Advanced Process Control

Pressure, Flow, and Level

Process Automation

Workbook

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Process Control

Advanced Process Control

Pressure, Flow, and Level

Instructor Guide
85983-10
Order no.: 85983-10
First Edition
Revision level: 07/2015

By the staff of Festo Didactic

© Festo Didactic Ltée/Ltd, Quebec, Canada 2010

Internet: www.festo-didactic.com
e-mail: [email protected]

Printed in Canada
All rights reserved
ISBN 978-2-89640-388-2 (Printed version)
Legal Deposit – Bibliothèque et Archives nationales du Québec, 2010
Legal Deposit – Library and Archives Canada, 2010

The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.

The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical
colleges, training centers, and universities, the right of use shall also include use by school and college
students and trainees at the purchaser's site/location for teaching purposes.

The right of use shall in all cases exclude the right to publish the copyright material or to make this
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access by a wide variety of users, including those outside of the purchaser's site/location.

Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
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require the prior consent of Festo Didactic GmbH & Co. KG.

Information in this document is subject to change without notice and does not represent a commitment on
the part of Festo Didactic. The Festo materials described in this document are furnished under a license
agreement or a nondisclosure agreement.

Festo Didactic recognizes product names as trademarks or registered trademarks of their respective
holders.

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Festo Didactic disclaims any proprietary interest in trademarks and trade names other than its own.
 Safety and Common Symbols
The following safety and common symbols may be used in this manual and on
the equipment:

Symbol Description

DANGER indicates a hazard with a high level of risk which, if not

avoided, will result in death or serious injury.

WARNING indicates a hazard with a medium level of risk which,

if not avoided, could result in death or serious injury.

CAUTION indicates a hazard with a low level of risk which, if not

avoided, could result in minor or moderate injury.

CAUTION used without the Caution, risk of danger sign ,

indicates a hazard with a potentially hazardous situation which,
if not avoided, may result in property damage.

Caution, risk of electric shock

Caution, hot surface

Caution, risk of danger

Caution, lifting hazard

Caution, hand entanglement hazard

Notice, non-ionizing radiation

Direct current

Alternating current

Both direct and alternating current

Three-phase alternating current

© Festo Didactic 85983-10 III

 Safety and Common Symbols

Symbol Description

Earth (ground) terminal

Protective conductor terminal

Frame or chassis terminal

Equipotentiality

On (supply)

Off (supply)

Equipment protected throughout by double insulation or

reinforced insulation

In position of a bi-stable push control

Out position of a bi-stable push control

IV © Festo Didactic 85983-10

 Preface
Automated process control offers so many advantages over manual control that
the majority of today’s industrial processes use it to some extent. Breweries,
wastewater treatment plants, mining facilities, and the automotive industry are
just a few industries that benefit from automated process control systems.

Maintaining process variables such as pressure, flow, level, temperature, and pH

within a desired operating range is of the utmost importance when manufacturing
products with a predictable composition and quality.

The Instrumentation and Process Control Training System, series 353X, is a

state-of-the-art system that faithfully reproduces an industrial environment.
Throughout this course, students develop skills in the installation and operation
of equipment used in the process control field. The use of modern, industrial-
grade equipment is instrumental in teaching theoretical and hands-on knowledge
required to work in the process control industry.

The modularity of the system allows the instructor to select the equipment
required to meet the objectives of a specific course. Two mobile workstations, on
which all of the equipment is installed, form the basis of the system. Several
optional components used in pressure, flow, level, temperature, and pH control
loops are available, as well as various valves, calibration equipment, and
software. These add-ons can replace basic components having the same
functionality, depending on the context. During control exercises, a variety of
controllers can be used interchangeably depending on the instructor’s
preference.

We hope that your learning experience with the Instrumentation and Process
Control Training System will be the first step toward a successful career in the
process control industry.

We invite readers of this manual to send us their tips, feedback, and

suggestions for improving the book.

Please send these to [email protected].

