Laboratory ERT 321 Sem II 20182019

ERT 321 Process Control & Dynamics Sem II 2018/2019
LAB SCHEDULE
WEEK SESSION EXPERIMENT 1 /GROUP INSTRUCTORS
WEEK 3 THURSDAY 2.30 – 4.00PM 1-8 MRS. HAFIZAH

18-22/2 21/02 4.00-5.30PM 9-16
EXPERIMENT EXPERIMENT
2 /GROUP 3/GROUP
WEEK 4 TUESDAY 12.00 – 1.20 PM 1 2 MRS. HAFIZAH

(25 /2- 26/02 MR. LEE BOON BENG
1.20 – 2.40 PM 3 4
1/3)
THURSDAY 2.30 – 3.50PM 5 6 MRS. HAFIZAH
28/02 DR. RAHIMAH OTHMAN
3.50- 5.10 PM 7 8
DR. WAN KHAIRUNNISA
5.10-6.30PM 9 10
(4-8/3) 05/03
1.20 – 2.40 PM 14
13 MR. LEE BOON BENG

3.50- 5.10 PM 2 1
DR. WAN KHAIRUNNISA
5.10-6.30PM 4 3
(11- 12/03 MR. LEE BOON BENG
1.20 – 2.40 PM 8 7
15/3)
3.50- 5.10 PM 12 11
DR. WAN KHAIRUNNISA
5.10-6.30PM 14 13
(18- 19/03 MR. LEE BOON BENG
1.20 – 2.40 PM
22/3)
WEEK 8 MID SEMESTER BREAK
(25-
29/3)
WEEK 9 LAB TEST (HANDS-ON)
(1-5/4)
EXP 1: INTRODUCTION TO PROCESS CONTROL SYSTEM

EXP 2: AIR PRESSURE CONTROL SYSTEM
EXP 3: LEVEL CONTROL SYSTEM
Reminder:
Student attendance to lecture/tutorial/lab is MANDATORY. Failure to do so without any relevant
justification will cause he/she to be barred from taking the examination.
ERT 321 Process Control & Dynamics Sem II 2018/2019
LAB GROUPING
GROUP
Group 1 Group 9
'UZAIR BIN ISHAK LEONG SIEW MEI
GHEETHA A/P CHINAPAN MUHAMMAD ASYRAF BIN ABU HASAN
LOOI YEE TENG NOORSYAZLINA BINTI AHMAD ROZI
MAISARA ATASSHA BINTI AZMI NOR ARINA IZZATI BINTI JASMAN
Group 2 Group 10
NUR FARHANA NAJWA BINTI NASARUDDIN NUR FARHAH HIKMAH BINTI RADZI
NUR HANISAH BINTI AMRAN HENG PEY SHI
NESHAANTHNY A/P MARDAIYAH CHEONG YI XIN
MUHAMMAD FAHMI SAFUAN BIN MOHD YUSOFF NABILAH SHAFIQAH BINTI ABU HASSAN
Group 3 Group 11
PHOON KIN CHUNG SHAHRIL NIZAM BIN KALBEH
SHARIFAH NAZURA BINTI SYED SABEER ALI NURUL HUSNA BINTI MOHD RAZALI
SARAH QISTINA BINTI ZALIMAN NG WEI JIE
SIEW JIN YEE NURUL AZIERAH BINTI RAZALI
Group 4 Group 12
NUR MAHIRAH BINTI MAZLAN SITI HAJAR BINTI MOHD SALEH
NURAIFAA NAZIHAH BINTI RAMBELI NOR FATIHAH BINTI MOHD HUSIN
NG KAH MUN TAN YEE YUN
TANUSHA BINTI IMRAN SHAH @ TAMIL SELVAN TUAN MOHD AIDIL ASHRAF BIN TUAN RAMLI
Group 5 Group 13
SITI NAJIHAH BINTI BADERUL HISHAM TEO SHARON
YAP KAH YAN SUHAILA BINTI OTHMAN
YUSRINA YASMIN BINTI MOHD YUSOF NG NORNAZIHAH BINTI ZAKARIA
ABDULLAHI HAGAR FARAH ZARUL SYAZWAN BIN ZULKIFLI
Group 6 Group 14
NUR HIDAYAH BINTI MOHAMAD ISA NUR HANI SOFEA BINTI MOHD PADHLI
MADIHAH NAIM BINTI MUSTAPA ZATI SYARAFINA BINTI SHAHARUDDIN
NOOR AFZA BINTI BURHANUDDIN KHAIRUL MUZZAMMIL BIN BERHANUNDIN
GAYATHIRI A/P MUNIANDY LOO EUNICE
Group 7 Group 15
LAU KUAN YEE LAI JIAN YU
NOR ARIFAH IZZATI BINTI JOHARI NADIA AQILAH BINTI KHALID
NURUL AIN BINTI MOHD RUSLI NOR AQILAH MUSFIRAH BINTI YUSRI
FARAH DHIA BINTI ABDUL KARIM SITI NAJWA BINTI HANAFI
AARON LEE WENG HOE
Group 8 Group 16
SRI ANIS AZIRA BINTI MD AMIN NURUL AINSYAH BINTI AHMAD
BRYAN TANG JITT JYMM SITI NUR MARIANA BINTI ABDUL RAMAN
AYU LIYANA BINTI ABDUZAIDI ANIES SYAFIRA BINTI MOHD ROSLI
NUR SYAHIRAH BINTI MOHD SHAARI ANG SHU YING
ERT 321 Process Control and Dynamics Laboratory Module
Sem II 2018/2019
EXPERIMENT 1
INTRODUCTION TO PROCESS CONTROL SYSTEM
1.0 OBJECTIVE
1. Understand the basic concept in process control system

