve MV-T and MV-D = Shut Fully
• Operate T31 as an Open Tank with the top vent (V) and overflow drain valves
FULLY OPENED. The pressurizing air inlet to T31 is isolated at its inlet manual valve
(with the valve handle at 90º to the air supply inlet tubing), locate next to the preset Air
Regulator AR31.
• Operate T31 as a Self Regulating process. Open only the manual GATE valve at the
gravity discharge pipe at the tank bottom. The second manual GLOBE valve at the
second gravity discharge pipe must remain SHUT.
• The bottom manual drain valve of Tank T32 is always SHUT.
• Compressed air is required to operate the control valve system LCY31/PP/LCV31 and to
pressurize tank T31.
• Check that the pressure is in accordance to the pressure indicated at the air pressure
regulator (IAS). There is no need to adjust this pressure (IAS) too frequently.
4) Note the following switches and pushbuttons but do not switch ON any pump yet.

PANEL, SCADA/DDC : Switch to ‘DDC’ position for DCS control.

EXPERIMENT PROCEDURES

1) Call up the DCS graphic display for ModelWLF922. Make sure LIC31 controller selected to
‘PID’ control mode as shown.

2) Switch the LEVEL-FLOW CONTROL selector switch to position 2 “at LIC31 position”.
Note that the LIC31 shall be in AUTO (AUT) mode and FIC31 shall be in MANUAL
(MAN) mode.
Process Control & Instrumentation Laboratory BKF4791

3) Call up the LIC31 Detail faceplate from the DCS graphic display and set the First (I) trial
PID Tuning Parameters (Gain, Reset and Rate) values for LIC31 as follow:

Tank T31 Level Control

Controller : LIC31
Set point : 400mm

First (I) Trial PID Tuning Parameters

Gain (100/P) : 30
Reset (I) : 30 secs
Rate (D) : 0 sec

4) Start the pump P32 and shut its by-pass manual valve BV32.
5) Call up the Historical Trend for LIC31 from its Detail faceplate. Observe the level
response for the level.
6) Apply the Level Load Disturbance to Level of Tank T31 when the level response is
within ±2mm of its Set point (SP). Perform the Level Load Disturbance as follows:
• Switch the LIC31 controller to Manual (MAN) mode and decrease its manipulated
(MV) Output (OUT) by 10% for 20 sec.
• Switch LIC31 controller back to Auto (AUT) mode
At the LIC31 Process Historical Trend, observe the Tank T31 level response similarly.
7) Repeat the above procedures 3 and 6 for next PID trial Tuning Parameters values in Table
8.0

TABLE 8.0: Single Loop PID Level control at Independent Operation mode

SINGLE LOOP PID LEVEL CONTROL : LIC31

Reset Rate
Trial Set point Gain
(I) (D) Remarks: Test disturbance
PID (mm) (100/P)
sec sec
Set the recommended PID trial tuning parameters
I 400 30 30 0
value and set point. Perform the Load Disturbance
step change as described in procedure 6.
II 400 5 30 20

III 400 5 30 0 Observe the level response from the Process

Historical Trend to see if damp out to its set point
Process Control & Instrumentation Laboratory BKF4791

within 3 cycle to ±2mm of its set point (SP) OR it

IV 400 0.5 30 0 continues to oscillate after 3 cycles.

V 400 5 3 0

Experiment Observation

Single Loop PID Level control (LIC31) at Independent Operation mode

SINGLE LOOP PID LEVEL CONTROL : LIC31

Reset Rate
Trial Set point Gain (I) (D)
Observation
PID (mm) (100/P)
sec sec

I 400 30 30 0

II 400 5 30 20

III 400 5 30 0

IV 400 0.5 30 0

V 400 5 3 0

Enclose the LIC31 level trend response for the above PID values and compare the response with the
different PID setting and comment in the observation column.
 Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 9: GAS PRESSURE CONTROL USING PID CONTROLLER

OBJECTIVES

1. To study the gas pressure single capacity control using PIC91A PID single control loop.
2. To study the gas pressure single capacity control using PIC92A PID single control loop.

