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EXPERIMENT 1: AIR PRESSURE CONTROL: MODEL AP922

(A) OVERVIEW
Study Model AP922 carefully.
Walk around the plant and identify the various equipment, processes and the instrumentation and
control systems. Also refer to the Process and Instrument (P and I) drawing.
a)

The process plant consists of three air vessels T91, T92A and T92 with the associated
piping, valves and fittings. The air vessels are made from larger diameter standard pipe
sections. Each vessel generally has a single/multiple air inlets and multiple outlets and is to
be operated with continuous air inflow and outflow. Each vessel has its own vent (V),
bottom drain (D), pressure relief valve (PRV) and pressure gauge (PG).

b)

i.

An external air supply from the compressor air system is connected to the Model plant
at the process inlet at the pressure regulator, AR91, into the vessel T91.
This inlet pressure (Barg, psig) is preset according to the pressure indicated at AR91,
with its downstream manual valve MV91 shut.

ii. The maximum inflow rate can be varied by regulating the manual valve MV91
immediately downstream of AR91.
c)

The instrument air supply regulators (IAS) should be set according to the pressure indicated
at the respective air regulators.

d)

The process air inlet flows into T91 and then along pipeline PLI-T92A-T92-FI92-PCV91discharge via the process vent valve VP. The process air also flows from T92 along pipeline
PLII-PCV90-discharge via either manual globe valve MV92A/orifice OR manual gate
valve MV92B.
i. The air pressure in T91, T92A and T92 are monitored by their respective pressure
gauges PG91, PG92A and PG92. Excessive pressures will be relieved by their respective
pressure relief valves (PRV91, PRV92A and PRV92).
ii. The pressure in T91 is also measured by a gauge pressure transmitter PT91 and
controlled by PID pressure controller PIC91, which throttles control valve PCV91 via
the Current (4-20mA) to Air (3-15 psig) converter, PCY91 and the pneumatic Positioner
(PP). Control valve PCV91 is ATC (Air-to-Close) which means it will stay open if there
is no air signal to its actuator such as during instrument air failure or during shut-down.
The process air finally discharges to atmosphere via the process vent VP through
PCV91 and the variable area flowmeter FI92.

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iii. The pressure measured by the gauge pressure transmitter PT92 is controlled ON/OFF
by the ON/OFF pressure controller PIC90. PIC90 will switch to close the normallyopen (NO) solenoid valve PSV90, when the preset high pressure limit is exceeded. The
ON/OFF control valve PCV90 is ATC (Air-to-Close).
Thus when the pressure in T92 or its discharge pipeline is above the preset high limit,
PIC90 switches to close PSV90, cutting off the instrument air supply to the actuator of
PCV90. PCV90 then opens to vent (V) air to the atmosphere. The rate of discharge can
be manually set at the manual valves (MV92A, MV92B) at the common vent line (V)
downstream of PCV90.
Note that both the control valves PCV91 and PCV90 are Air-to-Close (ATC) so that
when there is instrument air failure, they stay open to vent out any pressure inside the
plant.
iv. Furthermore, PID Air Pressure Control system can be studied:
Process:

3-Capacities in series, vessels T91+T92A+T92 and its

discharge Pipeline.
Process inflow into T91 is from pipeline PLI.

Controlled Variable:

PT91, Pressure in T91.

Manipulated Variable:

At pressure control valve PCV91, outflow of T92.

PID Controller:

PIC91 (PID1)

Control Loop:

Single loop: PT91-PIC91-PCY91/PP-PCV91

e)

Outlet
The final process air discharge from Model AP922 is to atmosphere via its process vent VP
from T92/T92A/T91 and via its common vent V downstream of PCV90/MV92A or
MV92B.

f)

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In general, T91, T92A and T92 have their own individual vent valves which should fully
shut during normal operation.
They also have their own individual bottom drain valves which should be purged
occasionally of any condensed water vapour. Otherwise, these should remain fully shut
Trace the various discharge piping from the Model plant. The final discharge to
atmosphere is outside the building.

