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Lab Report Process UITM

This document provides calculations for liquid flow plant (FIC 21) and boiler drum heat exchanger (LIC 11) process control systems. For FIC 21, the time delay (Td) is calculated as 1.295 seconds and time constant (Tc) is 3.2375 seconds. For LIC 11, Td is 2.66 seconds and Tc is 5.32 seconds. Various PID controller tuning parameters are then calculated using Ziegler-Nichols, Cohen-Coon, and Chien-Hrones-Reswick tuning rules. Foxboro instrumentation data is also presented, calculating Td as 2 seconds and Tc as 0.85 seconds for flow process analysis. PID parameters are initialized

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0% found this document useful (0 votes)

61 views

Lab Report Process UITM

Uploaded by

Eiman Uzmi

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Download as DOCX, PDF, TXT or read online on Scribd

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CALCULATION

FIC 21 (Liquid Flow Plant)

∆MV = 5%
PVi = 1.25 m3/h = 1.25/6 x 100 = 20.83 %
PVf = 1.63 m3/h = 1.63/6 x 100 = 27.17 %
∆PV = 6.34 %
10 %
a) = 0.57 %/mm
17.5 𝑚𝑚

60 𝑠
b) = 1.295 s/mm
46.5 𝑚𝑚

Td = 1 mm x 1.295 s/mm = 1.295 s

Tc = 2.5 mm x 1.295 s/mm = 3.2375 s
∆𝑃𝑉 6.34 %
RR = ÷ ∆𝑀𝑉 = ÷ 5 = 0.39 s-1
∆𝑡 3.2375 𝑠

REFORMULATED TANGENT
1 1
Td = (∆PV) (b/a)[ − ]
tan 𝛽 tan 𝜃
1.295 1 1
= 6.34 ( )[ − ] = 1.96 s
0.57 tan 68 tan 75
1
Tc = (∆PV) (b/a)[ ]
tan 𝜃
1.295 1
= 6.34 ( )[ ] = 3.86 s
0.57 tan 75
TYPE OF TC
1. Tangent
T100% - Td = Tc
= 3.2375 s

2. Tangent & Point

Tc = T63.2% - Td
PV63.2% = 20.83 + 0.63 (6.34)
= 24.84
Tc = 1 mm x 1.295 s

3. 2 points
Tc = T28.3
PV28.3 = 20.83 + 0.283 (6.34)
= 22.624
Tc = 0.5 mm x 1.295s
= 0.6475 s

PI MODE = FLOW
Td = 1.295s Tc = 3.2373s RR = 0.39 s-1 𝜇 = Td/Tc = 0.4
1. Ziegler Nichols
P = 111.1 RR Td
= 111.1 (0.39) (1.295) = 56.111%
Kc = 100/P = 100/56.111 = 1.78
I = 3.33 Td
= 3.33 (1.295) = 4.31235 s

2. Cohen – Coon
100
P = 𝜇 RR Td
1+ 11
100
= 0.4 (0.39)(0.4) = 48.733%
1+ 11
Kc = 100/P = 100/48.733 = 2.05
𝜇
1+ 11
I = 11𝜇 Td
1+ 5
0.4
1+ 11
= 11(0.4) (1.295) = 2.38 s
1+ 5
3. Chien, Hrones & Reswick (CHR) –no overshoot & minimum response time; Performance
test – Set point.
P = 286 RR Td
= 286 (0.39) (1.295) = 144.44%
Kc = 100/P = 100/144.44 = 0.69
I = 1.2 Td = 1.2 (1.295) = 1.554 s

4. Chien, Hrones & Reswick (CHR) -20% overshoot & minimum response time;
Performance test – Set point
P = 167 RR Td
= 167 (0.39) (1.295) = 84.34%
Kc = 100/P = 100/84.34 = 1.185
I = Td = (1.295) s

5. Chien, Hrones & Reswick (CHR) -No overshoot & minimum response time;
Performance test – Disturbance in load variable
P = 167 RR Td
= 167 (0.39) (1.295) = 84.34%
Kc = 100/P = 100/84.34 = 1.185
I = 4 Td = 4 x (1.295) s = 5.18 s

6. Chien, Hrones & Reswick (CHR) -20% overshoot & minimum response time;
Performance test – Disturbance in load variable
P = 167 RR Td
= 167 (0.39) (1.295) = 84.34%
Kc = 100/P = 100/84.34 = 1.185
I = 4 Td = 4 x (1.295) s = 5.18 s

