CAMPUS : UniKL MICET EDITION: 1

LABORATORY: SECTION of 1
PROCESS TECHNOLOGY REVISION NO:
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

SECTION OF CHEMICAL PROCESS

MALAYSIAN INTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY
PROCESS CONTROL LABORATORY
LABORATORY INSTRUCTION SHEETS
SEMESTER SEPTEMBER 2022

COURSE CODE CPB 30004 PROCESS DYNAMICS AND CONTROL

EXPERIMENT NO. EXPERIMENT 4

EXPERIMENT TITLE Flow Ratio Process Control

DATE 29 Nov. 2022
GROUP NO. 4

1) Sir Zainal Abidin bin Mohd Yusof

LECTURER/INSTRUCTOR/TUTOR
2) Mr. Mohd Anif bin Basir
DATE OF REPORT SUBMISSION 18th Dec. 2022
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%

INTRODUCTION: /5%

PROCEDURE: /5%
RESULTS& CALCULATIONS /15%
ANALYSIS /15%
DISTRIBUTION OF MARKS FOR DISCUSSIONS: /20%
LABORATORY REPORT: ADDITIONAL QUESTIONS /15%
CONCLUSION /10%
SUGGESTIONS& RECOMENDATIONS /5%

REFERENCES: /5%

TOTAL: /100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

 CAMPUS: UniKL MICET EDITION: 1
LABORATORY: SECTION of 1
REVISION NO:
PROCESS TECHNOLOGY
29 SEPT
EFFECTIVE DATE:
EXPERIMENT: GAS 2014
PRESSUREPROCESS AMENDMENT Sept 2022
CONTROL DATE:

STUDENT CODE OF ETHICS

DEPARTMENT OF CHEMICAL ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit tonot

accept or provide any assistance in preparing this report and anything

that is in it is true.

RAIDI
1) Group Leader: (Signature)
Name : RAIDI SOFWAN BIN ROSDI @ RAZIF
Matrix No. : 55213120078
ANIS
2) Group Member 1: (Signature)
Name : NUR ANIS NATASHA BINTI MOHD AZLAN
Matrix No : 55213120082

NAJIHA
3) Group Member 2 : (Signature)
Name : NAJIHA SAFIA BINTI
NORULAMIN Matrix No. : 55222120143

SUGIE
4) Group Member 3: (Signature)
Name : SUGIE ANAK BAKI
Matrix No. : 55222

2
Table of Contents

1. INTRODUCTION............................................................................................................ 4

2. OBJECTIVES.................................................................................................................. 6

3. PROCEDURES................................................................................................................ 6

4. RESULTS & CALCULATIONS................................................................................... 13

5. ANALYSIS.................................................................................................................... 19

6. DISCUSSIONS.............................................................................................................. 20

7. CONCLUSION.............................................................................................................. 22

8. SUGGESTIONS& RECOMMENDATIONS................................................................22

9. REFERENCES............................................................................................................... 23

3
1.0 INTRODUCTION

This model employs flow measurements based on all of these concepts. At various set
points, a single loop PID controller controls the flow. Flow measurement is the process of
measuring the flow of liquids, gases, and vapours using a flow measurement equipment or
device that measures the rate or quantity of flow. Flow measurements show flow rate, total
flow, velocity, flow absence, flow presence, too much flow, too little flow, and flow direction.
(Flow Measurement Instrumentation Used in Engineering Design of Processes, n.d.) A ratio
flow control is also used, in which a wild stream flow rate is recorded, and the other stream is
managed to keep their flow rates at a consistent ratio. The size coefficient of control valves will
also be examined.
The first experiment that conducted is comparing flow measurements taken with
three distinct flow metres: variable area flow metre, orifice / differential pressure flow
transmitter, and vortex flow metre. The variable area flow metre monitors fluid flow by
allowing the device's cross-sectional area to fluctuate in reaction to the flow, resulting in a
detectable impact that reveals the rate. A rotameter is a type of flow metre that determines the
volumetric flow rate of a gas or fluid. It is made from a tapered tube with an interior float
that moves. Mechanical flow metres, gravity flowmeters, and variable area flowmeters are
all names for these devices. The gravity phrase refers to the fact that the rotameter must be
mounted vertically since the flow rate is dictated by the balance of forces underneath the
float caused by gravity. (What Is a Rotameter? n.d.)
The theory behind this experiment was Ratio Plant Control and Cascade Mode. A
ratio control system is a technique in which one of the variables (in the case of binary feed)
is regulated to keep/maintain a specified ratio of the output stream. A ratio control system is
a form of feed forward control system that is commonly employed in the process industries. The
objective of a ratio control system is to keep the ratio of two variables constant. To maintain
the proper ratio between the two flows, the ratio controller manipulates the other flow
(secondary flow). The flow controlled by the ratio controller is referred to as the controlled
flow.(WHAT IS RATIO CONTROL? - The Engineering Concepts, n.d.)