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(B) CONTROL SYSTEM AND INSTRUMENTATION

Identify the following summary list of instruments and control systems. Read Each row from
left to right as a control loop. The items that are asterisked * are field (plant) mounted.
Sensor/Transmitter
PT91*

Controller
PIC91 (PID1)

Final Control Element

PCY91*/PP*/PCV91*

NOTE:
PIC91 (PID1) is configured inside the single unit of microprocessor-based PID panel
controller (Programmable).

Field-Mount Instruments : Sensors, Transmitters, Control Valves, Variable Area Flowmeter,

Gauges etc
The instruments mounted at the field (plant) are asterisked (*) in the previous summary list
and further detailed below. For more details, please refer to a separate manual for their
specifications etc.
PT91

Gauge Pressure Transmitter

Measures air pressure in T91
Calibrated Range: 0-25 psig

PT92

Gauge Pressure Transmitter

Measures air pressure in T92 OR at its discharge Pipeline (i.e. one of
the tapping point must be manually shut always).
Calibrated Range: 0 25 psig

PCV91

PP
PCY91

:
:

Pressure control valve . Equal % characteristics, Air-to-Close

(ATC). Regulated by PID controller PIC91 or PIC92
Pneumatic Positioner, with By-pass.
Current-to-Air Converter (I/P) : 4-20mA to 3-15 psig

PSV90
PCV90

:
:

PG91, PG92,
:
P92A, PG93, PG94

Solenoid valve, Normally-Open (NO)

ON/OFF pneumatic control valve, Air-to-Close (ATC).
PCV90 is opened by ON/OFF controller PIC90 via PSV90, when
the pressure measured by PT92 is above its preset high pressure
limit.
Pressure Gauges

TG91, TG92

Temperature Gauges

FI92

Variable area flowmeter (Rotameter). Metal construction safety type.

PRV91,
PRV92

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PRV92A, :

Pressure Relief Valves

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Panel-Mount Instruments
The panel-mount instruments are listed below.
Switch the PANEL, SCADA/DDC selector switch at the front cubicle to the PANEL,
SCADA position for Panel operation.
PIC91

microprocessor-based Panel Controller (Programmable) configured for

pressure controls PIC91 : (PID1), PID control of PT91, pressure in T91.
PIC90 : ON/OFF control for PT92 using the High alarm limits set
at P01 and the Dead Band set at P02, at PT Register.

PR91

Chart Recorder analog inputs with pen/bar graph and selective display
in engineering units.
Red pen (Channel 1) : Pressure PT91, Calibrated range 0 - 25 psig.
Green pen (Channel 2): Pressure PT92, Calibrated range 0 - 25 psig.

Analog display in the form of horizontal coloured bar or pen-chart

paper are to be read as follows:Analog display in % x Maximum (calibrated range), engineering units =
Actual readings, engineering units

Annunciators
The Annunciators are:PAD91
: The pressure at T91, measured by PT91, exceeds its preset Deviation from
the setpoint, whether above or below. The Deviation alarm limit is set at
DL1 at the PID1 page or panel.
PAH92

: The pressure, measured by PT92, rises above its preset High alarm limit. The
High alarm limit is set at P01 at the PT Register page or panel.

A buzzer will come on and the respective alarm windows (PAD91, PAH92) will lit up when
the above abnormal or alarm conditions occur. Pressing the Acknowledge button will silence
the buzzer sound. The dedicated alarm window remains lit as long as its process variable is still
in the alarm condition. The alarm window light will go off when the process variable is
restored to normal.
The Test button is to test if the Annunciator alarm window lights are working.

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(C) EXPERIMENT PROCEDURES

AIM

: To study single loop gas pressure control

CONTROL
SYSTEM

: Single Loop Gas Pressure Control

PT91-PIC91-PCY91/PP/PCV91

SPECIAL
REMARKS

: The panel-mount 1-2 Position selector switch for the pressure

controller PIC91/PIC92/PIC90 should be in Position 1, operating
PIC91 (PID1, Loop1) only.
Select the PIC91 controller main faceplate display.

KEY PROCESS
VARIABLE

: Gauge pressure in the vessel T91, measured by PT91.

PROCEDURES
1.
Quickly check the following : Switch the PANEL, SCADA/DDC selector switch at the front cubicle to the PANEL,
SCADA position.

Switch ON the main power supply at the front of the cubicle. Power will be distributed
automatically to the control systems and instrumentation. The panel instruments will lit
up.
Also open the swing front cover of the recorder PR91 and press the RCD push button
to STOP its chart drive, if it is running. Start the recorder chart drive only during the
experiment proper.

