EKC 493 Chemical Engineering Laboratory III

PC 7

AIR FLOW SYSTEM

PROCESS CONTROL

OBJECTIVES

To identify the components of the air flow control system

To measure the flow rate of a gas and to obtain the mass flow rate using pressure
and temperature correction.
To control a gas flow process with PID controller
To tune the controller by Ziegler Nichols close-loop method.

KEYWORDS
Air flow, Ziegler Nichols Tuning, Air Flow control

1.0 PART A: IDENTIFICATION OF MAJOR COMPONENTS IN THE PLANT

Identify the following major components of the system:

Tanks T91, T92

Orifice meter FE91
Differential Pressure transmitter FT 91
Controller Valve FCV 91
Controller Valve FCV 92

The experimental set up is shown in Fig.

2.0 PART B: GAS FLOW MEASUREMENT

2.1 Objective:

To measure the flow rate of a gas and to obtain the mass flow rate using pressure and
temperature correction.

2.2 Introduction:

The most common method of flow measurement is by using an orifice meter. The
differential pressure across the orifice meter is related to the volumetric flow rate. In the case
of a gas, density is related to pressure and temperature. Hence the mass flow rate can be
determined from the volumetric flow rate given by the orifice meter.

2.3 Theory:

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The volumetric flowrate as measured by an orifice meter is given by an equation

P
Q = Cv (1)

where
Q = Volumetric flowrate at temperature t10C and pressure P1 psia.

P = Pressure drop measured across orifice meter.

Cv = Orifice coefficient.

The corresponding volumetric flow at standard conditions is given by

273 P
Q STP = Q 1 (2)
(273 + t 1 ) 14.7

The density at Standard Temperature and pressure can be derived from the ideal gas law.

m
PV = RT
M
m 14.7 x M
Therefore = = (3)
V R x 273

where = density
m = mass of gas
M = molecular weight
R = gas constant

The mass flow rate of gas W is given by

P1 M 273
W = Q STP = C v P (4)
(273 + t 1 ) R 14.7
P1
= K P
(273 + t 1 )
The constants are given by

Cv
= 0.1513

K = 2.1218

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2.4 Experimental Equipment:

The experiment is conducted in Flow Pilot Plant (see figure 2).

2.5 Procedures:

1. Set the air supply pressure at 3 bars with valve V1 shut. Release the valve to supply
air to the pressure tank T91.

2. Put controller FIC 91 in manual mode.

2. Adjust the air flow rate by setting MV (manipulated variable) at 20% (refers to valve
opening).

3. Read the variables (I/O data) in the controller register as shown below.

* Controller FIC 91 Register Data

X1 P, % of 10000 mm WG. (Water Gauge)

X2 Temperature, % of 2000C

X3 Pressure, % of 60 psia.

Y1 Controller output, MV, to FCV91

% of 72.825 kg/hour
Y3 k v h , Output to FIC 92, (Volumetric flow
rate), %

FIC 92 Q Volumetric flow rate, ft3/min

FIC 91 M (PV) Mass flow, kg/hour

4. Repeat the experiment at other flow rates by changing the MV to 30, 40, 50, 60, 70,
80, 90, 100%.

2.6 Results and Report:

1. Graphs showing Q calculated vs Q measured and M calculated vs M measured.

2. A neat sketch of a Differential Pressure Transmitter.

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3.0 PART B:: PID CONTROL OF AIR FLOW SYSTEM

Objectives:

1. To control a gas flow process with PID controller

2. To tune the controller by Ziegler Nichols close-loop method.

Introduction:

It is necessary to control the flow of gases into process units to avoid buildup of pressure,
maintaining a certain concentration in the vessel, etc. Gas flow measurement involves
pressure and temperature compensation. The signal may contain noise and require special
methods.

Experimental Equipment:

The experimental equipment consists of the flow control pilot plant shown in Fig 2. The
following units are used

Tanks T91 and T92

Pressure Transmitter PT91

Differential Pressure Transmitter FT91

Orifice meter FE91

Temperature Transmitter TE91 and TIT 91

PID controller FIC 91

Control Valve FCV 91

I/P Transducer FCY 91

Rotameter FI 91

Procedures:
Part A: To control a gas flow process with PID controller

1. With FIC91 in the Manual (M) mode, open the control valve FCV91 fully with MV =
0%.

For confirmation, check the control valve stem indicator at FCV91. Note that FCV91
is Air-to-Close(ATC) type.

2. With FIC91 still in Manual mode, adjust its setpoint to about 20kg/hr.

3. Access the PID parameters of FIC91 and set the following first (I) trial PID values:-

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I
______________

PB = 200%
TI = 6 secs
TD = 0 secs

4. Press the RCD button at the front of the recorder with its swing glass cover opened.

5. Transfer FIC91 to AUTO (A) mode and watch the recorder response until the flow
(Blue pen) is fairly steady. Introduce a pulse disturbance by quickly opening and
shutting fully the by-pass valve around FCV91.

6. Repeat with a second (II) and third (III) set of trial PID values:-

II III
____________ _______________

PB = 150% PB = 100%
TI = 6 secs TI = 6 secs
TD = 0 secs TD = 0 secs

At each change of PID values, upset the process by the following ways:-

o Open and shut the by-pass valve around FCV91 to introduce a pulse
disturbance.

7. Make minor adjustment to PB and TI till there is almost quarter amplitude damping
(QAD) with minimum offset.

8. When the loop is tuned, introduce Derivative control mode. Start with very small TD
of a few seconds. Watch the loop become unstable with increasing TD to say 24 secs
or more. Damp the oscillation by increasing the PB to say 400% or more.

Part B: To tune the controller by Ziegler Nichols close-loop method

1. Set FIC91 with a setpoint of about 25 kg/hr and with the following PID values.

PB = about 30%

TI = 9999 secs (max)

TD = 0 secs (min)

2. With FIC91 still in Manual (M) mode, adjust its output (MV) until the measurement (PV)
is close to the setpoint (SV = 25 kg/hr).

3. Transfer FIC91 to Auto (A) mode.

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4. Introduce a pulse disturbance by quickly opening/shutting the by-pass valve around

FCV91. Watch the response (blue pen) at the recorder.

5. Repeat the Closed Loop Method as above with a different PB until uniform (constant
amplitude) oscillation is observed.

Note the PB as PB* ultimate. Note that it will not oscillate at the setpoint but
will be based away from the setpoint as the OFFSET, because there is no
Integral control action.

Measure the distance between two adjacent peaks. This is Tn, the natural
period of oscillation in seconds by the conversion,
measured period in mm x 3600
Tn secs =
chart speed eg 500 mm / HR

The approximate PID settings are

Tn
PB = 2 x PB*, TI =
1.2

6. Set calculated values of PB, TI and TD into FIC91 and if the oscillation persists increase
the PB until the oscillation is damped out. Test the PID values with another pulse
disturbance. Fine-tune the PB and TI values to get as close to QAD as possible.

Results and Report:

1. P & I diagram of the process.

2. Tuned values of Kc, TI and TD.

3. Sample response curve.

4. Discussion of Ziegler-Nichols closed-loop method of tuning.

5. An example of calculated variable control.

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Figure: Engineering Drawing of Airflow System

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EKC 493 Chemical Engineering Laboratory III

Figure: Engineering Drawing of Airflow system

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