2. Identify the important process control terminology
3. Identify the major component of process control loop
2.0 INTRODUCTION
Process control engineering has been applied in most technologies. The majority of the
industrial processes use it to some extent. Food industries, wastewater treatment plants,
mining facilities, and the automotive industry are just a few industries that benefit from
automated process control systems. Maintaining process variables such as pressure, flow,
level, temperature, pH and concentration within a desired operating range is of the utmost
importance when manufacturing products with a predictable composition and quality.
2.1 Fundamental concept of process control
A feedback loop is a common and powerful tool when designing a control system. Feedback
loops take the system output into consideration, which enables the system to adjust its
performance to meet a desired output response. In feedback control, the objective is to reduce
the error to zero.
Basic Process Control Block diagram
A process control loop consists of four control blocks which are controller, final control
element (FCE), process and sensor. Closed loop system is a process control when all of the
four blocks are connected whereas the open loop system is a process control when any of the
blocks is disconnected.
Figure 1: Block diagram for Close loop control system
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The main task of the feed-back control system is to maintain the process error as close to zero
as possible even when there are disturbances.
.
PID control
A Proportional –Integral-Derivative controller is widely used in feedback control of industrial

processes. A PID controller continuously calculates an error values as the difference between
the measured process variable and the desired setpoint. The controller attempts to minimize
the error over time by adjustment of the control variable such as the position of a control
valve, the damper, or the power supplied to a heating element. PID controllers have three
control modes and each of the three modes reacts differently to the error.
Table 1: key Characteristics of Commercial PID Controllers
Controller Function Controller Symbol Units

Parameter
Proportional The function of a Proportional Kc Dimensionless
Mode, P proportional control is to gain
anticipate the present error
and the controller output is
Proportional PB = 100/ Kc %
proportional to the error
band
signal. A type of control
that is prone to leave an
offset.
Integral The function of integral Integral time ɼI Time (min,s)

Mode, I control is to anticipate on
the accumulation of past
error and the controller Integral gain KI Time-1(min-
1 -1
output depends on the ,s )
integral of the error signal
over time. A type of
control that corrects error
and eliminates offset.
Derivative The function of derivative Derivative time ɼD Time (min,s)

Mode, D control is to anticipate the
future behaviour of the
error signal by considering Derivative gain KD Time (min,s)
its rate of change. A type of
control that achieve rapid
response to major
disturbance but produces
erratic output in fast
processes.
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The amount of response produced by each control mode is adjustable by changing the
controller’s tuning settings. Each process is unique. Different processes response differently
to different PID setting. The response of the controller can be describes in terms of its
responsiveness to an error, the degree to which the system overshoot a set point, and the
degree of any system oscillation.
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LABORATORY ASSIGNMENT
(ERT 321 PROCESS CONTROL AND DYNAMICS)
EXPERIMENT 1
INTRODUCTION TO PROCESS CONTROL SYSTEM
Name:
Matrix No.:
Date:
1. Briefly define each term.
• SETPOINT /SET VALUE (SV)
Definition:
• ERROR
Definition:
• OFFSET
Definition:
• CONTROLLED VARIABLE (CV)
Definition:
• MANIPULATED VARIABLE (MV)
Definition:
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• PROCESS VARIABLE (PV)
Definition:
• LOAD DISTURBANCE
Definition:
2. There are four basic items in a control loop system. Briefly explain the function of each
term and give example:
• PROCESS
Function:
Example:
• SENSOR/TRANSMITTER/TRANSDUCER
Function:
Example:
• CONTROLLER
Function:
Example:
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• FINAL CONTROL ELEMENT
Function:
Example:
3. Walk around the Air Pressure Process Control System (AP922). Refer to Experiment
2 (Air Pressure Control System) laboratory module. Get familiar with the equipment and the
control system and instrumentation. Identify the major component of the process control loop
system and draw the block diagram.
Process: __________________________________________________
Sensor/Transmitter: __________________________________________________
Controller: __________________________________________________
Final Control Element: __________________________________________________
Control Loop: __________________________________________________
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4. Walk around the Level Flow Process Control System (WLF922). Refer to Experiment
3 (Level Control System) laboratory module. Get familiar with the equipment and the control
system and instrumentation. Identify the major component of the process control loop system
and draw the block diagram.
Process: __________________________________________________
Sensor/Transmitter: __________________________________________________
Controller: __________________________________________________
Final Control Element: __________________________________________________
Control Loop: __________________________________________________
5. What is the different between Open Loop and Close Loop system? Give an example.
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AIR PRESSURE CONTROL SYSTEM
1.0 OBJECTIVE
1. To identify the important components of the air pressure control system