WHENEVER ANY ANNUNCIATOR IS ACTIVATED, PRESS THE

ACKNOWLEDGE (RED) BUTTON TO SILENCE THE BUZZER SOUND BUT
THE LIGHT REMAINS LIT. CHECK AND RATIONALISE THE CAUSE OF
THE ALARM CONDITION.

Check that the instrument air supply are set accordingly at their air supply regulators
(IAS). Frequent and exact pressure adjustment of the IAS is not necessary. Purge
regularly all the regulators to remove any condensed water, using their bottom drain
valves.

The valve Positioner (PP) at PCV91 is ON and connected i.e. USE THE
POSITIONER
With PIC91 in Manual (M) mode, stroke the control valve PCV91 manually with MV
= 100%, 50% and 0% and note that the corresponding valve stem position at its stem
indicator scale is 0%, 50% and 100% opened, only if the Positioner (PP) is
connected.

Check that the by-pass valves around the two control valves PCV91 and PCV90 are
always shut but the adjacent pair of manual valves upstream/downstream of these
control valves are opened.

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2.

Check that the individual vent valves and bottom drain valves of T91, T92A and T92
are shut. Occasionally purge the bottom drain valves to remove any condensed water
vapour.

Check that the final discharge manual valve VP downstream of PCV91 is fully opened,
for air final discharge.
Both pipelines PLI and PLII must remain opened throughout unless otherwise
instructed. Check that the manual discharge globe valve MV92A at the common vent
(V) of pipeline II, downstream of PCV90 is opened but the gate valve MV92B is shut,
before proceeding further. If ever PCV90 is opened and shut during the course of the
following experiments, let the pressure response stabilise by itself. OTHERWISE, shut
MV92A as well.

Operate the pressure process using the 3 vessels T91, T92A and T92 for air to flow in
series from one vessel to the next. Check that the By-pass valves B92A and B92 around
T92A and T92 are shut, but all the direct interconnecting manual valves between T91T92A-T92 are fully opened.

Model AP922 runs with compressed air as the process medium.

The process air is from the air compressor via the pressure regulator AR91.
The maximum Pressure and Flow rate can be set as follows :a) Shut fully the manual valves MV91B and MVIII at the process air pipeline coming from
any other interconnected Model Air plant. Check and make sure that the manual
discharge valve MV901 from Model AFT922 is fully SHUT.
b) Set Pressure
With the process flow totally shut at the process inlet manual valve MV91, check that
AR91 is approximately at the pressure indicated at AR91 (26-28 psig). Open MV91 by
about turn and then shut it again. Reconfirm the pressure at AR91 is 26-28 psig.
Otherwise, adjust AR91 to the pressure indicated and then recheck again with MV91
open and then shut to read the pressure. Leave MV91 fully shut, after having confirm
that the pressure at AR91 is correctly set.
c) Shut pipeline PLII by shutting both its manual discharge valves MV92A and MV92B.
d) Check that pipeline PL1 with the control valve PCV91 and the final discharge manual
vent valve (VP) downstream of FI92/PCV91 are fully opened. PCV91 is opened from
the panel controller PIC91 in Manual (M) mode with MV = -0%, e.g. 6.3%.
e) Set Flowrate
Open the process inlet manual valve MV91 by about 1/2 turn (180) and regulate MV91
till the process air flowrate at the variable area flowmeter FI92 read 20Nm/Hr MAX
and NOT more.. Observe the flowrate till it remains steady for about 1 minute.

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f) Check Pressure/ Flowrate are correctly set

To check that the correct supply inlet pressure/flowrate are set, check (i) and (ii) as
follows before proceeding.
(i) From the panel controller PIC91, shut PCV91 fully with its MV=106.3%. The
pressure at tank T91 indicated at the PV of PIC91 must exceed 22 psig but not
exceed 27 psig.
See OTHERWISEbelow
(ii) From PIC91, open PCV91 fully with its MV= - 6.3%. The residue pressure at tank
T91 indicated at the PV of PIC91 must not exceed 5 to 6 psig, or else, the flowrate
set at MV91 is too high. FI92 must be less than the flowrate stated above.
See OTHERWISEbelow
- OTHERWISE, refer back to the previous procedures and start again setting the
pressure at AR91 (procedure b) and flowrate (procedure e) at the manual valve
MV91.
g) The instructions are summarised in the Table below.

