Model WLF922: LEVEL FLOW TRAINER

Experiment No. 6:

(For this experiment you only need to do all the start up procedure from step 1 to
9 and experiment procedure 10 and 12 only.)

6.1 Objective:
To study level control.

Control System:
It consists of the following single loop Level control in feedback:
LT31-LIC31-LCY31/PP/LCV31

6.2 START-UP CHECK LIST AND PRELIMINARY EXERCISES

The following is a start-up checklist and preliminary exercises. Please go through them before
starting any experiment. Also refer to the P and I sketch enclosed.

1. Tank T32 should be filled with water up to and just below the level of the shortest level probe
(not visible) of the Level Switch LS32 which is slightly below the tank (T32) overflow pipe
outlet. Top up the water later whenever necessary.

2.
a.Interconnected Operation
NOTE THAT INTERCONNECTED OPERATION IS NOT POSSIBLE UNLESS THERE
ARE MODELS WLF922, WF922 AND WT922 FOR THE PIPING INTERCONNECTIONS*.
IF INTERCONNECTED OPERATION IS NOT POSSIBLE, PROCEED STRAIGHT TO
PROCEDURE 2(b) FOR INDEPENDENT OPERATION AND IGNORE ANY
INSTRUCTIONS PERTAINING INTERCONNECTED OPERATION.
If Model WLF922 is to be operated interconnected with Models WF922 and WT922, open
their interconnecting pipelines at the appropriate manual valves.
Thus, the manual valve MV-T (To WT922) should be opened but shut the manual drain MV-
D (To Drain).

b.Independent Operation
To operate Model WLF922 independently, open the by-pass manual valve B33 of pump
P33 to divert any flow back to T32. Shut the interconnecting pipeline from Model WLF922
to Model WT922 at the appropriate manual valves MV-T. Also shut the manual valve MV-D
at the discharge of pump P33, leading to the drain.
For Independent Operation, the panel-mount selector switch for P33 must be in the
Manual or “OVER-RIDE P33” position.

c. Pump P33 has an Auto/manual Over-ride selector switch. Over-ride P33 i.e. leave it in
Manual i.e. ‘OVER-RIDE P33’ position for the time being.
In position LS32-P33. Pump P33 is Started/Stopped automatically by the
“AUTO,P33”: level switch LS32 at tank T32. The manual pushbuttons for
pump P33 cannot Start or Stop P33.
If Model WLF922 is in Interconnected Operation, the
selector switch should be in AUTO position.

In position Manual Over Ride P33. Pump P33 can be Started/Stopped by

“OVER-RIDE P33”: its manual pushbuttons. The level switch LS32 cannot start or
stop P33.
If the Model WLF32 is in Independent Operation, the
selector switch should be in this MAN position (i.e. ‘Over Ride
P33’).

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3. Quickly check the various manual valves as follows:
 Locate the Inflow pump P32. Check that its manual suction, discharge and by-pass
valves are fully opened.
For the Outflow pump P31, open fully its manual suction valve but shut fully its two
manual parallel discharge valves.
For pump P33, open fully its manual suction and by-pass valve but make sure its manual
discharge valves MV-T and MV-D are fully shut.

 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), located 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, thus operating only one gravity discharge
pipelines at the bottom of tank T31.
Shut the two manual discharge valves of Outflow pump P31, one of which is at the
strainer inlet. For a Self Regulating process, pump P31 must be OFF.

 The manual by-pass valve around the control valve LCV31 should be always shut but its
two adjacent manual valves should be always opened.

 The bottom manual drain valve of T32 is always shut.

 Model WLF922 is connected to a common drain system for draining outside the building.
Trace the drain piping system from the tank T32 overflow pipe to its final discharge.

4. 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.

 It is good practice to purge the air regulator (IAS) to remove any condensed water. Use
the drain/bleed valve at the bottom of the air regulator (IAS).

 The air regulator (AR31) for pressurizing tank T31 is preset to about 3.0 psig and need no
adjustment. Any higher pressure will cause the pressure relief valve PRV31 to open.

 Do not pressurize T31 yet. Shut the pressurizing air inlet manual isolation valve (with the
valve handle at 90o to the air supply inlet tubing) located next to AR31 near the top of
tank T31.