INTRODUCTION

Model AFPT921 is a process control training system (PCTS) that uses only air to simulate gas,
vapour or steam. Air is readily available from a compressor. (It is deemed unsafe for students
without any industrial experience and safety training to deal with steam or gas). It provides the
simple gas physical processes where the measurement and control of their important variables of
flow, temperature and pressure can be studied.

The gauge pressures at vessels T91 and T92 OR its discharge Pipeline are measured by their
respective gauge pressure transmitters PT91 and PT92. Note that PT92 can be connected to either
ONE of the following tapping points viz at T92 OR at the discharge Pipeline of T92. The vessel
T92 and T92A are interconnected with a large interconnecting pipe so that their pressure and
pressure response are usually the same. Hence T92 + T92A behave like a 1-Capacity process of
double tank volume.

There are five basic process control loops found in this plant for Air Pressure Control system.

1. ON/OFF Air Pressure Control: PT92-PIC90-PSV90/PCV90

2. PID Air Pressure Control, Single Loop: PT911-PIC911-FCY91/PP-FCV91
3. PID Air Pressure Control, Single Loop, Single Capacity or Pipeline: PT92-PIC92-
PCY91/PP-PCV91
4. PID Air Pressure Control, Single Loop, Multi-capacities: PT91-PIC91-PCY91/PP-PCV91
5. PID Air Pressure Control, Cascade: PT91-PIC91-PIC92-PCY91/PP-PCV91
(PT92)
Process Control & Instrumentation Laboratory BKF4791

PROCEDURES:

1. Please refer to the Section “PLANT START-UP CHECK LIST”. It is assumed that the
readers have already performed Start-up Check List Procedures.
2. Check that compressed air is available as process air and is connected to the Model plant at
the process Air Regulator AR90. (Check that its upstream process air. Supply manual valve
(PASV) is fully opened). With the manual downstream valve MV90A fully shut, set the
pressure at AR90 to the pressure indicated. Then open MV90A by 1 turn and shut it again.
Recheck that the pressure at AR90 is correctly set. Once AR90 is set, it needs no further
adjustment.
3. To set the maximum process flowrate, adjust the manual valve MV90A at the process inlet
so that PV1 (i.e. Fm) at FIC91 panel controller reads from 40 to 50 kg/h.
4. Switch on the main power supply. The main switch is at the front of the cubicle. Make sure
the PANEL, SCADA/DDC selector switch is at the “PANEL, SCADA” position. All the
panel instruments will lit up.
5. Switch the “PANEL, SCADA/DDC” selector switch to “DDC” position.
6. Call up the Model AFPT921 DCS graphic display on one of the DCS workstation.
Process Control & Instrumentation Laboratory BKF4791

7. Always select the PIC91A controller to PID control mode by pressing the “PID” soft button
on the Model AFPT921 graphic display as shown below:

8. Call up the TIC91A faceplate. Set the TIC91A to Manual mode and make sure its Output is
0%.
9. Call up the TIC92A faceplate. Set the TIC92A to Manual mode and make sure its Output is
0%.
10. Call up the FIC91A faceplate and set the FIC91A to Auto mode. Set its PID values as
follow:
Mass Gas Flow controller
Controller : FIC91A
Setpoint : 35 kg/h

11. Call up the SV90A faceplate from the Model AFPT921 graphic display and open the
SV90A valve by switching its faceplate to ON or OPEN position.
12. Switch OFF the Heater (Thyristor, TCY90A) in Manual (MAN) mode i.e. ‘MAN’ from the
DCS graphic of Model AFPT921. These experiments do not require heating element, hence;
make sure that the Heater remains OFF throughout this experiment.
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 9.1: STUDY GAS PRESSURE CONTROL USING PID SINGLE CONTROL
LOOPS

13. For the T91 tank pressure single capacity control, make sure the bypass valves B92B and
B92 shall be opened. To enable the PIC91A single loopPID control, switch the selector
switch to “PIC91” position as shown below:

14. Call up the PIC91A faceplate. Set the subsequent trials of PID parameters values Gain
(100/P), Reset (I) and Rate (D) values as shown in the Table 3a. Observe the IC91A flow
response from its Process History View.
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 9.2 MULTI-CAPACITY T92 TANK PRESSURE (PIC92A) PID CONTROL

