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OBJECTIVES

1. To identify the major component of the heat exchanger process control training
system.
2. To systematically start-up the process.
3. To study ON/OFF temperature of control of electrical heaters.
4. To study temperature control in the heat exchanger using PID controller.

SUMMARY

The experiment was conducted to determine the main objective which is to identify
the major component of the heat exchanger process control training system and learn how
to start-up the process systematically. Moreover, the experiment was run to study ON/OFF
temperature control of electrical heaters and finally the temperature control in the
exchanger using PID controller. Based on the theory, the main purpose of a heat exchanger
system is to transfer heat from a hot fluid to a cooler fluid, so the temperature control of
outlet fluid is of prime importance. It also functions to control the temperature of outlet fluid
of the heat exchanger system by using a conventional PID controller. The designed controller
regulates the temperature of the outgoing fluid to a desired set point in the shortest possible
time irrespective of load and process disturbance, equipment saturation and nonlinearity.
Hence, there are few types of heat exchanger that works on its own design. The experiment
was begun with the filling up both the tank until it overflows, and certain valves were opened
and shut according to the procedure. Next, the set point, PB1, TI1 and TD1 was set and
changed accordingly until the experiment end. The result was recorded using PID controller
and results were tabulated in chart paper. Based on the discussion, the green and red pen
played an important role. Finally, the objective of doing this experiment was achieved but
some recommendation such as having good knowledge on control prior of conduction the
experiment will be a good value to avoid misconduct during the experiment.
INTRODUCTION AND THEORY

Heat exchanger system is widely used in chemical plants because it can sustain wide
range of the temperature and pressure. The main purpose of the heat exchanger system is to
transfer heat from a hot fluid to cooler fluid, so temperature control of outlet fluid is of prime
importance. To control the temperature of outlet fluid of the heat exchanger system a
conventional PID controller can be used. Due to inherent disadvantages of conventional
control techniques, model based control techniques is employed and an internal model
based PID controller is developed to control the temperature of outlet fluid of the heat
exchanger system. The designed controller regulates the temperature of the outgoing fluids
to a desired set point in the shortest possible time irrespective of load and process
disturbance, equipment saturation and nonlinearity. The developed internal model based
PID controller has demonstrated 84% improvement in the overshoot and 44.6%
improvement in settling time as compared to the classical controller.

A shell-and -tube exchanger is used for larger flows, which are very common in
chemical process industries. The design of this exchanger is a shell with a bundle of tubes
inside. The tubes are in parallel and a fluid flows around them in the shell. Each arrangement
allows for a different type of flow such as co-current, counter-current and cross flow. The
tube-side can have one or more passes to increase the energy exchange from the tube-side
fluid. The shell-side may contain baffles, or walls, that channel the fluid flow and induce
turbulence, and thus, increase energy exchange.

Figure 3.1: Shell and Tube Heat Exchanger Controller System in Industry
Heat exchanger find widespread used in refrigeration, power generation, heating and
air conditioning, chemical process, manufacturing, and medical application. A heat is
installed in an extension of the double pipe configuration. Instead of single pipe within a
large pipe, a heat exchanger consists of bundles of pipes or tubes enclosed within a
cylindrical shell. In the heat exchanger one fluid flows through a tube and a second fluid flows
though within the space between the tubes and the shell.

The outlet temperature of the heat exchanger system must be kept at a desired set
point according to a process requirement. Firstly, a classical PID controller is implemented
in a feedback control loop to achieve the control objectives. PID controller exhibits high
overshoot which is undesirable. To reduce the overshoot and optimize the control
performance, a feed forward controller is used along with a feedback controller. The
combined effect of feedback and feed forward control schemes gives a much better result
than the feedback PID controller.

Figure 3.2: ON/OFF Controller working scheme to achieve Set Point (SV).
RESULT AND DISCUSSION

The purpose of this experiment are to identify the major components of the heat
exchanger process control training system, to systematically start-up the process, to study
ON/OFF temperaute control of electric heaters and to study temperature control in the heat
exchanger using PID controller. For the first objective, the process consist of two tanks T61
and T62, one shell and tube heat exchanger, three centrifugal pump, (P61, P62, P611), and
resistance temperature detector (RTD) as a temperature detector fot T61 while
thermocouple is temperature sensor for T62. The heat exchanger used hot water form tank,
T62 as heating medium to heat cold water form tank T61. In this experiment also, the green
line indicated the temperature of the flowrate while the red line indicated wall of the heater
temperature. The results obtained while conducting this experiment can be divided into two
parts which were ON/OFF temperature control and PID control of temperature.