5.
a. Main power supply is pre-connected to the Model plant.
Turn on the main power supply switch at the front cubicle. The panel instruments all lit up.

WHENEVER ANY ANNUCIATOR IS ACTIVATED, PRESS THE ACKNOWLEDGE BUTTON

TO SILENCE THE BUZZER. REFER TO THE EARLIER SECTION “(j) ANNUCIATORS”
AND RATIONALIZE THE CAUSE OF THE ALARM CONDITION.

b. Note the following switches and pushbuttons but do not switch ON any pump yet.

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 PANEL, SCADA/DCS : Switch to “PANEL, SCADA” position for Panel operation
selector switch

Pump P32 : Pumping inflow from T32 to T31. To be switched ON during

operation.

Pump P31 : Do not use unless T31 is to be operated as a Non-Self

regulating process, in which case the bottom gravity
discharge pipes of T31 must be all shut. Check that the two
manual discharge valves of P31 are shut.

Pump P33 : Pump P33 can be selected to either the ‘AUTO’ or ‘MAN’
position. ‘MAN’ position is the ‘OVER-RIDE P33’ position.
In ‘Auto’ position, P33 is switched ON by Level switch LS32
automatically when the Level in T32 switch LS32
automatically when the Level in T32 exceeds the High level
limit. When Model WLF922 is to be operated interconnected
with WT922 and WF922, P33 should be in ‘AUTO’ position.
When P33 is in the ‘OVER-RIDE P33’ position, it can be
manually started or stopped at the P33 panel pushbuttons,
and LS32 will not be able to start or stop P33. Leave it in
‘OVER-RIDE P33’ position for the time being.

6. PID CONTROLLER: LIC31/FIC31

Controller LIC31/FIC31 is one unit of Yokogawa YS 170 Single Loop Programmable
Controller configured with two PID controllers: LIC31 (PID1, Loop1) and FIC31 (PID2,
Loop2). Be familiar with the controller as follows:

 Use the 1-2 Position selector switch as follows:

Switch to Position 1: : Single Level Loop LIC31 (PID1, Loop1).

LIC31 Note PV1, SV1, MV. Control output to the control valve.

In Position 1, PV1, SV1 are displayed as PV, SV for LIC31

PV1 is process variable i.e. Level of T31, SV1, is its setpoint
and MV is manipulated variable or control output to the to the
control valve.

: FIC31 (PID2, Loop2) is not operating in Position 1.

Switch to Position 2: : Can be

CASCADE LIC31-FIC31
Either Single Flow Loop FIC31
(PID2, Loop2) when FIC31 is in Auto (A) mode. Note
PV2, SV2, MV. In Position 2 FIC31 in Auto (A) LIC31
(PID1, Loop1) is not controlling.

OR Level-Flow Cascade Loops LIC31-FIC31 when FIC31

is in Cascade (C) mode.

In Cascade (C) mode, MV displays the control output to the

Control Valve LCV31.

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 Note that Cascade operation is only possible if the selector
switch is in Position 2 and FIC31 is in Cascade (C) mode.
In Position 2 with FIC31 in Cascade (C) mode, both LIC31
(Loop1, PID1) and FIC31 (Loop2, PID2) are controlling in
Cascade (C) mode.

 When in Position 2, note the respective measurement and setpoints PV1/SV1 for the
Level Loop LIC31/PID1/Loop1 and PV2/SV2 for the Flow Loop FIC31/PID2/Loop2. Note
that when FIC31 is in the Cascade (C) mode, SV2 is no longer set by the Operator.

 With the 1-2 Selector switch in Position 1, display LIC31. (Press the blue push button
located at the bottom right side of the controller LIC31/FIC31, to select the display of
LIC31, if necessary.) Note the A (Auto) and M (Manual) pushbuttons. Press M and leave
LIC31 in Manual (M) mode.

 With the 1-2 Selector switch in Position 2, display FIC31. Note the A (Auto), M (Manual)
and C (Cascade) pushbuttons. Press C to select the Cascade (C) mode. Press M and
leave it in Manual (M) mode.
Note that only FIC31 can be Cascade (i.e. press C) and the Selector switch must be in
Position 2.