15. To control the T92 tank pressure using the PIC92A single PID loop, switch the selector
switch to “PIC92” position as shown below:

16. Setup the Multi-Capacity T92 Tank Pressure system by manipulating the following manual
valves:

Manual valves between tanks (MV92A2, T92A and T92) = OPENED

Bypass Valves (B92A and B92) = CLOSED
Manual valve TP-T = OPENED
Manual valve TP-P = CLOSED
Process Control & Instrumentation Laboratory BKF4791

17. Call up the PIC92A faceplate and switch to Auto mode. Set the subsequent trials of Gain
(100/P), Reset (I) and Rate (D) values as shown in the Table 3b. Observe the PIC92A flow
response from its Process History View.
Process Control & Instrumentation Laboratory BKF4791

RESULTS

EXPERIMENT 9.1: STUDY GAS PRESSURE CONTROL USING PID SINGLE CONTROL
LOOPS

EXPERIMENT 9.2: STUDY GAS PRESSURE CONTROL USING PID SINGLE CONTROL
LOOPS
 Process Control & Instrumentation Laboratory BKF4791

DISCUSSION

1. Based on your observation in experiment 9.1 & 9.2, discuss briefly for each process that was
occurred.
2. Which is the best PID for each experiment?
3. Give an example for every process that is used in industry.
4. Is it possible to use PI controller in both cases? Explain briefly either yes or no?
Process Control & Instrumentation Laboratory BKF4791

EXPERIMENT 10: DYNAMIC STUDIES OF SIMULATED GAS MASS FLOW PROCESS

INTRODUCTION
Model SPC211 is developed to study the application of Single Loop controls of some
common simulated processes (Flow and Level). The key topics are how to identify and characterize
some real plant processes available at some physical Plants and how to tune their control loops
using the Ziegler- Nichols, Cohen-Coon and IMC etc Tuning techniques for Quarter Decay Ratio
(QDR) or other performance criteria. Model SPC211 was developed to help teach these key topics
in Process Control and to provide the hands-on opportunity for controller tuning skills to be
acquired.
The Simulated Gas Flow Process consists of a main pipeline where process air
representing gas/vapour flows and then discharge to atmosphere via the process vent manual valve
VF. The process air that flows into the system is conditioned to have air temperature of 100°C.
With reference to the dynamic graphic of the Simulated Gas Mass Flow Process at Model
SPC211, for PID control, mass flowrate measured by Gas Mass Flowmeter (FE91/FT91), is the
measurement input into PID Flow controller FIC91A which in turn throttles the Control valve
FCV91, via a Current-to-Air Converter (I/P), FCY91, and a Positioner (PP).

Table 1: Instrumentation and control configuration for gas mass flow process

Measurement FE91/ FT91 FT91 represents the gas mass

flowmeter

Control Type FIC91A PID Controller configured at DCS

Control Output FCY91 Current-to-Air Converter (I/P)

PP Pneumatic Position
FCV91 Air Mass Flow Control Value.
Air-to-close (ATC) type
Process Control & Instrumentation Laboratory BKF4791

Figure 1: Simulated gas mass flow process diagram

OBJECTIVE
1. To analyze the behaviour of the gas mass flow process by simulation

METHODOLOGY (PRELIMINARY EXERCISES)

1. Switch ON the operator workstation. (Press the Acknowledge button to silence the alarm
buzzer sound).
2. Select the Gas Mass Flow Process.
3. The following Preliminary Exercises are for Dynamic Graphic check for the Simulated
Gas Mass Flow Process.
a) Familiarize and identify the single loop simulated plant process at Model SPC211.
Single Loop Simulated Process Simulated Process at Syntek
MODEL SPC211
Gas Mass Flow Process Simulated Gas Mass Flow Process

b) For the Single Loop Simulated process, identify its control loop (i.e. measuring
instrument, controller and final control element with the tag name).
c) Next, check for the engineering units for the measured variable (PV), setpoint (SP) and
controller output (MV (OUT)) for the process at the DCS Controller.
Process Control & Instrumentation Laboratory BKF4791