2. To study the response of gas pressure control using P Controller, PI Controller and PID
controller.
2.0 INTRODUCTION
Pressure vessels play an important role in chemical industries as storage vessels for gas phase
components. Precise control of pressure in the pressure vessels is necessary in order to
maintain a constant concentration of components in the vessel, to maintain the number of
moles in the vessel, and to protect the vessel from being damaged due to very high pressures.
The equipment uses in this experiment is the air pressure process control training system,
Model AP922. This model, AP922, uses AIR to simulate a gas phase pressure process.
3.1 EXPERIMENTAL EQUIPMENT
a) The process plant consists of two air vessels T91 and T92 with the associated piping,
valves and fittings.
b) An external air supply from the compressor air system is connected to the Model plant at
the process inlet at the pressure regulator, AR91, into the vessel T91. This inlet pressure
(Barg, psig) is preset according to the pressure indicated at AR91, with its downstream
manual valve MV91 shut. The maximum inflow rate can be varied by regulating the
manual valve MV91 immediately downstream of AR91.
c) The process air inlet flows into T91 and then along pipeline PLI-T92-FI92-PCV91-
discharge via the process vent valve VP. The process air also flows from T92 along
pipeline PLII-PCV92-discharge via either manual globe valve MV92A/orifice OR
manual gate valve MV92B.
The pressure in T91 is also measured by a gauge pressure transmitter PT91 and
controlled by PID pressure controller PIC91, which throttles control valve PCV91 via the
Current (4-20mA) to Air (3-15 psig) converter, PCY91 and the pneumatic positioner
(PP). Control valve PCV91 is ATC (Air-to-Close) .The process air finally discharges to
atmosphere via the process vent VP through PCV91 and the variable area flowmeter
FI92.
d) The pressure measured by the gauge pressure transmitter PT92 is controlled ON/OFF by
the ON/OFF pressure controller PIC92. PIC92 will switch to close the normally-open
(NO) solenoid valve PSV92, when the preset high pressure limit is exceeded. The
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ON/OFF control valve PCV92 is ATC (Air-to-Close). Thus when the pressure in T92 or
its discharge pipeline is above the preset high limit, PIC92 switches to close PSV92,
cutting off the instrument air supply to the actuator of PCV92. PCV92 then opens to vent
(V) air to the atmosphere. The rate of discharge can be manually set at the manual valves
(MV92A, MV92B) at the common vent line (V) downstream of PCV92.
e) Note that both the control valves PCV91 and PCV92 are Air-to-Close (ATC) so that
when there is instrument air failure, they stay open to vent out any pressure inside the
plant.
3.2 CONTROL SYSTEM AND INSTRUMENTATION
The control system consists of a microprocessor based PID controller with an inbuilt ON/OFF
controller. It is equipped with the necessary instrumentation and signal transmission system. A
brief description of the control system and the major instrumentation is given below:
PT91 : Gauge Pressure Transmitter. Calibrated Range: 0-25 psig

Measures air pressure in T91
PCV91 : Pressure control valve ½”. Air-to-Close (ATC).

Regulated by PID controller PIC91 or PIC92
PP : Pneumatic Positioner, with By-pass.
PCY91 : Current-to-Air Converter (I/P) : 4-20mA to 3-15 psig
PSV92 : Solenoid valve, Normally-Open (NO)
PCV92 : ON/OFF pneumatic control valve, Air-to-Close (ATC).

