INTRODUCTION

The air flow process control system uses air to simulate gas or vapor phase flow
process. Gas volumetric flow using orifice plate are measured by differential pressure or by
variable are flow meter. The perfect gas law is used to find flow measurement by variation of
pressure and temperature.

Proportional Integral Derivative controller (PID controller is a control loop

mechanism that is widely used in industrial control systems and other application that
required a continuously modulated control. A PID controller can continuously calculates an
error value of a difference between desired setpoint (SP), a measured process variable (PV)
and corrected proportional, integral and derivatives terms according to the name. PID are
widely used in pneumatic, electronic and controllers and nowadays PID concept is used
universally in application that required an accurate and optimised automatic control.

The objectives of the experiment are to study gas volumetric flow rate measurement
using orifice plate, gas mass flow rate measurement using orifice plate and the perfect gas
law to compute the gas density from the pressure and temperature measurement and also
study gas mass flow rate using PID controller.

To design a PID controller, we used Ziegler Nichols close loop method. Ziegler and
Nichols used the following definition of acceptable stability as a basis for their controller
tuning rules. The ratio of amplitudes of subsequent peaks in the same direction (due to a step
change of the disturbance or a step change of setpoint in the control loop) is approximately ¼.
(Haugen F.,2010)

An orifice plate is a thin plate with a hole in the middle that used to measure the rate
of fluid flow. It constricts the flow and measuring the pressure differential across the
constriction gives the flow rate. It is from Bernoulli’s principle that states a relationship
between the pressure of the fluid and the velocity of the fluid.
PROCEDURE

Start-up procedure Shutdown procedure

"PANEL,SCADA/DDC" switch are
selected. Then switch of main power Recorder are stopped by pressing "RCD"
supply was on. button at FPTR91

Valves of PLI and PLII at various status

opened and CV90 are closed and control
valve FCV90 switched on/off. VF opened FIC91 are switched to manual mode with
and MV901 are closed. MV=0% and main power supply are
swicthed off.

Valves MV900A and MV900D opened and

MV900B and MV900C are closed. Panel
controller was in manual mode. Then, FIC91 Process air supply at AR900 and instrument
is setted up to -6.3% which opened fully. air supply are shutted off.

MV900A are adjusted untill air flow rate is

50 kg/hr. Vessel T90 are closed and FCV91
are setted at MV=106.3% to fully shut.

FI911 Air volumetric flow rate=0 and FIC91

mass flow rate=0 are checked. FCV91 are
setted MV=50%

A. Air Flow Measurement

FCV91 are setted at MV=-6.3 in manual mode so it fully opened.

The reading are recorded in Table 1.

The data are taken at control panel and recorded at table 1. At plant,
the reading at rotameter FI911 and pressure gauge PG900 are taken.
Experiment are repeated with MV=50% and MV=70& and the date
are recorded in table 1.
B. Control of Air Flow System

FIC91 in manual mode, FCV91 are opened fully at MV=-6.3%. Then, setpoint are adjusted
SV= 25kg/hr. the first PID trial values are setted into PB= 200%, T1=6s and TD=0s.

Recorder are started and FIC91 are switched to auto mode, recorder response are watched until the
air flow is steady. Then, pulse disturbance are introduced by quickly opening and shutting fully
FCV91. The response are observe untill it becomes steady.

Step above are repeated with PID (II) values are setted into PB=150%,T1=6s and TD=0s and PID
(III) values that setted into PB=100%, T1=6s, TD=0s. The experiment then are repeated for another
3 sets with different setpoint,SV=24kg/hr& 30kg/hr and the response are recorded untill it fairly
steady.

SV are setted at 25 kg/hr back and PID(I) is used but TD=20s. PID
values are marked on the chart simultaneously. the pulse diturbance are
applied again.
PID Controller Turning

FIC91 are set as manual mode with a setpoint

SV=25kg/hr. Then, PID value are setted with PB=100%,
T1=9999s, TD=0s

PV value are adjusted until it close to the SV value. Then, FIC91

switched to auto mode. Setpoint pulse disturbance are introduced with
SV=28kg/hr for 5 seconds and put it back to 25kg/hr.