The authors and Festo Didactic look forward to your comments.

© Festo Didactic 85983-10 V

VI © Festo Didactic 85983-10
 Table of Contents
Exercise 1-1 Feedforward Control ..................................................... 1

Exercise 1-2 Ratio Control.................................................................. 3

Exercise 1-3 Split-range Control ........................................................ 6

Exercise 2-1 Second-Order Non-Interacting Processes .................. 8

Exercise 2-2 Second-Order Interacting Processes ........................ 11

Appendix A Answers to Unit Test Questions ................................ 13

© Festo Didactic 85983-10 VII

Exercise 1-1 Feedforward Control

Exercise 1-1 Feedforward Control

ANSWERS TO PROCEDURE 16. Water exits the column under the force of gravity only. If the level of water
STEP QUESTIONS decreases in the column, the pressure the water exerts near the column
outlet decreases, thus the output flow decreases.

17. The output flow rate when the level is 30 cm (about 12 in) should be
around 12.5 L/min (3.3 gal/min).

18. The approximate set point to keep the level stable around 30 cm
(about 12 in) is the measured output flow divided by the transmitter range.
That is

12.5 L/min
100 31%
40 L/min

3.3 gal/min
100 33%
10 gal/min

23. No. It is not perfectly stable, it moves a little.

24. Yes, there is always a small offset between the input flow and the output
flow. Therefore the level is not perfectly stable.

25. No. In a feedforward installation, the controller tries to compensate for the
effects of disturbances occurring upstream of a process. The controlled
variable is not measured. Therefore, if the controlled variable actually
deviates from the set point, the controller has no way to know and it cannot
compensate for the offset and return the controlled variable to its original
value.

28. The level becomes stable quite rapidly and it stays stable. The input flow and
the output flow are equal.

ANSWERS TO REVIEW 1. Because in feedforward control the measurement is made on an input

QUESTIONS parameter to try to predict changes before they occur instead of trying to
compensate for the perturbation once it has already occurred.

2. In feedforward control, an input of the system is measured and we want to

infer from this measurement the reaction of the system. This cannot be done
without some kind of model.

3. The controller cannot compensate for the perturbation.

© Festo Didactic 85983-10 1

Exercise 1-1 Feedforward Control

4. Deviate from the set point.

5. A feedback component.

2 © Festo Didactic 85983-10

Exercise 1-2 Ratio Control

Exercise 1-2 Ratio Control

ANSWERS TO PROCEDURE 14. The flow rate measured by FIT1-A is smaller than the flow rate measured by
STEP QUESTIONS FIT1-B because the Venturi tube and the control valve cause a greater
resistance to flow than the orifice plate alone. Similar to electrical current, the
water flow is greater in the path of least resistance.

% FIT1-A
CH1 Venturi
100 (%)
FIT1-B
CH2 Orifice
(%)
80
CV CV
CH3
(%)
60

40

20

0
0 10 20 30 40 50 60 Time (s)

The flow rate measured by FIT1-A is smaller than the flow rate measured by FIT1-B.

21.
% CH1 Venturi
FIT1-A
(%)
100
CH2 Orifice
FIT1-B
(%)
80
CH3
CV CV
(%)
60

40

20

0 Time (s)
0 5 10 15 20 25 30

Response to a perturbation ( ).

© Festo Didactic 85983-10 3

Exercise 1-2 Ratio Control

22. The ratio constant should be set to 1.33 to obtain a set point equal
to 0.75  FIT1-B:

FIT1‐‐– B output FIT1– B output

Set point 0.75 FIT1– B output
R 1.33

24. No, the tuning is not conserved when the ratio parameter is changed. You
may have to tune your system again depending on the change in the ratio
constant.

% CH1 Venturi
FIT1-A
(%)
100
CH2 Orifice
FIT1-B
(%)
80
CV CV
CH3
(%)
60

40

20

0 Time (s)
0 5 10 15 20 25 30 35 40

Response to a perturbation ( . ).