PCV92 is opened by ON/OFF controller PIC92 via PSV92,
when the pressure measured by PT91 is above its preset high
pressure limit.
PG91, PG92, PG93, PG94 : Pressure Gauges
TG91, TG92 : Temperature Gauges
FI92 : Variable area flowmeter (Rotameter). Metal construction

safety type.
PRV91, PRV92 : Pressure Relief Valves
SV91 : ON/OFF Solenoid Valve
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The Annunciators are:
PAD91 : The pressure at T91, measured by PT91, exceeds its preset Deviation
from the setpoint, whether above or below. The Deviation alarm limit
is set at DL1 at the “PID1” page or panel.
PAL91 : The pressure at T91, measured by PT91, drops below its preset Low
alarm limit. The Low alarm limit is set at PL1 at the “PID1” page or
panel.
3.3 EXPERIMENTAL PROCEDURE
3.3.1 START UP PROCEDURE
1.
Switch the "PANEL, SCADA/DDC" selector switch at the front of the cubicle to the
"PANEL, SCADA" position. Switch ON the main power supply at the front of the
cubicle. All the panel instruments will lit up.
2. Make sure the Instrument Air Supply (IAS) or AR91 is set at 26-28 psig. Adjust the
manual valve MV91 till rotameter FI92 is at flow rate of 30Nm³/Hr max. DO NOT
exceed the stated flow rate.
3. Make sure the valve Positioner (PP) at PC91 is ON and connected. With PIC91 in
Manual (M) mode, stroke the control valve PCV91 manually with MV = 100%, 50%
and 0% and note that the corresponding valve stem position at its stem indicator scale
is 0%, 50% and 100% opened.
4. With PIC91 in the Manual (M) mode, open the control valve PCV91 fully with
MV= -6.3%. For confirmation, check the control valve stem position at PCV91.
Take note of the minimum pressure PV1 (in PIC91). Concentrate on the Pressure PID
panel controller PIC91/PIC92 and the recorder PR91.
5. Check that vessels T91 and T92 are connected for air to flow in series from one vessel
to the next. Check their respective pressure at the pressure gauges PG91 and
PG92.The reading at the pressure gauges PG91 and PG92 should be the same with
reading at the panel controller PIC91/PIC92. The manual By-pass valve B92 around
T92 should be fully shut. The final manual discharge valve (VP) downstream of the
pressure control valve PCV91 should be fully opened.
3.3.2 PID CONTROL OF PRESSURE IN TWO CAPACITY PROCESS
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1.
Make sure that you have gone through the START-UP procedures very carefully. For two
capacity process, vessels T91 and T92 are connected.
2. Start the recorder PR91 by pressing the ‘RCD’ pushbutton at the front of the recorder
with its swing front cover opened. Note that PT91 response is shown by the Red
pen (Channel 1), Input Range: % of 0-25 psig.
NOTE:The Recorder chart speed is occasionally printed on the chart, for example at
500 mm or 0.139 mm or 7.2 secs
Hr sec mm
3. Adjust the setpoint SV to 15 psig at PIC91. Make sure the chart drive of the recorder
PR91 is running.
4. Access the PID values in the pressure PID controller PIC91, at the PID1 page or
panel. Set the following first (I) trial PID values.
PB1 = 70 %, TI1 = 40 secs, TD1 = 0
5. Transfer PIC91 to Auto (A) mode and watch the response at the recorder PR91 till it
is steady or continues to oscillate even after 3 cycles or approximately 3 min.
6. Apply the load step test (disturbance) as follows:

When the response is steady, switch PIC91 to Manual (M) mode and decrease its MV
by 10 (For instance, if current MV value is 60.5, reduces it to 50.5). Quickly switch
PIC91 back to Auto (A) and observe the pressure response at the recorder PR91 till it
is almost steady to within ± 0.1 psi, or continue to show oscillatory response even
after 3 cycles (approximately 5 mins). The chart recording constitutes the results of
your experiment. Note down on the chart the PB1, TI1, TD1 and SV values.
7. DO NOT FORGET TO NOTE DOWN ON THE CHART THE PB1, TI1, TD1
AND SV VALUES ON THE CHART PAPER WHENEVER THE VALUES ARE
CHANGED. ALSO MARK ON THE CHART WHENEVER THE LOAD STEP
TEST (DISTURBANCE) IS APPLIED.
8. Continue the experiment using the different PID settings:
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PIC91 PID Pressure Control of T91/92
PID (% ,s ,s) Setpoint Type of Disturbance

Values (psig)
PI setting:
70/40/0 15 Load step test
40/20/0 15 Load step test
Load step test
P Control only: Load step test
40/9999/0 15
.
PID setting:
15 Load step test
70/40/10
3.3.3 SHUTDOWN PROCEDURE
1. Shut MV91 but do not adjust AR91.

