CCB 3072 Process Instrumentation & Control Lab

September 2013
Group Project
Title

: Pressure Control System

Group

: B2

Group Members

: Chong Jia Ling

14892

: Izyan Farhana Binti A.Kaher

14736

: Kalisvaran A/L Muniandy

14995

: Kevin Kan Shiu Kwang

16059

: Kuan Chuan Hong

14802

: Muhamad Arief Fikri Bin Muhamad Nasir

15521

1.0 SUMMARY
In this project, we managed to prove on how a pressure loop can be controlled by using
three basic feedback control modes which are:
1. Proportional(P) controller
2. Proportional and Integrative(PI) controller
3. Proportional, Integral and Derivative(PID) controller
Starting with the simplest mode, Proportional Controller. Proportional Controller attempts
to stabilize the system and avoid fluctuations from occur by responding the magnitude as
well as the direction of the error. When Proportional Controller is used, large gain is needed
in a way to improve the steady state error since stable systems do not have problems when
large gain is used. By other means, Proportional Controller helps in calculating the amount
of error between the measurement and the set point, amplifies it and positions the final
control element to reduce the error. The measurement of Proportional Controller can
completely eliminate offset at only one load condition since the magnitude of its corrective
action is proportional to the error. However, Proportional Controller only can accommodate
one fixed relationship between input and output in order to obtain a zero error if properly
tuned.
Next is Proportional Integral Controller. Integral control has a negative effect on speed of
the response and overall stability of the system. Plus, it is almost never used alone. Rather it
is combined with Proportional Control. Generally, this combination of PI Controller is used
when no amount of offset can be tolerated. That makes PI Controller as a very often used
controllers in industry since speed of the response is not an issue when we are dealing with
PI Controller. When a process upset occurs, the P Controller will register an error and
respond to it. Meanwhile, the Integral Control mode will detect the offset error in the
proportional mode and tries to eliminate the error.
Besides, Proportional, Integral and Derivative(PID) Controller is also to control the
pressure. PID Control have been the dominant control technique for process control for
many decades. A survey has indicated that large scale continuous process typically have
between 500 and 5,000 feedback controllers for individual process variables such as flow
rate and liquid level. Of these controllers, 97% utilize some form of PID control (Desborough
& Miller, 2001). However, its application should be considered carefully because it has
limitations with some processes. It is hard to tune. Hence, the controlled process which is
stabilized using the Derivative Control helps to reduce the oscillation and offset thereby
producing the same speed of response as with proportional action but without offset.
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APPLICATIONS OF PRESSURE CONTROL

There are a bunch of applications in industry which requiring precise pressure control
module in purpose to maximize their production.
1. Steam boiler.
Steam boilers are usually design to work at high pressure in order to reduce their
physical size. Operating them at lower pressure can result in reduced output and
carryover of boiler water.Plus, reduced pressure will lower the temperature of the
downstream pipework and reduce standing losses. Plus, it might also cause the
amount flash steam generated when condensate from drain taps is discharging into
vented condensate collecting tanks to be reduced. Because steam pressure and
temperature are related, control of pressure is important to control temperature in
some processes.
2. Heat exchanger
For the same heating duty as steam boilers, heat exchanger is designed to operate
on low pressure steam rather than high pressure steam. This is where the pressure
control module is practiced. The low pressure heat exchanger might be less
expensive because of lower design specification.

2.0 OBJECTIVES
The objectives of this experiment are:
i.

To study the characteristic of Proportional Only Control.

ii.

To study the characteristic of Proportional Band and Integral Action on a pressure

loop control.

iii.

To understand the characteristic of Proportional Band, Integral Action and Derivative

Action on a pressure loop control.

iv.

To demonstrate the loop tuning procedure on a pressure loop control.

v.

