TECHNICAL/EXECUTIVE REPORT : CHEMICAL ENGINEERING

PROCESS CONTROL AND

Lab No. : 4 Module :
INSTRUMENTATION

Topic : DCS. EMERSON SIMULATION SOFTWARE Mark :

100 Date : 18 JAN 2017
Participant Group EH110
Course : CHE 239 Semester : 4
*Please cancel which : 4B(A4)
is not necessary. Signatur
No. Name Matrix No.
e
201582794
1 AINA NAJWA BINTI MOHD
8
201583559
2 AINA SABRINA BINTI MUHAMMAD ZU
7
201584123
3 KU SYAFIQA BINTI KU HUSSIN
2
MUHAMMAD ZA’IM BIIN MD FARIDUL 201582398
4
ATHAS 2
201583558
5 MUHAMMAD IZAT HILMAN BIN IKRODI
4
Instructor NURUL BASHIRAH BINTI YUSOF

Objective :
1. Understand how flow, pressure, temperature, level process control system works.
2. Study the method offsetting PID parameter to achieve the optimum stability.
3. Study the method of setting PID controller to achieve the optimum recovery.

Abstract :
There are 3 main elements in the process control system which is manipulated
variable, control variable and the disturbance. The PID control algorithm is used for the
control of almost all loops in industries and is also the basis for many advanced control
algorithms and strategies. The laboratory experiments will hopefully confirm this.
There are three types of experiments such as flow, pressure, temperature, level of
process control system. Every experiment have a different value set point. For example,
the pressure process control system is 50 bar. Wait for few second until the manipulated
variable and process variable is stable. Increase the manipulated variable around 10%. By
using the P controller, the gain value is setting from the table P controller. For load
disturbances, the gain value is set and every time to change the gain value , make sure
click “MAN” and increases the manipulated variable around 10%. Wait for a few second
until the process variable is stable before change the gain value. Next, the experiment is
proceeding by repeating the experiment by using PI and PID controller. Each controller is
compare to know which one is better for every type of control system.

FLOW PROCESS CONTROL SYSTEM

Data/Results
/Calculation: P CONTROLLER:

GAIN RESET RATE RESPOND

0.5 0.0 0.0 Undershoot and
overshoot, stable
1.33 0.0 0.0 Undershoot, stable
4.33 0.0 0.0 Oscillate vigorously,
unstable

PI CONTROLLER:

GAIN RESET RATE RESPOND

0.5 1.66 0.0 Unstable oscillation
3.3 1.66 0.0 Unstable oscillation
2.0 1.43 0.0 Unstable oscillation

PID CONTROLLER:

GAIN RESET RATE RESPOND

3.0 2.0 2.5 Fast response,unstable
2.4 2.0 2.5 Fast response,unstable
1.0 1.43 0.4 Slow response,unstable

PRESSURE PROCESS CONTROL SYSTEM

P CONTROLLER:

GAIN RESET RATE RESPOND

0.5 0.0 0.0 Undershoot and
overshoot, damping
1.07 0.0 0.0 Oscillate, damping
3.15 0.0 0.0 Unstable oscillation

PI CONTROLLER:

GAIN RESET RATE RESPOND

0.72 2.28 0.0 No oscillation
0.80 3.0 0.0 No oscillation
2.5 0.79 0.0 Sluggish oscillation

PID CONTROLLER:

GAIN RESET RATE RESPOND

0.8 3.0 0.67 No oscillation
 1.27 4.0 6.6 Sluggish,unstable
oscillation
5.45 3.62 2.15 Sluggish,unstable
oscillation

TEMPERATURE PROCESS CONTROL SYSTEM

P CONTROLLER:

GAIN RESET RATE RESPOND

0.5 0.0 0.0 Stable oscillatory
1.34 0.0 0.0 Stable oscillatory
3.33 0.0 0.0 Stable oscillatory

PI CONTROLLER:

GAIN RESET RATE RESPOND

1.0 32.54 0.0 Match the set point and
stable
43.0 5.0 0.0 Continuous oscillatory
0.91 92.40 0.0 Match set point slowly

PID CONTROLLER:

GAIN RESET RATE RESPOND

1.60 51.06 30.31 Unstable oscillatory
15.32 9.45 14.0 Continuous oscillatory
1.00 43.0 9.44 Match set point slowly

LEVEL PROCESS CONTROL SYSTEM

P CONTROLLER:

GAIN RESET RATE RESPOND

0.5 0.0 0.0 Slower respond
4.51 0.0 0.0 Fast respond
6.26 0.0 0.0 Fastest respond

PI CONTROLLER:

GAIN RESET RATE RESPOND

5.44 3.3 0.0 Slow-oscillatory
respond
5.44 2.7 0.0 Fast-oscillatory respond
4.25 9.5 0.0 Medium-non-oscillatory
 respond

PID CONTROLLER:

GAIN RESET RATE RESPOND

4.25 9.5 0.5 Unstable-oscillatory
4.25 9.5 18.04 Unstable-oscillatory
2.45 9.5 0.5 Fast-non-oscillatory

Discussion: FLOW PROCESS CONTROL SYSTEM

P CONTROLLER:

PI CONTROLLER:

PID CONTROLLER:
Based on the graph, we can see that there are least oscillation in P
controller mode which the response is good. When we set the gain at
0.5, there are just a little undershoot and overshoot. Then, we set the
gain at 1.33. The response for the gain is faster and returns to the set
point quickly same as gain at 0.5. But when we set the gain at 4.33, the
response is too fast until the unstable oscillation ascillate vigorously and
hard for the disturbances to return to the set point.

In PI controller mode, we can see that there are unstable oscillation

which takes longer time for the disturbances to return to the set point.
First, we set the lower gain and reset which is 0.55 and 1.66. And, what
we can see from the graph is unstable oscillation. Then, we increase the
gain and maintain the reset value to 3.3 and 1.66. After that, we increase
the value of the gain and decrease reset to 2.0 and 1.43. The response
are still the same which is unstable oscillation.

Lastly, for PID controller, we observe on the graph that the oscillation is
unstable. When we set the highest gain value at 3.0 while value for reset
and rate is 2.0 and 2.5 respectively. The response shows is faster but
unstable oscillation occurred. The same observation that we get when
we lower the gain to 2.4 and maintaining the reset and rate value.
Lastly, we lowered the gain and rate to 1.0 and1.4 but the value of reset
had been increase to 9.5. It become slower but the unstable oscillation
still happening.
PRESSURE PROCESS CONTROL SYSTEM

P CONTROLLER:

PI CONTROLLER:
PID CONTROLLER:

Based on the graph, we can observed that P controller mode shows the
better response. We can see that there are the least oscillation from the
graph. First, when we set the gain value at 0.5, it will shows the better
response. There are only a few undershoot and overshoot on the graph
which is easily lead the disturbances to the set point. Then we increase
the gain value to 1.07, we can see that there are oscillation but the
damping process occurred which caused the disturbances to slowly
return to the set point. Lastly, we increase again the value of gain to
3.15 and unstable oscillation occurred.

For PI controller mode, we can see the best response graph. First, we set
the lowest gain and the reset value at 0.72 and 2.28 respectively. It
shows that there is no oscillation, undershoot and overshoot. The
response is too fast so that the disturbance quickly return to the set
point. Same goes happen when we increase the gain value at 0.8 and
the reset value at 3.0. But when we change the gain and the reset value
to 2.5 and 0.79, the graph become oscillate and the graph become more
sluggish when the longer the disturbances to return to the set point.

Lastly, we set the gain, reset and rate values at 0.8, 3.0 and 0.67 for PID
controller. The graph shows that the better response which is no
oscillation, overshoot and undershoot occurred. But when we change the
values to 1.27 for the gain, 4.0 for the reset and 6.6 for the rate, the
response become slower and unstable oscillation occurred. Lastly, when
we change the gain, reset and rate values to 5.45, 3.62 and 2.15
respectively, the response is slower an unstable oscillation formed.