 In Manual (M) mode, manually stroke the control valve LCV31 with MV = 50%, from both
(a) FIC31 (when in Position 2) and then from (b) LIC31 (when in Position 1). Note that the
MV is the same MV from either FIC31 or from LIC31, being the control signal to the
control valve LCV31.

 Practice adjusting the setpoints Sv1, Sv2 at the respective main face plates of
LIC31/FIC31, and the PID trial values at the respective PID1, PID2 panels as follows,
whilst in the Manual (M) mode:-

LIC31, PID1, Loop1 FIC31, PID2, Loop2

First (I) Second (II) First (I) Second (II)
Trial PID Trial PID Trial PID Trial PID
SETPOINT 200-600 mm 200-600 mm SETPOINT 0.9-2.4 m3/hr 0.9-2.4 m3/hr
SV1 SV2
PB1 30% 10% PB2 250% 100%
TI1 25 secs 15 secs TI2 10 secs 6 secs
TD1 0 sec 0sec TD2 0 sec 0 sec
PH1 640 mm PH2 0.5 m3/hr
(Do not change this High (Do not change this low flow
level alarm limit for LAH31) alarm limit for FAL31)

 Change to the Self-Tuning page (STC1, STC2). The ‘STC’ should both be in the “DISP”
(Display) mode. Make sure ‘STC’ is not in ‘ON’ mode.

7. Check the Positioner (PP) manual By-pass sitch at LCV31/PP. Make sure the Positioner (PP)
is connected to LCV31 i.e. do not by-pass it, but USE THE Positioner (PP).
 Set the 1-2 Selector switch to Position 1 to operate LIC31 and display
LIC31, Loop 1 accordingly.

 With LIC31 in Manual (M) mode, adjust MV = 25%. Check that LCV31
is about 25% OPENED (see the indicator scale at the valve stem).
Also note that the control valve LCV31 is Air-to-Open (ATO).

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8. By-pass the Positioner (PP) using its manual By-pass switch at LCV31/PP. Thus means the
Positioner is disconnected from the control valve and the control output from LIC31/LCY31 us
stroking LCV31 directly, with MV = 25% = 6.0 psig.
The Positioner (PP) is not used.
 Check that LCV31 is now almost shut, because LCV31 has a 7-15 psig
actuator spring.
 After this test, connect back the Positioner (PP) to LCV31 i.e. USE THE
POSITIONER (PP). Note that the control valve position is about 25% opened.

9. Start the recorder, LFR31 by pressing the RCD button ON, with the front swing cover opened.
Check the recorder chart speed (500 mm/hr) which is regularly printed out on the chart.
The recorder chart drive should be stopped (press RCD) when its chart recording is not
required. Switch OFF the recorder chart drive.
.

6.3 Procedures:

THE FOLLOWING PROCEDURES ASSUME YOU HAVE ATTEMPTED THE EARLIER SECTION
ON “START-UP CHECK LIST AND PRELIMINARY EXERCISES”.

1. to 9. Please refer to the Section “START-UP CHECK LIST AND PRELIMINARY

EXERCISES”. It is assumed that the readers have already performed Procedures
from 1 to 9.
In particular, repeat Procedure 2, depending on whether Model WLF922 is to be
operated independently OR interconnected with other Models.
If operated INDEPEDENTLY, shut both manual valves MV-D, MV-T but open
B33. The panel-mount selector switch for pump P33 must be in the Manual or
“OVER-RIDE P33” position.
(If operated INTERCONNECTED with Model WT922, open MV-T but shut MV-D
and B33. The panel-mount selector Switch for pump P33 must be in the
“AUTO, P33” position.)
NOTE THAT INTERCONNECTED OPERATION IS NOT POSSIBLE UNLESS
THERE ARE MODELS WLF922, WF922 AND WT922 FOR THE PIPING
2.
3.
INTERCONNECTION.*
makan
tidoq
4. selimut
5. katil
6. bantal
7. baju
8. seluar
9. tennis

10. Tank T31 as a Self Regulating process, Open tank

a. Operate tank T31 as a Self Regulating Open tank process as follows:
 Self regulating process: Outflow of T31 is by gravity flow via one of the two
manual discharge valves of pump P31. do not switch on pump P31.
 Open Tank: T31 is opened to atmosphere.
i. Open only the GATE manual valve at the gravity discharge pipeline at
the bottom of T31. Shut the second manual globe valve. Shut the two
manual discharge valves of pump P31. Do not switch on pump P31.
ii. Open the manual valves at the vent (V) and at the overflow drain
pipeline, near the top of tank T31.

