CEV544 PROCESS CONTROL AND

INSTRUMENTATIONS

TEAM: 4

EXPERIMENT: Process control system

DATE OF 16th OCTOBER 2018

EXPERIMENT:
GROUP STUDENT
MEMBERS: ID:

MUHAMMAD AMIRUL BIN MAT DZAKI 2016706485

MUHAMMAD HAZRY RAFIEQ 2016321741
JAMAATUL HASANAH BINTI MD WAZIR 2016354415

LECTURER NAME:
MADAM NUR ALWANI BINTI ALI BASHAH

1
TABLE OF CONTENT

1.0 ABSTRACT .......................................................................................................................................... 3

2.0 INTRODUCTION ................................................................................................................................. 4
3.0 OBJECTIVE ......................................................................................................................................... 6
4.0 APPARATUS ....................................................................................................................................... 7
5.0 EXPERIMENTAL PROCEDURE ............................................................................................................ 9
6.0 CALCULATION.................................................................................................................................. 11
7.0 DISCUSSION..................................................................................................................................... 14
8.0 CONCLUSION ................................................................................................................................... 15
9.0 RECOMMENDATION ....................................................................................................................... 15
10.0 REFERENCE ...................................................................................................................................... 16
11.0 APPENDICES .................................................................................................................................... 17

2
1.0 ABSTRACT

The experiment is about open loop test and closed loop test with load disturbance. An open
loop test is carry out to calculate the value of response rate (RR), time constant(T C) and dead
time(Td) by using tangent method (TM) and reformulated tangent method (RTM). By using value
of RR, TC and Td the value of P and I was calculated using Ziegler-Nichols tuning rules. Then,
the value of P and I was used to performed closed loop test. Next, for closed loop that used
tangent method, the value of P and I is 38.9 and 13.3s respectively while for reformulated
tangent method the value of P and I is 6.1 and 2.3 respectively. The value of P and I were times
by 4 twice for the reformulated tangent method to tuned the process in order to stabilize the
process. From the process, load disturbance was also performed for tangent method and
reformulated tangent method. Finally, the result shows that the system can undergo sudden
changes before it came to stabilize again.

3
2.0 INTRODUCTION

PID controller is universally accepted and most commonly used controller in industrial

application because PID controller is simple, provide good stability and rapid response.

A proportional–integral–derivative (PID) controller or kwon as three term controller is a control

loop feedback mechanism which is widely used in industrial control systems. In each

application, coefficient of these three actions are varied to get optimal response and control.

Controller input is error signal and output is given to the plant/process (Nichols, 1942). Output

signal of controller is generated, in such a way that, output of plant is try to achieve desired

value. In other words, A PID controller continuously calculates an error value e(t) as the

difference between a desired set point (SP) and a measured process variable (PV) and applies

a correction based on proportional, integral, and derivative terms (denoted P, I, and D

respectively) which give the controller its name (Li, March 2006). In practical terms it

automatically applies accurate and responsive correction to a control function. PID controller

packs the benefits of all of the above controller.

Figure 1 : A block diagram of a PID controller in a feedback loop. r(t) is the desired process

value or setpoint (SP), and y(t) is the measured process value (PV).

4
 Figure 1 shows the principles of how these terms are generated and applied. Role of a

Proportional Controller (PC). The role of a proportional depends on the present error, I on the

accumulation of past error and D on prediction of future error. The weighted sum of these three

actions is used to adjust Proportional control is a simple and widely used method of control for

many kinds of systems. In a proportional controller, steady state error tends to depend inversely

upon the proportional gain. The proportional response can be adjusted by multiplying the error

by a constant Kp, called the proportional gain (Mpanda, 29, February 2012) . A high proportional

gain results in a large change in the output for a given change in the error. If the proportional

gain is very high, the system can become unstable. In contrast, a small gain results in a small

output response to a large input error . If the proportional gain is very low, the control action may

be too small when responding to system disturbances. Consequently, a proportional controller

(Kp) will have the effect of reducing the rise time and will reduce, but never eliminate, the

steady-state error (Mpanda, 29, February 2012).

Integral Controller role (IC) is proportional to both the magnitude of the error and the duration of

the error. The integral in in a PID controller is the sum of the instantaneous error over time and

gives the accumulated offset that should have been corrected previously (Sena Temel, 2013).

Consequently, an integral control (Ki) will have the effect of eliminating the steady-state error,

but it may make the transient response worse (Mpanda, 29, February 2012). The role of

Derivative Controller (DC) is derivative of the process error is calculated by determining the

slope of the error over time and multiplying this rate of change by the derivative gain Kd (Sena

Temel, 2013). The derivative term slows the rate of change of the controller output. A derivative

control (Kd) will have the effect of increasing the stability of the system, reducing the overshoot,

and improving the transient response (Sena Temel, 2013)

Open-loop system, also referred to as non-feedback system, is a type of continuous

control. The system happen in a physical system when there is no automatic correction of the

5
variation in its output. The system on its own is not in a position to give the desired output and it

cannot take into account the disturbances (Astrom, 2002). In these systems, the changes in

output can be corrected only by changing the input manually.