TABLE : SUMMARY INSTRUCTIONS TO SET THE PRESSURE AND FLOWRATE

AT MODEL AP922
Set Pressure
Set AR91 at 26-28 psig
Set Flowrate

If FI92 is calibrated at 2 Barg, 200C,

Adjust MV91 till FI92 is 20Nm/Hr max and NOT more.
DO NOT exceed the above stated flowrate.

Check Pressure

With PCV91 fully shut, PV1 at PIC91 (i.e. PT91) should be 22-27 psig.
OTHERWISE, reset AR91.

Check Flowrate

With PCV91 fully open, PV1 at PIC91 (i.e. PT91) should be less than 5-6
psig and FI92 is not more than the recommended flowrate.
OTHERWISE, readjust MV91 for maximum Flowrate.

3.

Locate the Gauge Pressure Transmitter PT92 and trace its impulse lines to two pressure
tapping points:
- TP-T at T92
- TP-P at the discharge pipeline of T92
Open TP-T and Shut TP-P

4.

With PIC91 in the Manual (M) mode, open the control valve PCV91 fully with MV= 6.3%. For confirmation, check the control valve stem position at PCV91. Take note of the
minimum pressure PV1 (in PIC91).

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5.

Concentrate on the Pressure PID panel controller PIC91/PIC92/PIC90 and the recorder
PR91.
Within the Pressure PID panel controller PIC91/PIC92/PIC90, note the following
controls:
PIC91:
PID controller for PT91 throttling the control valve PCV91 to control
the pressure PT91 at T91, in a 3-Capacity pressure process comprising
T91/T92A/T92/discharge Pipeline T92 to PCV91.
1-2 Position:
Selector
Switch

Switch to Position 1, to select PIC91 only, for Single loop control.

Start the recorder PR91 by pressing the RCD pushbutton at the front of the recorder with
its swing front cover opened. Note that
PT91: Red pen (Channel 1), Input Range: % of 0-25 psig.
Channel 1 is in psig
The recorder chart drive is preset for fast speed (500mm/Hr).
6.

Check that vessels T91, T92A and T92 are connected for air to flow in series from one
vessel to the next. Check their respective pressure at the pressure gauges PG91, PG92A
and PG92. The manual By-pass valves B92A and B92 around T92A and T92 should be
fully shut. The final manual discharge valve (VP) downstream of the pressure control valve
PCV91 should be fully opened.

7.

a) Open PCV91 fully from PIC91 in Manual (M) mode, with MV = -6.3%. Make sure the
by-pass valve around PCV91 is shut but its two adjacent manual valves are opened.
b) Access the PID values in the pressure PID controller PIC91, at the PID1 page or panel.
Set the following first (I) trial PID values.
PB1 = 70 %,
TI1 = 40 secs,
TD1 = 0

Adjust the setpoint SV to 18 psig (72%) at PIC91.

Make sure the chart drive of the recorder PR91 is running. Otherwise, press the
RCD button at the front of the recorder with its swing front cover opened.

Transfer PIC91 to Auto (A) mode and watch the response at the recorder PR91 till
it is steady at its setpoint SV to within 0.1 psig or continues to oscillate even after
3 cycles.

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PIC91 PID Pressure Control of T91/92A/T92

Procedure
Reference
7
c.
d.
e.

PID
Values
3-Capacity pressure process,
Controller: PIC91
Same PID, different SV.
First (I):
70/40/0
First (I):
70/40/0

Setpoint,
psig
T91/T92A/T92.

Test
With

Positioner.

18
18-9

Load step test

Setpoint step test

(i).
(ii).

Same PID, different SV.

Second (II): 45/30/0
Second (II): 45/30/0

9
9-18

Load step test

Setpoint step test

(i).
(ii).
(iii).

Same PID, different SV.

Third (III): 35/30/0
Third (III): 35/30/0
Third (III): 35/30/0

18
18-15
15-9

Load step test

Setpoint step test
Setpoint step test

(i).

Different PID, same SV.