4
 Figure 1.1: Ratio Control System
The ratio control system in this figure was comprised of the flow rates of two flow streams.
Flow transmitters installed in the different pipelines detect both. In the aforementioned pipe,
(A) represents uncontrolled flow and (B) represents regulated flow. The flow controller
regulates the flow rate of the second stream in relation to the flow rate of the first pipe stream.
(WHAT IS RATIO CONTROL? - The Engineering Concepts, n.d.)
Cascade control is used when there is more than one measurement, but only one control
variable is available. For our example, it is note that although the valve opening is used for
control purposes, the steam flow rate is the variable which actually determines the process
outlet temperature. As the steam flow rate is determined both by the valve opening and by
the steam pressure, a flow controller is used to keep the steam flow rate constant despite
steam pressure disturbances. (Cascade Control - an Overview | ScienceDirect Topics, n.d.)

Figure 1.2: Cascade Control

Upon this experiment, PID controller had been used to study the single loop flow control as
well as flow ratio control. The flow controlled by the ratio controller is therefore referred to
as the controlled flow. When using ratio control, one process input, known as the dependent
input, is proportioned to the other process input, known as the independent input. As the
value of the independent input changes, the other process input is altered via ratio control to
preserve the percentage of the inputs determined by the ratio set point.

5
2.0 OBJECTIVES

 To compare flow measurements by three different flow meters

 To study single loop flow control using PID controller
 To study ratio flow control using linear PID controller
 To check the control valve sizing

3.0 PROCEDURES
3.1 STARTUP PROCEDURES

The following steps" constitute the start-up procedure. They are gone through before
the experiment started.

1) Tank T21 was filled with water up to almost the level of its lower overflow pipe.

2) To operate the plant independently, interconnecting pipelines from the other

plants WLF922 and WT922 was shut at the appropriate manual valves.

3) The various manual valves used are as follows:

 All pumps (P20, P21, P22A, P22B) suction, discharge and by-pass valves
were fully opened. The by-pass valves can be closed after checking that there is
water flow in the pipeline when the respective pump is started.
 The manual by-pass valve around the control valve FCV21 was shut and the
two adjacent manual valves was opened.
 The manual drain valve at the bottom of the tank T21 was shut.
 The interconnecting manual valve MVX was shut fully.

 The manual discharge valve at the discharge of pump P20 was shut.
4) The instrument air pressure was checked and adjusted as indicated at the air
pressure regulators (IAS).
5) The main power supply at the front cubicle was switched on. The panel
instruments lit up after.

i. "PANEL, SCADA/DDC" selector switch at was put at "PANEL, SCADA"

position.

ii. If the ANNUNCIATOR get activated, the buzzer was silenced by pressing the
ACKNOWLEDGE button.

iii. Controller FIC21 was switched to Manual (M) mode with its MV = 106.3%
to open the control valve FCV21 fully.

iv. The selector switch was switched to position 1: "FT21 = PV = CF", for

6
 NORMAL OPERATION.

v. CF1/WF1 was open fully.

vi. CF2/WF2, MVX, MF was shut fully.

vii. Pumps P21, P22A and P22B were switched on with their by-pass valves
opened.

viii. The water flow from these pumps was ensured and theby-pass valves B21,
B22A, and B22B were shut.
6) Recording was started by pushing the RCD button.
7) .FIC21 is a single loop controller configured for Ratio Control using one PID (PID1).
The controller were familiarized as follows:

i. FIC21 was displayed and changed from Auto (A) to Manal (M) mode and vice
versa.

ii. The set point SV was changed to 3.6 m3/Hr.