The quantity of the output being measured is called the “feedback signal”, and the type

of control system which uses feedback signals to both control and adjust itself is called a close

loop system (Li, March 2006). A close loop system also known as a feedback control system is

a control system which uses the concept of an open loop system as its forward path but has one

or more feedback loops (hence its name) or paths between its output and its input (Astrom,

2002). The reference to “feedback”, simply means that some portion of the output is returned

“back” to the input to form part of the systems excitation ( (Li, March 2006). Closed-loop

systems are designed to automatically achieve and maintain the desired output condition by

comparing it with the actual condition (Nichols, 1942). It does this by generating an error signal

which is the difference between the output and the reference input. In other words, a “closed-

loop system” is a fully automatic control system in which its control action being dependent on

the output in some way (Nichols, 1942). Most modern appliances and machinery are equipped

with closed loop control systems. Examples include air conditioners, refrigerators and

automatic rice cookers.

3.0 OBJECTIVE

The objective of this experiment is to study the disturbance test by adapting the pressure
in the tank and to illustrate the characteristic of open loop and close loop system by using
Tangent method ( TM) and Reformulated Tangent Method (RTM).

6
4.0 APPARATUS

Control panel

Incoming air supply

(IAS) valve

Pressure
tank (T91)

Chart
Process air supply recorder
(PAS) valve

Main switch

Figure 2: Gas pressure control system

Pressure gauge for
PAS

7
Figure 3: Process and Instrumentation Diagram ( P& ID) of gas pressure control system

8
5.0 EXPERIMENTAL PROCEDURE

Start up

1) Fully open inlet air supply valve and control Pressure Air Supply (PAS) valve until the

pressure gauge indicates at 27and 30 psig respectively

2) Power supply is switch on

3) The MV92 was adjusted until F192 at 25 Nm3/Hr max.

Open loop test

1) The speed chart was set at 1800 mm/hr in control panel

2) The system has to set as a manual mode before entering the output value

3) Insert 20 psig as a output and 40% as manipulated variable into control panel

4) Then, press the record button

5) Wait until the process reach a stabilize condition and record the PV and MV initial

6) The manipulated variable was change to 50%

7) Wait until the process reach a stabilize condition and record the PV and MV final.

8) Finally The value of proportional (P) and integral (I) are manually calculated by using

tangent method (TM),reformulated tangent method (RTM) and Ziegler-Nichols method.

9) Tuning method will be used if any oscillate happen

9
Close loop and disturbance test

1) The system was set as in manual mode and insert P and I values based on Tangent

method calculation

2) Change the system to auto mode and press record button

3) Tuning method has to apply if oscillate happen in the process

4) Record PV and MV initial when the process is stabilize.

5) The process was continued with disturbance test

6) Change the system to manual mode and insert manipulated variable value at 54% and

wait for 3 second before change to auto mode

7) The process have to be wait until it stabilize

8) Repeat step 1 until step 7 for RTM method

Shut down procedure

1) Record button has to switch off

2) The system has to change to manual mode and manipulated variable has to be zero

3) Switch off power supply , PAS and IAS valve

10
6.0 CALCULATION

Open loop test

Parameter Initial Final (Final – Initial)
Manipulated Variable, MV 40 50 10
(%)
Process variable, PV (%) 64 78 14

∆𝑃𝑉 = 𝑃𝑉𝑓 − 𝑃𝑉𝑖

= 78% − 64%
= 14%
∆𝑀𝑉 = 𝑀𝑉𝑓 − 𝑀𝑉𝑖

= 50% − 40%
= 10%
Tangent Method (TM)
a) Based on recorded chart
%
𝑎 = 1 𝑚𝑚

3600𝑠
𝑏=
1800𝑚
𝑠
=2 𝑚𝑚

b) Dead Time (Td), Time Constant (Tc), Respond Rate (RR), P and I
𝑇𝑑 = 𝑇𝑑 (𝑙𝑒𝑛𝑔𝑡ℎ) × 𝑏
𝑠
= 2𝑚𝑚 × 2 𝑚𝑚

= 4𝑠
𝑇𝑐 = 𝑇𝑐 (𝑙𝑒𝑛𝑔𝑡ℎ) × 𝑏 b
𝑠
= 8𝑚𝑚 × 2 𝑚𝑚

= 16𝑠

11
 ∆𝑃𝑣/∆𝑡
𝑅𝑅 = ∆𝑀𝑣
14%/16𝑠
= 10%

= 0.0875 𝑠 −1

𝑃 = 111.1𝑅𝑅𝑇𝐷
= 111.1 × 0.0875 𝑠 −1 × 4𝑠
= 38.9
𝐼 = 3.33𝑇𝑑
= 3.33 × 4𝑠
= 13.3𝑠
REFORMULATED TANGENT METHOD (RTM)
a) Based on recorded chart
%
𝑎 = 1 𝑚𝑚

