Basrah University

College of Engineering
CHEMICAL ENGINEERING DEPARTMENT
Process control lab.
Asst. Prof. Abdulwahid Al-Hajjaj
EXPERIMENT NO. 1

PCT53 Pressure control process

Objective:
The objective of this experiment is:
 To control the air pressure in the process vessel using an on/off controller to
automatically start and stop the water feed pump as required to maintain the
required pressure in the process vessel (inflow control).
 To determine the variations in pressure due to the dead band inherent in an on/off
controller.
 To change the air pressure inside the process vessel by changing the set point on
the on/off controller and to determine the effect of disturbances to the process.
 To investigate the effect of different ranges of inflow and outflow to / from the
process vessel.
 To control the air pressure in the process vessel using a proportional controller to
automatically vary the speed of the water feed pump (inflow control).
 To determine the response of a pressure process when using a P only controller to
vary the pump speed.
 To determine the response of a pressure process when using a P+I controller to
vary the pump speed.
 To change the air pressure inside the process vessel by changing the set point on
the P or P+I controller and to determine the effect of disturbances to the process.
 To investigate the effect of different ranges of inflow and outflow to / from the
process vessel.

Introduction:

The PCT53 Pressure Control Process consists of a combined sump tank / process vessel
assembly together with an electrical connection box, mounted on a common base plate.
The process is free standing, without the need for a permanent water supply or drain
connection, and suitable for locating on a work bench alongside a PC.

The process incorporates an electronic interface with sensor conditioning, drive circuits
and integrated USB connection. This means that the user only needs to fill the process
with water (where appropriate), connect the mains adaptor and connect the supplied USB
cable to a suitable PC for the equipment to be operational. In addition to control of the

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process and initiation of step changes, the software supplied will also allow recording of
the responses, graphing etc. when testing any of the control loops.

The electrical interface, mounted alongside the process, incorporates additional front
panel connectors that allow the input and output signals to be connected to an alternative
PID controller, Programmable Logic Controller or similar control equipment if required
by the end user. The electrical supply is provided by a universal 24 Volt DC in-line
adaptor with interchangeable leads to suit the local electrical supply

Theory

1) On/off control

An on/off controller is a simple and effective way of controlling many processes but does
have disadvantages because its output can only be on or off. In the case of the pressure
process in this exercise the water pump is started and stopped.

An on/off controller incorporates a dead band to avoid rapid switching of the controlled
variable when at the setpoint i.e. in this case the pressure must rise above the setpoint by
a fixed amount before the pump switches off and the pressure must fall below the
setpoint by a fixed amount before the pump starts again.

On PCT53 an On/off controller with fixed dead band is created by setting the
Proportional Band to 0% in the PID controller. In a commercial On/off controller the
dead band can be varied to suit the process. This allows the choice of less frequent
switching but larger variations in the process variable or closer control of the process
variable but more frequent switching with attendant wear etc. of the components.

2) Proportional term (P)

The Proportional Band, P, setting on a process controller makes a change to the output
(pump speed on PCT53) that is proportional to the current error value (the difference
between the measured pressure and the set point on the controller). The proportional
response can be adjusted by multiplying the error by a constant Kp, called the
Proportional Gain. This is related to the Proportional Band setting on the controller as
follows:

Proportional Gain (Kp) = 100% / Proportional Band %

i.e. 100% P term means unity gain (change in controller output = error at input)

and 50% P term means a gain of 2 (change in controller output = 2x error at input)

A low setting of the P term (large gain) results in a large change in the output for a given
change in the error. If the P term is too low, the system can become unstable. In contrast,
a large setting of the P term (low gain) results in a small output response to a large input

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error, and a less responsive or less sensitive controller. If the P term is too high, the
control action may be too small when responding to system disturbances resulting in slow
response and offsets of the resulting process variable from the set point.

A Proportional-only controller will not always settle at the set point, but may retain a
steady-state offset. Offset can be reduced in Proportional-only control by reducing the P
term setting. However, if the P-term is set too small then hunting or oscillating will occur.
The offset can be minimised by adding a bias to the set point (setting the set point above
or below the required value to compensate for the offset) but this technique is only
appropriate if the system characteristics are known and fixed. A better solution is to
remove the offset by adding Integral action to the controller (P+I) as described below.

