OBJECTIVES

1. To identify the important components of the air flow control system and to mark them in
the P&I diagram.
2. To carry out the start up procedure systematically.
3. To study gas volumetric flow rate measurement using the orifice plate and perfect gas law
to compute the gas density from the pressure and temperature measurements.
4. To study gas mass flow rate (Fm) control using PID controller.
5. To design a PID controller using Ziegler Nicholas closed loop method.
SUMMARY

In this experiment, the objectives are to identify the important components of the air flow
control system and to mark them in the P&I diagram, to carry out the start up procedure
systematically, to study gas volumetric flow rate measurement using the orifice plate and perfect
gas law to compute the gas density from the pressure and temperature measurements. Lastly, to
study gas mass flow rate (Fm) control using PID controller and design a PID controller using
Ziegler Nicholas closed loop method. The air flow process control system (Model AF922) uses
air to animate a gas or vapor stage stream process. Gas/vapor volumetric stream can be measured
either by the differential weight over a hole or by a variable range stream meter. The air flow
measurement is the first part that needs to be measured in order to make sure that the air at
medium is equal to the ambient conditions. The readings for all parameters were decreasing
when the MVs increased. However the pressure gauge shows the pressure is decreased when the
MV were increased. Second part of this experiment is how to control the air flow system.
Different PB will affected on how long the response will reach steady state at the beginning and
how long the time taken for the response to eliminate the error or disturbance. Lastly, from the
graph, it shows that the PID controller has managed to eliminate the oscillation.
INTRODUCTION

The air flow process control system (Model AF922) uses air to animate a gas or vapor
stage stream process. Gas/vapor volumetric stream can be measured either by the differential
weight over a hole or by a variable range stream meter. Pay for weight and temperature variety
utilizing the Perfect Gas Law can be made to the stream estimation by the differential weight
estimation.

This model comprise of a principle pipeline PLI where procedure wind streams from the
vessel T90 and afterward release to environment by means of the procedure vent manual valve
VF or to another air procedure control preparing framework AP922. In the event that the wind
stream through PLI is too low, the air will course during that time pipeline PLI1 consequently.
Wind stream is measured utilizing a hole plate (FE91) and a differential weight transmitter with a
square root capacity (FT91). A variable range stream meter (rotameter) FI911 is likewise given to
quantify the volumetric flowrate.

A hole plate is a gadget utilized for measuring the volumetric stream rate. It utilizes the
same standard as a Venturi spout, in particular Bernoulli's rule which expresses that there is a
relationship between the weight of the liquid and the speed of the liquid. At the point when the
speed builds, the weight abatements and the other way around.
RESULTS

Instrument Controller I II III

readings MV = -6.3% MV = 50% MV = 70%
At the panel FIC91, I/O Data

FT91, h X1: % of 0- 54.2% 35.0% 22.9%

100nm H2O
X2: % of 0- 22.1% 22.2% 22.2%
TIT911, T
120C
X3: % of 0-60 65.0% 78.6% 86.7%
PT911, P
psia
FIC91, Main
Fm
Face Plate 34.3 24.2 16.8
PV, kg/Hr
FIC90, PT
Fv
Register 13.9 8.8 15.9
PO1, m3/Hr

Recorder FPTR91
Fm, kg/Hr 34.2 24.1 16.8
Channel 1(Red)
Fv, m3/Hr 13.8 8.9 5.9
Channel 2 (Green)

Fvb, Nm3/Hr 12.10 10.67 9.08

By calculation
Fm, kg/Hr 15.65 13.70 11.72
At the plant
FI911, Nm3/hr 47.8 32.0 22.0
PG900, psig 28 34.5 39.0
DISCUSSION

The objective of this experiment is to identify the important components of the air
pressure control system and to mark them in the P&I Diagram. This experiment showed on how
air is used in order to stimulate a gas or vapor phase flow process. The machine consists of a
main pipeline, PLI where process air flows from vessel T90 and then discharge to atmosphere
via the process vent manual valve, VF or to another air process control training system. The air
flow is then measured using an orifice plate and a differential pressure transmitter with a square
root function.