4. The following Preliminary Exercises are for dynamic behaviour of the process when the
controller output is changed (Operating Data Check) at the Simulated Gas Mass Flow Process.
a) View the dynamic graphic of the Simulated Gas Mass Flow Process at the operator
workstation of Model SPC211.
b) ‘OPEN’ solenoid valve SV90 at the dynamic graphic page. It should be green in colour.
c) Select the PID control scheme; call up the controller FIC91A Faceplate. Switch the
controller FIC91A to Manual (MAN) mode. Quickly step change the controller output,
MV (OUT) to 100%.
d) Call up the Process History View from the FIC91A Faceplate to observe the gas mass
flow response (red trend). Wait till the flow response reaches a new steady state (check
the PV value). Note the steady state air mass flowrate.
e) Then, step change MV (OUT) to 50%. Note that FIC91A is still in Manual (MAN)
mode. At the Process History View, observe that the gas mass flowrate (red trend)
increases. Note the steady state air mass flowrate.
f) Step change the controller output, MV(OUT) further to 0% with FIC91A still remain in
Manual (MAN) mode. At the Process History View, observe that the gas mass flowrate
(red trend) increases. Note the steady state gas mass flowrate.
g) ‘Print screen’ the observed gas mass flow response and enclose together with the results
sheets.
h) With FIC91A in Manual (MAN) mode, step change the controller output, MV(OUT)
back to 100%.
5. Observations and Results of Experiments.
The DCS trending records at the Process History View of each respective controller constitute
the results of the experiments. During any experiments, note down the observations
corresponding to the obtained response. Check the OBSERVATIONS AND RESULTS
SECTION for the types of results to observe collect and submit them as results of your
exercise and experiments.
Process Control & Instrumentation Laboratory BKF4791

6. To Shut down Model SPC211

a) Close all the windows (including DeltaV Operate page) at the operator workstation.
b) Log Off from the operator workstation.
c) Shut down the operator workstation.

OBSERVATIONS AND RESULTS

Dynamic Graphic Check (Visual and Static Check) for the Simulated Gas Mass Flow Process
(Refer to Methodology in step 3)
Single Loop Simulated Process Control Loop Engineering units
PlantProcess
Gas Mass Flow Process Tag Process Units
Name Parameter
Measuring PV
Instrument
Controller SP
Final Control MV(OUT)
Element

Dynamic Behaviour of the process (Operating Datas Check) at the Simulated Gas Mass Flow
Process (Refer to Methodology in step 4)
Actions Observations Remarks
With FIC91A in Manual (MAN) mode,
i) at MV (OUT) = 100% What is the current air 1. ______kg/h
mass flowrate at steady 2. Is the control value
state? FCV91 fully shut?
______
ii) at MV (OUT) = 50% What is the air mass 3. ______kg/h
flowrate at steady state?
iii) at MV (OUT) = 0% What is the air mass 4. ______kg/h
flowrate at steady state? 5. Is the control value
FCV91 fully open?
______
Note: Enclose the trend response for the Simulated Gas Mass Flow Process

QUESTIONS
1. From the result obtained, discuss the dynamic behavior of the process (i.e order of the
response)
Process Control & Instrumentation Laboratory BKF4791

2. Give suggestions to improve the process performance.

Process Control & Instrumentation Laboratory BKF4791

INDUSTRIAL PROBLEM BASED LEARNING 1: OPEN LOOP STUDIES OF

SIMULATED GAS MASS FLOW PROCESS

INTRODUCTION

The Simulated Gas Flow Process consists of a main pipeline where process air
representing gas/vapour flows and then discharge to atmosphere via the process vent manual valve
VF. The process air that flows into the system is conditioned to have air temperature of 100°C.
With reference to the dynamic graphic of the Simulated Gas Mass Flow Process at Model
SPC211, for PID control, mass flowrate measured by Gas Mass Flowmeter (FE91/FT91), is the
measurement input into PID Flow controller FIC91A which in turn throttles the Control valve
FCV91, via a Current-to-Air Converter (I/P), FCY91, and a Positioner (PP).