1. START-UP PROCESS

During the start-up procedures (No. 3.2 according to Lab Manual), the manual (M) mode
of manipulated valve (MV) was 100% has been set with the valve of proportional band (PB1)
was 15%, the integral (TI1) was 35 seconds and the time derivative (TD1) was 8 seconds.
The set value (SV) or simply set point was 40 Celsius and the chart speed was ensured at

500 . By referring to the graph, green line indicated the temperature of TE62 whilst the
red line indicated TE61 temperature.

Basically, the control valve TCV61 is Air-to-Open and has a current-to-air positioner (EP),
in which it was tagged as TCY61 in the plant. Air to open valve is normally held closed by the
spring and require air pressure (a control signal) to open them they open progressively as
the air pressure increase. Then, a test on control valve, TCV61 has been done by adjusting
the MV values. When MV = 25%, 50% and 100% opened, the control valve, TCV61 steam
position also opened according to MV adjustments. Figure 4.1 shows a pneumatic Actuator,
Air to Open and the position of steam that will drive the position indicator to shows the value
of MV.
Figure 4.1: Pneumatic Actuator with Air-to-Open function.

2. ON/OFF TEMPERATURE CONTROL

In this experiment, there are two types of controller that we study which is ON/OFF
controller of heater, and the heat exchanger controller using PID controller. Firstly, the
ON/OFF temperature controller of heater experiment is performed. The equipment was
tested by running some trial in order to ensure it runs in a good condition. Besides that, it
helps a better understanding on how an ON/OFF controller functions; the function of
controller in order to maintain the set point.

For ON/OFF temperature control, the heater will be turned on till it reaches the set point of
40C. Then, the heater will be switched off when the temperature went above the set point
temperature that was 40C. Due to the tank is an open tank, thus the temperature will drop.
Thus, the heater will than be switched on when the temperature was 0.5C less than the set
point which also known as Deadband. Figure 4.2 explains the theory of deadband.
The parameters of the ON/OFF controller were then set up at high temperature limit
as shown in Table 4.1 in which (PO1) equal to 55C as the high limit for annunciator TAH62
(PO3) and deadband (PO2) indicated 0.5C same as the dead band for annunciator TAH61
(PO4). The I/O data showed the value of X2 was 44.3 with DO2 was off (0) and DO1 (1) was
on position. The data and the graph were shown below as in Figure 4.3.

Figure 4.2: Deadband in a temperature operating control system

PT Register Temperature Value


PO1 (high temperature limit) 55C
PO2 (dead band) 0.5C
PO3 (high limit for annunciator) 55C
PO4 (dead band for annunciator) 0.5C

Table 4.1: The PT Register valve set up (According to Lab Manual, 3.3 No. 4)

I/O Data
Status X2
TIC62 Controller DO1: 0 55C
TAH62, Annunciator DO2: 1 55C

Table 4.2: The I/O Data recorded


The graph are represented in Figure 4.3 No1 marked in the graph shows that the recorder
TR61 has been started. During this process (Refer Lab Manual -3.3 No.6), TE62 or TIT62
rises and exceeds the High Limit, 55 C. When the temperature go above 55 C, the heaters
are noted to be switched off and the Annunciator TAH61 is activated (with alarm sounds).
This indicates the temperature that already exceeds the highest point that has been set in
the system, 55 C. Then, temperature drops to the High Limit Temperature, 55 C. The
temperature drops further by an amount equal to deadband which is 0.5 C (drops 0.5 C
below high limit), this is represented as No.2 in the graph. In this stage, the heaters are
switched on again. The temperature will rise till it reaches the High Limit of 55 C and
exceeds further. When it exceeds the high limit, (56 C) the annunciator will sound and
TAH62 is switched OFF by pressing the acknowledge button on the control panel. The
status and the I/O Data has been recorded in Table 4.2.

The process continues in the same mode as shown in graph, a full of 3 cycles with
decay ratio (the measure of the amount by which the controlled variable exceeds the set-
point in successive peaks) is achieved and indicated as No/ 3 (56 C), No. 4 (57 C) and No.
5 (56 C) on the graph in Figure 4.3. It produces an oscillatory curve which is the nature of
ON/OFF controller as shown in Figure 3.2.

Basically, an On-Off control is like operating a switch. This type of temperature


controller will turn on the heat when the process variable is below the set point and turn it
off when the process variable is above the set point. These controllers normally include a
delay, hysteresis and or a cycle time to reduce the cycling or hunting when the process
variable is close to the set point.

