Data

Table 1 : Data of Flow Ratio Control Test

Test R PR SV PV SV=PV
1 1.0 1.0 2.00 2.00 EQUAL
2 1.0 1.0 4.00 4.00 EQUAL
3 1.8 1.8 3.67 3.67 EQUAL
4 1.8 1.08 6.38 4.39 NOT
EQUAL

Discussion

The purposes of the experiment are to identify the major components of the flow ratio
process control system, to perform start-up procedures systematically, to study single loop
flow control using PID controller and to study flow ratio control using linear PID controller.

Flow Ratio Plant model WF922 use water to simulate a liquid phase flow process. Three
different flow-measuring principles are commonly used in industries and applied in this model.
The three types are :-

i) Differential pressure measurement across by an orifice.

ii) Measurement by variable area flow meter
iii) Measurement by von Karman vortex shedding /principle.

For the first objectives, the major component of the this process control system has been
identified and marked in the PID diagram attached in Appendix. For the next objectives which
is to perform start-up procedures systematically, the start-up procedure has been performed
based on the lab manual provided. Tank T21 has been filled with water up to almost the level
of its overflow pipe. The pipeline WLF922 to WT922 has been shut to make sure the plant
operated independently. All by pass valves stated in manual has been checked properly. The
manual discharge valve at the bottom of tank T21 , manual valve MVX and manual discharge
valve at the discharge of pump P20 as been shut.

The third objective of this experiment is to study the PID single loop flow control. At this step,
3 normal operation has been tested which are Single Loop, Single Point Test Step and PID
Controller Tuning. In the first operation which is single loop, the MV = 100% , SV= 1.8 m 3/hr
the first trial PID values (PB1 = 100%, TI1= 5 sec, TD1 = 0 sec) in Manual (M) mode and then
turned to Auto (A) mode. The response on graph for the single loop the process able to achieve
its setpoint when switch to Auto mode.

For setpoint step test in normal operation, the first trial PID controller has been set to
lower Proportional Band (PB) (PB1=100% TI1= 5 sec, TD1 = 0 sec) and the 2nd trial the PB
was set to be high compared to first trial ( PB1 =150% TI1=10 sec, TD1= 0 sec) the set point
(SV) of 1.8 m3/hr to 4.2 m3/hr has been used to for the setpoint test. Based on theory, PB is
defined as the amount of change in the controlled variable required to drive loop output from
0 to 100%. Higher PB needed to achieve stability in control when subjected to abrupt change
in load or setpoint. The integral (TI) component of a control loop has the effect of continuing
to increase or decrease the output as any offset or droop continues to exist (Eriks, 2017). At
the first trial, the graph smoothly increased by increasing the SV but at the SV 2.8 m 3/hr the
graph too oscillatory, this is because the control not stable and higher PB and TI is needed.
At the second trial, the graph smoothly increased when SV increased, it shown that at higher
PB and TI the control is stable (Micet, 2018).

For the PID controller tuning in normal operation, the controller has been switched to
cascade (c ) mode. This means the SV is no longer operate. The cascade mode caused the
flow to be controlled at specific value. Ratio control, the output changed was the ratio factor.
The process has been disturbed by manipulating CF and WF , either using one WF pump or
two WF pump. Below is the formula of process ratio (PR).

𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 21)

𝑃𝑅 =
𝑊𝑖𝑙𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 22)

In the manual mode, the first trial has been set to PBI =100%, TI1=5 sec, TD1 =0 sec and
MV has been set to 100% for maximum flowrate. The value obtained for CF is 4.33 m3/hr and
WF is 4.13 m3/hr , and the ratio that has been calculated is 1.048. The good ratio has been
achieved if the PR equal to instrument ratio, R. This showed that the plant ratio was almost
equivalent to equipment ratio hence the system was successfully controlled the whole
process.

For the Second Part, which is the Flow Ratio Control, Linear PID (normal control) , the PID
trial value has been set to PB1=150%, TI1=10 sec, TD1= 0 sec, the PB and TI value has been
increased. Four tests have been run to observe the performance of flow ratio control system.
WF pump has been switched on and off to apply the disturbance. CF pump is on for all tests.

For the first test (Using one WF pump, with instrument ratio, R=1), the CF pump and WF pump
has been used in this test. The controller has been switched to cascade mode so that the
controller is functioned as Ratio Controller. The value of CF and WF has been recorded when
the flow system is almost (within ± 0.02 to 0.05) and value of PR has been calculated. The
value of PR is 1 and the value of PV = SV which is 2.00. For the second test (Using two WF
pump, with instrument ratio, R=1), the disturbance has been applied by switching on the
second pump (P22B). The value of PR is 1 and the value of PV = SV which is 4.06. Based on
the PV = SV for both test it shown that, there is no error and the process was successfully
controlled by using the PID controller.

For the third test (Using one WF pump, with instrument ratio, R=1.8. The value of PR is 1.8
and the value of PV = SV which is 3.67. For the last test (Using two WF pump, with instrument
ratio, R=1.8. The value of PR is 1.08 and the value of PV= 6.38 not equal to SV which is 6.38.
Based on third test, the PR is equal to equipment ratio but in the last test , the PR has lower
value than equipment ratio. In the third test, the PV = SV showed that error is eliminated and
the PID controller successfully controlled the process. The forth test, the PV not equal to SV,
the error cannot be eliminated unsuccessful controlled of MV cause the PV unable to achieve
the SV. Based from the overall results, it shown that cascade control give a better performance
of the process control because the disturbance is quickly eliminated as 3 out of 4 test was
successful manage the PV = SV.

There is an error while conducting this experiment, students should understand the procedure
and directly asked the technician if there are some misunderstanding during experiment to
avoid students obtained the wrong result.
Reference

Eriks. (2017). Basics of PID Control. Retrieved from Industrial Controls on Eriks Company:
http://www.industrialcontrolsonline.com/training/online/basics-pid-control-
proportionalintegralderivative

Micet. (2018). Lab Manual Experiment 4 : Flow Ratio Plant Control . Process Dynamic Control, 1-6.
Appendix

1. PID Controller Tuning Process Ratio (PR)

𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 21)

𝑃𝑅 =
𝑊𝑖𝑙𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 22)

4.33
𝑃𝑅 =
4.13

𝑃𝑅 = 1.048

2. Flow ratio control , linear PID

a) Using one WF pump, with instrument ratio R=1

𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 21)

𝑃𝑅 =
𝑊𝑖𝑙𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 22)

2.0
𝑃𝑅 =
2.0

𝑃𝑅 = 1.0

b) Using two WF pump, with instrument ratio R=1

𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 21)

𝑃𝑅 =
𝑊𝑖𝑙𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 22)

4.0
𝑃𝑅 =
4.0

𝑃𝑅 = 1.0

c) Using one WF pump, with instrument ratio R=1.8

𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 21)

𝑃𝑅 =
𝑊𝑖𝑙𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 22)

3.6
𝑃𝑅 =
2.0

𝑃𝑅 = 1.8
d) Using two WF pump, with instrument ratio R=1.8

𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 21)

𝑃𝑅 =
𝑊𝑖𝑙𝑑 𝐹𝑙𝑜𝑤 (𝐹𝑇 22)

4.4
𝑃𝑅 =
4.0

𝑃𝑅 = 1.08