Measurement FE91/ FT91 FT91 represents the gas mass

flowmeter

Control Type FIC91A PID Controller configured at DCS

Control Output FCY91 Current-to-Air Converter (I/P)

PP Pneumatic Positione
FCV91 Air Mass Flow Control Value.
Air-to-close (ATC) type
Table 1: Instrumentation and control configuration for gas mass flow process

Figure 1: Simulated gas mass flow process diagram

OBJECTIVE
Process Control & Instrumentation Laboratory BKF4791

1. To perform open loop test at the Simulated Gas Mass Flow process.
2. To determine process parameters such as steady state gain (Kp), dead time (tD), response rate
(RR) and time constant ( τc ).

METHODOLOGY (OPEN LOOP TEST)

1. View the dynamic graphic of the Simulated Gas Mass Flow Process at the operator
workstation.
2. ‘OPEN’ the solenoid valve SV90 at the dynamic graphic page. It should be green in colour.
3. Select the PID control scheme. Then, call up the FIC91A Faceplate and its Detail Faceplate.
4. Practice changing the controller setpoint SP = 18kg/h to 25kg/h to 35kg/h. Switch the
controller to Manual (MAN) mode, practice changing the controller output MV(OUT) = 0%
to 50% to 100%.
5. Next, switch the controller to Auto (AUTO) mode. Practice changing the Gain, Reset and
Rate values from the detail faceplate of FIC91A. Then, set the following Gain, Reset and
Rate (PID) values:

FIC91A: Gain = 0.40, Reset = 3 sec, Rate = 0 sec

Use a setpoint of 25kg/h for the flow controller FIC91A.

User may refer to the “DCS Quick Reference Manual” for more practice.

6. Call up the Process History View from FIC91A to view the flow response (red trend).
NOTE: At the Process History View window, click at the “Chart” menu to select the
“Configure Chart”option and change the “Time Scale” span to 00:02
7. When the response is fairly steady, switch FIC91A to Manual (MAN) mode and step
decrease its MV (OUT) by about 5%. The flow response will rise and then gradually flattens
out exponentially. Wait till the response is fairly steady at the new steady state flowrate
(about 28.10kg/h).
“Print screen” and “save” the observed flow response to be enclosed together with the results
sheets.
8. Use the obtained response curve (for 25kg/h) to determine the process parameters i.e. process
gain, Kp, dead time, tD, response rate, RR and time constant, τc . Refer to Appendix for
the technique applied to determine these parameters.
 Process Control & Instrumentation Laboratory BKF4791

9. Next, switch the controller to Auto (AUTO) mode, with a setpoint of 18kg/h. View the flow
response (red trend) at the Process History View page. When the response is fairly steady,
switch FIC91A to Manual (MAN) mode and step decrease its MV(OUT) by about 5%. Wait
till the response is fairly steady at the new steady state flowrate (about 22.60kg/h).
“Print screen” and “save” the observed flow response to be enclosed with the results sheets.
10. Use the obtained response curve (for 18kg/h) to determine the process parameters i.e. process
gain, Kp, dead time, tD, response rate, RR and time constant, τc .
11. Next, switch the controller to Auto (AUTO) mode, with a setpoint of 35kg/h. View the flow
response (red trend) at the Process History View page. When the response is fairly steady,
switch FIC91A to Manual (MAN) mode and step decrease its MV(OUT) by about 5%. Wait
till the response is fairly steady at the new steady State flowrate (about 35.90kg/h). “Print
screen” and “save” the observed flow response to be enclosed with the results sheets.
12. Use the obtained response curve (for 35kg/h) to determine the process parameters i.e. process
gain, Kp, dead time, tD, response rate, RR and time constant, τc .
Note: The process parameters obtained from this experiment will be used later in PID tuning
experiment.

OBSERVATIONS AND RESULTS

1. Show detailed calculation of the Process Parameters obtained for the Simulated Gas Mass
Flow Process at different operating flow setpoints.
2. Summarise the Process Parameters at the Table below.

Process Parameters Setpoints (SP)

18kh/h 25kg/h 35kg/h
Process gain, Kp
Dead time, tD (sec)
Response Rate, RR
(sec-1)
Time constant, τc
(sec)

3. Enclose the trend response of the Open Loop Test at different operating flow setpoint.

QUESTION
Process Control & Instrumentation Laboratory BKF4791

1. For the different operating setpoints of gas mass flow, check whether the process parameters
remain constant or vary. Comment on the process variability if the process parameter varies
for different operating gas mass flow setpoints.