iii. Switch to Auto (A) mode for single loop PID flow control. Switch to Cascade
(C) mode for Ratio Control. (It was not actually executed, For Info Only)
iv. In Manual (M) mode, control valve FCV21 was manually stroked fully opened
with MV = 106.3% and checked.

v. The PID tuning page at PID1 was accessed and the PID values were changed to
the following trial PID values (I trial) :
PB 1 = 100%, TI 1 = 5 sec, TD1= 0sec GW1=0.0%, GG1=1.0
vi. The high alarm and low alarm limits were set as PHI = 4.0 m3/Hr and PL1 =
1.2 m3/Hr.

vii. The instrument ratio factor R were accessed at the PARAMETER page at
CGN 1 and set R=1.0
8) The valve positioner (PP) was made into active (ON).

3.2 FLOW MEASUREMENT BY 3 DIFFERENT FLOWMETERS

1. The start-up procedures given in the previous section was gone through carefully.
2. The three flow meters FI22, FE21/FT21, FT22 and control valve FCV21 were
connected in series in the same pipeline from pump P20 as follows:
P20-MF-FE21/FT21-M VX-FI22-FT22-CF2-FC V 21-T21
3. The selector switch was made sure to be in Position 1: "FT21=PV=CF".

4. The positioner (PP) at the control valve was made sure to be CONNECTED.
5. The pumps P21 and P22A/B were switched OFF. Their manual discharge

7
 valves were shut fully.
6. The above pipeline and SHUT/OPEN the valves were traced as follows:
 Discharge manual valve MF of Pump P20 : OPEN FULLY
 Discharge manual valve of pump P2 : SHUT FULLY
 Interconnecting manual valve MV : OPEN FULLY
 Discharge manual valves of pumps P22A/B : SHUT FULLY
 CF1, WF1, WF2 : SHUT FULLY
 CF2 & FCV2 : OPEN FULLY

7. B20, the by-pass valve of pump P20 were OPEN fully and pump P20 was started.
The by-pass valve B20 was shut fully and the manual discharge valve MF was
open fully.

The flow rates and the pressure gauge readings were noted down as follows:

 FI22: was read at FI22, the rotameter, The reading at the recorder chart paper
were written down.

 FE21/FT21: was read FT21 at channel 1 and the reading at the Recorder
chart, beside the RED response were noted down.

 FT22: FT22 was read at channel 2 and the reading at the recorder chart, beside
the GREEN response was noted down.

 PG21, PG22: After the readings are steady, the pressure drop across the
control valve FCV21, i.e. PG21- PG22 were noted down. Pressure drop
readings was done LAST.

 The readings taken in the RESULTS SHEET given in the results section
were taken, which is Reading No. 1.
8. The by-pass valve B20 was opened manually by about one turn so that FI22
reads about 10% less flow. The four readings were recorded, given above in step
(7), as Reading No. 2.
9. With FIC21 in manual mode, MV = 70% was adjusted. The four readings
was recorded with the pressure drop readings done LAST as Reading No. 3
10. With FCV21 at 50% opened, the pump by-pass valve B20 was shut fully. The four
readings was recorded with the pressure drop readings done LAST as Reading No.
4.
11. The manual discharge valve MF of pump P20 was manually shut until FI22 reads
about 1.2 m3/Hr. If the control valve pressure drop is too low to be taken, only the
3 flow meter readings were taken. This was Reading No. 5.
12. The recording was STOPPED. The relevant portions of the chart paper was
retrieved to enclose along with the results later.

8
 13. The pump P20 was switched off and its manual discharge valve MF was shut.
14. TYPICAL RESULTS SHEET at the RESULTS section were referred.

3.3 FLOW CONTROL USING SINGLE LOOP PID CONTROLLER (NORMAL

OPERATION

The PID flow controller is FIC21 (PID1) and the controller variable PV is FT21. The flow
single loop is FT21-FIC21-FCY21/PP/FCV21.

1. The pipelines were restored and controlled to NORMAL operation position, i.e.

 CF1/WFI was opened fully, and CF2/WF2 was shut fully.

 The interconnecting manual valve MVX was shut.
 The manual discharge valve MF of pump P20 was shut.
 Manual discharge valves of pumps P21, P22A,P22B was opened.
 Controller selector was switched in position 1: "FT21=PV=CF".
 The adjacent manual valves of FCV2 I were fullyopened, and its manual by-
pass valve was fully shut.
 The positioner (PP) at FCV21 was ensured to be CONNECTED.
2. Pump P21 was opened and its manual by-pass valve B21 was shut.