Mass flowrate have been observed.The steps are repeated with decrease PB until chart shows uniform
oscillation. New PID value are obtained using formula given.To test new PI controller settings, FIC91 are
stt in auto mode with pulse disturbance. PB value are increased to damp the oscillation and fine tune PB and
T1 to get closed to Quater Amplitude Damping response.
RESULT & CALCULATIONS

Instruments Controller I II III

Reading MV = -6.3% MV = 50% MV = 70%
At the PANEL FIC91, I/O Data
FT91, √ h X1 - % of 0-100mm 84.8 44.2 22.3

TIT911, T X2 - % of 0 - 120oC 23.6 23.9 24.0

PT911, P X3 - % of 0 – 60 psi 72.5 92.9 102.6

FIC91 Main Face

Fm Plate 53.1 33.2 17.5
PV, kg/Hr

Fv FIC90, PT Register 21.7 11.2 5.6

PO1, m3/Hr

Channel 1(Red) Recorder FPTR91 50.0 33.3 18.0

Fm, kg/Hr
Channel 2 21.7 11.3 5.9
(Green) Fv, m3/Hr
By Calculation 21.84 17.77 12.24
Fvb, Nm3/Hr
28.23 22.98 17.12
Fm, kg/Hr

At the Plant

FI911, Nm3/Hr 49.0 23.0 12.0

PG900, psig 33.5 43.0 48.0

 Ziegler-Nichols method of controlling tuning was used and applied in this experiment.
The values of parameter given for this experiment are different in each process and no
specific value for every plant. Theoretically, a good combination of the P,I,D values can
produce less oscillation and better settling time. In this method, there were several
considerations to the key of the element of control, load disturbance, sensor noise, process
uncertainty and reference signals. But if unfamiliar with the system, it is need to thee
experimentation and selects the controller settings, obtained from Ziegler-Nichols method as
applied in this experiment. So, Ziegler-Nichols method provides initial setting that will
ensure good tuning of plant. The Ziegler-Nichols tuning rules were created to give closed
loop system with load of disturbance.

Tn secs = measured period (mm) x 3600

Chart speed (500 mm/Hr)

= 35mm x 3600 s

500 mm

= 252 s

Approximate PI setting by Ziegler Nichols formula:

PB = 2 x PB* = 2 x 20 = 40

TI = Tn / 1.2

TI = 252 / 1.2 = 210s

Ziegler-Nichols Method

The First Method

The first method usually used and applied to a plant basis. It can be applied to a plant
with first order system. System models maybe determined using system identification
technique such as measuring output for an impulse or step input. Most PID controllers are
tuned on-site due to machine and process variation. The theoretical calculation for an initial
setting of PID parameter can be by-passed using a few tuning rules. Ziegler-Nichols method
to determine values of Kp, KI and KD based on the transient step response of plant. It applies to
plants with neither integrators nor dominant complex-conjugate poles, whose unit-step
response resemble an S-shaped curve with no overshoot. Diagram 1 shows the S-shaped
curve is called response curve Ziegler-Nichols first method.

Figure 1: Response curve Ziegler-Nichols first method

The S-shaped reaction curve can be characterized by two constants which are delay time L
and time constant T where its determined by drawing a tangent line at the inflection point of
the curve and finding the intersections of the tangent line with the time axis and the steady-
state level line. The plant equation is:

K e−sL
G ( s )=
Ts+1

Ziegler and Nichols derived the following control parameters based on this model:

PID Type Kp Ti=Kp/Ki Td=Kd/Kp

T
P ∞ 0
L
T L
PI 0.9 0
L 0.3
T
PID 1.2 2L 0.5L
L

The Second Method

Ziegler-Nichols tuning method to determine an initial or estimated set of working PID

parameter for an unknown system. This method usually included with industrial process
controllers and motor controllers as part of the set-up utilities. These parameters will typically
give a response with an overshoot on the order of 25% with a good settling time. The second

PID Type Kp Ti Td
P 0.5Kcr ∞ 0
Pcr
PI 0.45Kcr 0
1.2
Pcr Pcr
PID 0.6Kcr
2 8
method target plants that can be assumed unstable under proportional control. The steps for
tuning a PID controller via the 2nd method are as follow:

a) Reduce the intergrator and derivative gains to 0.

b) Increase Kp from 0 to some critical value K p = KCR at which sustained
oscillations occurs.
c) Note the value of KCR and the corresponding period of sustained oscillation,
PCR

The controller gains are now specified as follows:

 Figure 2: Step response for system tuned via second method

Graphs obtained from Recorder PIC91:

ANALYSIS

A compressible fluid is one in which the fluid density changes when it is in the high-
pressure gradients. For gasses, changes in density are accompanied by changes in
temperature, and this complicates considerably the analysis of compressible flow. There were
different between of compressible and incompressible flow which is the way that forces are
transmitted through the fluid. In a long piping, if a pump is turned on at one end, water will
immediately begin to flow out of the end of pipe. Rangeability is usually stated as the ratio of
maximum to minimum flow. There are two definition of maximum flow, which are
commonly used in specifying the rangeability of a flowmeter. The other way to define the
maximum flow is the maximum flowrate that actually occurs in a particular application. This
is how most DP flowmeter are specified. Derivative gain is defined as larger values decrease
overshoot, but low down transient response and may lead to instability due to signal noise
amplification in the differentiation of the error. For the flow process control, derivative
control mode is not used because of the process is fast and high gain process which means it
does not usually overshoot. Overshoot is means when a signal exceeds its steady state value.
APPENDIX

Without P/T compensation:

Fv = k1 √h

With P/T compensation:

Fvb = kvb
√ hP
T

The mass flow rate measurement is given by:

Assuming perfect gas law:

F m = km
√ hP
T

Where Fv = Volumetric flow rate, m3/Hr

Fvb = Volumetric flow rate, Nm3/Hr

Fm= Mass flow rate, kg/Hr

h = Absolute pressure, psi

T = Temperature, K

For the given 6.35 mm bore orifice plate,

k1 = 0.256

kvb = 1.356

Controller I) MV= -6.3% II) MV= 50% III) MV= 70%

Fvb, Nm3/Hr =1.356√84.8 x 72.5 =1.356√44.2 x 92.9 =1.356√22.3x102.6
=kvb√ hP 23.6 23.9 24.0
T = 21.835 = 17.774 = 13.240

Fm, kg/Hr =1.753√84.8 x 72.5 =1.753√44.2 x 92.9 =1.753√22.3x102.6

= km √ hP 26.3 23.9 24.0
 T = 28.227 = 22.977 = 17.116

km = 1.753
DISCUSSION

The measure of bulk fluid movement known as flow measurement. The equipment
used was the gas flow process control training system, Model AF 922. This gas flow process
control experiment was done to identify the important components of the air pressure control
system, to study gas volumetric flow rate measurement by using orifice plate, to determine
the gas mass flow rate measurement using orifice plate and perfect gas law to complete the
gas density from the pressure and temperature measurements, to study gas mass flow rate
(Fm) control using PID controller by using Ziegler Nichols closed loop method. In this
experiment, in order to detect the differential pressure throughout the flow orifice plate was
used and the differential pressure measurement was calculated. The volumetric flow rate and
mass flow rate was recorded in the chart by the gas flow process control training system,
where the RED colour in the chart showed the mass flow rate (kg/hr) and the GREEN colour
showed the volumetric flow rate (m3/hr) throughout the experiment.

The experiment was conducted by control the air flow system by using the different
set of PID parameters. In manual mode (M), the control valve FCV91 was fully open with
MV value was -6.3% and the SV value was set at its set point which is 25 kg/hr. This
experiment was run in three different trial values. For the first set (I), the PB was set at 200%,
TI at 6s and TD at 0s. The experiment then was set in auto mode (A) and waited until the
recorder response of the air flow (red pen) was fairly steady. Then, a pulse disturbance was
introduced by quickly opening and shutting fully the by-pass valve at control valve FCV91.
The same steps were used for set II and set III with the same values of TI and TD but
different in values of PB which were 150% and 100 % respectively.

Based on the result in table 1, the value of mass flow rate and volumetric flow rate
were taken from the panel and also were calculated by using the formula at different values of
MV. Form the results obtained from the experiment, the reading of the mass flow rate from
the panel showed that, the increased the values of MV, the increased the mass flow rate (F m).
From the calculation result, the values of mass flow rate also decreased when then MV value
increased. On the other hand, the result obtained from the experiment for volumetric flow rate
(Fvb) on the panel decreased when the values of MV increased. The values for volumetric rate
also decreased in calculation when the values MV increased.
 The proportional control mode is the main driving force in a controller. It changes the
controller output in proportion to the error. When the error is bigger, the action will become
bigger since more control action needs to be correct the larger errors. If the proportional
band, PB is set too high, the control loop will begin oscillating and become unstable.
However, if the PB is set too low, it will not respond adequately to disturbance changes (F.
Smuts, 2011). Based on the Figure 1 (Result for trial I, II and II at SV = 25 kg/hr), the set for
trial I showed the longest peak of disturbance while the set for trial III showed the shortest
peak for the disturbance. The proportional band, PB for trial I is higher compared to trial I
and II. Based on the result showed in chart, its follow the method where the trial I had longest
peak with the highest PB value which is 200%.