3600𝑠
𝑏=
1800𝑚
𝑠
=2 𝑚𝑚

𝜃 = 58°
𝛽 = 57°

b) Dead Time (Td), Time Constant (Tc), Respond Rate (RR), P and I
𝑏 1 1
𝑇𝑑 = (𝑃𝑉𝑓 − 𝑃𝑉𝑖 ) × 𝑎 × (𝑡𝑎𝑛𝛽 − )
𝑡𝑎𝑛𝜃
𝑠
2 1 1
𝑚𝑚
= (78% − 64%) × % × ( 𝑡𝑎𝑛59 − )
1 𝑡𝑎𝑛58
𝑚𝑚

= 0.6869𝑠
𝑏 1
𝑇𝑐 = (𝑃𝑉𝑓 − 𝑃𝑉𝑖 ) × 𝑎 × (𝑡𝑎𝑛𝛽 )
𝑠
2 1
𝑚𝑚
= (78% − 64%) × % × ( 𝑡𝑎𝑛58 )
1
𝑚𝑚

12
 = 17.496𝑠

𝑡𝑎𝑛𝜃 𝑎
𝑅𝑅 = ×𝑏
∆𝑀𝑉
1% 𝑚𝑚
= 𝑡𝑎𝑛58° ÷ 10% × 𝑚𝑚 × 2𝑠

= 0.08𝑠 −1
𝑃 = 111.1𝑅𝑅𝑇𝑑
= 111.1 × 0.08 𝑠 −1 × 0.6869𝑠
= 6.1𝑠
𝐼 = 3.33𝑇𝑑
= 3.33 × 0.6869𝑠
= 2.3𝑠
Tuning method
First tuning
𝑃 = 6.1 × 4
= 24.4
𝐼 = 2.3 × 4
= 9.2
Second tuning
𝑃 = 24.4 × 4
= 97.6
𝐼 = 9.2 × 4
= 36.8

13
7.0 DISCUSSION

This experiment is to illustrate the characteristic of open loop and closed loop system .In
process control system, there are 4 control elements that include controller, final control
element, process and sensor .Open loop system is where the controller has no control over final
control elements and the adjustment of final control elements has to be made manually whereas
in closed loop system, controller has control over final control elements. The initial step is to
perform the open loop test. The test is carried out manually to get brief characteristic of the
system by manipulating the outlet flow rate of the gas. By manipulating the percentages of
opening valve the value of PV initial and PV final can be obtained. The PV value is importance
in open loop test as value to calculate the optimum P and I value that need to perform closed
loop test. The open loop test has two methods to calculate P and I value which is Tangent
Method and Reformulated Tangent Method. For Tangent Method after calculating the P and I
value by using Ziegler-Nichols tuning rule, the value need to insert into the system to perform
closed loop test where this test is to determine whether the value of the P and I that have been
calculated is optimum or not. After obtained P and I value ,experiment proceed with closed loop
system by using 20 psig as set point .For tangent method ,value of P and I give stable condition
,however in reformulated tangent method ,process is unstable ,thus the value of P and I has to
be tuned by multiply the value by 4 .The process still unstable and to be time by 4 again .This
time the process is in stable condition . The process is self-regulating process based on the
result obtained .Self-regulating system is when the process will regulated until it reaches its final
steady state position. In this experiment, load disturbance test also performed .This is to
determine how the process reacts when there is disturbance in the process. Disturbance test
performed by increased it MV to 54%. The act causes the system to change from the set point
but it progressively returned to the set point back. This shows that the system can adapt any
changes from the system to perform the correction act to maintain the set point.

14
8.0 CONCLUSION

The conclusive factor for this experiment gas pressure system is a self-regulating
system, the P and I are the only values used in this system because it is a fast response
process. The calculated P and I by Ziegler Nichols tuning method show that the system is self-
regulating system. Throughout the experiment it shows that there’s a major disturbance to the
system that could not stabilize the system. To stabilize it by using tuning method to get proper P
an I values when it’s have a disturbance occur in the system.

9.0 RECOMMENDATION

The recommendations of this experiment are :

a) To prevent any confusing from happening, make sure one of the team members mark

the initial point of response and the final point of the response on the graph obtained to

get a accurate value for the P and I values.

b) Bring the protractor to get an accurate angle but if there is no protractor, use Pythagoras

Theorem to calculate the angle of α and β.

c) To prevent the equipment from getting damage, make sure to get the guidance and

advices from the lab assistant during the simulation is done.

d) To obtain better and correct result, it is necessary to have the good understanding on

how to use the Tangent Method (TM) and Reformulated Tangent Method (RTM).

15
10.0 REFERENCE
1. Astrom, K. J. (2002). PID Control. Control System Design , 216-217.
2. Li, Y. (March 2006). Patent, software and hardware for PID control: An overview and analysis of
the current art. Patent, software and hardware for PID control: An overview and analysis of the
current art, 46-47.

3. Mpanda, K. A. (29, February 2012). PID Control Theory. PID Control Theory, 213-218.

4. Nichols, J. Z. (1942). Optimum settings for automatic controllers. Trans. ASME, vol. 64, no. 8,
759-760.

5. Sena Temel, S. Y. (2013). EE402- DISCRETE TIME CONTROL SYSTEMS RECITATION 4 REPORT .
EE402- DISCRETE TIME CONTROL SYSTEMS RECITATION 4 REPORT , 3-5.

16
11.0 APPENDICES

17