PROCESS CONTROL PRACTICES

(CPE 622)
REPORT

NAME
STUDENT ID
COURSE CODE
COURSE NAME
GROUP
SEMESTER
DATE OF SUBMISSION
NAME OF LECTURER

: NUR AFIQAH BINTI MOHD YASIN

: 2010621648
: CPE 622
: PROCESS CONTROL PRACTICES
: EH221 6A
: MAC 2013-JUN 2013
: 04 MAY 2013
: ABDUL AZIZ BIN ISHAK

ABSTRACT

The objective of this report is to know the details about the process control simulation that
use in industry nowadays.The method to get the exact value of optimum tuning also studied.In this
report,various method of tuning is being practice in order to get exact value for optimum
tuning.Every changing of value was recorded in order to get optimum value of tuning.For this
report,the value for response rate (RR), dead time (Td) and time constant (Tc) was calculated by
using tangent method and reformulated tangent method.

INTRODUCTION

Process control is the active changing of the process based on results of process
monitoring.Besides that it is also refers to the methods that are used to control process variables
when manufacturing product.Term of process is referring to any operation and sequence operation
involving a change in the substances being treated.Process control is a statistics and engineering
discipline that deals with architecture,mechanism and algorithms for controlling the output of a
specific process.It is a field in designing of control system,specifying instrumentations and selecting
correct parameters of controllers for chemical process.The purpose of process control is to maintain
certain process parameters such as pressure,flow,temperature and level to achieve a desired result.

The characteristic of process control can be form as discrete,batch and continous.All these
three process control form are often applied in hybrid application.Discrete process can be found in
many manufacturing,motion and packaging applications.Batch process requires specific quantities
of raw materials be combined in specifics ways for particular durations to produce an intermediate
or end result.One example is the production of adhesives and glues which normally required the
mixing of raw materials in a heated vessel for a period of time to form a quantity of end
product.Other important examples are the production of food,beverages and medicine.Batch process
is generally used to produce relatively low to intermediate quantity of product per year.The
continous process control is applied to the production of fuels,chemicals and plastics.

THEORY

In control theory, a controller is a device which monitors and affects the operationals
conditions of a given dynamic system.The operational conditions are typically referred to as output
variables of the systems which can be affected by adjusting certain input variables.For example,the
heating system of a house can be equipped with a thermostat (controller) for sensing air temperature
(output variables) which can turn on or off a furnace or heater when the air temperature becomes
too low or too high.
In this example,the thermostat is the controller and directs the activities of the heater.The
heater is the processor that warms the air inside the house to the desired temperature (setpoint).The
air temperature reading inside the house is the feedback.And finally, the house is the environment in
which the heating system operates.The notion of controllers can be extended to more complex
systems.In the natural world,individual organism also appear to be equipped with controllers that
assure the homoeostesis necessary for survival of each individual.Both human-made and natural
systems exhibit collective behaviors amongst individuals in which the controllers seek some form
of equilibrium.
In control theory there are two basic types of control.These are feedforward and
feedback.The input to a feedback controller is the same as what it is trying to control-the controlled
variables is fed back into the controller.Feedback controller is a method of control at which the
action is based on past result.However,feedback control usually results in intermediate period where
the controlled variables is not at the desired setpoint.Feedforward control control can avoid the
slownwess of feedback control.It is the method of control at which the action is based on changes in
load variables.

RESULTS AND CALCULATIONS

FIC 21
OPEN LOOP TEST

FIC 21
CLOSED LOOP TEST

FIC 21
OPEN LOOP TEST
MV = 2.5
a = y = 10 %
Length 17 mm
b=

= 0.588

x = 15 s
= 1.2 s/mm
Length 12.5 mm

= 800
Response Rate,RR
RR = tan . a = ( tan 80). (0.588) = 1.112 s-1
MV b
2.5
1.2
Dead Time,Td
Td(time) = Td(length) x b
1mm x1.2 s/mm
= 1.2 s
Time Constant,Tc
Tc(time) = Tc(length) x b
4mm x 1.2 s/mm
= 4.8 s
Ziegler-Nichols's (Z-N)
PB(%) = 111.1RRTd
111.1 (1.112)(1.2)
= 148.25%

I = 3.33Td
3.33(1.2)
= 3.996 s

CLOSED LOOP TEST

SET POINT TEST (SP)

LOAD DISTURBANCES

Kc = 0.67
I = 3.996

Kc = 0.67
I = 3.996
MV = 44.9%

FIC 91
OPEN LOOP TEST

FIC 91
CLOSED LOOP TEST

FIC 91
OPEN LOOP TEST
MV = 5
a = y = 5 %
= 2.941
Length 1.7 mm
b=

x = 15 s
Length 1.2 mm

= 12.5 s/mm

= 810
Response Rate,RR
RR = tan . a = ( tan 81). (2.941) = 0.3 s-1
MV b
5
12.5
Dead Time,Td
Td(time) = Td(length) x b
0,3mm x12.5 s/mm
= 3.75 s
Time Constant,Tc
Tc(time) = Tc(length) x b
0.3mm x 12.5 s/mm
= 3.75 s
Ziegler-Nichols's (Z-N)
PB(%) = 111.1RRTd
111.1 (0.3)(3.75)
= 103.125%

