Electric Power In Engineering Technology

2022

FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF ELECTRICAL ENGINEERING

TECHNOLOGY

ELECTRICAL WORKSHOP II

Course and BNE 32302

Name

Code and title Report intro flow

experiment

Date of 11/5/2022
experiment

Group 5

Group members 1. Muhammad Nazmi bin abdul Rahim

(cn190104)

2. Muhammad syurahbil bin shamsudin

(cn190114)

3. Muhammad zulhilmie bin mohd Yaacob

(an190021)

4. ngien seng xiang (an1901084)

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5. nik nur athirah syamimi binti noorlan

(cn190181)

Instructor’s Puan Mardzulliana Binti Zulkifli

name

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3.0 INTRODUCTION

Process control systems provide precise control of liquids and gases in

industrial areas including power generation, petrochemicals, food
processing, and manufacturing. These systems control liquid and gas
variables like flow rate, pressure, temperature, liquid level, density, and
pH levels. Amatrol’s Level and Flow Process Control training system
(T5552) covers two types of process control systems, flow and liquid
level. Learners use this process control training system to study process
control concepts and practice hands-on process control skills like
calibrating, adjusting, installing, operating, and connecting process
control systems in industrial applications.

This level and flow process control simulator includes a

bench-top workstation, process control network, control panel, and an
interactive online process control training course. The workstation is
constructed of heavy-duty, welded steel. Industrial quality components
are mounted and plumbed in a closed loop circuit to control the water
flow between two tanks or the liquid level in one tank. All components
are connected to banana jacks on the control panel, allowing students to
measure signals and connect devices in a variety of control
configurations.

This process control training system offers three types of

controllers: relay control, standard, and two options: PID controller and
PLC control. This allows students to study a wide range of process
control methods. The relay control includes manual input switches,
control relays, solenoid valves, and float switches to perform automatic
on/off liquid level control. The PID controller option enables variable
electronic control of either liquid level or flow and the PLC controller
option enables both on/off and PID control of the system. Manual
valves are used to switch between the PID and on/off control methods.

The Level Flow Process Control Training System (Model: SE

665) has been designed for students’ demonstration and to give them
better understanding on how open and closed tank level measurement
and level control is done, and to provide them with a hands on
experience on manipulating various control parameters using a
microprocessor based controller. It can also be coupled with a flow

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metering loop to enable cascade control studies. The equipment consists

of industrial grade instrumentation to exhibit a realistic working
environment of a true level process using various types of measuring
instruments and control strategy. The equipment is self contained and
constructed on a stainless steel frame with four lockable castor wheels.
The pumps, tanks, instrumentation and valves are strategically located
for easy access. For safety reasons, the control panel is protected
against water splashes. The process piping is made of stainless steel
pipes. A mimic diagram is included showing the flow of the process.

The SOLTEQ Model: SE 665 Level Flow Process Control

Training System is a water process. Water from the sump tank, T-601 is
pumped by P-601 to the level tank, T-602. There are two discharge
possibilities from the T-602 back to the T-601. One is known as the
“self-regulatory” mode using gravity flow for the water to return to the
sump tank. The other is the “non self-regulatory” mode, using a pump
P-602 to drain the water from the tank.

Various types of instrumentations are installed in the process.

There are two PID control loops in the process controller that controls
the process, namely FIC-601 and LIC-603. There is a switch at the local
control panel, which allows selection of either flow control or level
control or a combination of the two, called the flow/level cascade
control.
For the level control loop, the level transmitter LT-603 feed
the signal to LIC-603, which controls the valve FCV-601 while he
orifice flow transmitter FT-601 feed the signal to FIC-601, which
controls the valve FCV-601 is for the flow control loop. Moreover, the
cascade control loop is the level transmitter LT-603 feeds the signal to
LIC-603. The output from LIC-603 is then used as the set point for
FIC-601. The orifice flow transmitter is the measurement signal for
FIC-601 and the output from FIC-601 is used to control the valve FCV-
601. LIC-603 is also known as the primary loop and the FIC-601 is
known as the secondary loop.

