Declaration

I declare that the work contained in this report is my individual and unaided work with the
exception of the assistance got from duly cited literature sources and teaching staff
Acknowledgement

Abstract
This study is aimed at evaluating the concepts of process control system and conducting flow
process control test for determination of the behavior of the system. The experiment is done with
closed loop proportional flow control then with closed loop proportional plus integral flow
control. Response curves are generated once the process stabilizes.
Introduction
Process control has an integral role to play in the way of controlling a process plant. Process
control is aimed at ensuring a process is maintained at a recommended, constant conditions of
operation in the face of disruptions or even less typically within conventional process
applications for ensuring the process maintained the desired route with time. it is as well one of
the most extensively adopted by chemical engineers in chemical reactors, mass transfer and heat
exchange equipment in keeping major process operating parameters within thin bounds of
reference setpoint or value.
This experimental study is conducted on process control simulator with the aim of observing the
features of proportional band on level control loop and illustrate the various features of
proportional band alongside Integrated Action on level loop. The key objectives include:
 Evaluate closed loop for flow control
 Gain an understanding of the process control system concept
 Carry out experiment on flow control system for closed loop proportional flow control
and closed loop proportional alongside integrated flow control
Theoretical Background
The feedback control loop is one of the most fundamental components of an industrial process. It
is made up of a measurement, process, controller alongside final control element. The flow of
information offers a control means that permits efficient use of energy and raw materials.
Interconnection of all these elements in such a way that continuous passage of information
around the loop can be achieved results in closed loop control. On the other hand, interruption of
a loop for any reason for instance when the control is set on manual control results in an open-
loop control.
Attempts of proportional control for stabilization of the system and prevention of fluctuations
through response to the magnitude and error direction. The correlation between the measurement
span width and the output is called proportional band. For instance, a 20% proportional band
tends to be narrow hence offering sensitive control as 100% output change is generated by just
20% measurement change.
The proportional controller, in operation, determines the amount of error between set point and
measurement, amplifies the same and locates the final control element for reduction of the error.
The corrective action magnitude tends to be proportional to the error. A very wide proportional
band results in much large offset, leading to a reduction in the amount of control over the
process. The amount of offset can be reduced by thinning the proportional band.
The movement process is accelerated by the integral term in the direction of the set point and
ignores the created offset in proportional only control. As the integral term, however, responds to
the past accumulated errors, it might result in overshooting of the set point value by the present
value. It is a system automatic rebalancing, operating provided there is an error within the
system. Integral control is nearly combined with proportional control.
Proportional-plus-integral control is often adopted in processes in which offset cannot be
tolerated. Integral action in this controller can be given in terms of minutes per repeat, defining
the amount of time needed for the integral controller for repeating the open-loop response due to
the proportional mode for step change in the error. Faster integral action is generated when the
integral time value is smaller.

Experimental Procedure
Experiment 1: System step response
The demonstration mode was turned out through the main switch
Throttle valve (3) was fully open and extraction valve (8) slightly open for air emergence
The controller was switched to manual mode and manipulated variable y set to 30%
The pressure in the tanks was monitored using two manometers
The reference variable was increased to 40%, 50%, 60%, 70% and 80% through the controller
Experiment 2: PI-controller
The demonstration model was turned out through the main switch
Throttle and extraction valves and the controller were set as illustrated below

The pressure in the tanks was monitored using two manometers. The pressure assumed 2 bar
constant value after some time
The reference variable was increased to 3 bar value
Results & Findings
Discussion
As the experiment was directly done on the computer situated next to the equipment which
automatic controller is deployed in controlling the system, the flow control system tends to be
closed loop system. An automatic controller only using Proportional and Integral mode is used in
this experiment for water flow. This is due to the fact that Proportional and Integral control mode
is deployed in fast process response as well as noisy responses for instance level flow, level and
pressure control. The amount of output being measured in a closed loop system is known as
feedback signal and achieve and maintained the recommended output condition automatically by
comparing the same with the actual condition.
The values of the manipulated variable are manually adjusted at the start of the experiment so
that the process variable value tends to set point prior to shifting the system to automatic mode.
The step is repeated using a different proportional value. The set point is maintained as shown in
the graph even as the proportional value keeps on changing resulting in the change in behavior f
the graph.
The rise in the oscillation as well means there is an overshoot or even undershoot taking place in
the graph. An increase in the number of oscillations result in an increase in the time taken to
achieve set point by the system as more time is required for stabilization. It is noted from the
graphs that the overshoot tends to be shorter even as the undershoot is relatively higher.
An integral value at 1 second result in shorter time rise even though there is oscillation. A
decline in the oscillation means a decline in overshoot and hence the integral tends to be
eliminated the offset from the graph. An increase in the integral value leads to a decrease in the
number of overshoots. As can be noted from the graphs, higher integral value lead to a reduction
in the stabilization time and the time taken to attain set point. There is as well a decline in the
time interval between two successive peaks with a decline in the integral value with a reduction
in the oscillation.
Conclusion
The objectives of this study were successfully attained in this experimental analysis. The
experiment illustrate that flow control system tends to be a self-regulating process pegged on the
process response curve which illustrates that the process would stabilize after some period. The
system stabilization time can only be noted at flow measurement through integral mode and
proportional graph as a result of less oscillation.
Recommendations
A few errors were noted during this experimental study that resulted in the findings becoming
less reliable in comparison with theoretical values. Errors for instance instruction errors and
disruptions were conducting this experiment are some of them. It is recommended that the pump
be properly tightened and disruptions avoided which lead to pressure drops and result
inaccuracies.