EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

TABLE OF CONTENTS

Bil. Title Page

1 Objectives 2

2 Summary 3

3 Introduction and Theory 4

4 Results and Discussions 5

5 Conclusion 10

6 References 11

7 Appendices 12

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

OBJECTIVES

There are several objectives in experiment gas temperature (at 922) process control. The
objectives of this experiment are:

1. To identify the important components of the air temperature control system and to
mark them in the P&I Diagram
2. To carry out the start-up procedures systematically.
3. To determine the values of the parameters for a first order plus dead time transfer
function model of a thermal process.
4. To control the Air-Heater process using PID controller

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

SUMMARY

The objectives of this experiment is to identify the important components of the air
temperature control system and to mark them in the P&I Diagram, to carry out the start-up
procedures systematically, to determine the values of the parameters for a first order plus
dead time transfer function model of a thermal process and to control the Air-Heater process
using PID controller. Lag occurred when the process started. This is also known as dead time.
It uses a transistor to adjust the heat flow to the heater. The air flow rate is measured using a
rotameter. PID algorithm is used for direct field control. That is either both of its input (PV)
and output (MV) is directly connected to field or process equipment. Three different PID trial
values show different results based on the tuning. Experiment was also done on load
disturbance and set point change to observe the responses Temperature measuring device
used in these experiment are RTD and type K. Using PID controller as a process controller,
tuning a temperature controller involves setting the proportional, integral and derivatives to
get the best possible control for a particular process. The MV is first adjusted to 24.4% and
then it is increased to 50%, it is shown that there is disturbance occurred when the valve is
being closed, the dead time was 28.8 secs. The tangent for the increase is calculated using
Pythagoras theorem. The tangent calculated is the response rate of the process.

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

INTRODUCTION

The objective of this experiment is to determine the gas temperature process control
type AT 922 uses to stimulate a gas or vapor phase temperature process. The temperature
process is a lag/dead time process with no noise. The dead time in time unit is:

[𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑖𝑛 𝑚𝑚 𝑥 3600𝑠 ]
Dead time = 𝑅𝑒𝑐𝑜𝑟𝑑 𝑐ℎ𝑎𝑟𝑡 𝑠𝑝𝑒𝑒𝑑 ,500 𝑚𝑚/𝐻𝑟

It uses a transistor to adjust the heat flow to the heater. The air flow rate is measured
using a rotameter. A selective control technique is employed here that automatically select
only a less heat demanding output to manipulate only one final control element (the
transistor/heater). This system requires a high gain PID controller.

Temperature measuring device used in these experiment are RTD and type K. A
resistance temperature detector (RTD) is a temperature sensing probe of finely wound
platinum wire that displays a linear resistance increase for a corresponding temperature
increase. RTDs are built on the principle that most metals have a positive charge in electrical
resistance with a change in temperature. When quality control is importance, a RTD is
unequalled for accuracy and repeatability.

Using PID controller as a process controller, tuning a temperature controller involves

setting the proportional, integral and derivatives to get the best possible control for a
particular process. The PID function uses system feedback to continuously control a dynamic
process. The purpose of PID control is to keep process running as close as possible to a
desired set point.

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

RESULT AND DISCUSSION

First order plus time delay (FOPTD) transfer function as follows:

𝐾
G(s) = e−Ѳs
𝑇𝑠+1

The chart below shows how dead time value can be determined. Distance of point 1 to
point 2 is measured by using ruler and substituted to the formula to get value. Based on the
graph, it shows that as the heater is on the heated temperature is starting to increase slowly.
The MV is first adjusted to 24.4% and then it is increased to 50%, it is shown that there is
disturbance occurred when the valve is being closed. This experiment chart was run at
500mm/Hr.

Figure 1: dead time

(𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑖𝑛 𝑚𝑚 𝑥 3600𝑠𝑒𝑐)
Dead time =
𝑅𝑒𝑐𝑜𝑟𝑑 𝑐ℎ𝑎𝑟𝑡 𝑠𝑝𝑒𝑒𝑑,500 𝑚𝑚/𝐻𝑟

(4𝑚𝑚 𝑥 3600𝑠𝑒𝑐)
=
𝑅𝑒𝑐𝑜𝑟𝑑 𝑐ℎ𝑎𝑟𝑡 𝑠𝑝𝑒𝑒𝑑,500 𝑚𝑚/𝐻𝑟

= 28.8 secs

The dead time is the time after each event during which the system is not able to record
another event. After the increase, for 4 seconds, there is a dead time as shown in the chart.