b. With the controller Selector switch in Position 1, display LIC31 faceplate at the
controller. Note that position 1, PV1, SV1, and MV1 are displayed as PV, SV and
MV in the main display page (faceplate). Please refer to the “TABLE FOR PV, SV,
MV AT SELECTOR SWITCH POSITION 1 AND 2” for details.
 Set the setpoint (SV1) of LIC31 to 400mm. note that SV1 should be operated
from 200 (25%) to 640mm (80%) only.

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  With LIC31 in Manual (M) mode, set MV = 75%. Check that the stem position
of control valve LCV321is about 75%. The positioner (PP) should be
connected I.E. USE THE POSITIONER.
 Set the first (I) trial PID values at the ‘PID1’ page or panel as follows: LIC31
(PID1,Loop1): PB1 = 30%, TI1 = 25 secs, TD1 = 0.
 The first (I) and second (II) trial PID values are listed below for quick
reference, together with their expected responses.
 The procedure to try both the PID values are given below, (c) to (g). What is
the suitable values that you should use for the second trial for PID values in
Table 6.1. Try to reduce the values in the first trial by a small percentage

TABLE 6.1: PID trial values for LIC31, Loop 1

First (I) trial PID values for Second (II) trial PID values
LIC31 for LIC31
PB1 30%
TI1 25 secs
TD1 0 sec
Comment

 Check that the recorder (LFR31) chart drive is running i.e. “RCD” is displayed
at the recorder. Otherwise, press the RCD pushbutton with the front swing
cover opened.

c. Start pump P32 and watch the level (PV1) increases. Shut the pump by-pass
valve B32.

d. When the level is near to the setpoint SV1, switch LIC31 to Auto (A) mode and
observe the Level (red pen) response at the recorder LFR31. Throughout the
following test and observation, LIC31 is to remain in Auto (A) mode and the
control valve Positioner (PP) must be used ad connected unless instructed
otherwise.

e. The recorder LFR31 chart drive should be fast speed (500 mm/hr) with RCD ON.
Check the chart speed with regularly printed out on the chart. OBSERVE THE
LEVEL RESPONSE AT THE RED PEN UNTIL THE RESPONSE IS ALMOST
STEADY TO WITH 1.0 MM OR IT DISPLAYS OSCILLATORY RESPONSE
EVEN AFTER 3 CYCLES. WRITE DOWN THE SETPOINT (SV1) AND PID
VALUES ON THE RECORDER CHART PAPER BESIDES ITS RESPONSE.
THESE CHARTS RECORDINGS CONSTITUTE THE RESULTS OF YOUR
EXPERIMENT AND SHOULD BE KEPT FOR YOUR REPORTS.

f. Test disturbance
Repeat the Level (Red Pen) observation by using the following TEST
DISTURBANCE, one test at a time. Start and each test when the level response
is reasonably steady or remains oscillating even after 3 cycles.
i. Step increase or decrease the setpoint (SV1) by about 10%. This simulates
the setpoint step test. Observe the level (red pen) response at the recorder
LFR31. Work within an SV1 of 200 to 640 mm.
ii. Switch LIC31 to Manual (M) mode and quickly step change MV (inflow) by
about 10% to 20%. Then quickly switch LIC31 back to Auto (A) mode. This
simulates a load step test at the inflow. Observe the level (red pen)
response similarly.

