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.1)Group Leader: ……….. (Signature) Name : __________________________________
MatrixNo. :__________________________________
2)Group Member 1: ………. (Signature) Name : __________________________________
Matrix No : __________________________________
3)Group Member 2:……….. (Signature) Name :__________________________________
MatrixNo. :__________________________________
4)Group Member 3:……….. (Signature) Name :__________________________________
1.0 OBJECTIVES
a) To study On/Off temperature control of electric heaters
b) To study temperature control in heat exchanger using PID controller
2.0 LEARNING OUTCOMES
At the end of the study, student will be able to:
a)
To be familiar with the basic steps of machine from start-up to shut-down with proper handling and setting.b)
To identify the major component of the heat exchanger process control trainingsystem3.0 INTRODUCTION
Shell and tube heat exchanger is the most commonly used in the industries. Heat exchangers are one medium of fluid flows inside and through the bundles of tubes while the other medium flows in the shell side. The heat from the hot fluid transferred through the metal wall of the tubes to the cold fluid due to the
difference in their temperature. Control of temperature in the outlet stream of the hot/cold fluid is essential in order to minimize the energy losses and also to meet temperature specification in the downstream process.
4.1 INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS 4.2 The process plant consist of two tank (T61 & T62)
Centrifugal Pump : P61, P62, P611 Shell and Tube Heat Exchanger Control Valve: TCV61
Measurement: TE61/TIT61, RTD, and TE62/TIT62, Type K On/Off Controller: TIC62
PID Controller: TIC61
4.3 Apparatus
a)
Heat Exchanger process control training system.5.0 PROCEDURE
5.1 STARTUP PROCEDURES
1.The following steps must be carried out before starting the experiment:
a)Fill the tank T62 and the product Tank T61 with water up their overflow drain pipe.
b)Check the manual valve at the product downstream pipeline TSV62 is open to the external drain system.
c)Turn on the main power supply at the front cubicle. 2.Check the various manual valve as follow
• OPEN all suction and discharge valve pumps (P61,P62,P611) • Manual by-pass valve for each pumps and control valve TCV61,
TSV61,TSV62 and LSV61 is shut.
• OPEN the manual valve at the inlet of LSV61
• Bottom drain valves of tank T61 and T62 always shut
• Display TIC61 inManual (M) mode. SetMV = 100% to open the
controlvalve.Checkthecontrolvalveisopen(attheplant)
• Set theSV to 40oc
• Access the PID tuning page “PID1” and change the PID values to
thefirst(I)trialvalues
PB1=15% TI1=35sec TD1= 8sec
• Access On/Off control (TIC62, TIC611) at the “P/T Register page at
PO1 and PO5
• Start the recorder TR61 by pressingONtheRCDpushbutton.
4.With TIC61 in Manual(M) mode, stroke the control valve with MV=25% , 50% and 100%.(Check the opening of TCV61 at the plant)
5.2 ON/OFF TEMPERATURE CONTROL
The heating medium for the heat exchanger is produced by heating water in the tank T62. Its maintained constant by the On/Off controller TIC62. Its controlled with ±0.5oc less or more from the setpoint values.
1.START the heating medium circulation
• Make sure the valves MV62 and B62 are opened • START pump P62
• Ensure the water flow through the heat exchanger and back to
T62
• SHUT the by-pass valve B62
• Switch On the heaters. Make sure there is a temperature
increase in the tank T62 so that the heater is ON
• Top-up the water in the tank T62 if necessary
2.START the chart recorder by pressing the RCD button at the recorder TR61
• Use the selector and switch to TE62/TIT62 to select only Green
pen to record
• Observed the rise in temperature of water in tank T62 • It will take 15-20 minutes for TE62 reach 55oc.duringthis
time, STOP the recorder, by push the RCD button and proceeds tosteps(3)and(4).
3.Whenever any annunciator buzzer on, press the ACKNOWLEDGE
button to silence the buzzer. Try to rationalize the cause of the alarm. 4.Set parameters of the On/Off controller TIC62 as follow:
• Access the menu and select “P/T Register” button to set the
High temperature limit and Dead Band of controller TIC62 PO1: High temperature limit = 55oc
PO2: Dead Band = 0.5oc
PO3: High limit for annunciator TAH62.(Same as PO1) PO4: Dead Band for annunciator TAH61.(Same as PO2)
• Access to menu and select “I/O Data” button and note the
followingdata:
X2 : TE62/TIT62, % of 0-100oc,inputvariabletothecontroller DO1 : Heater status in T62. 1(ON), 0(OFF)
DO2 : Annunciator TAH62 status. 1(On), 0(Off)
5.When the temperature is approaching 55oc, start recorder TR61 buy
pushing the RCD button.