Figure1: Result for trial I, II and III at SV = 25 kg/hr

Lastly, the last testing of this experiment is PID controller tuning where Ziegler
Nichols method by setting the controller as below:

PB TI TD
100% 9999s 0s

The set point pulse disturbance was given to the process by increase the SV value from 25
kg/hr to 28 kg/hr for five second and change back to its original SV which is 25 kg/hr. Auto
mode (A) was done to ensure the turning process done by the system itself. The PB was
decrease from 100% to 50% and last to 30% in order to get the uniform oscillation. The
response form is shown in Figure 2 (The increasing of SV from 25 kg/hr to 28 kg/hr with PB
decrease from 100% to 30%). The result showed there were the oscillation on the chart. The
new value of PID controller can be calculated as there was oscillation showed in chart. Based
on the calculation, the new value of PID controller for T n was 252 s for PB was 40 and TI was
210 s.

Figure 2: The increasing of SV from 25kg/hr to 28kg/hr with PB decrease from 100% to
30%.

Ziegler Nichols method has two methods in order to tuning the process control that
was developed in 1940s. The first method is being used in this experiment. It is a direct
measurement on the controller parameter or closed loop tuning method. The integral and
derivative gain, TD is set to zero. The proportional gain is decreased until the system start to
form the uniform oscillatory response. Based on oscillatory response, the critical value of Kc
= Kcu and the period of oscillation, Tc = Tn are formed. Figure 3 (Closed loop tuning method
response), shows the example of closed loop tuning method response:
 Figure 3: Closed loop tuning method response. Retrieved from:
https://blog.opticontrols.com/archives/131

Next, the second method of Ziegler Nichols method is based on the determination of
the open loop step response of the process. By applying the step input to the process and
recording the process, the step response is measured. The response is scaled to correspond to
a unit step input and characterized by parameter a and Tdel. Tdel is the time delay of the system
and a/ Tdel is the steepest slope of the step response. Figure 4: (Open loop tuning method
responses) showed the example of open loop tuning method response:

Figure 4: Open loop Tuning method response. Retrieved from:

https://blog.opticontrols.com/archives/477

There were a few errors that occurred during conducting the experiment. The control
valve FCV91 not opened half when MV was set at 56.3%. Supposedly, the control valve can
open half.

ADDITIONAL QUESTIONS

1) Water has been analysed for pH, conductivity and dissolve oxygen. What does each
of this measurement tell you about the water?

The pH measures the acidity or alkalinity of water, with a pH 1-6 is acid, pH 7

is neutral and pH 8-14 is alkali. Electrical conductivity (ED) is a measure of the
ability of water to conduct an electrical current due to presence of dissolved salts.
Dissolve oxygen (DO) are amount of oxygen gas dissolve (mg) in each litre of water
 or percentage of maximum amount of dissolve oxygen that is possible in a waterbody
at a specified temperature and salinity (%saturation).

2) Includes short essay on your understanding on pH, conductivity and dissolve oxygen.
Related your discussion on the requirement of industrial effluent released (if
applicable).

The pH measures the acidity or alkalinity of water with a pH 1-6 is acid, pH 7 is