3) Integral term (I)

The contribution from the integral term is proportional to magnitude and duration of the
error. The Integral term in a PID controller is the sum of the instantaneous error over time
and gives the accumulated offset that should have been corrected previously. The
resulting controller output is the sum of the contribution from the Integral term and the
contribution from the P term.

When the I term is correctly adjusted any residual offset in the process variable due to the
P term will be gradually reduced by the Integral term until the offset is eliminated. If the
time setting of the I term is too long then correction to any offset will be very slow.

However, since the integral term responds to accumulated errors from the past, it can
cause the present value to overshoot the setpoint value or to make the process completely
unstable if the time setting of the I term is too short. If this occurs the I term makes
adjustments to the controller output faster than the process can respond. I.e. the I term
winds up the controller output so that the process overshoots considerably, hence the term
Integral Wind-up or Integral saturation.

Careful selection of the I term in combination with the P term will give efficient response
to changes in the system.

Apparatus

PCT53 is a pressure control process using water and air in combination as the working
fluids for safety and convenience in use as shown in Figures (1 and 2).

Water stored in the lower sump tank is transferred to the upper process vessel via a
submerged, variable speed centrifugal pump (9). A quick release connector (8) allows
the flexible pump outlet tube to be disconnected to aid priming of the pump after filling
the sump tank with water. An inline ball valve (CV1) above the quick release connector
allows the flow of water through the process loop to be varied to suit a particular
demonstration.

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Figure 1: Photographic image of the apparatus

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 Figure 2: Schematic diagram of the PCT53 Pressure Control Process

The upper process vessel is sealed from the atmosphere so that the air inside the vessel is
compressed as the vessel fills with water. A non-return valve (7) integrated into the inlet
(6) to the process vessel prevents water from draining back into the sump tank when the
pump speed is reduced or stopped.

Air pressure inside the process vessel, above the water, is measured using an electronic
pressure sensor (5) and indicated on a pressure gauge (1).

Water drains from the process vessel back into the lower sump tank via two outlets in the
floor of the process vessel. Flow through the main outlet is continuous. The second outlet
incorporates a solenoid valve (SOL) that allows the flow to be started and stopped under
remote control. Both outlets incorporate a hand operated valve (CV2 and CV3) that
allows the flow of water to be varied continuously to suit a particular demonstration.
Both outlets also incorporate an interchangeable orifice (2, 4) that allows the flow to be
fixed at a predetermined value, varying only with the pressure inside the process vessel,
so that system characteristics, step changes etc. can be repeated precisely allowing direct
comparison of different controller settings. The orifice size is changed by unscrewing the

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plastic fitting containing the orifice and replacing it with the required alternative. The
fitting incorporates an ‘O’ ring seal and only requires hand tightening. The alternative
sizes of orifice (11) are stored in threaded holes at the front of the base plate when not in
use.

An additional hand operated valve (CV4) connected to a vertical stand pipe allows the air
pressure to be reduced when necessary. The position of the valve ensures that water is
returned to the sump tank if the valve is left open.

The sensor measuring the air pressure, the centrifugal pump and the solenoid valve are
connected to an electrical interface (3) that incorporates the necessary signal
conditioning, allowing the process to be operated directly from a PC using one USB port.
Alternatively the process can be operated using a controller such as PCT54 (PID
Controller) or PCT55 (PLC with PID controller) connected to the electrical interface.

The computer software supplied with PCT53 allows control of the pressure process and
data logging of the responses using a PC. Alternatively the software allows data logging
only while operating the process remotely using a PID controller or PLC.

When filled with water, the PCT53 is self contained requiring only a mains electrical
supply to the in-line DC adapter and connection to either a PC via the USB port or to a
process controller such as PCT54 (PID Controller) or PCT55 (PLC with PID controller.

Water is drained from the unit using the ball valve (10) located at the rear

Experimental procedure
a. On-off control

1. Choose the PID box on the mimic diagram; set the Proportional Band, Integral
Time and Derivation time to 0 then set the Set Point to 0.2 bar (default at start
up). Click Apply to enter the changes to the settings as shown in Figure (3)
2. Select the icon to begin data logging.