3. With the controller FIC21 still in Manual (M) mode at MV=100%, its first (I) trial
PID values was set as:
PB 1 = 100% TI 1 = 5 sec. TD 1 = 0 sec.GW1=0.0% GG1=1.0
4. The set point SV = 1.8 m3/Hr was set.

5. The MV was manually adjusted so that PV approaches SV. FIC21was switched to Auto
(A) mode.

6. RECORD (RCD) was started.

7. The response of FT21 at the RED pen was observed until it is almost steady at the set
point, or it continues to oscillate even after 3 cycles. The set point and the PID values
was written down on the chart paper beside its response.

8. Set point disturbance: The set point was step increase from 1.8 to 2.4 m3/Hr. The flow
response (Red pen) was observed patiently until it is stable, or it continues to oscillate
even after 3 cycles.

9. The set point step test was repeated. The following set points SV = 2.8, 3.6, and 4.2
m3/Hr were used. Then, the step point step test was repeated using the second (II) trial
PID values:

PB1 = 150% TI l = 10 sec. TD 1 = 0 sec. GW 1 = 0.0% GG 1 = 1.0

10. The response for each set point was observed.

9
11. Any irregular oscillations in the response with both the PID trial values and mark
them was observed.
12. The recorder chart drive was stopped.
3.4 FLOW RATIO CONTROL

The aim of the control here is to control FT21 in a fixed ratio toFT22, with FT22
varying.
The flow closed loop is FT21-FIC21 FCY21/PP/FCV21. The general equation for
ratio control is
Controlled flow (CF) = R x Wild Flow (WF)
In this experiment, FT21 is CF and FT22 is WF. R is the ratio to bemaintained
between the two flow streams.

1. All the pumps were stopped, the pipelines were checked ,and controls are
restored to normal operation.
 The controller selector was switched in Position 1:"FT21=PV=CF".
 CFI/WF1 are fully opened, CF2/WF2 are fully shut.
 Interconnecting manual valve MVX was shut.

 MF at the discharge of pump P20 were ensured to be fully shut.

 Discharge manual valves of pumps P21, P22A/B are fully opened.
2. With controller FIC21 in Manual (M) mode , MV = 100% was set.
3. The maximum CF and WF flow rates were checked as follows:
 For CF, pump P21 was started and CF was read at the recorderFR21 (Red
Pen/Channel 1).
 For WF, both pumps P22A/B were started and WF was read at the recorder
FR21 (Green pen/Channel 2).
 The by-pass valves were fully shut and the flows were at the maximum.
 The maximum CF and WF flow rates, and the ratio were noted down.
Max CF: m3/Hr
Max WF: m3/Hr

 All the pumps P21, P22A/B were switched off.

4. The second trial (II) PID values were used as follows:
PB1 = 150% TI l = 10 sec. TD 1 = 0 sec. GW1=0.0% GG1=1.0
5. Test 1: One WF pump, R=1
 Test 1 started with using one WF pump only. Pumps P21 and P22A were
started. Their manual by-pass valves B21, B22A were shut fully as well as
B22B but their

10
 discharge manual valves were opened fully.
 The PARAMETER button was pressed to access the instrument ratio factor R,
which is CGNI at the PARAMETER page. The R value can be changed. The
R=1.0 was started by setting CGNI = 1.0.
 The recorder chart drive was started by pressing the RCD pushbutton.
 The PID controller FIC21 (PID 1) was switched to Cascade (C)
 The recorder FR21 was observed at both FT21 and FT22. The response was
waited till FT21 is almost steady at its set point or it continues to oscillate even
after 3 cycles.
 From the recorder flow rates display at Channel 1 and 2, the two flow rates in
engineering units, m3/Hr was worked out and their process flow ratio PR was
checked to be the same as R, i.e.,
𝐶𝐹 𝑜𝑟 𝐹𝑇21 𝑖𝑛 𝑚3/𝐻𝑟
𝑃𝑅 =
𝑊𝐹𝑜𝑟 𝐹𝑇22 𝑖𝑛 𝑚3/𝐻𝑟