neutral and pH 8-14 is alkali. Generally, the pH of fresh surface waters is between 6.5
and 8.0, and the pH of most marine waters is close to 8.2 (ANZECC and ARMCANZ
2000). Marine water generally has a stable pH because of high concentrations of
dissolved carbonates provide a high buffering capacity (resistance to pH change) by
neutralise hydrogen ions (from acid). There are many processes (natural or human
induced) that may increase or decrease pH of water. For example, acid rock drainage
(natural or human induced) or acid sulphate soils can drop pH of a water body to 2, or
an algal bloom can raise pH readings to 9.5. The pH can adjust the toxicity of
ammonia, aluminium and cyanide, and must be measured at the same location and
time when analysing for these chemicals. Excessively high and low pH can be
harmful for the use of water. A high pH makes the taste bitter and decreases the
effectiveness of the chlorine disinfection, then, causing the need for additional
chlorine. The amount of oxygen in water increases as pH increases. Corrosion will
happen with low-pH water. Water pH will change due to pollution that damage
animals and plants in water. Dissolved oxygen (DO) are amounts of oxygen gas (mg)
dissolved in each litre of water (mg/L) or as a percentage of the maximum amount of
dissolve oxygen that is possible in a waterbody at a specified temperature and salinity
(% saturation). Salinity is a measure of the dissolved salt content of a body of water.
Dissolved oxygen (DO) is considered as one of the most important parameters of
water quality in streams, rivers, and lakes. The higher the concentration of dissolved
oxygen, the better the water quality. Oxygens is slightly water soluble and very
sensitive to temperature. The factor of variety actual amount of dissolved oxygen are
pressure, temperature, and salinity of the water. Dissolved oxygen has no direct effect
on public health but drinking water will tastes unpalatable to some people. There are
three main methods used for measuring dissolved oxygen concentrations: the
colorimetric method—quick and inexpensive, the Winkler titration method—
traditional method, and the electrometric method.
Electrical conductivity (EC), often simply called conductivity, is a measure of
the capability of water to conduct an electrical current. This ability is directly related
to the concentration of ions in the water. These conductive ions come from dissolved
salts and inorganic materials such as alkalis, chlorides, sulphides and carbonate
compounds. Increasing present of ions will increase conductivity of water. Distilled or
deionized water can act as an insulator due to its very low conductivity value. Sea
water, on the other hand, has a very high conductivity. Ions conducts electric due to
their positive and negative charges.
CONCLUSION

As a conclusion, this experiment had achieved its objective of Air Flow Control (FIC
91). When we increase the changing in MV value, the value of controller gain, Kc will
increase and can affect the respond of the process to become more faster and the process
become more stable. By decreasing the controller gain, Kc it also reduces the oscillatory and
make the process become more stable. The integral time, I value is decreased, and it
accelerates the process to the set point. On the other hand, the result obtained from the
experiment for volumetric flow rate (F vb) on the panel decreased when the values of MV
increased. The values for volumetric rate also decreased in calculation when the values MV
increased. For the flow process control, derivative control mode is not used because of the
process is fast and high gain process which means it does not usually overshoot. Overshoot is
means when a signal exceeds its steady state value.
RECOMMENDATION

The students should plan and thoroughly understand the purpose of the experiment
and how to carry out the method of experiment flow control in advance. It allows the students
to perform the experiment smoothly without any complications, such as uncertainty about
what the next step in the experiment process is to be achieved. In addition, the student will be
able to identify the equipment and its purpose throughout the experiment.

During the briefing on how to treat and perform the experiments, students will give
full attention to the individual being charged and write down the required points regarding the
experimental procedure. This is very critical as the equipment is very fragile and must be
handled with care. This also helps the students to get a full idea of how they should have
performed the experiments.

Students should not mess around during the experiments process and be careful in
order to obtain the most accurate results. Students should carry out the experiments without
causing accidents or disrupting others. Any wrong step from the start would result in the
repeat of the experiment. This will cause time-waste. This also helps to eliminate the human
error that could arise because the students misconduct the process of flow control of the
experiment.
REFERENCES

ANZECC and ARMCANZ 2000, Australian and New Zealand guidelines for fresh and
marine water quality, Volume 2, Aquatic ecosystems, Australian and New Zealand
Environment and Conservation Council, Agriculture and Resource Management Council
of Australia and New Zealand.

Conductivity, Salinity & Total Dissolved Solids. (n.d.). Retrieved March 1, 2020, from
https://www.fondriest.com/environmental-measurements/parameters/water-
quality/conductivity-salinity-tds/

F. Smuts, J. (2011). PID Controllers Explained | Control Notes. Blog.opticontrols.com.

Retrieved 28 February 2020, from http://blog.opticontrols.com/archives/344

Haugen F, 2010. Ziegler-Nichols’ Closed-Loop Method [online] Available at:

http://techteach.no/publications/articles/zn_closed_loop_method/zn_closed_loop_method.
pdf [Accessed 29 March 2020].

Omer, N. H. (2019, October 16). Water Quality Parameters. Retrieved March 1, 2020, from
https://www.intechopen.com/online-first/water-quality-parameters

Steinberge, B. (2013). Gas mass flow rate units of measure. Retrieved 28 February 2020,
from https://sagemetering.com/back-to-basics/gas-mass-flow-rate-units-of-measure