• Observed both recorder TR61 Green pen and the “I/O Data”
X2, DO1 and DO2
• Write down the high temperature limit and Dead Band data on
the chart paper beside the Green pen
6.Observed the temperature TE62/TIT62 at X2 and go through the followingcheck list:
• TE62/TIT62 rise and exceeds the High limit (55oc)
The heater is Off
• Check the Status DO1, DO2, and X2 at the “I/O Data” and
record the data on the chart paper
• TE62/TIT62 continues to rise. i.e overshoot beyond the High
limit
• TE62/TIT62 drops to the High limit (55oc)buttheheaterisstill
OFF
• TE62/TIT62 drops further by an amount equal to the Dead
band (0.5oc)
Heater are switched ON again
The annunciator TAH62 is switched OFF
Check the status DO1, DO2 and X2 at the “I/O Data” and record the data on the chart paper
• Continuetheobservation togetafullcycle,i.e;2temperature
peaks or bottom
• Note the oscillatory nature of On/Off control at the Green pen
oftherecorder
7.Stop Record by push the RCD button at the recorder. Note at the chart paper your experiment name.
5.3 PID CONTROL OF TEMPERATURE
1.The temperature of the heated product at the exit of the heat exchanger measured by TE61/TIT61 is controller PID (Loop 1) of TIC61
2.The On/Off controller TIC62 maintains the temperature of tank T62 at 55oc.SetthecontrollerTIC asfollow:
• Endure the setpoint SV = 40oc
• With TIC61 inManual(M) mode, set the outputMV=100% • CheckthatthePID valuearesettothe(I)trialvalue
PB1=15% TI1=35sec TD1=8sec
3.START the cold water circulation
• Make sure that valves MV61 and B61 are opened • START pump P61, and ensure the water flow through
rotameter FI61
• Adjust manual valve at MV61 to set the flow rate to 1.3m3/Hr • START the circulating pump P611
4.Switch TIC61 to AUTO(A) mode
• Write the product flow rate FI61, Setpoint (SV) and PID value
on the chart paper beside its response
• Observed the response of TE61/TIT61 at the recorder RED pen
till it becomes steady around 40ocoritcontinuestooscillates
eveafter3cycle
5. Test Disturbance –Setpoint Change
• SetthePID valuesofthecontrollerTIC61tothesecond(II)trial
values
PB1=10% TI1=30sec TD1=7sec
• Change the setpoint SV=42oc. Mark on the chart paper the new
setpoint value. DO NOT increase setpoint obove 44oc
• Watch the response at the recorder till it is almost steady or
continuestooscillateseven after3cycle 6. Test Disturbance – Load Change
• Makes sure the system is at steady state
• Step change the product flow rate by opening fully MV61. Note
the flow rate FI61 and write the value at the chart paper
• Watch the relevant portions of the chart paper and attach the
resultinthereport
7.Retrieve the relevant portions of the chart paper and attach to the resultsinthereport.
8.
1.4 SHUTDOWN PROCEDURE
1.Switch the controller TIC61 to Manual(M) mode, and set the MV=100%
2.Switch Off heater
3.Stop all the pump P61, P62 and P611 4.Switch Off the main power supply
The recorder TR61 records the results of the experiment.
1.Submit the P & I diagram with major components of the system marked in it 2.Prepare a report on the start-up procedure
3.For On/Off control, note the high alarm limit and Dead band at various values. Submit the results of On/Off controller in the results sheet table below
P T Register I/O Data High Temp
Limit Dead Band Status TIC62, Controller PO1 =_____oc PO2 = ____oc DO1:
TAH62, Annunciator PO3 =_____oc PO4 =____oc DO2:
4.Study and compare the different response with different PID value. Submit relevantportionsoftherecorderchartresponsewiththefollowingdata marked on it:
• Controller in Auto(A) mode or Manual(M) mode • Setpoint (SV), PB%, TI secs, TD secs
• Product flow rate FI61 • Any annuciator initiated
Discuss on the nature of response, such as fast/slow, smooth/oscillator, overshoot.Decayratioetc.
PreparetheresultsofthePID controllertestisaresultssheettablebelow PID temperature control of the heat exchanger
TE61 – TIT61 – TIC61 – TCY61/TCV61 Controller parameter value: TIC61 (PID)
PB1 = ______% TI1 = _______secs TD1 = _________secs Setpoint(SV)=_______oc
Product flow rate (FI61) = __________ m3/Hr
Test disturbance: Step/pulse
At Setpoint SV1 =________ At product flow rate =________
7.0 ANALYSIS OF THE RESULTS
Analysed critically each results obtain in section 6.0 by referring to the theory/introduction parts. Find reasons (suggested reasons) on each occurrence shown in the results.
8.0 DISCUSSIONS
Discuss the overall experiment on data obtain based on your understanding. Discussion should relate reasons for the phenomena/results obtained, theoretical parts, suggested reasons (if necessary but back with sound theoretical knowledge) and your overview understanding.
9.0 ADDITIONAL QUESTIONS
i. Based on the results, discuss the difference/characteristics of measurement taken by Thermocouple and RTD.
ii. Temperature is considered as a process variable with a slow response. Discuss the statement.
10.0 CONCLUSION
Conclusion is merely a summary of the important findings already reported in thediscussion section.Italsorelatestotheobjectivesstated earlier.
11.0 SUGGESTIONS & RECOMMENDATIONS
Your ideas of suggestion & recommendation to improve the learning process for this experiment or anything related to the experimental procedure etc.
12.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter based)