To develop a suitable control system to regulate the reaction based on the identified
variables and suggested models by using SIMULINK software

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3.0 METHODOLOGY

Background study of process control and design

Formulate control objectives

Identify the problem statement

Determine the operating conditions (pressure)

Determine the process variables (constant, manipulated, disturbance variables)

Determine the constant parameters

Devise control strategy (feedback, PID controller)

Select control hardware and software (HYSIS,

MATLAB or SIMULINK) and test in simulation
lab
Analyze the results

Achieve set-point?
Yes

Discuss the results

Finalize the process control and design

process in the report

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No

4.0 RESULTS AND DISCUSSIONS

1. Develop a dynamic model of the process and analyze the behavior of the system
using MATLAB/SIMULINK

Focus on the control tank, V-302 to derive a transfer function:

Control tank

V-302

Assumptions:
1. Negligible temperature change,
2. Constant volume in control tank (

.
),

. Hence, constant in

volumetric flow rate (

). (Provided in lab manual)
3. Input feed is air. Hence, assume as ideal gas behaviour,

Since there is no change is volumetric flow rate, hence in order to change the pressure,
there will be change in mass flow rate.

Dividing by volumetric flow rate,

From ideal gas law,

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Besides that, from ideal gas law,

Substituting (iii) & (iv) into (ii),

Since volume, temperature and molar mass of air is constant, hence

At steady-state,

(vi) (v), and at derivative form,

Applying Laplace transformation to equation (vii),

Where

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Simulink
The transfer function and block diagram are plotted in SIMULINK as shown in figure below.

Figure 1: Block diagram

The result of simulation without controller is as shown in figure below.

Figure 2: SIMULINK Stimulation Results

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Figure 3: Source Block Parameter of Step

From the simulation above, it can be seen that the process have not reached the expected
final value due to the reason that the controller was not installed to control the pressure.
Controller play an important role in making sure that the process reached the desired value
and the set point of the process. For example in a feedback loop of a control system,
feedback loops take the system output into consideration, which enables the system to
adjust its performance to meet a desired output response. Without controller, the desired
process cannot be done and the process will be dangerous as overpressure might cause
explosion.
To test the effectiveness of the process without controller, the process was run using
SIMULINK. As shown in the block diagram in Figure 1, there is no controller (Gc) and also
pressure transmitter (Gm) but the process do have final control element which is valve (Gc).
The process transfer function which is Gp is derived and inserted into the block diagram to
complete the process. After the whole process is completed, source block parameter of step
is adjusted to see the response of the reaction. As shown in Figure 3, the initial value is set
to 0 and the final value is set to 4, after simulation, the graph reached steady state at 2 but
not 4. This is because there is no controller to control and tune the response to desired value
and this caused the ineffectiveness of the process. With the existence of controller at the
tank, the process will be effective and reach desired value. This will be studied at the next
discussion.

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2. Analyze basic instruments of the process control system

From the description of the equipment in the lab manual, a diagram is drawn:

P1=6 bar

Receiver
tank
V-301

P2=4 bar

PSV-301
Control tank
V-302
PT-302

PT

PIC-302

PC

P3=2 bar
PSV-302

1. PID controller (PIC-302)

In this experiment, PID controller is the main tool that is used to achieve the objective. PID is
a abbreviation of the three terms that presence in the controller, that is Proportional (P),
Integral (I) and Derivative (D) term. Figure below shows the block diagram of a PID
Controller.
PID Controller calculates an "error" value as the
difference between a measured process variable
and a desired set-point and it attempts to
minimize the error by adjusting the process
control inputs. A typical Proportional Controller
able to response quickly to upsets however the
measurement of the P-Controller can completely
eliminate only one offset at a load condition.
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PID-controller able to responds to all aspect of process error-direction, magnitude, duration

and rate of change of the process. The only problem of using PID-controller is the tuning
process may be complicated and difficult as it deals with three different types of terms.

2. Pressure transmitter (PT-301)

Pressure is an expression of force that acts on a fluid and prevent it from expending and
measures in terms of force per unit area. Pressure transmitter measures pressure typically
gases or liquids. The transmitter usually acts as a transducer and generates a type of signal
as a function of the pressure imposed.
Pressure transmitter is used to control and monitor in thousands of application in our daily
life such as measuring flow rate, speed, water, level and so on. Types of pressure
transmitter may vary differently in terms of technology, design, performance, application
suitability as well as the cost of the transmitter.
3. Recorder (PR-302)
In the instrument that is used for pressure control
experiment contains a pair of continuous 2 pen
chart recorder. The function of this recorder is used
to record the response of the process instrument of
the input and output through chart representation.

