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STARTUP PROCEDURES

1 Switched the "PANEL, SCADA/DDC" selector switch to the


"PANEL, SCADA" position.
2 Switched ON the main power supply. All the panel instruments
will light up. Stop when recorder is running by pressing the `RCD'
pushbutton.
3 Pressed the ACKNOWLEDGE button when annunciator gets
activated to silence the buzzer.
4 Set the instrument air supply regulator at the pneumatic control
valves PCV91 and PCV92. Valves PCV91 and PCV92 were shut off
fully.
5 Checked that the control valve positioner (PP) of PCV91 was
connected (ON).
6 Make sure the compressed air was available at the pressure inlet
air regulator AR91.
7 Check that the vent valve (V) and bottom drain valve (D) of vessel
T91 are shut.
8 Shut off fully the manual valves MV91B and MVIII.
9 Shut off fully the process inlet manual valve MV91.
10 Placed the panel controller PIC91 in manual (M) mode and adjust
its MV = - 6.3% to open the control valve PCV91 fully.
11 Opened fully the final discharge manual valve (VP).
12 traced the two pipe lines PLI and PLII
Pipeline PLI: Single capacity process:
AR91-MV91-T91-PLI-B92- FI92 -P CV9 1 VP
Two-capacity process
AR9 1 -MV9 1 -T91 -PLI-MVI-T92-MV92-FI92 -PCV 9 1 VP
Pipeline II (PLII):
AR9 1 -MV9 1 -T91-PLII-MVII-PCV92-MV92A/MV92B-V

13 Opened fully the pipelines PLI and PLII. Make sure the manual bypass valve B92 around vessel T92 was opened and the manual
valves at the inlet MVI and outlet MV92 of T92 are shut.

14 Checked and adjusted the pressure at AR91 was approximately at


the pressure indicated at AR91. Check MV91 is fully shut off.
15 Slowly opened MV91 and regulated it until the flow rate at flow
meter FI92 reads 35 Nm3/Hr
16 Checked the pressure and flow rate setting:
a Shut off fully PCV91 from PIC91 in manual (M) mode with
MV=106.3%. Read the pressure at vessel T91 at the PV
reading of PIC91. If the pressure was about 22 27 psig, the
b

pressure was correctly set.


Opened fully PCV91 from PIC91 in manual (M) mode with
MV=-6.3%. Read the pressure at vessel T91 at the PV
reading of PIC91. If the pressure was not more than 10 psig
and the flow rate at FI92 also reads 35 Nm3/Hr, the air flow

rate was correctly set. DO NOT read just AR91 and MV91
ON/OFF PRESSURE CONTROL
1 Started the chart drive of the recorder by pressing the `RCD'.
2 Shut fully PCV91 from PIC91 in manual (M) mode with
MV=106.3%. Read PV at PIC91, the pressure at vessel T91. The
pressure in the range of 22-27 psig.
3 To open PLII: Opened only the manual discharge globe valve
MV92A at the common vent of PLII. Kept the gate valve MV92B
at the common outlet of PLII closed.
PCV92 opened when PT91 exceeds 21 psig and closes when PT91
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dropped below a fixed Dead Band (0.5 psig), 20.5 psig.


Repeated the ON/OFF action by opening and closing PC 91.
This was done by reducing the MV such that pressure PV
dropped below 20 psig. Then shut PCV91 fully again with MV =
106.3%.

PID CONTROL OF PRESSURE IN SINGLE CAPACITY PROCESS

Make sure that you have gone through the START-UP

procedures very carefully.


Start the chart drive of the recorder by pressing the `RCD'

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pushbutton at the front of the recorder.


Make sure that pipelines PLI and PLII are opened throughout.
Open only the manual discharge globe valve MV92A at the

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common vent of PLII.


Close the gate valve MV92B at the common outlet of PLII
For single capacity operation, only vessel T91 is used. Vessel
T92 is by-passed
a Open by-pass valve B92 around T92
b Shut the manual valves at the inlet, MVI, and at the
c

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outlet, MV92, of T92.


Make sure the air flow path T91-PLI-FI92-PCV91-VP is

opened through B92.


Set the set point of PIC91 as SV = 15 psig.
Set the PID controller with the first (I) trial values: PB1 = 70%,
T11 = 40 secs, TD1 = 0 sec.
9 Transferred the controller to Auto (A) mode and wait for the

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response to become almost stable.


Switched PIC91 to Manual (M) mode, decrease MV by about 5
to 10%, switch back to Auto (A) mode and observed the

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response for a few minutes.


If the response is slow to return to the set point SV = 15 psig
Now set the PID controller with the second (II) trial values:
PB1 = 45%, TI1 = 30 secs, TD1 = 0 sec.
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Switched PIC91 to Manual (M) mode, decrease MV by about 5
to 10%, switch back to Auto (A) mode and observe the
response for a few minutes.
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Increased PB1 by 5% and repeat the step (13).
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Tried the third (III) trial values for the PID controller:
-PB 1 = 20%, TI1 = 10 sec, TD1 = 2 sec.
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Introduced the disturbance in MV as in step (13) and observed
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the response.
STOP the chart drive and retrieve the relevant portions of the
chart paper. Attach the chart paper along with the results.