 R and PID values were noted down on the chart recordings. The relevant
portions of the chart paper were retrieved to be submitted along with the
report.
6. Test 2: Two WF pump, R=1
 WF was disturbed by switching ON its second pump P22B.
 The flow responses at the recorder was observed.
 PR was checked to be equal to R
7. Test 3: One WF pump, R=1.8
 Pump P22B was stopped.
 The instrument ratio was set to R = 1.8 at CGN 1 at the parameter page.
 The test with R = 1.8 was repeated using P22A only.
 The flow responses at the recorder were observed similarly.
 The PR and R were checked.
8. Test 4: Two WF pump, R=1.8
 Pump P22B was stopped.
 The instrument ratio was set to R = 1.8 at CGN 1 at the parameter page.
 The test with R = 1.8 was repeated using P22A only.
 The flow responses at the recorder were observed similarly.
 The PR and R were checked.

11
3.5 CONTROL VALVE SIZING CHECK

The control valve FCV21 has Equal % characteristics with a rated Cv of 9.5.
1. NORMAL OPERATION was restored back.
 Controller selector switch was made sure in Position I: "FT2I=PV=CF".
 CFI/WF1 were fully opened, CF2/WF2, MVX and MF were fully shut.
 The chart drive of the recorder was switchedOFF.
2. With controller FIC21 in Manual (M) mode, MV = 100% was set and FCV21
was fully opened. The positioner (PP) was made sure to be CONNECTED.
3. Pump P21 was started and its manual by-pass valve B21 was shut fully.
4. 5 minutes was waited and the following readings when were taken after they
were steady.

 Maximum flow rate: FT21, m3/Hr

 Pressure drops across FCV21, PI-P2 psi: PG21 — PG22(psig)

5. The control valve sizing coefficient Cv was calculated as follows:

 The Max. flow rate in m3/Hr was conv er t ed to USGPM bymultiplying by

4.4
 SG, the specific gravity of water is 1.0

 The pressure drop must be in psi.

 Calculated Cv = Max flow rate,
√𝑆𝐺
USGPM x
√(𝑃1−𝑃2)

6. The pump was SWITCHED OFF and the chart recording was stopped.

3.6 SHUTDOWN PROCEDURE.

1. Controller FIC21 was switched to Manual(M) mode and MV=100% was set.
2. All the pump P20, P21 and P22A/B were stopped.
3. The main power supply were switched off.

12
4.0 RESULTS AND CALCULATIONS
Flow measurement by 3 different

flowmeters:

Figure 4.1: FTC21 (PTD1): PB1=100%, TDI=0s, GW1=0%, CG1=1.0

Until the reading No. 2, when the bypassed valve was changed by one turn to lower the 10% flow, the
reading No. 1 indicated a steady position with the configuration of MV=106.3% SV=3.6 m$ /Hr. The
result for reading number two decreased along with the flow because of the lower flow. When it came
to reading No. 3, we first set the MV=106.3% until we were told to lower it to 70%. This was referred
to as a disruption in the flow since it caused the pressure to drop and the reading to decrease as a
result of the adjustment. Reading No. 4 indicated a decline in the result after being directed to open
50% of the experiment from the beginning, and reading No. 5 revealed a sharp drop in the result after
changing the SV from 3.6 m°/hour to 1.2 m°/hour.

13
 Flow control using single loop PID Controller (Normal Operation):

Figure 4.2: Trial 1 the reading of the flow using different set value, SV = 1.8 – 4.2 m3 / Hr.
FIC21 (PID1): PB1 = 100 %, TI1 = 5 secs, TD1 = 0 secs, GW1 = 0 %, GG1 = 1.0
Setpoint (SV1): 1.8, 2.8, 3.6, 4.2 m3 / Hr

Based on the findings, we initially set the MV to 100% and the set point to 1.8 m°/Hr for the first (I) trial. Manually
adjust MV1 till PV1 gets closer to SV1, then change the set point for every experiment until 4.2 m/Hris is attained. The
rising time and oscillation both increase when the set point is at 1.8 m'/Hr. At the set point of 2.4 m°/h, this likewise
occurs. But when the oscillation reaches the set point of 2.8 m°/hr, it starts to display some disturbance but moves quickly
because of the system's increasing disturbance. The oscillation chart continues to rise until it reaches 3.6 m3/hr to 4.2
m/hr, when it becomes stable.