2. Switch PIC91 to Manual (M) mode with its MV = 0%
3. Shut fully the isolation manual valve at the main air supply line to Model
AP922.
4.0 LABORATORY REPORT GUIDELINE
Laboratory report should be HANDWRITTEN and INDIVIDUAL. Report is due ONE

WEEK after performing the experiment. Laboratory report should contain:
a) FRONT PAGE
• Course ( ERT 321 Process Control and Dynamics), experiment title, name, group,
date of experiment, date of report submission
b) EXPERIMENTAL OBJECTIVE
• State the objective of the experiment
c) EXPERIMENTAL PROCEDURE
1. List down the major component of the process control loop system and draw the
block diagram.
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2. Experimental Parameter
• Summarize the experimental parameter in table form
PID (% ,s ,s) Setpoint, Type of Disturbance
Values (psig) (state the change of the MV )
c) RESULTS
Relevant portions of the recorder chart responses should be submitted as results of the
experiment, with the following pertinent data marked on the corresponding chart recording:-
• Setpoint (SV), PB%, TI seconds, TD seconds, and disturbance applied.
GAS PRESSURE PID CONTROL: PIC91
Process for Single loop : 2-Capacity

PIC91 Setpoint(SV1): __ psig
PIC91: PB1: ________ %, TI1: ________ seconds, TD1: ________ seconds
Type of Disturbance (state the change of MV values if load step test is done):
______________________________________
(Enclose the respective portion of the chart response here)
Pressure control is an underdamped process. Calculate the SETTLING TIME, TIME TO

FIRST PEAK, AND PERIOD OF OSCILLATION(if any) .
Hr sec mm
Hint: Refer to textbook Seborg, D.E., Edgar, T.F., Mellicamp D.A.(2011).”Process Dynamic
and Control” JohnWiley, 3rd Edition . Look up for ‘Settling time’ in the Index and find the
relevant information needed.
• NOTE: REPEAT THE ABOVE ANALYSIS FOR OTHER PID SETTINGS
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d) QUESTIONS
Answer all following questions:
a) What is the purpose of testing the PID at different setpoint?
b) Study and compare the different pressure responses for different PID values:
1. For P control only, does the PV reach the setpoint? If not, state the error (PV-SV) and
briefly explain why. Suggest how you can solve the problem.
2. For PI control, what happens if you increase the controller gain (Kc ) parameter?
(Note: PB= 100/ Kc , discuss base on the settling time, time to first peak, period of
oscillation)
3. For PI control, what happens if you decrease the time integral (ɼI) parameter?
(Note: Discuss base on the settling time, time to first peak, period of oscillation)
4. What happen when Derivative control is added? In your opinion, is PID a good
controller for gas pressure control? State your reason(s).
c) Justify the purpose of process control and why it is important.
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EXPERIMENT 3
LEVEL CONTROL SYSTEM

1.0 OBJECTIVE
1. To identify the important components of the level control system

2. To study the response of level control using PI Controller and PID controller.
2.0 INTRODUCTION
Level control application is an important system in many industries process such as petro chemical and
water treatment where the industries use the tank system to control the liquid level. The liquid level must
be controlled by the proper controller. The objective of the controller in the level control is to maintain a
level set point at a given value and be able to accept new set point. The conventional proportional-
integral- derivative (PID) is commonly utilized in controlling the level. In this experiment, water is used
to stimulate liquid phase physical processes.
3.1 EXPERIMENTAL EQUIPMENT
a) The process consists of a level tank T31 and a collection tank T32 connected with the appropriate
pumps and piping system. Water is pumped by pump P32 from tank T32 into T31.
b) T31 can be operated as an Open or Closed Tank. To operate T31 as an Open tank, the top vent (V)
and overflow drain (D) manual valves are opened, so that the top space of T31 is at atmospheric
pressure. In this experiment, the T31 is operated as an Open tank.
3.2 CONTROL SYSTEM AND INSTRUMENTATION
Field-Mount Instruments: Transmitters, Control Valve, Gauges, etc
LT31 : Differential Pressure (DP) Level Transmitter

Measures level of tank T31, Open or Closed.
Calibrated Range = -800 to 0mm Water Gauge (WG)
Impulse line from the top space of T31 to the low pressure
chamber of LT31 must always be completely filled with water.
Transmitted to LIC31.
FE31 : Orifice plate connected to FT31
FT31 : Differential Pressure (DP) Flow Transmitter with square root

function
Calibrated for 0-3.0 m3/Hr
Transmitted to FIC31
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LCV31 : 1” Control Valve, Air-to-Open (ATO)
PP : Pneumatic Positioner (PP) for LCV31, with By-pass.
LCY31 : Current-to-Air Converter

Converts 4-20 mA to 3-15 psig proportionally for PP/LCV31
LS32 : Conductivity Level Switch with three conductivity probes :
PG31, PG32 : Pressure Gauges
SV31 : Solenoid Valve, normally open (NO)
PRV31, PRV32, PRV33 : Pressure Relief Valves
Panel-Mount Instruments and Annunciators
LIC31/FIC31 : One unit panel Controller configured for:-