3. Choose the Automatic Mode of Operation.

4. The pump will switch on, the water level and air pressure will gradually rise and
water will drain from the vessel via outlet valve CV2. The water level and the air
pressure will continue to rise until the pressure reaches the pressure set on the
controller i.e. the setpoint of 0.2 bar. When the pressure rises above the setpoint
by a fixed amount (the dead band) the pump will switch off and the pressure will
fall as water drains via outlet valve CV2. When the pressure falls below the
setpoint by a fixed amount (the dead band) the pump will switch on again and the
cycle will continue.

5. In the PID controller adjust the set point to 0.3 bar, click Apply then observe that
the pump switches on and off as before to maintain the new pressure.

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 Figure (3) PID controller

6. Adjust the set point to 0.7 bar and observe the response of the process. The pump
is unable to achieve the required set point.
7. Return the set point to 0.2 bar and allow the system to stabilise.

Effect of Disturbances

1. Open the solenoid valve by clicking the button on the mimic diagram (1 indicates
that the valve is open). Observe that the air pressure falls due to the additional
outflow via the solenoid valve then the controller switches on the pump to restore
the original pressure.
2. Close the solenoid valve by clicking the button on the mimic diagram (0 indicates
that the valve is closed). Observe that the process returns to the original
characteristics.

Effect of differences in Inflow Rate and Outflow rate

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1. Partly close inlet valve CV1 so that the pressure only just exceeds 0.3 bar when
the pump is running at full speed. Allow the pressure to rise and fall through
several cycles then open the solenoid valve to disturb the process. If the combined
outflow exceeds the inflow then the pressure will continue to fall with the pump
operating and the required pressure cannot be maintained. Close the solenoid
valve again.
2. Fully open the inlet valve CV1 so that the pressure rises rapidly when the pump is
running. Allow the pressure to rise and fall through several cycles then open the
solenoid valve to disturb the process.

3. Choose the icon to finish data logging.

4. If time permits repeat the exercise with a different size of orifice fitted to the
outlet valve CV2 and solenoid valve, E.g. 2.0mm at CV2 and 1.5mm at the
solenoid valve (larger outflow with smaller disturbance). The pressurising
characteristics with different settings of CV1 could also be investigated.

5. Create a new results sheet for each run by selecting the icon in the tool bar of
the software

b. P only controller

1. Choose the PID box on the mimic diagram, set the Proportional Band, P, to 200%,
the Integral Time I to 0 and the Derivation time D to 0 then set the Set Point to 0.2
bar (default at start up) as shown in Figure (3). Click Apply to enter the changes
to the settings.

2. Choose the Automatic Mode of Operation.

3. Select the icon to begin data logging.

4. The pump will start, the pressure will gradually rise and water will drain from the
vessel via outlet valve CV2. The pressure will continue to rise until it reaches a
steady pressure but this will not correspond with the setpoint of 0.2 bar on the
controller because of the offset inherent in a P only controller.

5. Open the solenoid valve by clicking the button on the mimic diagram (1 indicates
that the valve is open) to disturb the process. Observe that the pressure falls
slightly, the pump speeds up slightly due to the increased error but a large offset
remains. When the pressure has settled close the solenoid valve and allow the
pressure to settle.

6. Adjust the set point to 0.3 bar then click apply and observe the response to a
requested increase in pressure. When the pressure has settled, return the set point
to 0.2 bar and observe the response.

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7. Adjust the P term to 100% in the PID controller then click Apply. Observe that
the pump speeds up and the offset reduces slightly. Open then close the solenoid
valve as before to disturb the process and observe the response, the stability of the
pressure and any reduction in offset.

8. Adjust the P term to 50% and repeat the above steps.

9. Adjust the P term to 20% and repeat the above steps.

10. Adjust the P term to 10% and repeat the above steps

11. Adjust the P term to 5% and repeat the above steps

12. Adjust the P term to 2% and repeat the above steps.

13. Choose the icon to finish data logging.

c. P + I controller

1. Create a new results sheet for this run by selecting the icon in the toolbar of the
software.

2. Choose the PID box on the mimic diagram, set the Proportional Band, P, to the
value selected above, the Integral Time, I, to 0 seconds and the Derivation time D
to 0 then set the Set Point to 0.2 bar as shown in Figure (3). Click Apply.