Open and closed tank measurement studies can also be carried

out by pressurization of the tank T-602 using PCV-602. Another
method of local level measurement is made via a bubbling tube and the
hydrostatic pressure in the tank is read from PI-602. Load changes can

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be made within the system by manipulating various hand valves,

depending upon the process loop being experimented upon, to observe
the effectiveness of the controller in use. Figure 3.1 show one of the
process control system.

Figure 3.1: Process control system

3.1 LITERATURE REVIEW

A fundamental component of any industrial process control system is

the feedback control loop. It consists of the process, the measurement,
the controller, and the final control element, as shown in figure 1. If all
these elements are interconnected, that is, if information can be passed
continuously around the loop, this is closed-loop control and automatic
feedback generally exists.

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This information flow provides the means for control, which allows
efficient utilization of raw materials and energy, if a loop is interrupted
for any reason, such as when the controller is placed on manual control,
as seen in figure 2, it is considered to be open-loop control and
automatic control no longer exists.

Automatic feedback control is not used universally. In figure 2, parts of

the system are disconnected, creating open-loop control. Open-loop
control does not feed information from the process back to the
controller. A familiar example is the domestic washing machine, which
may be programmed to control a series of operations necessary to wash
a load of clothing, it runs through its cycle and, since no information is
fed back to the control device regarding the condition of the wash, it
shuts down. Automatic control requires some sort of signal system to
close the loop and provide the means for information flow. This means
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that the controller must be able to move the valve, the valve must be
able to affect the measurement, and the measurement signal must be
reported to the controller.

3.1.1 On/off Control

On/off control is generally both the simplest and the least expensive
type of process control and has wide application in industry. A process
controlled by an on/off controller almost always has some error in it; in
fact, the controller turns on or off only at those times there is no error in
the measurement, when the measurement crosses the set point on its
way from one extreme error to another. On/off control best applied to a
large capacity process that has relatively little dead time and a small
mass or energy inflow with respect to the capacity of the system. Figure
3 shows the relationship between the temperature (the controlled
variable) and the action of the heater (the manipulated variable). In
industry, a typical application for on/off control is the temperature of a
large tank or bath. These also have large thermal capacities, with a
small source of heat (the energy inflow) warming the liquid in them
(the controlled variable) to the desired temperature (the set point).

3.1.2 Proportional Control

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On/off control works best on processes with large capacities, which

change slowly. When a process has small capacity, it usually responds
quickly to upsets. Therefore, precise continuous regulation of the
manipulated variable is needed. Proportional control attempts to
stabilize the system and avoid fluctuations by responding to the
magnitude as well as the direction of the error. In operation, the
proportional controller calculates the amount of error between the
measurement and set point, amplifies it, and positions the final control
element to reduce the error. The magnitude of the corrective action is
proportional to the error. Generally, the measurement of proportional-
only controller can completely eliminate offset at only one load
condition. When there is a process upset, such as when flow is suddenly
reduced, the valve must change position to keep the controlled variable
at a constant level (maintain the set point). The output from the
controller (which controls the valve position) must assume a new value,
different from the original (the set point), before equilibrium can again
be reached. This new value of the controlled variable is offset from the
set point. Figure 4, Curve C, shows system response when the
proportional band in which the oscillations settle out quickly. If the
proportional band is too wide (insensitive), the offset will be much
larger, reducing the amount of control over the process. Narrowing the
proportional band (increasing the gain) can reduce the amount of offset,
but too narrow a band creates cycling. The most important limitation of
proportional-only control is that it can accommodate only one fixed
relationship between input and output, one control load where input
error is zero and one output signal which positions the control valve in
the position required to make the error zero.

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3.1.3 Integral Control

Integral action avoids the offset created in proportional only control by

bringing the output back to the set point. It is an automatic rebalancing
of the system, which operates as long as an error exists. Therefore,
integral control responds to the duration of the error as well as its
magnitude and direction. Integral control is almost never used alone;
rather, it is combined with proportional control. At one time, the system
rebalancing had to be done manually; this was called "manual reset."
The term "reset" is occasionally still used, although a complete
definition of the function includes the mathematical concept of
integrating the error until it reaches zero. In a proportional-plus-integral
controller, integral action can be expressed in terms of minutes per
repeat—the amount of time necessary for the integral controller to
repeat the open-loop response caused by the proportional mode for a
step change in error. The smaller the time value, the faster the integral
action. (Some controller manufactures express integral action in repeats
per minute, which is the reciprocal of minutes per repeat.)