• LIC31-Loop 1, PID1, Level PID Controller
• FIC31-Loop 2, PID2, Flow PID Controller
• In Cascade mode, LIC31 is the primary, FIC31 is the
secondary.
Three control strategies can be operated as described earlier
• LIC31, Level Single Loop, PID1, Loop 1 :
LT31-LIC31-LCY31/PP/LCV31
Selector switch in Position 1: LIC31.
LIC31 in Auto (A) or Manual (M) mode.
• FIC31, Flow Single Loop, PID2, Loop 2 :
FE31/FT31-FIC31-LCY31/PP/LCV31
Selector switch in Position 2: CASCADE LIC31-FIC31.
FIC31 in Auto (A) or Manual (M) mode.
LFR31 : 2-Pen Recorder with pen/bar graph and selective display in

engineering units.
• Red pen (Channel 1): Level, Calibrated Range 0-800 mm WG
• Green pen (Channel 2): Flow, Calibrated Range 0-3 m3/Hr
: Analog display in % x Maximum (calibrated range), engineering
units = Actual reading, engineering units.
: The chart drive is set for fast speed (500 mm/Hr).
The Annunciators are:-
LAH31 : Tank level at T31 measured by LT31 exceeds the preset High level
alarm limit. The High alarm limit is set at PH1 at the “PID1” page
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FAL31 : Inflow to T31 measured by FE31/FT31 is below the preset Low

alarm limit. The Low alarm limit is set at PL2 at the “PID2” page
LAH32 : Tank level at T32 exceeds the High level limit (shortest probe) of
the Level Switch LS32.
3.3 EXPERIMENTAL PROCEDURE
3.3.1 START UP PROCEDURE
1. Switch the "PANEL, SCADA/DDC" selector switch at the front of the cubicle to the "PANEL, SCADA"
position. Switch ON the main power supply at the front of the cubicle. All the panel instruments will lit
up.
2. Tank T32 should be filled with water up to and just below the level of the shortest level probe (not
visible) of the Level Switch LS32 which is slightly below the tank (T32) overflow pipe outlet. Top
up the water later whenever necessary.
3. Operate Model WLF922 independently. Open the by-pass manual valve B33 of pump P33 to divert
any flow back into T32. Shut the interconnecting pipeline from Model WLF922 to Model WT922 at
the appropriate manual valve MV-T. Also shut the manual valve MV-D at the discharge of pump
P33, leading to the drain.
4. Quickly check the various manual valves as follows:-
• All pumps (P31, P32, P33) suction, discharge and by-pass valves are fully opened.
• Operate T31 as an Open tank with the top vent (V) and overflow drain valves fully opened. The
pressurizing air inlet to T31 is isolated at its inlet manual valve (with the valve handle at 90° to
the air supply inlet tubing), located next to the preset Air Regulator AR31 near the top of tank
T31.
• Operate T31 as a Self Regulating process. Open only the manual GATE valve at the gravity
discharge pipe at the tank bottom. The second manual globe valve at the second gravity
discharge pipe must remain shut, thus operating only one gravity discharge pipeline at the
bottom of tank T31.
Shut the two manual discharge valves of pump P31, one of which is at the strainer inlet.
For a Self Regulating process, pump P31 must be OFF.
• The manual by-pass valve around the control valve LCV31 should be always shut but its two
adjacent manual valves should be always opened.
• The bottom manual drain valve of T32 is always shut.
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5. Compressed air is required to operate the control valve system LCY31/PP/LCV31 and to pressurize
tank T31. Check that the pressure is in accordance to the pressure indicated at the air pressure
regulator (IAS. Do not pressurize T31 yet. Shut the pressurizing air inlet manual isolation valve.
6. Note the following switches and pushbuttons but do not switch ON any pump yet.
Pump P32 : Pumping inflow from T32 to T31. To be switched ON during

operation.
Pump P31 : Do not use unless T31 is to be operated as a Non-Self Regulating