APPENDIX
Open Loop Test (Process Reaction Curve)

Range for input variable: M∞ - Mo

M2

M1

Range for output variable: B∞ - Bo

B2
B3
B1

to t1 t2

Process Parameter Equations

1. Steady State Gain, Kp
∆Output%(at steady state)
Kp =
∆Input%(at steady state)
 B2 − B1 
 
B − B
=  ∞ o 
 M 2 − M1 
 
 M∞ −Mo 

2. Response Rate, RR Kp
RR =
τc
3. Dead time, tD t D =t 1−t0
4. Time constant, τC It is the time (t 2 − t1 ). When the measure variable,
B3 = ( 63 .2% × ( B2 − B1 ) ) + B1
Process Control & Instrumentation Laboratory BKF4791

INDUSTRIAL PROBLEM BASED LEARNING 2: PID CONTROLLER TUNING OF

SIMULATED GAS MASS FLOW PROCESS

INTRODUCTION
The Simulated Gas Flow Process consists of a main pipeline where process air
representing gas/vapour flows and then discharge to atmosphere via the process vent manual valve
VF. The process air that flows into the system is conditioned to have air temperature of 100°C.
With reference to the dynamic graphic of the Simulated Gas Mass Flow Process at Model
SPC211, for PID control, mass flowrate measured by Gas Mass Flowmeter (FE91/FT91), is the
measurement input into PID Flow controller FIC91A which in turn throttles the Control valve
FCV91, via a Current-to-Air Converter (I/P), FCY91, and a Positioner (PP).
Measurement FE91/ FT91 FT91 represents the gas mass
flowmeter

Control Type FIC91A PID Controller configured at DCS

Control Output FCY91 Current-to-Air Converter (I/P)

PP Pneumatic Positione
FCV91 Air Mass Flow Control Value.
Air-to-close (ATC) type
Table 1: Instrumentation and control configuration for gas mass flow process

Figure 1: Simulated gas mass flow process diagram

OBJECTIVE
Process Control & Instrumentation Laboratory BKF4791

To control the Simulated Gas Mass Flow Process, using PID controller parameters determined
manually from the following Controller Tuning techniques:
i) Ziegler-Nichols using the Process Reaction Curve Method
ii) Cohen-Coon (C-C) Method
iii) Internal Model Control (IMC Method)

METHODOLOGY (PID TUNING)

1. View the dynamic graphic of the Simulated Gas Mass Flow Process at the operator
workstation. ‘OPEN’ the solenoid valve SV90. It should be green in colour. Select PID
control scheme for FIC91A.
2. Call up the FIC91A faceplate and its Detail Faceplate. Then, set the following Gain, Reset
and Rate (PID) values:
FIC91A: Gain = 0.40, Reset = 3 sec, Rate = 0 sec

Use a setpoint SP of 18 kg/h for the flow controller FIC91A.

Switch the controller to Auto (AUTO) mode.
Call up the Process History View from FIC91A to view the flow response trend.
NOTE:
At the Process History View window, click at the “Chart” menu to select the “Configure Chart” option and
change the “Time Scale” span to 00:02

3. PID Tuning for the flow setpoint 18 kg/h:

a) Using the process parameters [process gain, Kp, dead time, tD, response rate, RR and
time constant, τc ] determined for flow setpoint of 18kg/h from Experiment Open
Loop Test, calculate its PID Tuning parameters using first the “Ziegler-Nichols Tuning
Relations (Process Reaction Curved Method)”.
* The PID Tuning Parameters determined for SP = 18 kg/h is PID1
Refer to the ‘PID CONTROLLER TUNING TECHNIQUES’ in the Appendix for the
appropriate formulae to establish the approximate Kc, τI and τD values for the flow
setpoint.