14
 Figure 4.3: Trial 1 the reading of the flow using different set value, SV = 1.8 – 4.2 m3 / Hr.
FIC21 (PID1): PB1 = 150 %, TI1 = 10 secs, TD1 = 0 secs, GW1 = 0 %, GG1 = 1.0
Setpoint (SV1): 1.8, 2.8, 3.6, 4.2 m3 / Hr.

We alter PB1 = 150% for the second (Il) trial, but we maintain MV = 100% and the set point value. The chart that was
captured demonstrated the outcome up to the set point disturbance, which increased at a rate of 4.2 m°/hour until it
reached a stable position.

15
 Figure 4.4: Trial 1 the reading of the flow using different set value, SV = 1.8 – 4.2 m3 / Hr.
FIC21 (PID1): PB1 = 150 %, TI1 = 10 secs, TD1 = 0 secs, GW1 = 0 %, GG1 =
1.0 Setpoint (SV1): 1.8, 2.8, 3.6, 4.2 m3 / Hr.

We maintain the set point value and the value for MV=100% for the second (Il) trial, but we modify PB1 = 150%. The
outcome was displayed on the recorded chart as a straight rise up to the steady position, or 4.2 m°/hr disturbance up to the
set point.

16
 Flow ratio control:

Figure 4.5: The reading of the flow using One WF pump, R = 1.0 & R = 1.8
FIC21 (PID1): PB1 = 150 %, TI1 = 10 secs, TD1 = 0 secs, GW1 = 0 %, GG1 = 1.0 One WF pump, R
=1.0

The oscillation effect is next tested using one WF pump with R = 1 and R = 1.8. We utilised the PID settings from the
second trial—PBI = 150%, TI1 = 10 seconds, and TD1 = 0 seconds—in this test. GG1 = 1.0 and GW1 = 0.0 percent. The
oscillation starts to lessen and stabilise at the R = 1 point. The graph started to undershoot before stabilising when we
adjusted it to R = 1.8.

17
 Flow Measurement By Different Flowmeters:

Table 4.1: Data observation recorded for flow measurement by 3 different flowmeters
Vortex Flowmeter P1-P2 Across FCV21 Orifice / DP FT21 Rotameter FI22
Reading Calculated 𝐹𝑇21 − 𝐹𝑇22 𝐹𝐼22 − 𝐹𝑇22
FT22, m3/hr PG21-PG22 FT21: m3/hr 𝑥 100% FI22, m3/hr 𝑥 100%
Flow rate 𝐹𝑇22 𝐹𝑇22
MV=100% 4.20 7.5 psi 2.7 4.60 9.52 % 4.5 7.14 %
MV=100% 4.20 7 psi 2.6 4.55 8.33 % 4.0 -4.76 %
MV=70% 4.20 7 psi 2.6 4.36 3.80 % 4.0 -4.76 %
MV=50% 4.20 9 psi 3.0 4.28 1.90 % 4.2 0%
MV=50% 1.20 0 psi 0 1.20 0% 1.2 0%

Flow Ratio Control

MV = 100%, PB1 = 150%, TI 1 = 10 second, TD 1 = 0 second, GW1 = 0.0%, GG1 = 1.0Max CF (FT21) = 4.20 m3/hr.

Max WF (FT22) = 4.18 m3/hr.