TEMPERATURE PROCESS CONTROL SYSTEM

P CONTROLLER:
PI CONTROLLER:

PID CONTROLLER:
For P controller mode, the response are observed and compared based
on the gain value which are 0.5, 1.34 and 3.33. Based on the data, the
response for gain, 0.5, is the fastest while the response for gain, 3.33, is
the slowest because of the oscillatory and settling time before it return
to the set point. The data shows that the higher the gain value, the
higher oscillatory occurs.

For PI controller mode, we set the gain and reset value at 1.0 and 32.54
respectively. The respond at this point is match to set point and there is
no oscillation occurred. Then, we set the gain value at 43.0 while the
reset value at 5.0. At this point, the oscillation occurred continuously
since the graph oscillate vigorously because of high gain and low reset.

In PID controller mode, the response is observed based on the different

value of gain, reset and rate. First, we set all the values at 1.00, 43.0 and
9.44 respectively. The response at the graph is the fastest and critically
damped since there is no oscillation occurred. Then, the different value
for gain at 15.32, reset value at 9.45 and the rate value at 14.0. From
the graph, we can see that the response is the slowest because more
undershoot and overshoot occurred. Moreover, due to the low value of
rate, oscillatory occurs and will take longer time to match the set point
since value of gain is higher. Basedon the results, the response for PID
controller is not depend on the rate value only but also depend on gain
and reset value.
LEVEL PROCESS CONTROL SYSTEM
P CONTROLLER:

PI CONTROLLER:
PID CONTROLLER:

For P controller mode, we set the gain at 0.5, the responds is slow for PV
to reach the new set point thatw e increase MV 10%, with large
underdamped and overdamped. When we increase the gain at 4.51, the
responds is fast with a few undershoot and overshoot to stabilize. We get
the fastest responds with a few overshoot and undershoot when we set
the gain value at 6.26.

For PI controller mode, we maintain the gain at 5.44 for the first two
values with the difference reset values which is 3.3 and 2.7 respectively.
From the graph, we get the slow responds with the 3.3 reset value.
Meanwhile, when the reset time is 2.7 with the same gain value, the
responds was too fast and oscillatory occurred. Then, we set the gain at
4.25 and the reset time at 9.5. We can observed that the responds was
not too fast but with non-oscillatory.

For PID controller mode, we set the gain at 4.25, reset value at 9.5 and
the rate value at 0.5, we got the unstable oscillatory responds. Then, we
increase the rate at 18.04 and retain the gain and the reset value, we
 got the same unstable oscillatory responds. Lastly, we decrease the gain,
reset and rate value, which is 2.45, 9.5 and 0.5 respectively. The respond
that we got is fast and non-oscillatory occurred. We can conclude that
the lower the gain value, the best respond that we got instead of
increasing the rate.

Based on experiment that we have carried out, we have achieved the

Conclusion:
objective for this experiment. As we can see, this experiment has carried
out three experiments of three types of controllers which are PI-
controller, and PID-controller. From the experiment, we can conclude
that, throughout this simulation, the process of how the controllers work
can be seen by the response of this controller towards different process
such as level control, flow control, temperature control and pressure
control based on the gain, reset and rate value. In the end of this
experiment, all the results were compared to see which one is better in
each of the experiment and we were able to understand about the basic
on how each of the control system works since tuning a control loop is
the adjustment of its control parameters (proportional band/gain,
integral gain/reset, derivative gain/rate) to the optimum values for the
desired control response while stability (no unbounded oscillation) is a
basic requirement, but beyond that, different systems have different
behavior, different applications have different requirements, and
requirements may conflict with one another. Hence, we were able to
understand how to tune the PID parameters to achieve the controller
process.

References:
1. https://en.wikipedia.org/wiki/Computer_simulation
2. www.emerson.com/en-us/automation/...dcs/.../deltav-dcs-
 simulation
3. classes.engineering.wustl.edu/.../ChE%20433%20Digital
%20Control%20

Authorize Person Initial Date Stamp

Technician
Approval

Instructor

Allocated Marks for Technical/Executive report

Criteria Full Marks

Abstract 10
Objective 10
Data/Results/Calculation 20
Discussion 30
Conclusion 10
References 10
Overall structure/organization and Quality 10
TOTAL 100

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