7. Takahashi – minimum control area; Performance test – Disturbance in load variable

P = 110 RR Td
= 110 (0.39) (1.295) = 55.56%
Kc = 100/P = 100/55.56 = 1.8
I = 3.3 Td = 3.3 x (1.295) s = 4.27 s
LIC 11 (Boiler Drum – Heat Exchanger PCTS)
∆MV = 10%
∆PV = (61.995 – 7.435) % = 7.435%
10 %
a) = 0.57 %/mm
17.5 𝑚𝑚

60 𝑠
b) = 1.33 s/mm
45 𝑚𝑚

Td = 2 mm x 1.33 s/mm = 2.66 s

Tc = 4 mm x 1.33 s/mm = 5.32 s
∆𝑃𝑉 7.435 %
RR = ÷ ∆𝑀𝑉 = ÷ 10 = 0.048 s-1
∆𝑡 29.993−14.663 𝑠

REFORMULATED TANGENT
1 1
Td = (∆PV) (b/a)[ − ]
tan 𝛽 tan 𝜃
1.33 1 1
= 7.435 ( )[ − ] = 7.63 s
0.57 tan 11 tan 12
1
Tc = (∆PV) (b/a)[ ]
tan 𝜃
1.33 1
= 7.435 ( )[ ] = 81.62 s
0.57 tan 12

TYPE of Tc
1. Tangent
T100% - Td = Tc
= 5.32 s

2. Tangent & Point

Tc = T63.2% - Td
PV63.2% = 54.5 + 0.632 (7.435)
= 59.199
Tc = 1 mm x 1.33 s = 1.33 s

3. 2 points
Tc = T28.3
PV28.3 = 54.5 + 0.283 (7.435)
= 56.6
Tc = 0.5 mm x 1.33s
= 0.665 s

PI Mode = Flow
Td = 2.66s Tc = 5.32s RR = 0.048 s-1 𝜇 = Td/Tc = 0.5
1. Ziegler Nichols
P = 111.1 RR Td
= 111.1 (0.048) (2.66) = 14.2%
Kc = 100/P = 100/14.2 = 7.05
I = 3.33 Td
= 3.33 (2.66) = 8.86 s

2. Cohen – Coon
100
P = 𝜇 RR Td
1+
11
100
= 0.5 (0.048)(2.66) = 12.22%
1+ 11
Kc = 100/P = 100/12.22 = 8.2
𝜇
1+ 11
I = 11𝜇 Td
1+ 5
0.5
1+ 11
= 11(0.5) (2.66) = 4.41 s
1+ 5

3. Chien, Hrones & Reswick (CHR) –no overshoot & minimum response time; Performance
test – Set point.
P = 286 RR Td
= 286 (0.048) (2.66) = 36.52%
Kc = 100/P = 100/36.52 = 2.74
I = 1.2 Td = 1.2 (2.66) = 3.192 s
4. Chien, Hrones & Reswick (CHR) -20% overshoot & minimum response time;
Performance test – Set point
P = 167 RR Td
= 167 (0.048) (2.66) = 21.32%
Kc = 100/P = 100/21.32 = 4.7
I = Td = (2.66) s

5. Chien, Hrones & Reswick (CHR) -No overshoot & minimum response time;
Performance test – Disturbance in load variable
P = 167 RR Td
= 167 (0.048) (2.66) = 21.32%
Kc = 100/P = 100/21.32 = 4.7
I = 4 Td = 4 x (2.66) s = 10.64 s

6. Chien, Hrones & Reswick (CHR) -20% overshoot & minimum response time;
Performance test – Disturbance in load variable
P = 167 RR Td
= 167 (0.048) (2.66) = 21.32%
Kc = 100/P = 100/21.32 = 4.7
I = 4 Td = 4 x (2.66) s = 10.64 s

7. Takahashi – minimum control area; Performance test – Disturbance in load variable

P = 110 RR Td
= 110 (0.048) (2.66) = 14.045%
Kc = 100/P = 100/14.045 = 17.12
I = 3.3 Td = 3.3 x (2.66) s = 8.778 s
FOXBORO INSTRUMENTATION