Figure 4.3: The graph produced for ON/OFF controller


4.3 PID CONTROL OF TEMPERATURE

For this experiment, the temperature of heated product at the exit of the heat
exchanger measured by TE61/TIT61 is controlled by the controller PID of TIC61.

On the temperature controller using the PID, the auto mode is being selected. The
first point is set at 40C and the PID values are recorded in Table 4.3.

Table 4.3: First Controller Parameters Values

PID PB1(%) TI1 (seconds) TD1(seconds) Product Setpoint


Flowrate (SV1) (C)
(FI61)
(m3/hr)
First Trail 15 35 8 1.3 40
PID

By referring to the graph in Figure 4.4, noted as No. 1 was the time during the chart start to
record. Whereas, No. 2 indicates the observation on response of TE61/TIT61 as it becomes
steady around 40C when the Auto mode has been activated with the PID values from Table 4.3.
The process response smoothly in short period of time.

Since this process use all three control algorithms (PID) together, this process can be explained:
Achieve rapid response to major disturbances with derivative control
Hold the process near setpoint without major fluctuations with proportional control
Eliminate offset with integral control

Then, the process maintains at 40C steadily as indicated No. 3 on the graph in Figure 4.4.

For the second temperature controller in heat exchanger, initially the cold-water
circulation was started up. Then, the mode will be changed into Auto (A) mode. Two tests
disturbances were being conducted; set point change and load change.
Set point change has been done according to Lab Manual, 3.4 No. 5. The second Set
point and PID trial values has been key in on the control panel as shown in Table 4.4. Whereas,
by referring the graph in Figure 4.4, its noted as No. 4. Since this is a temperature operating
process, thus a small dead time is encountered at No. 4 before it become steady at new setpoint,
42C at No.5 on the graph in Figure 4.4.

Table 4.4: Second Controller Parameters Values

PID PB1(%) TI1 (seconds) TD1(seconds) Product Setpoint


Flowrate (SV1) (C)
(FI61)
(m3/hr)
First Trail 10 30 7 2.8 42
PID

Then, as the system maintained in steady state, the step change of the product flowrate by
opeing fully the MV61 has been done. The flowrate at FI61 has been noted was at 2.8 m3/hr.
This was noted as No. 6 in the graph in Figure 4.4. The temperature drops to almost 40C before
becomes steady again as indicated as No. 7 in the graph in Figure 4.4.
One of the temperature sensor elements used in this system was, Platinum thin film RTD
temperature sensor elements. The surface of thin film RTD temperature sensor element is coated
with ceramic, so the element can withstand high voltage and show high insulation resistance.

4.4 CONTROL ALGORITHMS FOR DIFFERENT PROCESS VARIABLES

Figure 4.5: Control Algorithms for a few Controlled Variables

The heat transfer process is generally a slow and a low gain process compared to flow or
level processes. This is also can be explained that, the processes with heat transfer has a high
chance to produce dead time and decay ratio. Because of the time required to change the
temperature of a process fluid (time taken for the heat to be transferred from the heating medium
to the fluid), temperature loops tend to be relatively slow. Feedforward control strategies are
often used to increase the speed of the temperature loop response. RTDs or thermocouples are
typical temperature sensors. Temperature transmitters and controllers are used, although it is not
uncommon to see temperature sensors wired directly to the input interface of a controller.

Whereas, flow and level control loops are regarded as fast loops that respond to changes
quickly, since they are dealing with heat transfer, rather only with mass transfer. Therefore, flow
control equipment must have fast sampling and response times.

Furthermore, by referring to Figure 4.5, its stated that the one and only process that uses
all three algorithms was temperature process/controlled variable. Nevertheless, only temperature
variable uses derivative algorithm and not the flow or level control. This is due temperature
variable are very slow response. Thus, Derivative algorithm are needed to apply an immediate
response that is equal to the proportional plus reset action that would have occurred in the
process.

With integral action, the controller output is proportional to the amount of time the error
is present. Integral action eliminates offset.

Figure 4.6: P, I and D controller to show the response against Process Variable

It can be noted that the offset (deviation from set-point) in the time response plots is has
gone. Integral action has eliminated the offset. The response is somewhat oscillatory and can be
stabilized some by adding derivative action. (Graphic courtesy of ExperTune Loop Simulator.)

Integral action gives the controller a large gain at low frequencies that results in
eliminating offset and "beating down" load disturbances. The controller phase starts out at 90
degrees and increases to near 0 degrees at the break frequency. This additional phase lag is what
you give up by adding integral action. Derivative action adds phase lead and is used to
compensate for the lag introduced by integral action.

