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LABORATORY: SECTION of 1
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29 SEPT
EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
2014
PROCESS CONTROL
AMENDMENT
(ELECTRONIC)
DATE:

SECTION OF CHEMICAL PROCESS TECHNOLOGY

MALAYSIAN INTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

PROCESS CONTROL LABORATORY

LABORATORY INSTRUCTION SHEETS

COURSE CODE
EXPERIMENT NO. EXPERIMENT 7

EXPERIMENT TITLE Level Flow Process Control (Electronic)

DATE
GROUP NO.
1)
LECTURER/INSTRUCTOR/TUTOR
2)
DATE OF REPORT SUBMISSION
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%

INTRODUCTION: /5%

PROCEDURE: /5%
RESULTS& CALCULATIONS /15%
ANALYSIS /15%
DISTRIBUTION OF MARKS FOR DISCUSSIONS: /20%
LABORATORY REPORT: ADDITIONAL QUESTIONS /15%
CONCLUSION /10%

SUGGESTIONS& RECOMENDATIONS /5%

REFERENCES: /5%

TOTAL: /100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

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EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
2014
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DATE:

STUDENT CODE OF ETHICS

SECTION OF CHEMICAL PROCESS TECHNOLOGY

MALAYSIAN INSTITUTE OF CHEMICAL & BIO

ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit to

not accept or provide any assistance in preparing this report and anything

that is in it is true.

1) Group Leader: ………………………………………….. (Signature)

Name : __________________________________
Matrix No. : __________________________________

2) Group Member 1: ………………………………………. (Signature)

Name : __________________________________
Matrix No : __________________________________

3) Group Member 2:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________

4) Group Member 2:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________
 FACULTY : UniKL MICET EDITION: 1
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EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
2014
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1.0 OBJECTIVES
a) To study level measurement using level capacitance probe transmitter.
b) To study PID level control and PID tuning.
2.0 LEARNING OUTCOMES
At the end of the study, student will be able to:
a) To be familiar with the basic steps of machine from start-up to shut-down
with proper handling and setting.
b) To identify the important components of the level-flow (electronic) control
system.
3.0 INTRODUCTION
The a level-flow process control training system (Model WLF92E) consists of
a level tank, T82 and a collection tank, T81 connected with the appropriate pumps
and piping systems. Level is measured by capacitance probe element. Level tank,
T82 receives inflow from pump, P81. Its outflow is pumped by pump, P82 via level
control valve, LCV81 back into collection tank.

4.0 INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

4.1 The PID level control loop is LE81/LT81-LIC81-LCY81/PP/LCV81.

LE81 : Capacitance level probe element.

LT81 : Capacitance level probe transmitter.
Calibrated range: 0 – 800 mm WG for 4 – 20 mA output.
LIC81 : PID level controller.
LCY81 : Current-to-Air converter (I/P)
PP : Pneumatic Positioner for LCV81.
LCV81 : Pneumatic level control valve, LCV81.
4.2 Apparatus
a) Level Flow (Electronic) process control training system. The schematic
diagram is shown in Figure 1.
 FACULTY : UniKL MICET EDITION: 1
LABORATORY: SECTION of 1
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29 SEPT
EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
2014
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AMENDMENT
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Figure 1: Schematic diagram of Level Flow (Electronic) Process Control

Training System
 FACULTY : UniKL MICET EDITION: 1
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2014
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5.0 PROCEDURE
5.1 STARTUP PROCEDURES
1. Turn on the main power supply switch. All panel instrument will lit
up
2. Check the various manual valve as follow
• All pumps (P81 & P82) suction, and discharge valves are fully
opened
• Manual by-pass valve for each pumps is shut.
• Control valve positioners (PP) must be selected.
• Bottom drain valves of tank T81 and T82 always shut
• Open overflow valves for Tank T82 and T81
3. There are two controller FIC81, LIC81 and recorder LFR81 in front of
the panel. Be familiar with their basic operation before proceed with
the experiment.
• Make sure the two controllers VIC81, LIC81 are both in their
MANUAL (M) mode
• Set the two controller FIC81, LIC81 at their DEFAULT values as
follows:

Table1: DEFAULT VALUE FOR FIC81 & LIC81

FIC81 : YS 150 Yokogawa Lic81 : UY350
Setpoint SV 1.2m3/Hr SP 400mm
Proportional Band % PB 200% 1.P 20%
Intergral time, sec TI 5sec 1.I 20sec
Deriavetive time, sec TD 0sec 1.d for OFF
High Alarm PH1 1.6m3/Hr A1(for AL 1) 600mm
Low Alarm PL1 0.6m3/Hr A2(for AL 2) 100mm

• With both controller in MANUAL (M) mode, set their control output
at 50%. Check the valve position at FCV81 and LCV 81 are both
about 50% opened.
• Start the recorder LFR81 by pressing ON the RCD pushbutton.
4. Start pump P81 and verify there is a flow into T82. Otherwise, the
manual valves are not fully opened. Make sure pump by-pass valve
B81 fully shut to provide maximum flow to T82 only.
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5. Please noted:
• At tank T82, note the Level ruler and the Level: 0mm is just
above the bottom tip of the level probe LE81
• When the level in tank T82 is about 50%, start the outflow
pump P82 and verify its flow into T81. Otherwise the manual
valves are not fully opened. Shut fully pump bypass valve B82
for maximum flow.
• DO NOT START THE OUTFLOW PUMP P82 IF NO WATER IN
TANK T82
6. At the controller FIC81, set SV = 1.2 m3/Hr. Switch FIC81 to AUTO
(A) mode
7. Please noted:
• Tank T82 is non-Self Regulating and can overflow if the inflow
rate exceeds the Outflow rate
• With LIC81 in MANUAL (M) mode, manually adjust the control
output to LCV 81 so that the level in T82 approaches set point
400mm. Switch LIC81 to AUTO (A) mode
8. Check the recorder LFR81 and examine the level and flow response
9. If recording is no longer required, OFF the recorder by pressing RCD
pushbutton

5.2 RESULT FOR LEVEL MEASUREMENT

1. Take the level reading at various set point at LIC 81 when:
a. Pumps P81, P82 are ON and LIC is AUTO mode. FIC is in
MANUAL mode and MV= 50%
b. Pumps P81, P82 are OFF and LCV81 and one of the adjacent
valve is fully shut
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2. Take note of the following preset level measurement range in
LT82,LIC81 and LFR81
Calibrated range of LT81 : 0-800 mm water for 4-20 mA transmission
output
Level range set in LIC92 : 0-800 mm for 4-20 mA input representing:
0-800 mm Water
Level range set in LFR81 : 0-800 mm water / 0-100% for 4-20 mA
input

3. Inter –convert the reading from analog ( 0-100%) to Engineering unit (

0-800mm) or vice versa as follow:

% Reading x Max. calibrated range value = Reading Engineering Unit

i.e %Reading x 800mm = Reading in mm Water

5.3 LEVEL MEASUREMENT

1. Set FIC81 with MV = 50% so the control valve is opened to 50%
2. Please note that the experiment is conducted with LIC81 in AUTO (A)
mode using various setpoint (SP) of 200, 400, 500 and 700mM

