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CHE373
The process plant consists of three air vessels T91, T92A and T92 with the associated
piping, valves and fittings. The air vessels are made from larger diameter standard pipe
sections. Each vessel generally has a single/multiple air inlets and multiple outlets and is to
be operated with continuous air inflow and outflow. Each vessel has its own vent (V),
bottom drain (D), pressure relief valve (PRV) and pressure gauge (PG).
b)
i.
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.
ii. The maximum inflow rate can be varied by regulating the manual valve MV91
immediately downstream of AR91.
c)
The instrument air supply regulators (IAS) should be set according to the pressure indicated
at the respective air regulators.
d)
The process air inlet flows into T91 and then along pipeline PLI-T92A-T92-FI92-PCV91discharge via the process vent valve VP. The process air also flows from T92 along pipeline
PLII-PCV90-discharge via either manual globe valve MV92A/orifice OR manual gate
valve MV92B.
i. The air pressure in T91, T92A and T92 are monitored by their respective pressure
gauges PG91, PG92A and PG92. Excessive pressures will be relieved by their respective
pressure relief valves (PRV91, PRV92A and PRV92).
ii. 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) which means it will stay open if there
is no air signal to its actuator such as during instrument air failure or during shut-down.
The process air finally discharges to atmosphere via the process vent VP through
PCV91 and the variable area flowmeter FI92.
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iii. The pressure measured by the gauge pressure transmitter PT92 is controlled ON/OFF
by the ON/OFF pressure controller PIC90. PIC90 will switch to close the normallyopen (NO) solenoid valve PSV90, when the preset high pressure limit is exceeded. The
ON/OFF control valve PCV90 is ATC (Air-to-Close).
Thus when the pressure in T92 or its discharge pipeline is above the preset high limit,
PIC90 switches to close PSV90, cutting off the instrument air supply to the actuator of
PCV90. PCV90 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 PCV90.
Note that both the control valves PCV91 and PCV90 are Air-to-Close (ATC) so that
when there is instrument air failure, they stay open to vent out any pressure inside the
plant.
iv. Furthermore, PID Air Pressure Control system can be studied:
Process:
Controlled Variable:
Manipulated Variable:
PID Controller:
PIC91 (PID1)
Control Loop:
e)
Outlet
The final process air discharge from Model AP922 is to atmosphere via its process vent VP
from T92/T92A/T91 and via its common vent V downstream of PCV90/MV92A or
MV92B.
f)
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In general, T91, T92A and T92 have their own individual vent valves which should fully
shut during normal operation.
They also have their own individual bottom drain valves which should be purged
occasionally of any condensed water vapour. Otherwise, these should remain fully shut
Trace the various discharge piping from the Model plant. The final discharge to
atmosphere is outside the building.
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Controller
PIC91 (PID1)
NOTE:
PIC91 (PID1) is configured inside the single unit of microprocessor-based PID panel
controller (Programmable).
PT92
PCV91
PP
PCY91
:
:
PSV90
PCV90
:
:
PG91, PG92,
:
P92A, PG93, PG94
TG91, TG92
Temperature Gauges
FI92
PRV91,
PRV92
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PRV92A, :
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Panel-Mount Instruments
The panel-mount instruments are listed below.
Switch the PANEL, SCADA/DDC selector switch at the front cubicle to the PANEL,
SCADA position for Panel operation.
PIC91
PR91
Chart Recorder analog inputs with pen/bar graph and selective display
in engineering units.
Red pen (Channel 1) : Pressure PT91, Calibrated range 0 - 25 psig.
Green pen (Channel 2): Pressure PT92, Calibrated range 0 - 25 psig.
Annunciators
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.
PAH92
: The pressure, measured by PT92, rises above its preset High alarm limit. The
High alarm limit is set at P01 at the PT Register page or panel.
A buzzer will come on and the respective alarm windows (PAD91, PAH92) will lit up when
the above abnormal or alarm conditions occur. Pressing the Acknowledge button will silence
the buzzer sound. The dedicated alarm window remains lit as long as its process variable is still
in the alarm condition. The alarm window light will go off when the process variable is
restored to normal.
The Test button is to test if the Annunciator alarm window lights are working.
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CONTROL
SYSTEM
SPECIAL
REMARKS
KEY PROCESS
VARIABLE
PROCEDURES
1.
Quickly check the following : Switch the PANEL, SCADA/DDC selector switch at the front cubicle to the PANEL,
SCADA position.
Switch ON the main power supply at the front of the cubicle. Power will be distributed
automatically to the control systems and instrumentation. The panel instruments will lit
up.
Also open the swing front cover of the recorder PR91 and press the RCD push button
to STOP its chart drive, if it is running. Start the recorder chart drive only during the
experiment proper.
Check that the instrument air supply are set accordingly at their air supply regulators
(IAS). Frequent and exact pressure adjustment of the IAS is not necessary. Purge
regularly all the regulators to remove any condensed water, using their bottom drain
valves.
The valve Positioner (PP) at PCV91 is ON and connected i.e. USE THE
POSITIONER
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, only if the Positioner (PP) is
connected.
Check that the by-pass valves around the two control valves PCV91 and PCV90 are
always shut but the adjacent pair of manual valves upstream/downstream of these
control valves are opened.
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2.
Check that the individual vent valves and bottom drain valves of T91, T92A and T92
are shut. Occasionally purge the bottom drain valves to remove any condensed water
vapour.
