ABSTRACT

There are variables in each chemical process that need to be controlled to achieve the
desired result. Three main controller modes are the proportional controller (P), the integral
controller (I), the derived controller (D). Proportional (P) controllers, Proportional Integral (PI)
controllers and Proportional Integral Derivative (PID) controllers were used in this experiment.
It has two modification parameters to set for PI controller. The integral operation helps the PI
controllers to reduce the offset, which is a major weakness of a controller P-only. PI controllers
therefore provide a mix of both complexity and capacity. It has the optimal control dynamics
for PID controller, which include zero steady-state error, quick response (short rise time), no
oscillations and greater stability. The number of algorithm permutations increases
considerably, with the introduction of a third parameter dynamic adjustment derivative.

The main objectives of this experiment are to study how a pressure loop can be
controlled using a microprocessor-based controller as well as DCS system and to study pressure
and temperature compensated flow rate measurement for compressible fluids. Tuning the PID
controller parameter correctly will effectively reduce the error, decrease the over-shooting and
shorten the settling time. Too huge of Kc results in oscillatory and unstable response. If the
value τI is too large, it will take longer to get back to the set point. The maximum deviation
response time and degree of oscillation can be decreased to raise τD.
METHODOLOGY

A) START-UP PROCEDURE

1. Compressor was started and waited for sufficient air pressure to build up in receiver
tank, V-102, air supply pressure was set at 4 bar.
2. The instrument power supply was switched on.
3. Recorder was checked to ensure it was working and pens had ink.
4. Controller Manual Mode was set with 0% output
5. The following valves were checked to be as:
HV 315 was closed
HV318 was closed
HV 311 was closed
HV 312 was opened
HV 313 was opened
HV 314 was opened
HV 317 was opened
HV 316 was left alone

B) ON/OFF CONTROL

1. Pressure was allowed to build in V-102 to 4 bar(g) then it was set FI-302 to 10 m3/nr
by regulating hand valve HV 316.
2. Control loop was set to Manual Mode and the output was adjusted to about 50%.
3. The following values were entered:
PB = 2
I = 1000
D=0
4. The output was gradually adjusted so that the pressure in the tank V-302 matched the
setpoint.
5. The control loop was put into Auto Mode.
6. A load changes was simulated by opening HV 316 so that FI 301 read for 50m3/hr for
approximately 10 seconds.
7. HV 316 was restored to its original position and the measurement was observed for
about 2 minutes.
8. The setpoint was changed to 75% and the response of the system was observed for
another 2 minutes.

C) CLOSED LOOP PROPORTIONAL CONTROL

1. Pressure was allowed to build in V-301 to 4 bar(g) then it was set FI-302 to 10
m3/nr by regulating hand valve HV 316
2. Control loop was set to Manual Mode with setpoint 50%
3. The following values were entered:
PB = 250
I = 1000
D=0
4. The output was Gradually adjusted so that the pressure on the tank matched the
setpoint.
5. The control loop was put into Auto Mode.
6. A load changes was simulated by opening HV 316 so that FI 301 read for 50m3/hr
for approximately 10 seconds.
 7. HV 316 was restored to its original position and it was waited until the measurement
PT 302 exhibited a uniform pattern.
8. The setpoint was changed to 75% and the response was observed of the system.
9. Steps 2 through 8 were repeated for the following PB values. The previous I and D
values were retained.
PB = 25 and PB = 10
The offset values were recorded for each of the PB values.

D) CLOSED LOOP PROPORTIONAL AND INTEGRAL CONTROL

1. Pressure was allowed to build in V-302 then it was set FI-302 to 10 m3/nr by regulating
hand valve HV 316.
2. PIC-302 was set to Manual Mode with setpoint 50%.
3. The following values were entered:
PB = 100
I = 50
D=0
4. The output was gradually adjusted so that the pressure on the tank matched the
setpoint.
5. The control loop was put into Auto Mode.
6. A load changes was simulated by opening HV 316 so that FI 301 read for 50m3/hr for
approximately 10 seconds.
7. HV 316 was restored to its original position and it was waited until the measurement
exhibited a uniform pattern.
8. The setpoint was changed to 75% and the response was observed of the system.
9. Steps 2 through 8 were repeated for the following I values. The previous PB and D
values were retained.
I = 30 s, I = 10 s and I =1 s

E) PROPORTIONAL PLUS INTEGRAL AND DERIVATIVE (PID) CONTROL

1. Pressure was allowed to build in V-301 to 4 bar(g) then it was set FI-302 to 10 m3/nr
by regulating hand valve HV 316.
2. PIV-302 was set to Manual Mode with setpoint 50%.
3. The following values were entered:
PB = 1000
I = 30
D=0
4. The output was gradually adjusted so that the pressure on the tank matched the
setpoint of 50%.
5. The control loop was put into Auto Mode.
6. A load changes was simulated by opening HV 316 so that FI 301 read for 50m3/hr
for approximately 10 seconds.
7. HV 316 was restored to its original position and wait until the measurement exhibits
a uniform pattern.
8. The setpoint was changed to 75% and the response was observed of the system.
9. Steps 2 through 8 were repeated for the following D values. The previous PB and I
values were retained.
D = 30, D = 10 and D = 1

F) PID LOOP TUNING

1. Pressure was allowed to build in V-301 to 4 bar(g) then it was set FI-302 to 10 m3/nr
by regulating hand valve HV 316
 2. PIC-302-1 was set to Manual Mode with setpoint at 50%.
3. The following values were entered:
PB = 250
I = 1000
D=0
4. The output was gradually adjusted so that the pressure on the tank matched the
setpoint.
5. The control loop was put into Auto Mode.
6. The I and D values were retained. PB was slowly being decreased until the
measurement oscillated about the setpoint.
7. Steps 3 through 4 were repeated for the following PB values:
PB = 25, PB = 10 and PB = 2
8. The natural period was determined using the following method:
𝐷
𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝑃𝑒𝑟𝑖𝑜𝑑, 𝑇 = 𝑇𝑟𝑒𝑛𝑑 𝑆𝑝𝑒𝑒𝑑 𝑥 60 𝑚𝑖𝑛

D = distance in mm between successive crests or valleys

9. The integral time was set to natural period, T that was calculated and step 3 to 6
were repeated. The period of oscillation decreased by 40 %. If the period was longer
than this, the integral time was increased.
10. Finally, the PB was adjusted until the desired degree of damping was achieved.

ERROR & RECOMMENDATION

Systematic error

During the experiment, there was fluctuation observed when taking the values of the
readings. This error leads to inaccuracy in the calculation of Kc. To reduce the error,
we must wait for a few minutes until the reading is stabilized to ensure the taken value
is the most accurate one.