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LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
REVISION NO:
1
1
29 SEPT
2014
AMENDMENT
DATE:
COURSE CODE
EXPERIMENT NO.
EXPERIMENT TITLE
EXPERIMENT 7
Level Flow Process Control (Electronic)
DATE
GROUP NO.
LECTURER/INSTRUCTOR/TUTOR
1)
2)
ATTENDANCE/PARTICIPATION/DISIPLINE:
/5%
INTRODUCTION:
/5%
PROCEDURE:
/5%
RESULTS& CALCULATIONS
ANALYSIS
DISCUSSIONS:
ADDITIONAL QUESTIONS
CONCLUSION
/15%
SUGGESTIONS& RECOMMENDATIONS
/5%
REFERENCES:
/5%
TOTAL:
EXAMINER COMMENTS:
/15%
/20%
/15%
/10%
/100%
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
1
1
EFFECTIVE DATE:
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
(Signature)
(Signature)
(Signature)
(Signature)
1.0
2.0
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
OBJECTIVES
a)
b)
system.
INTRODUCTION
The a level-flow process control training system (Model WLF92E) consists of a
level tank, T82 and a collection tank, T81 connected with the appropriate pumps
and piping systems. Level is measured by capacitance probe element. Level tank,
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
T82 receives inflow from pump, P81. Its outflow is pumped by pump, P82 via level
control valve, LCV81 back into collection tank.
4.1
4.2
4.3
5.0
5.1
1.
2.
PROCEDURE
STARTUP PROCEDURES
Turn on the main power supply switch. All panel instrument will lit up
Check the various manual valve as follow
All pumps (P81 & P82) suction, and discharge valves are fully
opened
Manual by-pass valve for each pumps is shut.
Control valve positioners (PP) must be selected.
Bottom drain valves of tank T81 and T82 always shut
Open overflow valves for Tank T82 and T81
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
3. There are two controller FIC81, LIC81 and recorder LFR81 in front of
the panel. Be familiar with their basic operation before proceed with
the experiment.
Make sure the two controllers VIC81, LIC81 are both in their
Setpoint
Proportional Band %
Intergral time, sec
Deriavetive time, sec
High Alarm
Low Alarm
Lic81 : UY350
SP
400mm
1.P
20%
1.I
20sec
1.d for
OFF
A1(for AL 1)
600mm
A2(for AL 2)
100mm
With both controller in MANUAL (M) mode, set their control output
at 50%. Check the valve position at FCV81 and LCV 81 are both
5. Please noted:
At tank T82, note the Level ruler and the Level: 0mm is just
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
valves are not fully opened. Shut fully pump bypassvalve B82
TANK T82
6. At the controller FIC81, set SV = 1.2 m3/Hr. Switch FIC81 to AUTO
(A) mode
7. Please noted:
Tank T82 is non-Self Regulating and can overflow if the inflow
5.2
RESULT FOR LEVEL MEASUREMENT
1. Take the level reading at various set point at LIC 81 when:
a. Pumps P81, P82 are ON and LIC is AUTO mode. FIC is in
MANUAL mode and MV= 50%
b. Pumps P81, P82 are OFF and LCV81 and one of the adjacent
valve is fully shut
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
5.3
LEVEL MEASUREMENT
1. Set FIC81 with MV = 50% so the control valve is opened to 50%
2. Please note that the experiment is conducted with LIC81 in AUTO (A)
mode using various setpoint (SP) of 200, 400, 500 and 700mM
PART A:
a) With the SP of LIC81 at 200mm in AUTO mode, wait till the level PV
in LICD81 is steady at its SP.
b) Take the level reading at LIC81 and LFR81. Also take the level
measurement at the tank ruler.
c) Mark on the chart paper on the RED color that SP=200
d) Take a second set of reading when the level is not fluctuating and PV
is
PART B
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
a)
b)
c)
a)
b)
c)
2.
display panel.
Switch the flow controller FIC81 to Manual (M) mode and manually
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
disturbance test
Observe the level response of Red pen at LFR81 until it is
steady at it set point or continues to oscillate even after 3
cycles.
b. Outflow load step change or disturbance
LIC81 still in AUTO mode, SP = 400mm with same PID
value
Switch LIC81 to MANUAL mode, note that the SP value
display 0. Manually step increase or decrease the output
0 by about 30% and then switch back to AUTO mode. This
ii.
Level control with faster PI
LIC81 SP = 400mm, 1.P = 5%, 1I = 15 sec, 1. d = OFF
LIC81 still in AUTO mode, repeat test disturbance 4(I)(a)
and (b) with faster set of PID value than the DEFAULT
values, but without derivative control mode as follow:
o LIC81 , SP = 400mm , P = 5%, I = 15sec, d = OFF
o Observe the level response
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
3. The level remain unchanged over a very short Dead time and then rise
in straight line. Becautioned that the process is integrating and will
rise till level overflows.
Timetaken, secs=
500 mm/ Hr
1 Hr
time ( TI,secs )
100
0.9
p
DTxRR
5.5
SHUTDOWN PROCEDURE
6.0
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
RESULTS &CALCULATIONS
READINGS
LIC81 : PV
a) 200mm
b) P81, P82 OFF
LCV81/Manual
valve shut
B
a) 400mm
b) P81,P82 OFF
LCV81/Manual valve
shut
C
a) 500mm
b) P81,P82 OFF
LCV81/Manual
valve shut
a) 600mm
Engineering Unit
mm
LFR81
Red Pen
Channel 1
%
mm
T82
Ruler
mm
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
REVISION NO:
1
1
29 SEPT
2014
AMENDMENT
DATE:
b) P81,P82 OFF
LCV81/Manual
valve shut
Table 2: Level Measurement Result
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.
ii.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
EFFECTIVE DATE:
1
1
REVISION NO:
29 SEPT
2014
AMENDMENT
DATE:
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.
9.0
10.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter
based)