Recorder is needed for us to study the trend in

change of various tuning methods and how the
system response to it. By using recorder, the
change and trend can be obtained and studied
easily.

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4. Control valve (PCV-302)

Control valve is an important tool for any types of process that
requires controlling the amount of flow. All control valves have
inherent flow characteristics that define the relationship between
the valve openings with flow rate under constant pressure
conditions. Different type of valve with various sizes which are
subjected to the same volumetric flow rate and differential
pressure will have exactly the same orifice pass area.

The suitability of the types of control valve to be used varies on the function or unit process
that the control valve to be installed in.
5. Vortex flow meter (FT-301)
Flow meter is used to measure the flow of fluids
such as liquid or gas into the system. One of the
methods to measure the flow is by placing a body
such as shedder bar in the path of the fluid. As the
fluid passes the bar, there will be a disturbance to
the flow forming vortex. The frequency at which
these vortices alternate sides is essentially
proportional to the flow rate of the fluid.

6. Pressure indicator (PI-301, PI-302, PI-303 & PI-304)

Pressure measurements are usually made relative to
ambient air pressure such as absolute, gauge and
differential pressure. In pressure control instrument, dial
gauge pressure indicator is used to measure the pressure
inside the system
Gauge pressure is zero-referenced against ambient air
pressure. The indication on the gauge indicator is equal to
absolute pressure subtract atmospheric pressure and the
negative sign are omitted.

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7. Process tank (V-301 & V-302)

In this experiment, the process tank is used to study the

change in pressure by inserting air into the tank. It is
required to be able to sustain high pressure to avoid the
tank from exploding.

8. Alarm Annunciator (PAL-302 & PAH-302)

An Alarm annunciator, or better known as an annunciator panel, is a system to alert
operators of alarm conditions in the plant. In the case of pressure control, it is used for
controlling the tanks pressure and indicate the user when the tank pressure is too low or too
high, so that the user is able to make suitable changes to the tank.
9. Pressure Relief Valve (PSV-301 & PSC-302)
Pressure relief valve (PRV) is a type of relief valve, in which its function is to control or limit
the pressure in a system or vessel which can build up by a process upset or instrument
failure. PRV is a mechanically activated device, spring loaded normally closed valve. It can
open and purge air to atmosphere in case of over pressure in tank. It opens when there is
pressure greater than its spring tension.
10. Solenoid valves (HV-301, HV-302, & HV-303)
A solenoid valve is an electromechanically operated valve, in
which it is controlled by an electric current through a solenoid.
It offers fast and safe switching, high reliability, long service
life and good medium compatibility of the materials used. In
pressure control experiment, we use solenoid valves for fault
simulation.

11. Air regulator (PCV-301)

An air regulator regulates the air supply to the process
receiver tank so that it does not exceed the pressure limits.

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12. D/P transmitter (PDT-301)

A differential pressure sensor (D/P transmitter) measures the
difference between two pressures, one connected to each side
of the sensor. In the pressure control experiment, it acts as
differential pressure transmitter for process line, measuring
between the range of 0 60 psig.

13. Rotameter (FI-301 & FI-302)

A rotameter is a device that measures the flow rate of liquid or
gas in a closed tube. It belongs to a class of meters called
variable area meters, which measure flow rate by allowing the
cross-sectional area the fluid travels through to vary, making it
measurable. In this experiment, it acts as a variable area flow
meter for purpose line.

14. Hand valve (HV-304 & HV-309)

A hand valve is a kind of isolation valve, which its function is
to stop the flow of process media to a given location, usually
for maintenance or safety purposes. In the experiment, the
hand valves are input/output isolation valves. They determine
the direction of airflow and load changes.

15. Fault simulation switches (HS-301, HS-302, & HS-303)

Fault simulation switches act as a cut-off switch whenever there is leakage at the pressure
control tank. It can be also used during times of loss of instrument air supply, where they will
shut off the outlet to the pressure control tank.

16. Control Panel

A control panel acts as a motherboard of pressure control. It mounts the controller, alarm
annunciator, recorder, push button power supply switch and changeover switch between the
distributed control system (DCS) and local control.

