ABSTRACT The objective of this experiment is to perform open loop test at the Simulated Gas Mass Flow process.

From this experiment, we can determine the process parameters such as steady state gain (Kp), dead time (tD), response rate (RR) and time constant ( ). c This can be done by analysis the curve of controller output, set point and also measured variable. PID control scheme are used for this experiment. We have to change the controller set point SP from 18kg/h to 25kg/h to 35kg/h. While for the controller output MV (OUT) we change it from 0% to 50% to 100%. For all process we set the FIC91A: Gain = 0.40, Reset = 3 sec, Rate = 0 sec. In every changes of set point, we decrease its MV (OUT) by about 5%. Wait till the response is fairly steady at the new steady state flow rate, save the observed flow response. Then calculate all the process parameters. From the observation of the curve, we can see that when increasing set point, process gain and time constant of process parameter will decrease. While dead time and response rate of the process parameter will increase due to increasing of set point. All of this result can be calculate using basic concept of mathematic as included in our results sheet. After this experiment has been done, we can conclude that the set point process parameters response to any changes of set point. It is proven from the result we got that has the different values when the experiment was run.

1.0

INTRODUCTION 1.1 LITERATURE REVIEW AND THEORY

The Simulated Gas Flow Process using the DeltaV Batch software features a single, completely integrated database that coordinates all configuration activities. System information is transparently distributed globally in the run-time environment, so each part knows about the others. The objectives here are to perform open loop test at the Simulated Gas Mass Flow process. In order to identify and characterize some real plant processes is by tuning their control loops using the Ziegler-Nichols, Cohen-Coon and IMC for Quarter Decay Ratio (QDR) or other performance criteria while to determine process parameters such as steady state gain (Kp), dead time (tD), response rate (RR) and time constant ( ), some basic calculations need to be carried out. c There are a main pipeline in the simulated Gas Flow Process which represents the vapour flows with temperature of 1000C and also the discharge that are being aired out to the atmosphere via the process vent manual valve VF. Below is the dynamic graphic of the Simulated Gas Mass Flow Process at Model SPC211, for PID control, mass flow rate measured by Gas Mass Flow meter (FE91/FT91), is the measurement input into PID Flow controller FIC91A which in turn throttles the Control valve FCV91, via a Currentto-Air Converter (I/P), FCY91, and a Positioner (PP). Measurement FE91/ FT91 FT91 represents the gas mass

flowmeter Control Type FIC91A PID Controller configured at DCS

Control Output

FCY91 PP FCV91

Current-to-Air Converter (I/P) Pneumatic Positione Air Mass Flow Control Value. Air-to-close (ATC) type

Table 1: Instrumentation and control configuration for gas mass flow process

Figure 1: Simulated gas mass flow process diagram The result of this experiment is represented by the DCS trending records at the Process History View of each respective controller. The obtained response curve are used to determine the process parameters which are process gain, Kp, dead time, tD, response rate, RR and time constant, . All the process parameters that have been obtained from c this experiment will be used later in PID tuning experiment. During the experiments, observations are carried out to check whether the process parameters remain constant or vary. 1.2 OBJECTIVE To perform open loop test at the Simulated Gas Mass Flow process and observe the dynamic behavior of the process. Besides that process parameters determined according to the process dynamic response. Parameters determined are steady sate gain, dead time, response rate and time constant.

2.0 METHODOLOGY 2.1 PROCEDURE 1. 2. 3. 4. The dynamic graphic of the Simulated Gas Mass Flow Process is view at the operator workstation. The solenoid valve SV90 is OPEN at the dynamic graphic page. It should be green in color. The PID control scheme is selected. Then, call up the FIC91A Faceplate and its Detail Faceplate. Practice changing the controller set point SP = 18kg/Hr to 25kg/Hr to 35kg/Hr. The controller is switch to Manual (MAN) mode, practice changing the controller output MV(OUT) = 0% to 50% to 100%. 5. Next, the controller is switch to Auto (AUTO) mode. Practice changing the Gain, Reset and Rate values from the detail faceplate of FIC91A. Then, set the following Gain, Reset and Rate (PID) values: FIC91A: Gain = 0.40, Reset = 3 sec, Rate = 0 sec A set point of 25kg/Hr is use for the flow controller FIC91A. User may refer to the DCS Quick Reference Manual for more practice. 6. Call up the Process History View from FIC91A to view the flow response (red trend). NOTE: At the Process History View window, click at the Chart menu to select the Configure Chart option and change the Time Scale span to 00:02 7. When the response is fairly steady, switch FIC91A to Manual (MAN) mode and step decrease its MV (OUT) by about 5%. The flow response will rise and then gradually flattens out exponentially. The response is wait till it is fairly steady at the new steady state flow rate (about 28.10kg/Hr).