3. Select the icon to begin data logging.

4. Choose the Automatic mode of operation and allow the air pressure to stabilise.

5. Adjust the I term to 100 seconds in the PID controller then click Apply. Observe
that the pump speed varies very slowly to reduce the offset. When the pressure
has settled at the set point open the solenoid valve to disturb the process. Observe
that the pressure falls slightly, the pump speed varies and the pressure gradually
returns to the set point. When the pressure has settled close the solenoid valve and
allow the pressure to settle again.

6. Adjust the set point to 0.3 bar then click Apply and observe the response to a
requested increase in pressure. When the pressure has settled return the set point
to 0.2 bar and observe the response.

7. Adjust the I term to 50 seconds in the PID controller then click Apply. Observe
that the pressure returns to the set point faster than before. When the pressure is
settled at the set point open then close the solenoid valve as before to disturb the
process.

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 8. Adjust the set point to 0.3 bar then click Apply and observe the response to a
requested increase in pressure. When the pressure has settled return the set point
to 0.2 bar and observe the response.

9. Continue reducing the Integral time setting and repeating the disturbance and set
point changes until the air pressure becomes unstable.

Results:

a. On-off control
1. Choose the icon (or View \ Graph) to display a graph of the responses
obtained. Observe the rising and falling pressure about each of the set points as
the pump starts and stops to maintain the required pressure. Observe the change in
the rate of pressurising when the solenoid valve is opened to disturb the process
and when the inflow is reduced by partly closing valve CV1.

2. From the graph or the table of results ( icon or View\Table) determine the
variation in pressure about the set point to determine the dead band of the
controller. In a commercial controller the dead band would usually be adjustable
to suit the process but too small a variation would lead to wear of components
switching rapidly on and off.

3. From the graph observe that the rate of pressure rise when the pump is running is
not necessarily the same as the rate of pressure fall when the pump is stopped.

b. P only controller

1. Choose the icon (or View \ Graph) to display a graph of the responses
obtained.

2. Choose Format \ Graph Data and Plot Pressure P1 and Set point on 1 axis, and
Controller Output on the second axis.

3. Observe the changes in air pressure and the stability of the responses for each
change in P setting with a disturbance or change in set point.

4. Choose a setting for P that gives stable control with a reasonably small offset that
can be used in the next part of the exercise introducing Integral action.

c. P + I controller

1. Choose the icon (or View \ Graph) to display a graph of the responses
obtained.

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 2. Choose Format \ Graph Data and Plot Pressure P1 and Set point on 1 axis, and
Controller output on the second axis.

3. Observe the changes in pressure and the stability of the responses for each change
in I setting with a disturbance or change in set point.

4. Choose a setting for I that gives stable control and reduces any offset swiftly
without causing the system to become unstable.

5. Since the effect of Integral Action is related to the Proportional Band setting
(reduced P term gives greater effect for any setting of I) the above exercise should
be repeated at a completely different value of P term to determine the necessary
change in I for effective control of the level and to demonstrate the relationship
between P and I.

6. If time permits repeat the exercise with a different size of orifice fitted to the
outlet valve CV2 and solenoid valve, E.g. 2.0mm at CV2 and 1.5mm at the
solenoid valve (larger outflow with smaller disturbance). The filling
characteristics with different settings of CV1 could also be investigated e.g. partly
closing valve CV1 to reduce the flow or increasing the flow by opening the valve

References

1. D.R. Coughanowr and S.E. LeBlanc, Process System Analysis and Control, 3 rd
edition, McGraw-Hill, 2007.
2. D.E. Seborg, T.F. Edgar, D.A. Mellichamp and F.J. Doyle III, Process Dynamics and
Control, 4th edition, John Wiley, 2017.
3. W.L. Luyben, Process Modeling, Simulation, and Control for Chemical Engineers,
2nd edition, McGraw-Hill 1999.
4. P.K. Sarkar, Process Dynamics and Control, Delhi, 2014.

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