EXPERIMENT 1

Heat Exchanger Control

1.1 Objective

(i) To study the characteristics of On/Off Control.

(ii) To study the characteristics of Proportional Only Control.
(iii) To study the characteristics of Proportional Band and Integral Action on a
temperature process control loop.
(iv) To study the characteristics of Proportional Band, Integral Action and Derivative
Action on a temperature process control loop.
(v) To study the loop tuning procedure on a temperature process control loop.
(vi) To study the automatic selection of two controller output signals.

1.2 Introduction

The Heat Exchanger Control has been designed on how a temperature loop for an exchanger
can be controlled using a microprocessor based controller. The control panel is connected to
a Distributed Control System (DCS), which can remotely control the process plant using
supervisory control mode (SCADA) or direct digital control mode (DDC). A selector located at
the control panel is used to select between SCADA or DDC mode. In SCADA mode the DCS
can monitor and control the process through the process controller and in DDC mode, the
DDC can directly control the plant through the Field Control Station.

The Heat exchanger control is a water process. A double pass shell and tube exchanger E-
221 is used for the study of process control. Hot water is circulated in the system by pump P-
213 through the tube side of the heat exchanger and returns to hot water tank T-203. Cold
water is circulated by pump P-211 from tank T-201 through the shell side and is collected as
the heated product in tank T-202. The product can also be cooled down by an air-cooled
radiator E-222 and recirculated back to the cold water tank T-201.

1.3 Experimental Equipment

Various types of instrumentations are installed in the process line. An RTD Temperature
Transmitter, TT-221 monitors the product temperature and feeds the signal to a PID loop TIC-
221 in the process controller. The output from TIC-221 is fed to the control valve TCV-221
which regulate the amount of heating energy into the heat exchanger. There is another ON-
OFF temperature controller TIC-203 that controls the temperature in the hot water tank T-203
according to a preset temperature. Another ON-OFF controller LIC-202 is used as the
batching controller which controls LV-202 to batch a certain quantity of product in tank T-202.
Solenoid valves have been installed for the purpose of fault simulation in various sections of
the process line. Fault simulation switches have been installed to simulate these faults, which
will create errors in the process line.

Table 1.1 Instrument function and capabilities

No Instrument Tag No Description Range
1 PID controller TIC-221 Microprocessor based PID -
controller, heater, temp
2 On/Off TIC-203 Microprocessor based On/Off
controller, controlling hot water
Conttroller LIC-202
temp and batch volume
3 Recorder TR-221 Continuous 2 pen chart recorder -
0
4 RTD Transmitter TT-221 RTD PT 100, 4-20 mA 0-100 C
0
5 T/C Transmitter TT-203 T/C type K, 4-20 mA 0-100 C
6 Control valve TCV-221 1 inch globe type valve with 0-100%
Cv=2.5 equal % characteristic
with I/P positioner
7 Level Transmitter LT-202 To measure water volume/level 0-36’’ H2O
8 Pressure PI221-PI226 Dial gauge pressure indicator 0-4 bar
for pressure indication at heat
Indicator
exchanger inlet and outlet
0
9 Temperature TI201-TI203 Dial gauge temperature 0-100 C
TI221-TI224 indicator. Indication at heat
Indicator
exchanger inlet and outlet
Process Tank T-201 Cold water tank 120 L
T-202 Product tank 120 L
10
T-203 Hot-water tank 120 L
11 Alarm TAH-203 Product temperature high alarm
Hot-water tank temperature high
Annunciator TAH-221
alarm
12 Pressure Relief PSV-221 Mechanically activated device,
spring loaded normally closed
Valve
valve. Opens and purges air to
atmosphere in case of over
pressure in tank. Open prior to
pressure greater than its spring
tension.
13 Solenoid Valves HV-213 Solenoid valves for fault -
simulation
HV-222
14 D/P Transmitter PDT-221 Differential pressure transmitter 0-30 PSIG
for pressure drop measurement
15 Shell & Tube E-221 1 shell, 2 tube passes heat -
exchanger with cold and hot water
Heat Exchanger
circulation
2
Heat transfer area = 1.5 m
Duty = 25 kW
16 Process Pumps P-211 Cold water circulation pump 0-40 LPM
P-213 Hot-water circulation pump
P212 Product circulation pump
Table 1.1 Instrument function and capabilities
No Instrument Tag No Description Range
Fault simulation To simulate loss of heating fluid
17 HS-213 -
To simulate loss of instrument air
switches HS-222
supply
18 Radiator/Cooler E-222 For cooling down product -
temperature
19 Electric heater E-212 Immersion heater, for supply of -
heat input to hot water tank