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3.1.4 PID

PID control responds to all aspects of process error—direction,

magnitude, duration, and rate of change. The output of a PID controller
is a linear combination of P, I, and D modes of control. PID control can
be advantageous on many processes. However, its application should be
considered carefully because it has limitations with some processes.
Processes that benefit most from PID control have rapid and large
disturbances in which derivative action can respond to the rapidity of
the changes, and integral action can respond to the duration of them.
Derivative and integral action are complementary. Derivative action
permits an increase in proportional gain, offsetting the decrease
necessitated by integral action; where integral action tends to increase
the period of cycling of a loop, derivative action tends to reduce it,
thereby producing the same speed of response as with proportional
action but without offset. Temperature processes, such as the heat
exchanger, typical of those applications, which can benefit from PID
control. Figure 6 shows the effect of the addition of derivative action to
a properly adjusted PI controller. The period (time to complete a cycle)
is shorter than with proportional-plus- integral control.

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Figure 7 shows the response of a system to a process upset in the

primary analogue control mode: proportional, integral, and PID. The
uncontrolled response is shown for the sake of comparison.

Figure 8 shows the response of a system to a change in set point (as

would happen in tuning a controller) using the same analogue control
modes.

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3.1.5 Loop Tuning

The closed-loop control system attempts to achieve a balance between

supply and demand by comparing the controlled variable to the set
point and regulating the supply to an amount, which will maintain the
desired balance. Tuning the controller adjusts it so it can achieve that
balance as quickly as possible. This is done when the instrument is first
put in service and, later, on a periodic basis as part of preventive
maintenance. When tuning, remember that each controller is part of a
closed loop: all the parts of the loop are interactive, behavior of other
devices in that loop. The controller response must be matched to that of
the process. There are several procedures for doing this, some
mathematical, most using trial and error.

3.1.6 Cascade Control

Cascade Control system consists of one controller (primary/master)

controlling a variable that is to be kept at a constant value by adjusting
the set point of a second controller (secondary/slave), which controls
another, faster variable that affects the first one. The primary variable
controller positions the setpoint of the secondary controller and it, in
turn manipulates the control valve. The primary variable is slow, most
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commonly temperature, the secondary variable is as much as ten time

faster, usually flow. The secondary loop is introduced to reduce lags,
thus stabilizing inflow to make the whole operation more accurate and
responsive. The secondary controller may be regarded as an elaborate
final control element, positioned by the primary controller in the same
way a single controller would ordinarily position the control valve. If
for example, the secondary controller is a flow controller, then the
primary controller will not be dictating the prescribed flow (set point).
In cascade control an integral windup can occur when the process load
demands more than the control valve can deliver, a sustained deviation
of the secondary measurement from its set point results. The primary
controller then readjusts the set point of the secondary controller even
though it can apply no corrective action.

3.2 METHODOLOGY

The Level and Flow Control Trainer (Model: SE 665) was designed for
students to demonstrate and gain a better understanding of how open
and closed tank level measurement and control work, as well as to
provide them with hands-on experience manipulating various control
parameters using a microprocessor-based controller. It may also be
linked to a flow metering loop to conduct cascade control experiments.
The equipment is made up of industrial grade instruments that are used
to simulate the working environment of a genuine level process by
employing various types of measuring devices and control strategies.
All electrical wiring is run through flexible PVC conduit, and all
instrument wires are screened. Individual pump starters are provided.
Pump power cables are routed in a separate conduit from instrument
wires. A MCB is fitted to prevent overcurrent and an ELCB is installed
to avoid unintentional electrocution for electrical safety. The control
panel has an IP 55 certification to protect it from dust and water
splashes. Every key piece in the equipment is labelled with an
identification tag. A replica schematic of the Process and
Instrumentation Diagram (P&ID) is also supplied.