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 iii. Open 1 ½-turn. Hold for 5 seconds – Shut fully, the pump bypass manual
valve B32. This simulates a load pass disturbance test at the outflow.
Observe similarly.
iv. Note that the second gravity discharge globe manual valve at the bottom of
tank T31 is always shut. Open fully – Hold for 5 secs – Shut fully, the second
bottom gravity discharge manual globe valve. This simulates a load pulse
disturbance test at the outflow. Observe similarly. Make sure this globe
valve is fully shut.

g. Repeat the test with any if the above disturbances such as f(ii) above, using the
second (II) trial PID values as follows:
LIC31 (PID1, Loop1)
LIC31 must be in Auto (A) mode.
 Note from the recorder chart response that even though the inflow (Green
pen) is fluctuating, the level is held almost steady, Level is a capacity process
with a larger Time constant than flow to absorb the inflow fluctuation.
 Compare the level responses, caused by the first (I) and second (II) trial
PID values.
See the previous TABLE, for the expected responses. If the more aggressive
PID values with a smaller PB% x TI secs is able to control the level
satisfactorily, choose this PID i.e. PB1 = 10%, TI1 = 15 secs, TD1 = 0 secs
instead of PB1 = 30%, TI1 = 25 secs, TD1 = 0 secs.

h. Level PID control with only Proportional (P) control mode

Repeat the test with only Proportional mode. Integral control can be removed by
setting TI1 to its maximum (9999 secs). Proceed as follows:
 Set LIC31 (PID1,Loop1): PB1 = 10%, TI1 = 9999 secs (max), TD1 = 0 sec.
LIC31 must remain in Auto (A) mode with a setpoint, say SV1 = 400 mm.
 Apply a test disturbance such as the previous 10f(ii). LIC31 must remain in
Auto (A) mode after the test disturbance. Note that without Integral control
there will be OFFSET, which is the permanent deviation of the level from its
setpoint.
 When TI1 is rest to 15 secs (i.e. TI1 = 15 secs), note that the OFFSET will be
redused. Integral (I) control mode removes Offset.
 Remove Integral (I) control again with TI1 = 9999 secs. Set PB1 very low,
say 5%. Apply test disturbance 10f(ii). LIC31 must remain in Auto (A) mode
after the test disturbance. Apply test disturbance 10f(iv). Will level process
oscillate uniformly with only Proportional (P) control mode?

i. Level PID control with Derivative (D) control mode

Repeat the test with Proportional (P), Integral (I), and Deviation (D) control
modes as follows, using the same test disturbance 10f(ii)
 Set LIC31 (PID1, Loop1): PB1 = 10%, TI1 = 15 secs, TD1 = 30 secs Apply
the load test disturbance as in 10f(ii).
Note that the Derivative (D) control mode will cause instability.
 Observe the control valve (LCV31) fluctuation due to the controller output
(i.e. MV) fluctuation, which causes the inflow (Green pen) to fluctuate. Small
amplitude oscillation like Noise may appear at the level response as the
capacity time constant in the level tank (T31) is unable to provide adequate
damping (buffering) to the large fluctuating inflow, besides the level noise
itself which is always present in a level process.
 Double the PB1 to say 20% and observe the damping at both the inflow
(Green pen) and level (Red pen) response and at the control valve LCV31.

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 When the level is almost steady at its setpoint again, apply test disturbance
10f(ii) and observe.
 Better still, set TD1 = 0 sec i.e. do not use Derivative (D) control on level
control. Observe both the flow and level response without Derivative (D)
control.

j. PID tuning: Open Loop Method

 Refer to your Instructor and try to tune the Controller using the Open Loop
method. This is done when the level is steady with LIC31 in Manual (M)
mode and using a step change in MV of about 10%. The level will rise or fall
and then gradually flattens out exponentially. The steepest tangent is then
drawn on the response curve to determine the Response Rate (RR) and the
equivalent Dead Time (DT). Refer to the Appendix for the Ziegler and Nichols
formulae to establish the approximate PB1, TI1 values from the Response
Rate (RR) and the equivalent Dead Time (DT).

100 0. 9
 , TI sec  3.3DT sec, TD  0 sec
PB % DT  RR

As observed in 10(h) earlier, level (any single capacity) process will not oscillate uniformly
with only Proportional (P) control mode, the Closed Loop Tuning method is not
applicable this instance.

11. T31 as a Self regulating process, Closed tank

 Check that the Positioner (PP) is connected i.e. USE THE POSITIONER

 To operate T31 as a Self Regulating Closed tank process, check that only the
manual discharge GLOBE vale at the bottom gravity discharge pipelines of tank T31
is opened. (the second gravity discharge pipeline is not requirted and therefore its
manual gate discharge valve should be shut).

 To operate T31 as a Closed tank, shut its manual valves at the vent (V) and the
overflow drain pipe, near at the top of the tank.