26.
% CH1 Venturi
FIT1-A
(%)
100
CH2 Orifice
FIT1-B
(%)
80
CV CV
CH3
(%)
60

40

20

0 Time (s)
0 5 10 15 20 25 30 35 40

Response to a perturbation ( . ) with a tuned system.

4 © Festo Didactic 85983-10

Exercise 1-2 Ratio Control

28. No, it is impossible to obtain two equal flows with the present setup. When
the control valve is fully open, the flow reading of FIT1-A is smaller than the
flow reading of FIT1-B and the only thing the controller can do to correct any
perturbation is close the control valve, which further reduces the flow reading
of FIT1-A.

ANSWERS TO REVIEW 1. It is closer to feedforward control. Ratio control is an application of

QUESTIONS feedforward control since the measured variables are the input variables of
the process.

2. Preserve the proportion between two input variables.

3. The desired ratio between the two input variables.

4. In the first method, the set point is the desired ratio. In the second case, the
set point is the actual value of one of the input variables multiplied by a
constant.

5. No, must respect the physical limitations of the system.

© Festo Didactic 85983-10 5

Exercise 1-3 Split-range Control

Exercise 1-3 Split-range Control

ANSWERS TO PROCEDURE 17. The graph of the level in the column and the opening of both control valves
STEP QUESTIONS as a function of time should look like the graph below.

% Level
CH1 Venturi
(%)
100
CH2 Orifice
LCV1-B
(%)
80
LCV1-A
CH3 CV
(%)
60

40

20

0
0 10 20 30 40 50 Time (s)

Level, LCV1-A, and LCV1-B as a function of time.

18.
% Level
CH1 Venturi
(%)
100
CH2 Orifice
LCV1-B
(%)
80
LCV1-A
CH3 CV
(%)
60

40

20

0
0 20 40 60 80 100 Time (s)

Level, LCV1-A, and LCV1-B as a function of time.

19. No, with the actual controller gain and the controller set to proportional mode,
the system does not reach equilibrium. By the time the valves open or close,
the controlled variable is already below or above the set point.

6 © Festo Didactic 85983-10

Exercise 1-3 Split-range Control

21.
% Level
CH1 LIT1
(%)
100
LCV1-B
CH2 LCV1
(%)
80
LCV1-A
CH3 LCV2
(%)
60

40

20

0
0 50 100 150 Time (s)

ANSWERS TO REVIEW 1. Split-range control is a type of installation that allows controlling more than
QUESTIONS one final control element using a single controller and only one input variable.

2. The spring/diaphragm actuator of a valve determines if the valve opens or if it

closes for a 20 mA signal. Thus, it determines the opening of the control
valves as a function of the controller output, which is the heart of split-range
control.

3. A dead band is used to prevent a split-range system from switching between

two output ranges continuously, thus preventing the equipment from wearing
out prematurely.

4.
 Temperature control application
 Controlling the input and output of a reactor
 Flare application

5. Evacuate an excess of flammable gas from a reactor and burn it.

© Festo Didactic 85983-10 7

Exercise 2-1 Second-Order Non-Interacting Processes

Exercise 2-1 Second-Order Non-Interacting Processes

ANSWERS TO PROCEDURE 17. Flow rate = 11 L/min (2.9 gal/min)

STEP QUESTIONS
Level in the column = 73 cm (29 inches) or 90.5%

18. Required output: 43.5% or 10.94 mA

Flow rate = 8 L/min (2.1 gal/min)

Level in the column = 14.0 cm (5.5 inches)

. .
20. 1000 / 196.6 0.1271
/

196.6 0.008107 1.59

0.1271 12.566 1.59

21. 31 314 1.65

314
6.13
31 ∙ 1.65

These results were obtained with the 2-63.2% method.

%
100

80

60

40

20

0
0 200 400 600 800 1000 1200Time (s)

Response curve – Second-order non-interacting level process.