Check that the final discharge manual valve VP downstream of PCV91 is fully opened,
for air final discharge.
Both pipelines PLI and PLII must remain opened throughout unless otherwise
instructed. Check that the manual discharge globe valve MV92A at the common vent
(V) of pipeline II, downstream of PCV90 is opened but the gate valve MV92B is shut,
before proceeding further. If ever PCV90 is opened and shut during the course of the
following experiments, let the pressure response stabilise by itself. OTHERWISE, shut
MV92A as well.
Operate the pressure process using the 3 vessels T91, T92A and T92 for air to flow in
series from one vessel to the next. Check that the By-pass valves B92A and B92 around
T92A and T92 are shut, but all the direct interconnecting manual valves between T91T92A-T92 are fully opened.
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Check Pressure
With PCV91 fully shut, PV1 at PIC91 (i.e. PT91) should be 22-27 psig.
OTHERWISE, reset AR91.
Check Flowrate
With PCV91 fully open, PV1 at PIC91 (i.e. PT91) should be less than 5-6
psig and FI92 is not more than the recommended flowrate.
OTHERWISE, readjust MV91 for maximum Flowrate.
3.
Locate the Gauge Pressure Transmitter PT92 and trace its impulse lines to two pressure
tapping points:
- TP-T at T92
- TP-P at the discharge pipeline of T92
Open TP-T and Shut TP-P
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).
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5.
Concentrate on the Pressure PID panel controller PIC91/PIC92/PIC90 and the recorder
PR91.
Within the Pressure PID panel controller PIC91/PIC92/PIC90, note the following
controls:
PIC91:
PID controller for PT91 throttling the control valve PCV91 to control
the pressure PT91 at T91, in a 3-Capacity pressure process comprising
T91/T92A/T92/discharge Pipeline T92 to PCV91.
1-2 Position:
Selector
Switch
Start the recorder PR91 by pressing the RCD pushbutton at the front of the recorder with
its swing front cover opened. Note that
PT91: Red pen (Channel 1), Input Range: % of 0-25 psig.
Channel 1 is in psig
The recorder chart drive is preset for fast speed (500mm/Hr).
6.
Check that vessels T91, T92A 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, PG92A
and PG92. The manual By-pass valves B92A and B92 around T92A and T92 should be
fully shut. The final manual discharge valve (VP) downstream of the pressure control valve
PCV91 should be fully opened.
7.
a) Open PCV91 fully from PIC91 in Manual (M) mode, with MV = -6.3%. Make sure the
by-pass valve around PCV91 is shut but its two adjacent manual valves are opened.
b) 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
Transfer PIC91 to Auto (A) mode and watch the response at the recorder PR91 till
it is steady at its setpoint SV to within 0.1 psig or continues to oscillate even after
3 cycles.
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PID
Values
3-Capacity pressure process,
Controller: PIC91
Same PID, different SV.
First (I):
70/40/0
First (I):
70/40/0
Setpoint,
psig
T91/T92A/T92.
Test
With
Positioner.
18
18-9
(i).
(ii).
9
9-18
(i).
(ii).
(iii).
18
18-15
15-9
(i).
15
(ii).
(iii).
15
15
f.
g.
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f) (i) With the setpoint at 18 psig, use the third (III) trial PID values as follows:
PB1 = 35%
TI1 = 30 secs
TD1 = 0 sec
Repeat the previous (c) using the same load step test and observe similarly. If it is
oscillatory, observe for 10 cycles to see whether the oscillation can be damped out. It
is very likely that the controller gain is too high at PB%=35%, at setpoint SV= 18
psig
(ii) With PIC91 in Auto (A) mode, apply a setpoint step test by changing the setpoint
from 18 to 15 psig (72% to 60%). Observe the response patiently for a while. If it is
oscillating continuously, observe for about 10 peaks.
(iii) With PIC91 in Auto (A) mode, apply a setpoint step test by changing the setpoint
SV from 15 to 9 psig (60% to 36%). Observe the response patiently for a while. If it
is oscillating continuously, observe for about 10 peaks.
However, if the pressure control loop appears more or less oscillatory at different
operating setpoints (SV), then the pressure control loop in this application is NonLinear. i.e. the loop has variable gain. Discuss the likely cause of this Non-Linearity.
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PID
Parameters
PB1
TI1
TD1
Setpoint SV
Responses
8.
To shut-down AP922,
- Shut MV91 but do not adjust AR91.
Purge any water collected at the individual air supply regulator (IAS) but do NOT
adjust the top knob, which has been preset to the required pressure.
- Switch PIC91 to Manual (M) mode with its MV = 0%
- At the Recorder, press the RCD pushbutton to stop the chart drive.
- Switch off the power supply at the front of the panel.
- Shut fully the isolation manual valve at the main air supply line to Model AP922.
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RESULTS/DISCUSSION
The recorder PR91 records the results of the experiments.
RELEVANT PORTIONS OF THE RECORDER CHART RESPONSES SHOULD BE
SUBMITTED AS RESULTS OF THE EXPERIMENT, WITH THE FOLLOWING
PERTINENT DATAS MARKED ON THE CORRESPONDING CHART RECORDING: CONTROLLER IN AUTO (A), MANUAL (M) MODE.
SETPOINT (SV), PB, TI, TD.
ANY ANNUNCIATOR ACTIVATED.
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