Third (III): 35/30/0

15

(ii).
(iii).

Second (II): 45/30/0

First (I):
70/40/0

15
15

Setpoint step test

Load step test
Load step test
Load step test

f.

g.

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c) Load step test

With the setpoint SV=18 psig (72%) and the first (I) trial PID values of 70%/ 40
secs/ 0 sec, apply the load step test as follows:
When the response is steady, switch PIC91 to Manual (M) mode and decrease its MV
by 5-10%. Quickly switch PIC91 back to Auto (A) and observe the pressure response at
the recorder PR91 till it is almost steady to within 0.1 psi, or continue to show
oscillatory response even after 3 cycles.
THE CHART RECORDING CONSTITUTES THE RESULTS OF YOUR
EXPERIMENT. NOTE DOWN ON THE CHART THE PB1, TI1, TD1, SV
VALUES. WATCH CLOSELY FOR OVERDAMPED, UNDERDAMPED
RESPONSE AND THE POSSIBILITY OF ANY INLET LOAD DISTURBANCE.
CAREFUL CONSIDERATION MUST BE TAKEN THEN TO PROVIDE
EFFECTIVE CONTROL.
d) Setpoint Step disturbance
With PIC91 in Auto (A) mode, apply a step change in setpoint (SV) from 18 to 9 psig
(72% to 36%). Observe the chart response similarly and note down the SV and PID1
values on the chart. (Note: When the 1-2 Selector Switch is in Position 1, PV1, SV1
becomes PV, SV respectively).
Check for process inlet load disturbance
- If the response tends to oscillate outside the desired control band of 0.1 psig i.e.
below 8.9 and above 9.1 psig for SV = 9 psig OR below 17.9 and above 18.1 psig for
SV = 18 psig, switch PIC91 to Manual (M) mode and observe if the pressure is still
oscillating i.e. IF THE PROCESS AIR INLET SUPPLY PRESSURE IS
OSCILLATING, WHICH IS A LOAD DISTURBANCE AT THE PROCESS
INLET.
If it is, then the PID values (70% / 40 sec/ 0 sec) may have slowed down the
controller action, till it is slower than the process inlet disturbance.
- Try a faster TI i.e. set TI1 = 10 to 20 secs instead of 40 secs, for faster setpoint
recovery.
Observe similarly for any improvement.
e) Testing at different setpoints
(i) With the setpoint SV at 9 psig (36%), use the second (II) trial PID shown below:
PB1 = 45%
TI1 = 30 secs
TD1 = 0 sec
Repeat the previous (c) using the same load step test and observe similarly.
(ii) With PIC91 in Auto (A) mode, apply a setpoint step test by changing the setpoint
from 9 to 18 psig (36% to 72%) and observe.
- If the response oscillates outside the control band of SV 0.1 psig, and stays too long
away from the setpoint SV, try a faster TI secs and observe similarly, but note that a
stronger Intergral action (smaller TI secs) is more oscillatory.
PB1 = 45%
TI1 = 20 then 10 secs
TD1 = 0 sec
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f) (i) With the setpoint at 18 psig, use the third (III) trial PID values as follows:
PB1 = 35%
TI1 = 30 secs
TD1 = 0 sec
Repeat the previous (c) using the same load step test and observe similarly. If it is
oscillatory, observe for 10 cycles to see whether the oscillation can be damped out. It
is very likely that the controller gain is too high at PB%=35%, at setpoint SV= 18
psig
(ii) With PIC91 in Auto (A) mode, apply a setpoint step test by changing the setpoint
from 18 to 15 psig (72% to 60%). Observe the response patiently for a while. If it is
oscillating continuously, observe for about 10 peaks.
(iii) With PIC91 in Auto (A) mode, apply a setpoint step test by changing the setpoint
SV from 15 to 9 psig (60% to 36%). Observe the response patiently for a while. If it
is oscillating continuously, observe for about 10 peaks.