 Make sure the controller LIC31 is still in Auto (A) mode with a setpoint SV1 of
400mm.

 Check that only pump P32 is pumping. The manual by-pass valve P32 is fully shut.
Check that the pump P31 is OFF and the two manual discharge valves of pump P31
are fully shut.

 Manually crack open the pressurizing air inlet manual isolation valve (with its handle
pointing in the same direction as the air supply inlet tubing) located near the top of
tank T31 next to the air regulator AR31. Do not exceed 3 psig (observe the pressure
gauge PG31). The pressure relief valve PRV31 will pop open on excessive pressure.

 Observe the control performance using the best PID values established or else use
the second (II) trial PID values shown in the next TABLE:

PID trial Values for LIC31 (PID1, Loop1)

First (I) trial PID values Second (II) trial PID values
PB1 30% 10%
TI1 25 secs 15 secs

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 TD1 0 sec 0 sec

 If the second (II) trial PID values produce too oscillatory response, try the first (I)
trial PID values. Use any test disturbance mentioned in the previous Procedure 10f,
for example 10f(ii) for a load step disturbance test. Observe similarly.

 Restore T31 as an Open tank. Open the manual valves at the vent (V) and the
overflow drain pipe, near the top of T31. Shut the pressurizing air inlet manual
isolation valve to T31 (i.e. with its handle at 90o to the air supply tubing). At the
bottom gravity discharge pipelines of tank T31, shut fully the manual globe valve but
open fully the manual GATE valve.

TABLE6.2: OPERATION OF VARIOUS TANK LEVEL PROCESSES IN T31

T31: Open tank T31: Closed tank T31: Open T31: Closed
Level: Self- Level: Self- tank tank
Regulating Regulating Level: Non- Level: Non-
Self Self
Regulating Regulating
Open or Closed
tanks TOP OF T31
Vent (V) valve Open fully Shut fully Open fully Shut full
Overflow drain valve Open fully Shut fully Open fully Shut fully
Pressurizing Air Shut fully Open fully Shut fully Open fully
Atmospheric 3 psig Max Atmospheric 3 psig Max
T31 Pressure, at
PG31


T31 OUTFLOW via

gravity at T31
BOTTOM
 Globe valve Shut fully Open fully Shut fully Shut fully
 Gate valve Open fully Shut fully Shut fully Shut fully

T31 OUTFLOW via

Pump P31
 Pump P31 OFF OFF ON ON

NOTE
A Self Regulating (SR) level process can control itself to reach a steady state at some level
position within the operating range of the level, if the Inflow and Outflow rates are operating
within certain limits. This is because the Outflow rate depends on the tank level, being driven
by gravity flow in this case. The higher the level, the higher the Outflow rate. Similarly, the
lower the level, the lower the Outflow rate.
A Non-Self Regulating (NSR) level process cannot control itself to reach a steady state and
can overflow (if the Inflow exceeds the Outflow) or run dry (if the Outflow exceeds the Inflow).
The Outflow rate is independent of the tank level because its Outflow is driven by an outflow
pump instead, at almost constant rate.

12. Tank T31 as a Non-Self Regulating process. Open Tank.

 Check that the Positioner (PP) is connected i.e. USE THE POSITIONER.

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  Make sure that tank 31 is an Open tank, with its vent (V) and overflow drain valves
opened but the pressurizing air inlet isolation valve shut (i.e. its valve handle at 90 o to
the air supply tubing). Pump P32 is still ON with its manual by-pass valve B32 fully
shut.

 Set the best PID values you have established, into LIC31 (PID1, Loop1). Otherwise,
set the second (II) trial PID values as follows:
LIC31 (PID1,Loop1): PB1 = 10%, TI = 15 secs, TD1 = 0 sec.
If the response is too oscillatory, increase PB1 and TI1 i.i. use the first (I) trial PID
value:
LIC31 (PID31,Loop1): PB1 = 30%, TI1 = 25 secs, TD1 = 0 sec.
Make sure the setpoint Sv1 of LIC31 is 400mm. LIC31 is still in Auto(A) mode.

