Experiment 5 - Heat Exchanger Process Control
Experiment 5 - Heat Exchanger Process Control
Experiment 5 - Heat Exchanger Process Control
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
REVISION NO:
1
1
29 SEPT
2014
AMENDMENT
DATE:
COURSE CODE
EXPERIMENT NO.
EXPERIMENT TITLE
DATE
GROUP NO.
LECTURER/INSTRUCTOR/TUTOR
1)
2)
ATTENDANCE/PARTICIPATION/DISIPLINE:
/5%
INTRODUCTION:
/5%
PROCEDURE:
/5%
RESULTS& CALCULATIONS
ANALYSIS
DISCUSSIONS:
ADDITIONAL QUESTIONS
CONCLUSION
/15%
/20%
/15%
/10%
SUGGESTIONS& RECOMMENDATIONS
/5%
REFERENCES:
/5%
TOTAL:
EXAMINER COMMENTS:
/15%
/100%
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
1
1
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
(Signature)
2) Group Member 1: .
Name
: __________________________________
Matrix No
: __________________________________
(Signature)
(Signature)
(Signature)
1.0
2.0
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
OBJECTIVES
a)
b)
training system
INTRODUCTION
Shell and tube heat exchanger is the most commonly used in the industries.
Heat exchangers are one medium of fluid flows inside and through the bundles of
tubes while the other medium flows in the shell side. The heat from the hot fluid
transferred through the metal wall of the tubes to the cold fluid due to the
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
4.3
Apparatus
a) Heat Exchanger process control training system.
5.0
PROCEDURE
5.1
STARTUP PROCEDURES
1. The following steps must be carried out before starting the
experiment:
a) Fill the tank T62 and the product Tank T61 with water up their
overflow drain pipe.
b) Check the manual valve at the product downstream pipeline
TSV62 is open to the external drain system.
c) Turn on the main power supply at the front cubicle.
2. Check the various manual valve as follow
OPEN all suction and discharge valve pumps (P61,P62,P611)
Manual by-pass valve for each pumps and control valve TCV61,
TSV61,TSV62 and LSV61 is shut.
OPEN the manual valve at the inlet of LSV61
Bottom drain valves of tank T61 and T62 always shut
3. Learn to use the PID Controller TIC61
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
control valve. Check the control valve is open (at the plant)
Set the SV to 40oc
Access the PID tuning page PID1 and change the PID values to
5.2
T62
SHUT the by-pass valve B62
Switch On the heaters. Make sure there is a temperature
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
pen to record
Observed the rise in temperature of water in tank T62
It will take 15-20 minutes for TE62 reach 55oc. during this
time, STOP the recorder, by push the RCD button and proceeds
Access to menu and select I/O Data button and note the
following data:
X2 : TE62/TIT62, % of 0-100oc, input variable to the controller
DO1 : Heater status in T62. 1(ON), 0(OFF)
DO2 : Annunciator TAH62 status. 1(On), 0(Off)
5. When the temperature is approaching 55oc, start recorder TR61 buy
pushing the RCD button.
Observed both recorder TR61 Green pen and the I/O Data
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
Check the Status DO1, DO2, and X2 at the I/O Data and
limit
TE62/TIT62 drops to the High limit (55oc) but the heater is still
OFF
TE62/TIT62 drops further by an amount equal to the Dead
band (0.5oc)
Heater are switched ON again
The annunciator TAH62 is switched OFF
Check the status DO1, DO2 and X2 at the I/O Data and record the
peaks or bottom
Note the oscillatory nature of On/Off control at the Green pen
of the recorder
7. Stop Record by push the RCD button at the recorder. Note at the
chart paper your experiment name.
5.3
PID CONTROL OF TEMPERATURE
1. The temperature of the heated product at the exit of the heat
exchanger measured by TE61/TIT61 is controller PID (Loop 1) of
TIC61
2. The On/Off controller TIC62 maintains the temperature of tank T62
at 55oc. Set the controller TIC as follow:
Endure the setpoint SV = 40oc
With TIC61 in Manual(M) mode, set the output MV=100%
Check that the PID value are set to the (I) trial value
PB1=15%
TI1=35sec TD1=8sec
3. START the cold water circulation
Make sure that valves MV61 and B61 are opened
START pump P61, and ensure the water flow through
rotameter FI61
Shut the by-pass B61.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
values
PB1=10%
TI1=30sec TD1=7sec
Change the setpoint SV=42oc. Mark on the chart paper the new
the flow rate FI61 and write the value at the chart paper
Watch the relevant portions of the chart paper and attach the
8.
1.4
SHUTDOWN PROCEDURE
1. Switch the controller TIC61 to Manual(M) mode, and set the
MV=100%
2. Switch Off heater
3. Stop all the pump P61, P62 and P611
4. Switch Off the main power supply
6.0
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
I/O Data
Status
TIC62, Controller
PO1 =_____oc
PO2 = ____oc
DO1:
TAH62, Annunciator
PO3 =_____oc
PO4 =____oc
DO2:
TI1 = _______secs
TD1 = _________secs
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
Test disturbance:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
Step/pulse
At Setpoint SV1 =________
At product flow rate =________
7.0
8.0
DISCUSSIONS
Discuss the overall experiment on data obtain based on your understanding.
Discussion should relate reasons for the phenomena/results obtained,
theoretical parts, suggested reasons (if necessary but back with sound
theoretical knowledge) and your overview understanding.
9.0
ADDITIONAL QUESTIONS
i.
Based
on
the
results,
discuss
the
difference/characteristics
of
10.0 CONCLUSION
Conclusion is merely a summary of the important findings already reported
in the discussion section. It also relates to the objectives stated earlier.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
12.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter
based)