PART A:
a) With the SP of LIC81 at 200mm in AUTO mode, wait till the level PV
in LICD81 is steady at its SP.
b) Take the level reading at LIC81 and LFR81. Also take the level
measurement at the tank ruler.
c) Mark on the chart paper on the RED color that SP=200
d) Take a second set of reading when the level is not fluctuating and PV
is about 200mm as follow:
• Stop pump P81 and P82.
• With LIC81 in MANUAL mode, shut LCV81 fully with MV= 0
• Shut one of manual valve adjacent to LCV81.
• Take the level reading again as in above state. Its does not matter
that the PV is not at its SP for this second set reading.
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LABORATORY: SECTION of 1
REVISION NO:
CHEMICAL PROCESS
29 SEPT
EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
2014
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AMENDMENT
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PART B
a) REMEMBER TO OPEN FULLY ALL THE MANUAL VALVE ADJACENT
TO LVC81 BEFORE PROCEEDING TO NEW SETPOINT VALUE
b) View the SP at LIC81. Change the SP = 400mm and push BLUE
button once to register the new SP
c) Start pump P81 and P82. Make sure
LIC81 = Auto (A) mode with SP = 400mm
FIC81 = Manual (M) mode with MV = 50%

PART C
a) Take the level readings as previously (SP=200mm) when;
• the tank level PV is steady at its SP (view LIC81)
• when pumps P81, P82 are OFF and LCV81 and one of the adjacent
manual valve are fully shut.
b) Repeat the procedure (PART B) with various other level set point (SP)
at LIC81, i.e SP=500 ,SP=700
c) Record all the result in the Table 2. in the Result Section 6
5.4 LEVEL CONTROL AND TUNNING
1. Do the following quick check:
• Pumps P81 and P82 are pumping.
• By-pass valve of for control valve FCV81 and level control valve
LCV81 are shut.
• Both controllers LIC81 and FIC81 in MANUAL (M) mode set with
the DEFAULT value ( Table 1 )
• Check the IAS are set accordingly
• The chart recorder LFR81 is running and indicate “RCD” at the
display panel.
2. Switch the flow controller FIC81 to Manual (M) mode and manually
adjust MV = 50% observe the Inflow in to tank T82
3. The experiment is to be conducted with LIC81 in AUTO mode using
various PID value and disturbances.
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4. Check pump P82 is ON and pumping the outflow to T81.
With LIC81 in AUTO (A) mode, SP = 400mm and PID at Default value,
and apply of disturbance describe below:
i. LIC81, SP = 400mm , 1.P = 20%, 1.I = 20sec, 1.D = OFF
a. Inflow load step change disturbance
• LIC81 must be in AUTO mode with SP and PID value above
• In AUTO mode, observe the level response until it is almost
steady or consistent at 400mm
• Step decrease the inflow rate by shutting FCV81 from MV
=50% to MV = 70% . This is an inflow load step
disturbance test
• Observe the level response of Red pen at LFR81 until it is
steady at it set point or continues to oscillate even after 3
cycles.
b. Outflow load step change or disturbance
• LIC81 still in AUTO mode, SP = 400mm with same PID
value
• Switch LIC81 to MANUAL mode, note that the SP value
display “0”. Manually step increase or decrease the output
“0” by about 30% and then switch back to AUTO mode.
This is outflow load step disturbance
• Observe the level response (Red pen)