The air flow measurement is the first part that needs to be measured in order to make sure
that the air at medium is equal to the ambient conditions. 3 different MVs were set for testing
the air flow, which was MV at -6.3%, 50% and 70%. Several parameters such as the differential
pressure, the absolute pressure and temperature were considered. As can be seen from Table 1, it
shows that the readings for all parameters were decreasing when the MVs increased. The MV of
-6.3% gave the highest absolute pressure compared to the other two MV because of when the
MV decreased to -6.3%, it showed that the control valve of FCV91 is fully opened. Therefore, it
is reasonable why the MV of -6.3% had the highest absolute pressure reading as there was no
obstacle for the air to flow. Differ for the pressure gauge, the pressure is decreased when the MV
were increased. Then, the volumetric flow rate for all the 3 MVs were being compared between
recorded and calculated reading. The range of 1.0-3.0 was obtained for volumetric flow rate
without P and T compensation, Fv, and with P and T compensation, Fvb. The calculated for the
mass flow rate values for -6.3%, 50% and 70% were 15.65 kg/hr, 13.70 kg/hr and 11.72 kg/hr.
This shows that the air flow performed well as the readings from calculated one gives not much
different with the recorded value.

Next, after the air flow has been regulated, the second part of this experiment is how to
control the air flow system. 3 trials with different PB, TI and TD were set in order to observe
how these parameters affected the air flow response. A quickly opening and shutting fully the by-
pass valve around control valve FCV91 was done in order to introduce a pulse disturbance. The
set value or SV were fixed to 25kg/hr for all trials.
 Figure 1: The response of air flow control for the three trials with different PB, TI and TD

From Figure 1, the first trial with PB=200%, TI=6s and TD=0S showed that the time taken for
response to reach the steady state before and after a disturbance was introduced is longer. The
second trial with PB= 150%, TI=6s and TD=0s needs a long time to reach steady response and
the produced shorter time to reach steady state after disturbance. As for the third trial of
PB=100%, TI=6s and TD=0s, it was directly gave the steady response at the first point, and a
short disturbance with a quick time to reach steady response back. This shows that different PB
will affected on how long the response will reach steady state at the beginning and how long the
time taken for the response to eliminate the error or disturbance.

Next, the air flow response was measured by changing the SV from 25kg/hr to 30kg/hr
with using the first trial value. The purpose of changing the SV was to introduce the step change
in the set point for the mass flow rate.
 Figure 2 : The air flow response when the SV and TD changed

From Figure 2, it can be seen that the time taken for the response to become steady when the SV
changed to 30kg/hr was longer. The disturbance was applied and shorter time produced as the
response eliminated the error. The set point is then switched back to the originally value of
25kg/hr with different value of TD=20s. It shows that when TD is increased from 0s to 20s, the
response keep oscillated for a certain period of time and steady state response no longer
produced.

Therefore, in order to eliminate the oscillation, PID controller was introduced. . The PID
controller is a control loop feedback mechanism which is commonly used in the industries. A
PID controller continuously calculates the error value between a measured process variable and a
desired set point. By using the same set point value which was 25kg/hr, the PB was set to 100%
since it gave shorter time to be in steady response in previous part of this experiment. Then, the
TI is increased to 9999s which is the maximum value for this control process and TD of 0s. From
the graph, it shows that the PID controller has managed to eliminate the oscillation. The SV is
then increased to 28kg/hr to introduce disturbance and returned to the original SV as to make
sure the PID controller is working and could eliminate the error.
SAMPLE OF CALCULATIONS

1. To find Fvb of first trial at MV= -6.3% :

Fvb = kvb hP
T

= 1.356 (54.2 39)

26.52

= 12.10 Nm3/hr

2. To find Fm of first trial at MV= -6.3%

F m = km hP
T

= 1.753 (54.2 39)

26.52

= 15.65 kg/hr
CONCLUSION & RECOMMENDATION

In conclusion, identification of important components of the air pressure control system

and marking them in the P&I Diagram was achieved. Furthermore, all parameters decrease as
MV increases. This trend also shared with the pressure reading as well because the pressure also
decreases when MV increases. Based on trial 1, 2 and 3, it shows that different PB will affected
on how long the response will reach steady state at the beginning and how long the time taken
for the response to eliminate the error or disturbance. Lastly, the PID controller can be used to
eliminate the oscillation.

Graph obtained from the instrument should be marked during

experiment to ensure the accuracy of the data. This also to avoid any wrong
information gained during data interpretation. Secondly, all the valves
position that is must follow according to the manual. This is to avoid wrong
data produced at the panel. The instrument also should be calibrated, so that
the measurement would be accurate with no errors.