𝐶𝐹 𝑜𝑟 𝐹𝑇21 𝑖𝑛 𝑚3/ℎ𝑟 4.20 𝑚3/ℎ𝑟

𝑃𝑅 = = = 1.0
𝑊𝐹 𝑜𝑟 𝐹𝑇22 𝑖𝑛 𝑚3/ℎ𝑟 4.18 𝑚3/ℎ𝑟

Control Valve Seizing Checking

Max Flow rate: FT21, m3/hr = 4.20 m3/hrSG = 1.0

Pressure Drop across FCV21, P1-P2 psi: PG21-PG22 = 15-9 =6 psi

√𝑆𝐺 4.20𝑚3 √1.0

𝐶𝑣 = 𝑈𝑆𝐺𝑃𝑀 × = × 4.4 ×
(√𝑃1 − ℎ𝑟
𝑃2)𝑝𝑠𝑖
= 7.54 (𝑐𝑜𝑛𝑡𝑟𝑜𝑙 𝑣𝑎𝑙𝑣𝑒 𝑖𝑠 90%)
√6𝑝𝑠𝑖

18
5.0 ANALYSIS
Ratio Plant Control and Cascade Mode acted as the experiment theoretical framework. When
there are multiple measurements but only one control variable is accessible, cascade control is
employed. When two (or more) controllers are used in a cascade control system, one controller's
output drives the set point of another controller. Two control loops that use two measurement signals
to control one primary variable make up the simplest cascade control system. The secondary
controller output is required to modify the control variable. The primary controller often changes
slowly, whereas the secondary controller usually changes quickly. Once cascade control is in place,
the primary controller won't be disturbed by secondary controller adjustments that happen quickly.
Therefore, cascade control performs significantly better since the flow disturbance is quickly
corrected.
After the two setpoints were introduced, it can be said that the larger the proportional band,
the more stable the control. In addition, the less the oscillation, the greater the offset, and vice versa.
The first trial set point was set to PB = 100% and TIl = 5 secs, while the second trial set point was set
to PB
= 150% and TIl = 10 secs. As the PB and TI percentage values increased in the second trial, the
response was therefore more satisfactory than the first trial. Meanwhile, the flow was kept constant
when in the cascade mode.

19
6.0 DISCUSSION
The purpose of the experiment was to identify the major components of the flow ratio process
control system, to start up the process systematically, to compare flow measurements by three
different flow meters, to study single loop flow control using a PID controller and to study ratio flow
control using linear PID controller. The theory of simplest cascade control scheme involves two
control loops that use two measurement signals to control one primary variable. The output of the
primary controller determines the set point for the secondary controller. The output of the secondary
controller is used to adjust the control variable.
Generally, the secondary controller changes quickly while the primary controller changes
slowly. Once cascade control is implemented, disturbances will not affect the primary controller. The
experiment was begun with the involved valves were opened and closed beforehand. Then, the main
switch on the control panel was switched on. Next, the PID Single Loop Flow Control (Normal
Operation) was tested on, followed by the Set Point Step Test (Normal Operation). In addition to that,
the PID Controller Tuning (Normal Operation) and the Flow Ratio Control, Linear PID (Normal
Operation) were then carried out.
Based on figure 3, the results recorded when PB was 100%, TI1 was 5 secs and TD1 was 0
secs and when PB was 150%, TI1 was 10 secs and TD1 was 0 secs showed in increasing in MV as the
SV increases and PV increases. Meanwhile, based on figure 2, the dynamic response test for set point
test when PB was 100%, TI1 was 5 secs and TD1 was 0 secs showed that at first the flow rate was
stable, however it becomes more oscillatory and unstable as the set point increases. But when the set
point reached 4.2 m³ /hr, the manipulated valve was 100%, the flow rate become more stable. Besides
that, the flow rate from set point 1.8 m³ /hr increases when set point increases to 4.2 m³ /hr.
Next, the dynamic response test for set point test when PB was 150%, TI1 was 10 secs and
TD1 was 0 secs showed that at first the flow rate was stable, however it becomes unstable as the set
point increases. But when the set point reached 4.2 m³ /hr, the manipulated valve was 100%, the flow
rate become more stable. Besides that, the flow rate from set point 1.8 m³ /hr increases when set point
increases to 4.2 m³ /hr. However, when it was compared based on the PID setting, the oscillatory of
the dynamic response of each graph of figure 2 (when PB was 100%, TI1 was 5 secs and TD1 was 0
secs) was much more oscillatory and unstable then the dynamic response of each graph of figure 3.

Two trials conducted with different value of proportional band showed different observation.
The first trial was set with PB = 100% while the second trial set point with PB = 150%. From the
graph obtained, it can be conclude that the larger the proportional band, the more stable the control,
less oscillation but the greater the offset. In fact, the narrower the proportional band, the less stable the
process but the smaller the offset. As the proportional band is reduced, the controller response to any
change in measurement becomes greater and greater. At some point depending upon the characteristic
of each process, the response in the controller will be large enough to drive the measurement back in