NOTE: Flow is generally a fast process. A PI Controller should be used when the
Proportional control alone cannot provide sufficient small steady state errors (offset). It is
satisfactory because it eliminates offset and retains acceptable speed of the flow response.
Adding Derivative control action will actually destabilize the flow process system.
Process Control & Instrumentation Laboratory BKF4791

b) When the response is fairly steady at its setpoint SP = 18 kg/h, change PID setting; the
Gain (Kc), Reset ( τI ) and Rate ( τD ) values at the Detail Faceplate to the PID1 values
calculated for flow setpoint 18 kg/h.
c) Load Step Test:
• When the flow response is fairly steady at SP = 18 kg/h, switch FIC91A to Manual
(MAN) mode and quickly step increase its MV(OUT) by about 5% for about 5 sec.
Then, quickly switch FIC91A back to Auto (AUTO) mode.
• Observe the flow response (red trend) at the Process History View.
• Again when the flow response is fairly steady at SP = 18 kg/h, repeat the above
steps for the step increase MV(OUT) by about 10% for about 5 sec.
• Observe the flow response (red trend) similarly.
• “Print screen” and “save” the observed flow responses and enclose together with the
results sheets.
• Analyze the PID Control responses obtained for both the load step tests respectively.
d) Setpoint Step Test :
• When the flow response is fairly steady at SP = 18 kg/h, with the
Controller FIC91A remaining in Auto (AUTO) mode, step increase the setpoint SP
to 23 kg/h.
• Observe the flow response (red trend) at the Process History View.
• When the flow response is fairly steady at SP = 23 kg/h, step decrease the setpoint
SP back to 18 kg/h. Wait till the flow response is steady at SP =18 kg/h and then
step increase the setpoint to 28 kg/h.
• Observe the flow response/trend (red trend) similarly.
• With the controller FIC91A remaining in Auto (AUTO) mode at SP =28 kg/h, step
decrease the setpoint SP to 25 kg/h.
• Observed the flow response (red trend) similarly.
• “Print screen” and “save” the observed flow responses and enclose together with the
results sheets.
• Comment on the PID control responses obtained for both the setpoint step tests
respectively.

4. PID Tuning for the flow setpoint 25 kg/h:

Process Control & Instrumentation Laboratory BKF4791

a) Using the process parameters [process gain, Kp, dead time, tD, response rate, RR and
time constant, τc ] determined for flow setpoint of 25 kg/h from Experiment Open
Loop Test, calculate its PID Tuning parameters using first the “Ziegler-Nichols Tuning
Relations (Process Reaction Curved Method)”.
* The PID Tuning Parameters for SP = 25 kg/h is PID2
b) When the response is fairly steady at its setpoint SP = 25kg/h, change the Gain (Kc),
Reset ( τI ) and Rate ( τD ) values at the Detail Faceplate to the PID2 values calculated
for flow setpoint 25 kg/h.
c) Load Step Test:
• When the flow response is fairly steady at SP = 25 kg/h, switch FIC91A to
Manual (MAN) mode and quickly step increase its MV(OUT) by about 5% for
about 5 sec.
• Then, quickly switch FIC91A back to Auto (AUTO) mode.
• Observe the flow response (red trend) at the Process History View.
• Again when the flow response is fairly steady at SP = 25 kg/h, repeat the above
steps for the step increase of its MV(OUT) by about 10% for about 5 sec.
• Observe the flow response (red trend) similarly.
• “Print screen” and “save” the observed flow responses and enclose together with
the results sheets.
• Comment on the PID control responses obtained for both the setpoint step tests
respectively.
d) Set Point Step Test:
• When the flow response is fairly steady at SP = 25 kg/h, with the controller
FIC91A remaining in Auto (AUTO) mode, step increase the setpoint to 30 kg/h.
• Observe the flow response (red trend) at the Process History View.
• When the flow response is fairly steady at SP = 30 kg/h, then, step decrease the
setpoint SP back to 25 kg/h. Wait till the flow response is steady at SP =25 kg/h and
then step increase the setpoint to 35 kg/h.
• Observe the flow response (red trend) similarly.
• “Print screen” and “save” the observed flow responses and enclose together with the
results sheets.
• Comment on the PID control responses obtained for both the setpoint step tests
respectively.
5. PID tuning parameters robustness check:
Process Control & Instrumentation Laboratory BKF4791