Process Flow ∆MV ∆PV

MVi % 35 5% 31.1953 –
25.0703 =
6.125 %
MVf% 40

Time, (s) PV % RR (s)

0 25.0703 -

1 25.0703 0

2 25.0703 0

3 25.0703 0.2594

4 27.6641 0.4297

5 29.3672 0.2679

6 30.3437 0.1471

7 30.8379 0.0494

8 30.8379 0.0357

9 31.1953 0.0357
10 31.1953 -

RR max = 0.4297 s
RR1 = (PV1 – PV-1) / 2∆h∆MV

= 25.0703 − 25.0703⁄2(1)(5) = 0

RR3 = (PV1 – PV-1) / 2∆h∆MV

= 27.6641 − 25.0703⁄2(1)(5) = 0.2594

Td = T1 - 2∆h [(PV1 – PVi) / PV1 – PV-1)]

= 4 – 2(1) (29.3672 − 25.0703⁄29.3672 − 25.0703) = 2𝑠

Tc(tangent) = 2∆h [(PVf – PVi) / PV1 – PV-1)]

= 2(1) (31.1953 − 29.3672⁄29.3672 − 25.0703) = 0.85𝑠

General solution :
Tx = tn + (tn+1 – tn) [(PVx – PVn) / PVn+1 – PVn)]

1) Tangent & Point Method ( T 63.2%)

T63.2% = tn + (tn+1 – tn) [(PV63.2% – PVn) / PVn+1 – PVn)]

PV63.2% = PVi + 0.632(PVf – PVi)
= 23.0703 + 0.632 (31.1953 – 23.0703)
= 28.2053 % (in between 4-5 s)
4 27.6641

X 28.2053

5 293672

29.3672 − 27.6641⁄ 28.2053 − 27.6641⁄

5−4 = 𝑋−4
X = 4.317 s
Tc 63.2% = 4.317 s – 2 s
= 2.317 s

2) 2 – Point Method

T28.3% = tn + (tn+1 – tn) [(PV28.3% – PVn) / PVn+1 – PVn)]

PV28.3% = PVi + 0.283(PVf – PVi)
= 23.0703 + 0.283(31.1953 – 23.0703)
= 25.37% (in between 3-4s)
3 25.0703

X 25.37

4 27.6641

(27.6641 – 25.0703) / (4-3) = (25.37 – 25.0703) /(X – 3)

X = 3.116 s
Tc 28.3% = 4.317 s – 3.116 s
= 1.802 s

PI Mode = Flow

Td =2s Tc = 0.85 s RR = 0.43 s-1 𝜇 = Td/Tc = 2.35

1. Ziegler Nichols
P = 111.1 RR Td
= 111.1 (0.43) (2) = 95.55%
Kc = 100/P = 100/95.55 = 1.05
I = 3.33 Td
= 3.33 (2) = 6.66 s

2. Cohen – Coon
100
P = 𝜇 RR Td
1+ 11
100
= 2.35 (0.43)(2) = 42.74%
1+ 11
Kc = 100/P = 100/42.74 = 2.35
𝜇
1+ 11
I = 11𝜇 Td
1+ 5
2.35
1+ 11
= 11(2.35) (2) = 1.31 s
1+ 5

3. Chien, Hrones & Reswick (CHR) –no overshoot & minimum response time; Performance
test – Set point.
P = 286 RR Td
= 286 (0.43) (2) = 245.96%
Kc = 100/P = 100/245.96 = 0.41
I = 1.2 Td = 1.2 (2) = 2.4 s

4. Chien, Hrones & Reswick (CHR) -20% overshoot & minimum response time;
Performance test – Set point
P = 167 RR Td
= 167 (0.43) (2) = 143.62%
Kc = 100/P = 100/143.62 = 0.69
I = Td = (2) s

5. Chien, Hrones & Reswick (CHR) -No overshoot & minimum response time;
Performance test – Disturbance in load variable
P = 167 RR Td
= 167 (0.43) (2) = 143.62%
Kc = 100/P = 100/143.62 = 0.69
I = 4 Td = 4 x (2) s = 8 s

6. Chien, Hrones & Reswick (CHR) -20% overshoot & minimum response time;
Performance test – Disturbance in load variable
P = 167 RR Td
= 167 (0.43) (2) = 143.62%
Kc = 100/P = 100/143.62 = 0.69
I = 4 Td = 4 x (2) s = 8 s