However, if the pressure control loop appears more or less oscillatory at different
operating setpoints (SV), then the pressure control loop in this application is NonLinear. i.e. the loop has variable gain. Discuss the likely cause of this Non-Linearity.

g) Different PID comparison, at the same Setpoint SV

For the same setpoint SV, different PB% and TI secs will produce different control
responses, as generalised in the table below.
TABLE : INCREASING/DECREASING PB%, TI SECS
DIFFERENT
EFFECT OF PB%, TI secs ON CONTROL RESPONSES.
PB%, TI secs
Larger PB%
Lower controller gain : Stabilising.
Slower, more damped, less oscillatory.
Smaller PB%
Higher controller gain : Destablising.
Faster, less damped, more oscillatory.
Larger TI secs
Less powerful integral action : Stabilising.
Slower recovery to setpoint, less oscillatory, less overshoot/undershoot
Smaller TI secs
More powerful integral action : Destabilising
Faster recovery to setpoint, more oscillatory, higher
overshoot/undershoot.

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Try to verify the above using the following tests :

(i) With PIC91 still in Auto (A) mode, change the pressure setpoint SV to 15 psig
(60%) and observe similarly.
Set the third (III) trial PID values as shown in the next TABLE: TESTING
WITH DIFFERENT PID AT THE SAME SETPOINT.
Switch controller PIC91 to Manual (M) mode and decrease MV by about 5 to
10%.
Quickly switch PIC91 back to Auto (A) mode.
This is a load step disturbance of about 5 to10%. Watch the response at the
recorder PR91 until it stabilises to within 0.1 psi of its setpoint or shows
oscillatory response even after 3 cycles.
(ii) and (iii). Repeat the above at the same SV = 15 psig, using instead the (ii) second (II)
and (iii) first (I) PID values as shown below. Apply the same load step
disturbance after each change of PID values.
Compare the three responses at the three different PID values at SV = 15
psig, bearing in mind that the objective is to control the ressure of tank T91 at
its setpoint SV to within 0.1 psig.

TABLE : TESTING WITH DIFFERENT PID AT THE SAME SETPOINT

PID
Parameters
PB1
TI1
TD1
Setpoint SV
Responses

8.

PROCESS : Three (3) Capacity Pressure Process

First (I) trial
Second (II) trial
Third (III) trial
PID values
PID values
PID values
70 %
45 %
35 %
40 secs
30 secs
30 secs
0 sec
0 sec
0 sec
15 psig
15 psig
15 psig
Damped, slow recovery.
Is it between trial PID Is it faster?
Can control be improved (I) and (III) responses? Is it oscillatory?
by using a faster TI (i.e.
TI1= 10 to 20 secs)?

To shut-down AP922,
- Shut MV91 but do not adjust AR91.
Purge any water collected at the individual air supply regulator (IAS) but do NOT
adjust the top knob, which has been preset to the required pressure.
- Switch PIC91 to Manual (M) mode with its MV = 0%
- At the Recorder, press the RCD pushbutton to stop the chart drive.
- Switch off the power supply at the front of the panel.
- Shut fully the isolation manual valve at the main air supply line to Model AP922.

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RESULTS/DISCUSSION
The recorder PR91 records the results of the experiments.
RELEVANT PORTIONS OF THE RECORDER CHART RESPONSES SHOULD BE
SUBMITTED AS RESULTS OF THE EXPERIMENT, WITH THE FOLLOWING
PERTINENT DATAS MARKED ON THE CORRESPONDING CHART RECORDING: CONTROLLER IN AUTO (A), MANUAL (M) MODE.
SETPOINT (SV), PB, TI, TD.
ANY ANNUNCIATOR ACTIVATED.

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TYPICAL RESULT SHEET, EXPERIMENT 1, PROCEDURE 7

GAS PRESSURE PID CONTROL: PIC91
Enclose a few chart responses using different sets of PID values for PIC91.
Use the Positioner (PP) at PCV91.
PIC91 Setpoint(SV1): __ psig
Process for Single loop : T91+T92A+T92 and its discharge Pipeline.
PIC91: PB1: ________ %, TI1: ________ seconds,
TD1: ________ seconds
Test disturbance: Setpoint step change/Load step change (Tick which one)
Note any significant Annunciators activated :

PIC91 Setpoint(SV1): __ psig

Process for Single loop : T91+T92A+T92 and its discharge Pipeline.
PIC91: PB1: ________ %, TI1: ________ seconds,
TD1: ________ seconds
Test disturbance: Setpoint step change/Load step change (Tick which one)
Note any significant Annunciators activated :

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