I = 3.33Td
3.33(3.75)
= 4.26 s

CLOSED LOOP TEST

SET POINT TEST (SP)
Kc = 0.8286
I = 11.9

LOAD DISTURBANCES
Kc = 0.8286
I = 11.9
MV = 36.6%

PIC 91
OPEN LOOP TEST

PIC 91
CLOSE LOOP TEST

PIC 91
OPEN LOOP TEST
MV = 10
a = y = 10 %
= 0.571
Length 17.5 mm
b=

x = 15 s
= 1.304 s/mm
Length 11.5 mm

= 490
Response Rate,RR
RR = tan . a = ( tan 49). (0.571) = 0.05 s-1
MV b
10
1.304
Dead Time,Td
Td(time) = Td(length) x b
4mm x1.304 s/mm
= 5.216s
Time Constant,Tc
Tc(time) = Tc(length) x b
26mm x 1.304 s/mm
= 33.404 s
Ziegler-Nichols's (Z-N)
PB(%) = 111.1RRTd
111.1 (0.05)(5.216)
= 28.9%

I = 3.33Td
3.33(5.216)
= 17.363 s

CLOSED LOOP TEST

SET POINT TEST (SP)

LOAD DISTURBANCES

Kc = 4.20
I = 1.700

Kc = 4.20
I = 1.700
MV = 83%

LIC 11
OPEN LOOP TEST

LIC 11
CLOSED LOOP TEST

LIC 11
OPEN LOOP TEST
MV = 10.2
a = y = 10 %
Length 17 mm
b=

= 0.588

x = 15 s
= 1.2 s/mm
Length 12.5 mm

= 290
Response Rate,RR
RR = tan . a = ( tan 29). (0.588) = 0.0266 s-1
MV b
10.2
1.2
Dead Time,Td
Td(time) = Td(length) x b
1mm x1.2 s/mm
= 1.2 s
Time Constant,Tc
Tc(time) = Tc(length) x b
26mm x 1.2 s/mm
= 31.2 s
Ziegler-Nichols's (Z-N)
PB(%) = 111.1RRTd
111.1 (0.0266)(1.2)
= 3.546%

I = 3.33Td
3.33(1.2)
= 3.996 s

CLOSED LOOP TEST

SET POINT TEST (SP)
Kc = 20.016
I = 9.69

LOAD DISTURBANCES
Kc = 20.016
I = 9.69

FIC 31

FIC 31

MV = 5
Based on the table at result

(1)RR =

PV1 PV-1
2h MV

RR = 45.02 -42.51 = 0.251s-1

2(1)(5)

(2) Td = t1 2 h[ PV1 - PV0ss ]

PV1 PV-1
Td = 3-2( 45.02-42.51) = 1 second
45.02-42.51

(3) PB = 111.1 RRTd

111.1 (0.251)(1)
= 27.88 %

(4) I = 3.33 Td
3.33 (1)
= 3.33 second

DISCUSSION
An open loop test has been performed to the temperature control loop by making the MV
changes for all three processes.The purpose of the open loop test is to obtain the response rate RR
and dead time Td.These both value is used to calculate the optimum PID value that has been used in
the closed loop test.Set point change test or closed loop test was conducted in order to study the
effect of different response rate obtained from open loop test.These test was used the zieglerNichols's control tuned.From the processed,we can observed that the process with the min response
time have the tendency to have high setting time.These are occuring in all process.Settling time is
the time that required for the process to settled after the PID tuning is implemented.After we tuned
the process,the process will take time to settle down before reach the new steady value.Low or fast
settling time shows the process or PID tuned is appropriate.
From the discussion, we can conclude that if we choose the lowest or minimum response
rate RR,we can obtain the highest value of PB and the lowest value of Kc.Hence, from these values
we can get the better tuned with lowest overshoot and undershoot of the process as we can observe
from graph.But,unfortunately the rise time and settling time will rise.This is not good for the
industry because we only need less time to settle down after we make some changes to the
process.Thus,the middle value of all process is been choose as the best value for tuning as it is in
the midlle range of all parameter.

CONCLUSION

The optimum of PID controller settling for water flow control,gas pressure control and air
flow temperature control using Ziegler-Nichols's method has been studied to find the effect of
response rate on the process control.It was found the controller settling is suitable at the middle
range of the slope because the value obtain from this slope will produce middle effect of on the
overshoot,undershoot,rise time and settling time that will not significantly affect the process in the
industry.

APPENDIX