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the opposite direction so far as to cause constant cycling the measurement. This proportional band
valued is a limit on the adjustment of the controller in that loop.
On the other hand, if too wide a proportional band is used, the controller response to any
change in measurement is too small and the measurement is not controlled as tightly as possible.
However, as the set point increases, the MV increases and there was deviation of response in each
change of set point. In both set point trial, it can observe that the second (PB = 150% and TI1 = 10
secs) trial have satisfactory response than the first trial second (PB = 100% and TI1 = 5 secs). This is
because of the increases of PB and TI percentage value in the second trial.
Based on the theory, it was stated that increases in PB improved the damping, and the
response will be more stable. For first trial, it may control the lower flow rate and for higher flow rate,
the response may be too oscillatory. To damp out the oscillatory, the PB and TI1 should be increases.
Furthermore, by using the PID controller, it eliminates the offset remaining error. Integral actions give
a steadily increase of the corrective action as long as an error will continue to exist. It can compare
when the TD was remains constant and the value of TI was changed from 5s to 10s, the adjustable
parameter for the integral is termed’ repeats per minute” which the number of times per minute that
the integral action output changes by the proportional output.
The mode of the equipment was changed to the cascade mode caused the flow to be
maintained at a specific value. The cascade control accounts for the disturbances in the primary
variable more quickly. By the definition, ratio control used to maintain the relationship between two
variables to control a third variable. In contrast it is to maintain the flow rate of one stream in a
process. In the ratio control, the output changed was the ratio factor.

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7.0 CONCLUSION
According to the results of the two set point trials, it can be said that the broader the
proportional band, the more stable the control, the less oscillation, but the greater the offset, and vice
versa. This is because a smaller proportional band makes the controller more responsive to changes in
measurement. As the PB and TI % values increased in the second experiment, it may be concluded
that the second trial had a more satisfactory results than the first trial. The flow was kept constant
when the experiment was switched to cascade mode because the cascade control immediately corrects
for changes in the primary variable. The plant ratio was equal to the equipment ratio when the
instrument ratio, R=1.8, was conducted for a single WF pump, but when two WF pumps were used,
the plant ratio was lower than the equipment ratio. Due to the system's failure to completely remove
the mistake when the disturbance was applied and two WF pumps were involved, the PV was not
equal to the SV. Overall, it can be concluded that Cascade control performs significantly better
because the flow disturbance is immediately fixed.

8.0 SUGGESTIONS AND RECOMMENDATIONS

To avoid the potential mistakes, there were suggestions. Prior to starting the experiment, the
instrument needs to be checked and maintained as there might be a pipeline leaks could affect the
flow ratio measurements. The start up procedure must be done thoroughly to make sure to the valves'
configuration to ensure that nothing is misconfigured and causes errors. In order to correct errors that
result in inconsistent data being reported, the valve opening should also be examined. It s important to
wait until the data stabilised to avoid an unexpected trend in the results. In addition, the instrument
should be checked to make sure it is performing at its best. Consequently, the optimum desired
outcomes may be achieved. Lastly, Students need to read the laboratory manual and fully understand
the experimental procedure before conducting the experiment in order to conduct it correctly and
obtain more accurate results.

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9.0 REFERENCES
Cascade Control - an overview | ScienceDirect Topics. (n.d.). Retrieved December 13, 2022, from
https://www.sciencedirect.com/topics/engineering/cascade-control

Editorial Staff. (2020, March 9). How a Orifice Measures Flow ? Inst Tools. Retrieved on 16th
December 2022 from https://instrumentationtools.com/how-a-orifice-measures-flow/

Editorial Staff. (2019, July 16). What is Ratio Control ? Inst Tools. Retrieved on 16th DecembER 2022
from https://instrumentationtools.com/ratio-control/

Luthor, L. (2003, November 17). Vortex flowmeters from China, Vortex Flowmeters Manufacturer &
Supplier ... Vortex flow valve. Retrieved December 16, 2022, from
https://www.artang.com/vortex-flowmeters.html

Mortenson, T. (2022, October 28). What is a Control Valve? PLC Programming Courses for Beginners
| RealPars. Retrieve on 16th December 2022 from https://realpars.com/control-valve/

What is a Rotameter? (n.d.). Retrieved December 13, 2022, from

https://www.youngcalibration.co.uk/news/what-is-a-rotameter

WHAT IS RATIO CONTROL ? - The Engineering Concepts. (n.d.). Retrieved December 13, 2022,
from https://www.theengineeringconcepts.com/what-is-ratio-control/

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