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Figure 3.2: One of team members doing some working on level flow
process control training system (SE 665).
.

A water process is the SOLTEQ Model: SE 665 Level and Flow

Control Trainer. A water circulation pump transports water from the
sump tank to the level control tank. There are two ways to discharge
from the level control tank to the sump tank. One method is known as
the "self-regulatory" mode, which uses gravity flow to restore water to
the sump tank. The alternative option is "non-self-regulating," which
uses a pump to remove the water from the tank.

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Figure 3.3: Typical experiment result using

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Figure 3.4: Trial and error tuning method

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3.3 Problem Statement

1. If is the domestic washing machine, which may be

programmed to control a series of operations necessary
to wash a load of clothing, it runs through its cycle and,
since no information is fed back to the control device
regarding the condition of the wash, it shuts down?

 Only a human agent inspection the load, and

finding it unsatisfactory, can institute corrective
action.

2. Why automatic control requires some sort of signal

system to close the loop and provide the means for
information flow?
 This means that the controller must be able to
move the valve, the valve must be able to affect
the measurement, and the measurement signal
must be reported to the controller. Without this
feedback, you do not have automatic control.

3. Why the rate of rise (or fall) of the controlled variable is

small?
 Because the energy inflow is small compared to
the large capacity of the system.

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3.4 RESULTS AND ANALYSIS

N Instru Tag No. Descriptio Range

o. ment n
1 PID FIC-601 Microproce -
Controll LIC-603 ssor
er
based PID
controller,
controlling
level / flow

2 Recorde LR-603 Paperless -

r FR-603 Chart
Recorder (2
Channel)

3 Orifice Primary 0 – 40
FT-601
flow LPM
D/P
Transmi measureme

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tter nt device
giving 4 –
20 mA
output

4 D/P Level 0-
LT-603
Transmi 1000m
tter measurem mH2O
ent

using
differential
pressure.
1 inch
5 Control FCV-601 globe 1 –
Valve type 100%
valve
with
Cv=2.5,
linear
characteri
stic with
I/P
positioner
and I/P
converter
6 Pumps P-601 Water 80
P-602 circulatio LP
n pumps M
@

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16.2m

7 Process T-601 L 80 L
Tanks T-602 e 120
v L
e
l
control
tank
Sump
tank

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T-602

8 Alarm
Annunc LAL 603 Level
iator LAH 603 control tank
FAH 601 alarm high
Level
control tank
-
alarm low
Flow alarm
high

9 Pressure PCV-601
regulato PCV-602 Regulates
r the pressure 0-1
within the MPA
system

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10 Relief
valve Mechanic
PSV-602 ally
activated
device,
spring
loaded
normally -
closed
valve.
Opens
and
purges air
to
atmosphere
in case of
over
pressure in
tank.
11 Rotamet FI-601
er Flowrate 0-120
measureme LPM
nt for water

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12 Pressure
PI-601A
indicato
r PI-601B Dial gauge 0–2
pressure bar
PI-602 0–2
indicator at
location. bar
0–
3000m
mH2O

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13 Side SG-601
glass SG-602 Observation
of water
level in
tanks.
-

14 Control
panel Mounting/
installation
of controller,
alarm -
annunciator,
recorder,
push button,
power
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supply
switch and
changeover
switch
between IOT
and local
control

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3.5 CONCLUSION

In the conclusion, student able to familiarize & identify the instrument

of the Level Flow Process Control Training System for model SE 665
in lab such as PID controller, relief valve and side glass. It is an
excellent unit of practice for students to study the function and
capabilities of each instrument. In addition, students were able to learn
well about each component of the level flow process control training
system after taking a picture of the instrument using the tag number in
the instrument list in the pre-laboratory and explaining its function. For
example, the function of a rotameter with tag number FI-601 is for flow
rate measurement for water in the range 0-120 LPM only. Finally,
students are able to know well the function of the level flow process
control instrument for the next practical laboratory. It will make
students know how to do the next lab process.

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