a) With the controller FIC91A remaining in Auto (AUTO) mode at

SP = 35 kg/h at the previously set PID2 values, step decrease the setpoint to 18 kg/h.
At the Process History View, wait till the flow response is steady at SP = 18kg/h.
b) When the flow response is fairly steady at SP = 18 kg/h, switch FIC91A to Manual
(MAN) mode and quickly step increase its MV(OUT) by about 5% for about 5 sec.
Then quickly switch FIC91A back to Auto (AUTO) mode.
c) Observe the flow response (red trend) at the Process History View.
d) Print out the observed flow responses to be enclosed together with the results sheets.
Compare the flow control responses of SP = 25 kg/h and SP = 18kg/h for the same load
step tests respectively.
e) Comment on the robustness of PID2 tuning parameters in controlling
other flow setpoints of the Simulated Gas Mass Flow process.
6. Repeat the above steps 3 to 5 for other controller tuning techniques like Cohen-Coon (C-C)
Method, and Internal Model Control (IMC) Method. Compare the effectiveness of the
PID values determined from each of the tuning methods to control the process.

Take note that these methods actually provide approximate PID values for controller settings which
can be used as the starting point for fine tuning.

OBSERVATIONS AND RESULTS

1. Show detailed calculation of the PID parameters obtained from each of the tuning methods.
2. Summarise the PID values at the Table below.
Tuning SP = 18 kg/h SP = 25 kg/h
Methods
Gain Reset ( Rate ( Gain Reset ( Rate (
(Kc) τI ) τD ) (Kc) τI ) τD )
Z-N
Process
Reaction
Curve

Cohen-
Coon
Internal
Model
Control

3. Enclose the trend response of the Open Loop Test at different operating
Process Control & Instrumentation Laboratory BKF4791

flow setpoint.

QUESTION
1. For the different operating setpoints of gas mass flow, check whether the process parameters
remain constant or vary. Comment on the process variability if the process parameter varies
for different operating gas mass flow setpoints.
2. For flow setpoint of 18kg/h, enclose the observed Simulated Gas Mass Flow Process
responses of the load step tests carried out for each of the PID tuning methods. Comment on
the control responses obtained.
3. For flow setpoint of 18kg/h, enclose the observed Simulated Gas Mass Flow Process
responses of the setpoint step tests carried out for each of the PID tuning methods. Comment
on the control responses obtained.
4. For flow setpoint of 25kg/h, enclose the observed Simulated Gas Mass Flow Process
responses of the load step tests carried out for each of the PID tuning methods. Comment on
the control responses obtained.
5. For flow setpoint of 25kg/h, enclose the observed Simulated Gas Mass Flow Process
responses of the setpoint step tests carried out for each of the PID tuning methods. Comment
on the control responses obtained.
6. Enclose the observed Simulated Gas Mass Flow Process responses of the PID robustness
check carried out for each of the PID tuning methods. Comment on the robustness of the
PID tuning parameters for flow setpoint SP = 25kg/h in controlling other setpoints of the air
mass flow process.

APPENDIX
Process Control & Instrumentation Laboratory BKF4791

Cohen-Coon Tuning Relations

Controller Type Gain (Kc) Reset ( τI ) Rate ( τD )
P 1 τc  tD  - -
1 + 
K P t D  3τ c 
PI 1 τc  tD   t  -
0.9 +  t D 30 + 3 D 
K P tD  12τ c   τc 
t
9 + 20 D
τc
PID 1 τ c 16τ c + 3t D   t  14t D
  t D 32 + 6 D  t
K P t D  12τ c   τc  11 + 2 D
t τc
13 + 8 D
τc
Zeigler and Nichols Tuning Relations
Controller Type Gain (Kc) Reset ( τI ) Rate ( τD )
P 1 - -
t D × RR
PI 0 .9 3.3 ×t D -
t D × RR
PID 1.2 2 ×t D 0.5 ×t D
t D × RR
Internal Model Control Tuning Relation
Controller Type Gain (Kc) Reset ( τI ) Rate ( τD )
PI
τ 
when 2 c  + 1
1  tD 
λ tD
> 0.8 Kp  λ  +τ c
tD 2  + 1 2 -
τc  tD 
λ>
10
PID τ 
2 c  + 1 τc
1  tD 
when tD τ 
λ Kp  λ  +τ c 2 c  + 1
> 0.8 2  + 1 2
tD  tD   tD 
τc
λ>
10