ii. Level control with faster PI

LIC81 SP = 400mm, 1.P = 5%, 1I = 15 sec, 1. d = OFF
• LIC81 still in AUTO mode, repeat test disturbance 4(I)(a)
and (b) with faster set of PID value than the DEFAULT
values, but without derivative control mode as follow:
o LIC81 , SP = 400mm , P = 5%, I = 15sec, d = OFF
o Observe the level response
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5. Without a control valve positioner (PP) at LCV81
Restore LIC81 to its DEFAULTE PID values at SP = 400mm as follow:
LIC81 : SP = 400mm, P = 20%, I = 20 sec, d = OFF
Switch to AUTO mode.
a. When the level is steady, switch (PP) to No PP at the level control
valve LCV81. If observe, if the level response oscillates after 3
cycles. If not apply an outflow load step disturbance in 4(I)(b)
and observe similarity of the amplitude oscillation. Change the PID
value at LIC81 to the following at (a) and (b) below and observe
b. Detune the PID to a larger P (PB%) for higher damping of the
oscillation as follow:
SP = 400mm, P = 40%, I = 20 sec, d = OFF
If the oscillation cannot be damped, observe again for 2 cycles of
oscillations
c. Connect back the Positioners (PP) and observe again if limit cycling
is eliminated
Restore its PID value to DEFAULT PID values.
5.4 OPEN LOOP TEST
1. Check that LIC81 is in AUTO mode, its DEFAULT PID values. Check
the Positioner (PP) is connected at LVC81. When the level is steady at
SP = 400mm , switch LIC81 to MANUAL mode and note its manual
value is “0”
2. Mark the chart at RED PEN trend, and manually step decrease LIC81
value “0” , by about 10%.
Note down the new % output and LIC81 is remaining in MANUAL
mode throughout his test.
3. The level remain unchanged over a very short Dead time and then rise
in straight line. Be cautioned that the process is integrating and will
rise till level overflows.
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29 SEPT
EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
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4. The OPEN LOOP TEST is completed after a reasonable rise in level.
Switch back to AUTO mode. Extract the chart paper from the
recorder.
5. Determine the DEAD time (DT) and Response Rate (RR) from the chart
response.
• Measure DT in mm along the time axis with ruler
• Check the recorder chart speed
• Convert DT in mm to time in seconds as follow

𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒, 𝑚𝑚 3600𝑠𝑒𝑐𝑠
𝑇𝑖𝑚𝑒 𝑡𝑎𝑘𝑒𝑛, 𝑠𝑒𝑐𝑠 = ×
500𝑚𝑚/𝐻𝑟 1𝐻𝑟

• To determine RR, the steepest tangent must be drawn on

the rising part of the level response curve.
6. Use the Ziegler and Nichols open loop test fformulae for a PI controller
to determine the approximate Propotional Band (PB % ) and Intergral
time ( TI,secs )
i.e
100 0.9
×
𝑝% 𝐷𝑇 𝑥 𝑅𝑅

5.5 SHUTDOWN PROCEDURE

To shut-down the training system:

• Set FIC81 to DEFAULT set point and PID values
• Set LIC81 to DEFAULT set point and PID values
• Switch off pumps P81 , P82
• SHUT OFF external air supply valve to the system pipeline
• Press OFF recorder RCD button to stop the chart
• Switch off the main power supply at the front panel
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LABORATORY: SECTION of 1
REVISION NO:
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29 SEPT
EXPERIMENT: LEVEL FLOW EFFECTIVE DATE:
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6.0 RESULTS & CALCULATIONS

READINGS

LIC81 : PV LFR81 T82

Engineering Unit Red Pen Channel 1 Ruler
Setpoint (SP) at LIC81
mm % mm mm
A a) 200mm
b) P81, P82 OFF

LCV81/Manual
valve shut
B a) 400mm
b) P81,P82 OFF
LCV81/Manual
valve shut

C a) 500mm
b) P81,P82 OFF

LCV81/Manual
valve shut
D a) 600mm
b) P81,P82 OFF

LCV81/Manual
valve shut

Table 2: Level Measurement Result

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7.0 ANALYSIS OF THE RESULTS

Analysed critically each results obtain in section 6.0 by referring to the

theory/introduction parts. Find reasons (suggested reasons) on each
occurrence shown in the results.

8.0 DISCUSSIONS
Discuss the overall experiment on data obtain based on your understanding.
Discussion should relate reasons for the phenomena/results obtained,
theoretical parts, suggested reasons (if necessary but back with sound
theoretical knowledge) and your overview understanding.

9.0 CONCLUSION
Conclusion is merely a summary of the important findings already reported
in the discussion section. It also relates to the objectives stated earlier.

10.0 SUGGESTIONS & RECOMMENDATIONS

Your ideas of suggestion & recommendation to improve the learning process
for this experiment or anything related to the experimental procedure etc.

11.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter
based)