1.4 Process Control

Student may refer to section 0.3.1 for theory of process control

1.4.1 On/Off Control

Student may refer to section 0.3.2 for theory of On/Off Control

1.4.2 Proportional Control

Student may refer to section 0.3.3 for theory of proportional control

1.4.3 Integral Control

Student may refer to section 0.3.4 for theory of integral control

1.4.4 PID Control

Student may refer to section 0.3.5 for theory of PID control

1.4.5 Loop tuning

Student may refer to section 0.3.6 for theory of loop tuning

1.4.6 Batch Control

Student may refer to section 0.3.7 for theory of batch control

1.5 PROCEDURE

Table 1.2 Start up procedure

STEP ACTION REMARKS

Ensure that all valves are set according to Initial Valve

Positions outlined in Table below.
Open Close
HV231 HV232
HV234 HV233
HV235 HV240
HV236 HV242
HV241 HV248
Hand valves to be
HV243 HV249
1 Open/Closed Fully.
HV244 HV246
HV245 HV250
HV247 HV251
HV252
HV253
HV237
HV238
HV239

Fill in Cold Water Tank T-201 and Hot Water Tank T-203
2
respectively.

The instrument air regulator RG1 has been set to 2.8 bar
3 (40 psi). Check that the RG1 pressure is correct and
adjust if necessary to set it at 2.8 bar.

4 Switch on the main panel.

Wait for hot water temperature in T-203 to reach about

5 0
65 C.

Switch on pump P211 and adjust FI201 to 10 LPM by

6
using HV240.

7 Switch on pump P213.

Table 1.3 On/Off Control

STEP ACTION REMARKS

Enter the following values:

1 PB = 2, I = 1000 s and D = 0 s

Put the control loop into manual mode and then adjust the set
2
point to 45 C

Tune the output gradually so that the temperature

3
measurement matches the set point at 45 C

4 Turn on the recorder then put the control loop into auto mode

Stimulate load changes by increasing cold water flow rate FI-

5 211 to 20 LPM for 20 seconds then reduce back FI-201 to 10
LPM.

Once the measurement stabilize, turn off the recorder. Put

6
the control loop back into manual mode.

Tune the output gradually so that the temperature

7
measurement matches the set point at 45 C

8 Turn on the recorder

Stimulate set point changes by increasing the set point to

9 o
50 C put controller into auto mode

10 Observe the response of the system for a few minutes.

Table 1.4 Proportional only Heat exchanger control

STEP ACTION REMARKS

Enter the following values:

1 PB = 100, I = 1000 s and D = 0 s
Put the control loop into manual mode and then adjust the set
2 o
point to 45 C
Tune the output gradually so that the temperature
3 o
measurement matches the set point at 45 C

4 Turn on the recorder then put the control loop into auto mode

Stimulate load changes by increasing cold water flow rate FI-

5 211 to 20 LPM for 20 seconds then reduce back FI-201 to 10
LPM.

Once the measurement stabilize, turn off the recorder. Put

6
the control loop back into manual mode.

