6.

0 EXPERIMENTAL PROCEDURE

Start-up:
1. The sump tank, T32 was filled with three quarters of water.
2. The valve was opened anticlockwise for Instrument Air Supply (IAS) until it reached 30 psig.
3. The power supply was opened.

Open-loop
1. The speed chart was set at 1800 mm/hr.
2. The manual mode was selected before entering the output value.
3. 450mm was chosen as set point (S.P) and 30% as MV respectively.
4. The record button was pressed to gather the data.
5. Initial value for PVi and MVi were recorded when the process was stable.
6. 10% of the PV value for process span was calculated.
7. When the value of the PV achieved 10% of the process span value, the MV of the process
was changed to 40%.
7. Final value for PVf and MVf were recorded when the process got stable.
8. TM and RTM method were used to calculate P & I.

Close-loop
1. The manual mode was selected and P & I value that obtain from TM method were inserted.
2. Auto mode was selected and initial value for PVi and MVi were recorded when process got
stable.
3. Manual mode was selected prior to disturbance test.
4. The MV value was change to 44% and wait for 3 second before select auto mode again.
5. The process was wait until getting stable.
6. Step 1-5 were repeated for RTM method.

Shut-down
1. The record button was switch off
2. All variable value such as MV, SP, P, I was change to zero in manual mode.
3. The power supply was switch off and PAS and IAS valve were closed.
4. The water tank were emptied by opening the drain valve.
4.0 THEORY

Proportional, Integral and Derivative controller or PID which is a set of mathematical

equation is a standard feedback loop component in industrial control applications. It measures
an output of a process and controls an input, with a goal of maintaining the output at a target
value, which is called the setpoint. An example of a PID application is the control of a process
level, which can be affected by manipulating some other process variable.

Proportional Controller are used to stabilize the system and avoid fluctuations from
occur by responding the magnitude as well as the direction of error. When Proportional
Controller is used, large gain is needed in a way to recover the steady state error since stable
systems do not have problems when large gain is used. In other words, Proportional Controller
helps in calculating the amount of error between the measurement and the set point, magnifies
it and positions the final control element to eliminate the error. The measurement of
Proportional Controller can completely abolish 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.

Secondly, is Proportional Integral Controller. Integral control has a negative effect on

speed of the response and overall stability of the system and hence almost never used alone.
It is combined with P Controller and 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 while the Integral Control mode will detect the
offset error in the proportional mode and tries to eliminate the error.

Other than that, Proportional, Integral and Derivative (PID) Controller is also used to control
the pressure. However, its application should be considered carefully because it has
limitations with some processes which 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 (Ling,
Farhan, & Munindy, 2013).

. The optimal values of P, I and D values can be analyzed by several techniques. One
of them is open loop method. The method is preferable since it gives short test time and
minimum loss of product quality. The method starts with the open loop test. The result from
the open loop test is evaluated for response rate (RR), dead time (Td) and time constant (TC)
which will be used in tuning rule to get the optimum value of P, I and D. The analysis can be
calculated by using based on tangent method and reformulated tangent method (Ishak &
Abdullah, 2014).

Tangent method:
Dead time:
Td (time) = 𝑇𝑑 (𝑙𝑒𝑛𝑔𝑡ℎ) × 𝑏 (1)
Time constant:
Tc (time)= 𝑇𝑐 (𝑙𝑒𝑛𝑔𝑡ℎ) × 𝑏 (2)
Response rate:
∆𝑃𝑉/∆𝑡
RR = (3)
∆𝑀𝑉
Reformulated tangent method
Dead time:
Td (time) = 𝑇𝑑 (𝑙𝑒𝑛𝑔𝑡ℎ) × 𝑏 (4)
Time constant:
Tc (time) ) = 𝑇𝑐 (𝑙𝑒𝑛𝑔𝑡ℎ) × 𝑏 (5)

Response rate:
𝑡𝑎𝑛𝜃 𝑎
RR = (6)
∆𝑀𝑉 𝑏
A process in open loop system can be either in self-regulating or a non-self-regulating
process. Self-regulating process such as flow, temperature, pH and pressure is a process
which the process moves to a new steady position after making an open loop test. Meanwhile
for non-self-regulating process such as liquid level, the process keeps changing until it reaches
limit after running an open loop test. Hence, calculation of process variable for process span
must be done to set up the maximum limit for process to proceed (Ogunnaike & Ray, 1994).
On the other hand, closing the loop means that the system is provided with a way to measure
the controlled variables and automatically give any corrective adjustments is needed for the
actuator loading pressure. The selection of the tuning rules is based on the closed loop setting
criteria and the type of performance test and one of them is Ziegler-Nichols’s rules shown in
table 1.

Table 1: Tuning Rules by Ziegler-Nichols.

Mode P I D
P 100 RR Td
 I 111.1 RR Td 3.33 Td
PID 83.3 RR Td 2 Td 0.5 Td
5.0 APPARATUS

Level Alarm
Low &High
Indicator
chart

Start and
Shut Down
button

Figure 1: Level Process Control Training System Control Panel.

Water
Tank, T31
Instrument
Air Supply
(IAS) valve

Instrument
Air Supply
(IAS)
regulator

Sump Drain valve

Tank, T32

Figure 2: Water Tank and Control Valves.

Figure 3: Level gauge.
12.0 REFERENCES
Ishak, A. A., & Abdullah, Z. (2014). PID tuning: Fundamental concepts and applications. Shah
Alam: UiTM Press.

Ling, C. J., Farhan, A. I., & Munindy, K. (2013, September). CCB 3072 Process
Instrumentation & Control Lab [Scholarly project]. Retrieved April 1, 2018.

Ogunnaike, B. A., & Ray, W. H. (1994). Process dynamics, modeling, and control. New York,
NY: Oxford University Press.