process, in which case the bottom gravity discharge pipes of T31
must be all shut. Check that the two manual discharge valves of
pump P31 are shut.
Pump P33 : Pump P33 can be selected to either the ‘AUTO’ or ‘MAN’ position.
‘MAN’ position is the ‘OVER-RIDE P33’ position.
7. Check the Positioner (PP) manual By-pass switch at LCV31/PP. Make sure the Positioner (PP) is
connected to LCV31 i.e. do not by-pass it, but use the Positioner (PP).
• Set the 1-2 Selector switch to Position 1 to operate LIC31 and display LIC31, Loop 1
accordingly.
• With LIC31 in Manual (M) mode, adjust MV = 25%. Check that LCV31 is about 25%
OPENED (see the indicator scale at the valve stem). Also note that the control valve LCV31 is
Air-to-Open (ATO).
3.3.2 PID CONTROL OF LEVEL IN TANK 31 ( OPEN TANK AND SELF REGULATING)
1. Start the recorder, LFR31 by pressing the RCD button ON, with the front swing cover opened.
Check the recorder chart speed (500mm/Hr) which is regularly printed out on the chart. The
recorder chart drive should be stopped (press RCD) when its chart recording is not required.
2. Turn on pump 32 ONLY.
3. With the controller Selector switch in Position 1, display LIC31 faceplate at the controller. Note
that Position 1, PV1, SV1 and MV1 are displayed as PV, SV and MV in the main display page
(faceplate).
• Set the setpoint (SV1) of LIC31 to 400 mm. Note that SV1 should be operated from 200 (25%)
to 640mm (80%) only.
• Set the first (I) trial PID values at the ‘PID1’ page or panel as follows:-
LIC31 (PID1, Loop1): PB1 = 10%, TI1 = 15secs, TD1 = 0
4. Switch LIC31 to Auto (A) mode .Quickly change to the FIC31(PID2) page and make sure the
Cascade(C) mode indicator for FIC31 is lit up. Else press “C” once. Switch back to
LIC31(PID1) page.
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Sem II 20182019
5. The recorder LFR31 chart drive should be at fast speed (500 mm/Hr) with RCD ON. Check the
chart speed which is regularly printed out on the chart. Observe the level response at the red pen
until the response is almost steady to with ±1.0 mm or it displays oscillatory response even after
3 cycles. Write down the setpoint and PID values on the recorder chart paper beside its response.
These chart recordings constitute the results of your experiment and should be kept for your
reports.
6. Apply the test disturbance as follow:
• Open 1½-turn, hold for 30 seconds and shut fully the pump by-pass manual valve B32. This
simulates a load pulse disturbance test at the inflow. *LIC31 must remain in Auto (A) mode.
LIC31 (PID1, Loop1): PB1 = 10%, TI1 = 15 secs, TD1 = 0 secs
7. DO NOT FORGET TO NOTE DOWN ON THE CHART THE PB1, TI1, TD1 AND SV
VALUES ON THE CHART PAPER WHENEVER THE VALUES ARE CHANGED. ALSO
MARK ON THE CHART WHENEVER THE LOAD STEP TEST (DISTURBANCE) IS
APPLIED.
8. Continue the experiment using the different PID settings:
LIC31 PID Level Control in Tank 31
PID (% ,s ,s) Setpoint Type of Disturbance

Values (mm)
PI setting:
70/40/0 400 Load pulse test
10/15/0
PID setting: 400 Load pulse test

10/15/5
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Sem II 20182019
3.3.3 SHUTDOWN PROCEDURE
1. Stop all pumps.

2. Switch LIC31 to Manual (M) mode with its MV = 0%
3. Shut fully the isolation manual valve at the main air supply line to Model WLF922.
4.0 LABORATORY REPORT GUIDELINE
Laboratory report should be HANDWRITTEN and INDIVIDUAL. Report is due ONE

WEEK after performing the experiment. Laboratory report should contain:
a) FRONT PAGE
• Course ( ERT 321 Process Control and Dynamics), experiment title, name, group, date of
experiment, date of report submission
b) EXPERIMENTAL OBJECTIVE
• State the objective of the experiment
c) EXPERIMENTAL PROCEDURE
1. List down the major component of the level control loop system and draw the block
diagram.
2. Experimental Parameter
• Summarize the experimental parameter in table form
PID (% ,s ,s) Setpoint, Type of Disturbance
Values (mm)
d) RESULTS
Relevant portions of the recorder chart responses should be submitted as results of the experiment,
with the following pertinent data marked on the corresponding chart recording:-
• Setpoint (SV), PB%, TI seconds, TD seconds, and disturbance applied.
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Sem II 20182019
PID LEVEL CONTROL – SELF REGULATING, OPEN TANK
PROCESS: Level Single Loop, Open tank, Self Regulating

Selector switch Position: 1
Setpoint(SV1): _____ mm
LIC31 (PID1, Loop1): PB1 = ___ %, TI1 = ___ secs, TD1 = ___ secs
Type of disturbance:_______________________________________
(Enclose the respective portion of the chart response here)
Level control is an underdamped process. Calculate the SETTLING TIME, TIME TO FIRST PEAK,
AND PERIOD OF OSCILLATION (if any).
Hr sec mm
Hint: Refer to textbook Seborg, D.E., Edgar, T.F., Mellicamp D.A.(2011).”Process Dynamic and
Control” JohnWiley, 3rd Edition . Look up for ‘Settling time’ in the Index and find the relevant
information needed.
• NOTE: REPEAT THE ABOVE ANALYSIS FOR OTHER PID SETTINGS
e) QUESTIONS
Answer all following questions:
a) Study and compare the different level responses for different PID values:
1. For PI control, what happens if you increase the controller gain (Kc ) and decrease the
time integral (ɼI ) parameters?
(Note: PB= 100/ Kc , discuss base on the settling time,time to first peak, period of oscillation)
2. For PID control, compare the different PID settings.