 To operate T31 as a Non-Self Regulating process, shut all (two) the gravity
discharge pipes at the tank bottom, at the Globe and gate manual valvles.
Locate pump P31 and open fully its manual suction valve. Open fully one of its
manual discharge valves. Start pump P31 to pump the outflow from T31 into T32.

 Observe the control response with LIC31 in Auto (A) mode. Use any test disturbance
mentioned in the previous Procedure 10f, except 10f(iv). In particular, use test
procedure 10f(ii).

CAUTION: As level can overflow or run-dry easily, LIC31 must remain in Auto (A)
mode when left unattended. Use a level setpoint SV1 of 200 to 640 mm only.

 Restore T31 as a Self-Regulating Open Tank by switching OFF pump P31 and
opening fully the GATE manual valve at the gravity discharge pipe at the bottom of
T31. Shut fully the two manual discharge valves of pump P31.

13. Self Tuning (STC)

If time and opportunity permit, try the controller LIC31 on Self-tuning (STC) to establish
its own P, I, and D. Refer to your Instructor for assistance.
Do this on the Self Regulating Open Tank.

 Display the STC1 page. If the Self-Tuning STC1 has been at “DISPLAY” mode
(STC: DISP), the self-tuned PID values are displayed at the STC1 page as “PA1” (for
PB1 by STC1), “IA1” (for TI1 by STC1) and “DA1” (for TD1 by STC1). These PID
values ate however not implemented into LIC21/PID1, only displayed at the STC1
page. If the Self-tuned PID values mentioned above are displayed, implement these
in the PID1 page. Then test these PID values using the load step test disturbance
as in 10f(ii).

 If time and opportunity permit, try the controller (LIC31/PID1) on Self-Tuning (switch
STC”ON” where it establish and implement its own P(PB1), I(TI1) and D(TD1). Apply
any test disturbance such as the previous 10f(i) or (ii).

Make sure LIC31 is in the Auto (A) mode.

Let the controller LIC31 self-tune itself and implements its own PID values. Observe
patiently the STC1 page (and the recorder chart response) to see if the PID values
have been changed by the Self-Tuning and whether the control response is any
better.

 After the above, make sure STC (at the STC1 and STC2 pages) are switched back to
the “DISP” (Display) mde.

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 Also check the PID1 and PID2 pages and reset both SFA1, SFA2 to 1.000, and both
SFB1, SFB2 to 0.000

At LIC31/FIC31
At STC1 page for LIC31, set STC:DISP At PID page for LIC31,
Set SFA1 = 1.000; SFB1 = 0.000

At STC2 page for FIC31, set STC:DISP At PID2 page for FIC31
Set SFA2 = 1.000; SFB2 = 0.000

14. STOP ALL THE PUMPS. MAKE SURE BOTH THE MANUAL DISCHARGE VALVES OF
PUMP P31 ARE FULLY SHUT.

TABLE 6.3 FOR PV, SV, MV AT SELECTOR SWITCH POSITION 1 AND 2

DISPLAY AT THE MAIN DISPLAY PAGES (FACEPLATES)

SELECTOR SWITCH POSITION 1 SELECTOR SWITCH POSITION 2
AT AT AT AT
LIC31/LOOP1 page FIC31/LOOP2 page LIC31/LOOP1 page FIC31/LOOP2 page
Display for the Level Display for the Flow Display for the Level Display for the Flow
loop loop loop loop
PV Ignore PV1 PV2
SV Ignore SV1 SV2
MV Ignore MV1 MV
DISPLAY AT THE PID1 AND PID2 PAGES
SELECTOR SWITCH POSITION 1 SELECTOR SWITCH POSITION 2
AT PID1 page: AT PID2 page: AT PID1 page: AT PID2 page:
Display for the Level Display for the Flow Display for the Level Display for the Flow
loop loop loop loop
PV1 Ignore PV1 PV2
SV1 Ignore SV1 SV2
MV 1 is MV Ignore MV1 is MV, MV2 is MV
NOT MV1. THE
ACTUAL MV1 IS SV2
WHEN IN CASCADE
(C) MODE.

REMARKS:
MV is the actual control output in % to the Control Valve LCY31/PP/LCV31. It can be from
EITHER LIC31/LOOP1/PID1 (when is Selector Switch Position 1) OR from FIC31/LOOP2/PID2
(when in Selector Switch Position 2)

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