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3. Design a feedback control system and analyze its stability using various tuning
techniques

Feedback Pressure Control System

P-only, PI, and PID controller was used to test the stability of the feedback pressure control
system that was designed. A major setback was shown when the design was tested using Ponly controller in the feedback pressure control system. Next, when the design was
experimented using PI controller in the feedback pressure control system, it eliminates the
offset though with one disadvantage where it has more oscillatory. Finally the design was
tested using PID controller in the feedback pressure control system, where it does not only
eliminate the offset but also has less oscillatory hence proven to be superior to PI controller.
This shows that, to tune a feedback pressure control system, it is the best and optimum
selection to use PID controller. The attached diagrams contain the all the results. The
feedback pressure control system is stable using PID and PI controller. All the results are
shown in the attached diagram. The stability of using PID controller in the system using
Bode Diagram is shown stable. The stability of using PI controller in the system using Bode
Diagram is also stable. While only the stability of using P-only controller in the system using
Bode Diagram does not show any stability.

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P controller

Tuning Parameter : P = 22.3 ; I = 9999 ; D = 0

Figure 4: Experiment Result of P controller

Figure 5: Stimulation results from MATLAB/ SIMULINK of P controller

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Figure 6: Bode Diagram of P controller

PI controller

Tuning Parameter: P = 22.3; I = 10.4; D = 0

Figure 7: Experiment Result of PI controller

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Figure 8: Stimulation results from MATLAB/ SIMULINK of PI controller

Figure 9: Bode Diagram of PI controller

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PID controller

Tuning Parameter : P = 22.3 ; I = 10.4 ; D = 6.0

Figure 10: Experiment Result of PID controller

Figure 11: Stimulation results from MATLAB/ SIMULINK of PID controller

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Figure 12: Bode Diagram of PID controller

Discussion
In this project, we compared the outputs of Simulink with the actual results we obtained in
previous experiment for all 3 types of controller P, PI and PID Controller.
For PID controller, Simulink result shows that shorter time is taken to reach the new set point
compared to actual experiment result. Another difference is Simulink graph produced
overshoot whereas the actual experiment did not produce overshoot.
For the PI controller, the result simulated is better compared to the actual results obtained.
Although both the graphs produce overshoot but the graph from Simulink has lower
overshoot compared to the actual graph and also to the PID controller stimulated graph.
However the time taken for the both simulated and actual PI controller graphs takes longer
time compared to both PID graphs.
Lastly for P Controllers, actual experiment has shown that the process would be very
sluggish as it takes a very long time to respond. Simulink produced results where shorter
time is needed to response. Nevertheless, both actual experiment and Simulink graph have
shown that the desired set point could never be achieved by using P controller as it is very
sluggish.

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Transfer function and gain values that we included in running this Simulink software may
contribute to the errors or deviation from the actual experiment results. This may cause the
delay in the system. Besides that, the inaccurate transfer functions and the assumptions of
ideal system might cause the results to be different from the actual results. Besides that, the
order of the transfer function also plays an important role in producing accurate results. The
transfer functions in the stimulation we assumed to be a simpler system whereby the transfer
functions used are of first order. This may not be true as the system in the actual experiment
is more complex and may have transfer functions of other than first order.

5.0 CONCLUSION
Among the entire controller, PID controller is the best controller as it can eliminate
offset and oscillatory response. Furthermore, it does not overshoot too much thus saving
time in becoming stable faster.
For PI controller, it is less efficient and stable as compared to PID controller. This
kind of controller will produce oscillatory response which then affects the desired value.
Besides that, it overshoot from the desired value hence requires time to achieve steady
desired output.
It takes a very long time or near impossible for P controller to achieve desired value
although the set point had been set earlier. Apart from that, the offset cannot be eliminated
as there is no action of both integral and derivative.
From all these analysis, it is found that PID is the best controller to suit the feedback
pressure control system. The time taken for the respond curve for this method has the
shortest time compared to other methods. Besides that, the responds curves obtained are
less sluggish and more stable compared to other methods. This shows that PID is the best
choice for the saving time and most efficient.

6.0 REFERENCES
Hagglund, Tore, PID Controllers: Theory, Design & Tuning.
Rys, R.A. (1984). Advanced Control Methods, Chemical Engineering.49.

Seborg D.E., Edgar T.F. & MelliechampD.A. (1989). Process Dynamics and Control. John
Wiley and Sons: New York.116-118.
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