(Discuss base on the settling time,time to first peak, period of oscillation)
3. Discuss the response when adding derivative (D) control mode. Observe the fluctuation
of the flow(green pen) and level(red pen). Is derivative control suitable?Explain why.
b) In this experiment, there are three annunciators namely LAH31, FAL31,and LAH32. Explain the
purpose of these annunciators and how the work.
c) On-OFF control is another feedback control. Explain in brief.

Laboratory ERT 321 Sem II 20182019

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Laboratory ERT 321 Sem II 20182019

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ERT 321 Process Control & Dynamics Sem II 2018/2019

WEEK SESSION EXPERIMENT 1 /GROUP INSTRUCTORS

WEEK 3 THURSDAY 2.30 – 4.00PM 1-8 MRS. HAFIZAH

WEEK 4 TUESDAY 12.00 – 1.20 PM 1 2 MRS. HAFIZAH

THURSDAY 2.30 – 3.50PM 15 16 MRS. HAFIZAH

EXP 1: INTRODUCTION TO PROCESS CONTROL SYSTEM

INTRODUCTION TO PROCESS CONTROL SYSTEM

1. Understand the basic concept in process control system

2.1 Fundamental concept of process control

Basic Process Control Block diagram

Figure 1: Block diagram for Close loop control system

A Proportional –Integral-Derivative controller is widely used in feedback control of industrial

Table 1: key Characteristics of Commercial PID Controllers

Controller Function Controller Symbol Units

Integral The function of integral Integral time ɼI Time (min,s)

Derivative The function of derivative Derivative time ɼD Time (min,s)

(ERT 321 PROCESS CONTROL AND DYNAMICS)

INTRODUCTION TO PROCESS CONTROL SYSTEM

1. Briefly define each term.

• SETPOINT /SET VALUE (SV)

• CONTROLLED VARIABLE (CV)

• MANIPULATED VARIABLE (MV)

• PROCESS VARIABLE (PV)

• FINAL CONTROL ELEMENT

Control Loop: __________________________________________________

Control Loop: __________________________________________________

AIR PRESSURE CONTROL SYSTEM

1. To identify the important components of the air pressure control system

3.1 EXPERIMENTAL EQUIPMENT

3.2 CONTROL SYSTEM AND INSTRUMENTATION

PT91 : Gauge Pressure Transmitter. Calibrated Range: 0-25 psig

PCV91 : Pressure control valve ½”. Air-to-Close (ATC).

PP : Pneumatic Positioner, with By-pass.

PCY91 : Current-to-Air Converter (I/P) : 4-20mA to 3-15 psig

PSV92 : Solenoid valve, Normally-Open (NO)

PCV92 : ON/OFF pneumatic control valve, Air-to-Close (ATC).

PG91, PG92, PG93, PG94 : Pressure Gauges

TG91, TG92 : Temperature Gauges

FI92 : Variable area flowmeter (Rotameter). Metal construction

PRV91, PRV92 : Pressure Relief Valves

SV91 : ON/OFF Solenoid Valve

The Annunciators are:

3.3 EXPERIMENTAL PROCEDURE

3.3.1 START UP PROCEDURE

3.3.2 PID CONTROL OF PRESSURE IN TWO CAPACITY PROCESS

6. Apply the load step test (disturbance) as follows:

8. Continue the experiment using the different PID settings:

PIC91 PID Pressure Control of T91/92

PID (% ,s ,s) Setpoint Type of Disturbance

3.3.3 SHUTDOWN PROCEDURE

1. Shut MV91 but do not adjust AR91.

4.0 LABORATORY REPORT GUIDELINE

Laboratory report should be HANDWRITTEN and INDIVIDUAL. Report is due ONE

Process for Single loop : 2-Capacity

(Enclose the respective portion of the chart response here)

Pressure control is an underdamped process. Calculate the SETTLING TIME, TIME TO

• NOTE: REPEAT THE ABOVE ANALYSIS FOR OTHER PID SETTINGS

Answer all following questions:

a) What is the purpose of testing the PID at different setpoint?

c) Justify the purpose of process control and why it is important.

LEVEL CONTROL SYSTEM

1. To identify the important components of the level control system

3.1 EXPERIMENTAL EQUIPMENT

3.2 CONTROL SYSTEM AND INSTRUMENTATION

Field-Mount Instruments: Transmitters, Control Valve, Gauges, etc

LT31 : Differential Pressure (DP) Level Transmitter

FE31 : Orifice plate connected to FT31