Whereas, with derivative action, the controller output is proportional to the rate of change
of the measurement or error. The controller output is calculated by the rate of change of the
measurement with time. Some manufacturers use the term rate or pre-act instead of derivative.
Derivative, rate, and pre-act are the same thing.
DERIVATIVE = RATE = PRE ACT

Derivative action can compensate for a changing measurement. Thus, derivative takes
action to inhibit more rapid changes of the measurement than proportional action. When a load
or set-point change occurs, the derivative action causes the controller gain to move the "wrong"
way when the measurement gets near the set-point. Derivative is often used to avoid overshoot.
Derivative action can stabilize loops since it adds phase lead. Generally, if derivative action was
used, more controller gain, and reset can be used.

Figure 4.7: Phase degree and Amplitude Ratio for Derivative and Intergral

With a PID controller the amplitude ratio now has a dip near the center of the frequency
response. Integral action gives the controller high gain at low frequencies, and derivative action
causes the gain to start rising after the "dip". At higher frequencies the filter on derivative action
limits the derivative action. At very high frequencies (above 314 radians/time; the Nyquist
frequency) the controller phase and amplitude ratio increase and decrease quite a bit because of
discrete sampling. If the controller had no filter the controller amplitude ratio would steadily
increase at high frequencies up to the Nyquist frequency (1/2 the sampling frequency). The
controller phase now has a hump due to the derivative lead action and filtering.
Valve positioners compare a control signal to a valve actuators position and move the
actuator accordingly. They are used with both linear valves and rotary valves. Valve positioners
are used when the 0.2 to 1 bar pressure in the diaphragm chamber is not able to cope with
friction and high differential pressures. The positioner is fitted to the yoke of the actuator and is
linked to the spindle of the actuator by a feedback arm in order to monitor valve position. When
a control signal differs from the valve actuators position, the valve positioner sends the
necessary power to move the actuator until the correct position is reached. This uses a high air
supply.

Figure 3: shows the temperature and heat output in a room controlled by an ON/OFF controller.
In practice the use of ON/OFF control can cause problems. As can be seen in Figure 2, the
heating system rapidly switches ON an OFF leading to inefficient system operation and
increased mechanical wear.

Figure 2: ON/OFF control of air temperature


To address this deficiency a 'dead band' may be introduced. Effectively this
defines an upper and lower set-point. The control mechanism is now as summarised in
Figure 3:
if the sensed temperature is below the lower set-point then the heating system is ON;
if the sensed temperature rises above the lower set-point but is still below the upper set-
point then the heating system is ON;
if the sensed temperature is above the upper set-point then the heating system is OFF; and
if the sensed temperature falls below the upper set-point but is still above the lower set-
point then the heating system is ON.

The addition of the upper and lower set-points acts to reduce the frequency of the plant
switching at the expense of poorer control of the controlled variable (here temperature). ON/OFF
control offers a crude means of controlling conditions in a building and is typically employed
where close control is not required, e.g. temperature control of domestic boilers.
5.0 CONCLUSION
The experiment conducted meet the objective as were discussed earlier. The entire
four objectives were achieved and discussed with the accordance in theory of process control.

6.0Recommendation
As a recommendation, using more advance or intelligent machine can help to get accurate
and better result. Especially the recorder, by using more computational and visualize to show the
pattern of the response it would be much easier; the response can be record using software or cds
so that the students do not have to use paper to record because the papers got stucked. Besides,
students that handle the machine should get the overview how the machine running and also
should have some basic knowledge to obtain a correct reading. Mainly, the chart paper should be
placed correctly in order to avoid error during the recording. Furthermore, during the changes of
set point and other related parameters the student should jot down for discussion purpose and
their understanding. Ensure all the valves are closed and opened as mentioned in the
methodology. Set Point change for ON/OFF controller should be added in the experiment change
as well as the PID Controller system, and both types of control system should be discussed to
show the major difference of both control systems.
REFERENCES
Yuvraj, B.K, and Yaduvir, S. (2010). PID Control of Heat Exchanger System, International
Journal of Computer Applications, 22-23.

Mark, J.W. (1999). Some Conventional Pocess Control Schemes, Department of Chemical
and Process Engineering University of Newcastle, 2-5.

Process Control, 2012. [pdf]. Available


at:<http://www.newagepublishers.com/samplechapter/001308.pdf> [Accessed 4 September
2012]

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