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

Dead time can arise in a control loop for a number of reasons such as the time it takes for
material to travel from one point to another. The travel time is dead time. Not only that,
sensors can take precious time to yield their measurement result. The dead time is calculated
using a ruler and the limitation of the calculation is that the y-axis on the graph is precise only
up to one second. This is a problem because the time constants are in the order of one second.
Hence in calculation it is not possible to achieve a higher precision because of the lack of
measuring instruments with higher precision.

Figure 2: Response rate

Next, response rate must be calculated too using the chart which is shown in figure 2. The
tangent for the increase is calculated using Pythagoras theorem. The tangent calculated is the
response rate of the process.

1.02 cm
0.2 cm

1 cm

Figure 3: Response rate, RR = 1.02 cm

Using the response rate, the process gain, K and time constant of the process value,Ʈ
are obtained from the calculation using formula shown below.

For process gain, K can be calculated as follow:

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

max 𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑎𝑖𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

𝐾=
% 𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑡ℎ𝑒 𝑚𝑎𝑛𝑖𝑝𝑢𝑙𝑎𝑡𝑒𝑑 𝑣𝑎𝑟𝑖𝑎𝑏𝑙𝑒
42
𝐾=
50 − 24.4

𝐾 = 1.64

The constant time,Ʈ can be calculated as follow:

Maximum change in the air temperature at the exit = 1980C – 1560C = 420C

𝑅𝑅
Ʈ=
max 𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑎𝑖𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

102
Ʈ=
42

Ʈ = 2.429

The parameter of the First Order with Delay model is:

𝐾
G(s) = e−Ѳ s
𝑇𝑠+1

1.64
G(s) = e−28.8 s
2.429𝑠+1

Next, the air heater is controlled using the PID controller with load disturbances and set point
changes which are set point SV= 80ºC and 90 ºC at the temperature PID controller TIC91 and
is still in Manual (M) mode and its MV = 0%. For load disturbances the MV value changes
from 0 to 30%.

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

Figure 4: First trial values: PB (%) = 10%, TI (secs) = 100secs, TD (secs) = 25secs

For the first trial PID controller, the response for the air heated temperature is fast. It can be
said that when the load disturbance is being introduced the temperature is increases due to the
rapid opening of valve for the air flow rate. At set point, SV=80ᵒC, it reaches a steady state
after few cycles. While for SV=80ᵒC and load disturbance MV= 30%, it shows the overshoot
is smaller compared to the previous one. To reduce the offset, the temperature for set point
and the temperature after load disturbance introduced must be stable.

Figure 5: Second trial values: PB (%) = 20%, TI (secs) = 70secs, TD (secs) = 18secs

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

For the second trial PID values, the response for the air heated temperature started to oscillate
mildly as the process gain is increased. As the MV is increased to 50%, the response become
stable due to the opening of valve, then the response became little oscillatory when MV is
increased to 90%. As in theory, the response is slower but the offset can be reduced much
faster.

Figure 6: Third trial values: PB (%) = 20%, TI (secs) = 150secs, TD (secs) = 37secs

For the third values, the hart is becoming more stable. That is why it has a very small
oscillation. When the set point is changed to 900C, the response shows some oscillation and it
is undershoot as the temperature is being increased. After the response is stable, the set point
is then increased to 1000C and it shows that response is overshoots due to the changes of set
point and the response is became stable again.

Error might happen in opening of valve and air inlet valve. This will produce error in the
process. Since for measuring gas temperature uses heater instrument kept in air temperature,
the temperature reading may fluctuate.

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

CONCLUSION

Firstly, the experiment shows that lag occurred when the process started. This is also
known as dead time. Dead time can arise in a control loop for a number of reasons such as the
long distance for material to travel from one point to another. However, there are limitations
to calculate dead time, for example high precision equipment acquired. Next is the control of
process using PID controller. PID algorithm is used for direct field control. That is either both
of its input (PV) and output (MV) is directly connected to field or process equipment. It is
designed to cope with any electrical noise induced into its circuits by equipment in the plant
or factory. Three different PID trial values show different results based on the tuning.
Experiment was also done on load disturbance and set point change to observe the responses,
whether they are overshoot or undershoot according to changes made. Several errors occurred
during the experiment was done and the results are no exactly precise or accurate. Some
recommendations to improve the results are following the procedures accordingly and
monitoring the panel closely.

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

REFERENCES

1. Altmann W. (2005). Practical Process Control of Engineers and Technicians.

Oxford: Elsevier.
2. Carlos A. Smith, Armando Corrpion (2006). Principles and practice of Automatic
Control [Third Edition]
3. http://neogeo.kent.edu/munro/physical/Notes_Fall09/air%20temp.pdf(acsessed on 3
October 2011)
4. http://iseinc.com/what%20is%20pid.htm(acsessed on 3 October 2011)

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 EXP 6 - GAS TEMPERATURE (AT 922) PROCESS CONTROL

APPENDICES

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