Tune the output gradually so that the temperature

7 o
measurement matches the set point at 45 C

8 Turn on the recorder

Stimulate set point changes by increasing the set point to

9 o
50 C put controller into auto mode

Once the measurement stabilize turn off the recorder. Put the
10
control loop back into Manual mode

With the I and D values maintained, repeat step 2 to step 10

with the following PB values

Compare the results and
comment
PB Offset value Offset value
the differences.
Load changes Set point changes

11 100

50

10

2
Table 1.5 Proportional and Integral Heat exchanger control

STEP ACTION REMARKS

Enter the following values:

1 PB = 100, I = 300 s and D = 0 s

Put the control loop into manual mode and then adjust the set
2 o
point to 45 C

Tune the output gradually so that the temperature

3 o
measurement matches the set point at 45 C

4 Turn on the recorder then put the control loop into auto mode

Stimulate load changes by increasing cold water flow rate FI-

5 211 to 20 LPM for 20 seconds then reduce back FI-201 to 10
LPM.

Once the measurement stabilize, turn off the recorder. Put

6
the control loop back into manual mode.

Tune the output gradually so that the temperature

7 o
measurement matches the set point at 45 C

8 Turn on the recorder

Stimulate set point changes by increasing the set point to 50

9
C put controller into auto mode

Once the measurement stabilize turn off the recorder. Put the
10
control loop back into Manual mode

With the PB and D values maintained, repeat step 2 to step

11 10 with the following I values

I Compare the results and

comment
120
the differences.
30
Table 1.6 PID Heat exchanger control

STEP ACTION REMARKS

Enter the following values:

1 PB = 100, I = 60 s and D = 6 s

Put the control loop into manual mode and then adjust the set
2 o
point to 45 C

Tune the output gradually so that the temperature

3 o
measurement matches the set point at 45 C

Turn on the recorder then put the control loop into auto
4
mode

Stimulate load changes by increasing cold water flow rate FI-

5 211 to 20 LPM for 20 seconds then reduce back FI-201 to 10
LPM.

Once the measurement stabilize, turn off the recorder. Put

6
the control loop back into manual mode.

Tune the output gradually so that the temperature

7
measurement matches the set point at 45 C

8 Turn on the recorder

Stimulate set point changes by increasing the set point to 50

9
C put controller into auto mode

Once the measurement stabilize turn off the recorder. Put the
10
control loop back into Manual mode

With the PB and I values maintained, repeat step 2 to step 10

11 with the following D values

D Compare the results and

3 comment

60 the differences.

300
Table 1.7 PID Heat exchanger control loop tuning

STEP ACTION REMARKS

Put the control loop into manual mode and then adjust the
output gradually so that temperature matches the set point of
1 o
45 C

Enter the following values: Thisprovides

2
PB = 1000, I = 1000 s and D = 0 s proportional only control

Turn on the recorder then put the control loop into auto
3
mode

Stimulate load changes by increasing cold water flow rate FI-

4 211 to 20 LPM for 20 seconds then reduce back FI-211 to 10
LPM.
With the I and D values maintained, repeat step 3 and step 4
with reduced PB until the measurement oscillates about the
set point. The suggested values are as follows:
PB
5
100
10
2
Determine the natural period using the following method
D
Natural period, T   60 min
6 Trend Speed
where
D = distance in mm between successive crests or valleys
Maintain the PB value at which the measurement oscillates
about the set point. Set I to 0.4T and D to 0.15T. Repeat step
2 and 4 and observe the response. There should be a 25%
7
decrease in period. If the new period of the oscillation is
shorter than this, reduce derivative time, if the period is
longer increase integral time.
Finally adjust (increase) the PB until the desire degree of
8
damping is achieved
During the experiment, various faults can be simulated by the unit, to create errors similar to
those that can be experienced in the industry. This can be done with switches that have been
installed for this purpose. It is required to detect the errors, its location and solve the error.

Switch HS-213 : Loss of heating fluid

Switch HS-222 : Loss of instrument air supply

1.6 REFERENCES

Seborg D.E., T.F. Edgar and D.A. Mellichamp, ‘Process Dynamics and Control’, John Wiley
nd
and Sons, 2 Ed, New York, 2004, pp 116-118.
Piping and Instrumentation Diagram