22. The PID coefficients obtained with the Ziegler-Nichols method are given
below for the quoted value of , , and .

8 © Festo Didactic 85983-10

Exercise 2-1 Second-Order Non-Interacting Processes

Calculated control parameters for the Ziegler-Nichols method.

Mode Proportional Gain Integral Time Derivative Time

3.33
PI 0.9 5.525 —
103.2

PID 1.2 7.367 2 62 0.5 15.5

24. The response of the level process to a step change from a set point of 40%
to a set point of 60% looks like this for the parameters given above:

70

60

50
Process variable

40 Set point

30
Time (s)
0 100 200 300 400

Response of the process to a change in set point – PID mode.

ANSWERS TO REVIEW 1. The large-diameter column has a larger cross-section area than the small-
QUESTIONS diameter column. Consequently, the time constant for the column ( )
would also be larger, resulting in a larger global time constant for the
process.

2. Increasing the resistance would diminish the flow going into the column since
the maximum height is fixed for the upper tank (thanks to the overflow). This
would cause the level of liquid to diminish, unless adjustments are made on
as well.

3. The fact that the zero level on the column is not the height at which the liquid
flows freely out of the tank. A certain height has to be considered during
which the liquid flows in a hose leading to the reservoir.

4. The first-order process has a shorter global time constant than the second-
order one. As well, the second-order process has an inflexion point (a point
of maximum slope not located at the origin), whereas it is not the case for a
first-order process.

© Festo Didactic 85983-10 9

Exercise 2-1 Second-Order Non-Interacting Processes

5. One could diminish the cross-section area of one or both tanks in order to
decrease the tank(s) time constant(s). This would have the desired effect on
the global time constant of the process.

10 © Festo Didactic 85983-10

Exercise 2-2 Second-Order Interacting Processes

Exercise 2-2 Second-Order Interacting Processes

ANSWERS TO PROCEDURE 14. Control signal: 39.5% (or 10.275 mA).

STEP QUESTIONS
a All quoted values are subject to be different for each setup and should only be
used as a guide.

16. Level in the small-diameter column: 42.2 cm (16.6 inch)

Level in the large-diameter column: 73.7 cm (29.0 inch)

17. Flow rate: about 10 L/min (2.6 gal/min)

Control output: 44.5% or 11.075 mA

Level in the small-diameter column: 14.2 cm (5.6 inches)

Level in the large-diameter column: 37.5 cm (14.75 inches)

18. Using the 2-63.2% method yielded the following results:

21.2 371 12.85

371
1.36
21.2 ∙ 12.85

%
100

80

60

40

20

0 Time (s)
0 200 400 600 800 1000 1200 1400

Response curve – Second-order interacting level process.

19. The PID coefficients obtained with the Ziegler-Nichols method are given
below for the quoted value of , , and .

© Festo Didactic 85983-10 11

Exercise 2-2 Second-Order Interacting Processes

Calculated control parameters for the Ziegler-Nichols method.

Mode Proportional Gain Integral Time Derivative Time

PI 0.9 1.23 3.33 70.6 —

PID 1.2 1.63 2 42.4 0.5 10.6

21. The response of the level process to a step change from a set point of 40%
to a set point of 60% looks like this for the parameters given above:

60

55

50

45 Process variable

40 Set point

35 Time (s)
0 50 100 150 200 250

Response of the process to a change in set point – PID mode.

Further adjustments to the PID parameters can be made if required.

ANSWERS TO REVIEW 1. In a second-order non-interacting process, the behavior of the system

QUESTIONS depends upon the level of liquid in both tanks. This dependency introduces a
new flow rate and an additional resistance, which affects the overall transfer
function of the process.

2. Yes. If two identical tanks are used, the time constant and are identical
and the transfer function is simpler.

12 © Festo Didactic 85983-10

 Appendix A

Answers to Unit Test Questions

Question 1 2 3 4 5 6 7 8 9 10

Unit 1 c d b b a c a d a c

Unit 2 c b a c d c a b a a

© Festo Didactic 85983-10 13