The observed flow response is Print screen and save to be enclosed together with the results sheets. 8. The obtained response curve (for 25kg/Hr) is use to determine the process parameters i.e. process gain, Kp, dead time, tD, response rate, RR and time constant, . Refer to Appendix for the technique applied to determine these c parameters. 9. Next, the controller is switch to Auto (AUTO) mode, with a set point of 18kg/Hr. The flow response (red trend) is view at the Process History View page. When the response is fairly steady, switch FIC91A to Manual (MAN) mode and step decrease its MV (OUT) by about 5%. The response is wait till it is fairly steady at the new steady state flow rate (about 22.60kg/Hr). The observed flow response is Print screen and save to be enclosed with the results sheets. 10. The obtained response curve (for 18kg/Hr) is use to determine the process parameters i.e. process gain, Kp, dead time, tD, response rate, RR and time constant, . c 11. Next, the controller is switch to Auto (AUTO) mode, with a set point of 35kg/Hr. The flow response (red trend) is view at the Process History View page. Switch FIC91A to Manual (MAN) mode and step decrease its MV (OUT) by about 5% when the response is fairly steady. The response is wait till it is fairly steady at the new steady State flow rate (about 35.90kg/Hr). The observed flow response is Print screen and saveto be enclosed with the results sheets. 12. The obtained response curve (for 35kg/Hr) is use to determine the process parameters i.e. process gain, Kp, dead time, tD, response rate, RR and time constant, . c

3.0 RESULT AND DISCUSSION 3.1 RESULT AND CALCULATION i) 18 kg/hr From graph, t0 = 9.49.49 t1 = 9.49.50 Therefore, dead time, tD = t1-t0 = 1 sec Time constant, c = t2-t1 = 9.49.52 9.49.50 = 2 sec Steady state gain, Kp = Output% Input % = (4.8/50 x 100) 5 = 1.92 Response rate, RR = Kp c = 1.92 2 = 0.96 sec-1

ii) 25 kg/hr From graph, t0 = 9.46.32 t1 = 9.46.34 Therefore, dead time, tD = t1-t0 = 2 sec Time constant, c = t2-t1 = 9.46.35 9.46.34 = 1 sec

Steady state gain, Kp = Output% Input % = (28.1 25/50 x 100) 5 = 1.24 Response rate, RR = Kp c = 1.24 1 = 1.24 sec-1

iii) 35 kg/hr From graph, t0 = 9.54.02

t1 = 9.54.04 Therefore, dead time, tD = t1-t0 = 2 sec

Time constant, c = t2-t1 = 9.54.05 9.54.04 = 1 sec Steady state gain, Kp = Output% Input % = (35.9 -35/50) x 100 5 = 0.36

Response rate, RR = Kp c = 0.36 1 = 0.36 sec-1

Process Parameters Process gain, Kp Dead time, tD (sec)

Set points (SP) 18kg/hr 1.92 1

25kg/hr 1.24 2

35kg/hr 0.36 2

Response Rate, RR 0.96 (sec-1) Time constant, (sec)

1.24 1

0.36 1

3.2 DISCUSSION
1. The results of the experiment are rather prone to error due to the imprecision of the tools used to measure the necessary readings.

2. The dead time is calculated using a ruler and the limitation of the calculation is that the yaxis on the graph is precise only up to one second. This is a problem because the time constants are in the order of one second. Hence in calculation it is not possible to achieve a higher precision because of the lack of measuring instruments with higher precision.

3. To measure the time constant, a point on the graph must be singled out. Because the
response of the process is so quick, the change mostly happens over one very short period of time. However again since the precision of the measurement is not high, the results are prone to error. For example the measured time constant of 1 second could actually be 0.76 seconds but because the reference point used is the real time setting in which the response occurred, only complete periods of 1 seconds can be measured. If the response starts at 9.54.05 and converges at 9.54.06, we cannot account for the transgressions into the next period of 9.54.07 thus contributing to possible error.

4. The results show that the process gain decreases with higher setpoints and the dead time
decreases as setpoints increase. The process gain decreases because the process response is constant. Hence when the gain is calculated in percentages, the greater the difference between the process variable and the setpoint, the smaller the response will appear in percentages. Conversely the dead time would increase because the larger the setpoint the quicker the response due to the shift in the graph profile. A large setpoint would be like pressing hard on an accelerator causing the dead time to decrease and accelerating the process. 5. As the setpoint increases, the time constant decreases. This is because the increasing setpoint would increase the gradient of the slope before converging. Since the time constant is calculated based on a point on the slope, a higher gradient would mean a lower period and therefore a lower time constant.

4.0 CONCLUSION The process parameter values change with setpoint changes for an open loop simulated gas flow model. Process gains and time constants decrease with increasing setpoints where as dead times increase with increasing setpoint changes.

5.0 REFERENCES
www.wikipedia.com Process Dynamic and Control second Edition by Dale E. Seborg, Thomas F.Edgar and Duncan A. Mellichamp

www.sciencedirect.com

6.0 Appendix