RESULTS

Table 1: Parameters of the Flow Measurement

Instrument Controller I II III

reading MV=-6.3% MV=50% MV=70%
At the panel FIC91, I/0 Data
FT91, √ h XI - % of 0-100mm 79.9 52.8 35.7
H2O

TIT911, T X2- % of 0-120℃ 28.4 28.8 28.9

PT911, P X3- % of 0-60psia 66.0 98.7 109.9

FIC91, Main Face

Fm Plate 50.4 40.4 28.9
PV, kg/hr

Fv FIC90, MAIN FACE

PLATE 20.4 13.5 9.1
PO1, m3/hr

Channel I(Red) Recorder FPTR91

Fm, kg/hr 50.2 40.5 28.8
Channel
2(Green) Fv, m3/hr 20.4 13.5 9.1

By calculation Fvb, Nm3/hr 50.6873 40.9340 29.2003

Fm, kg/hr 65.5271 52.9184 37.7494

At the plant
F1911, Nm3/hr 46.0 32.0 21.0

PG900, psig 29.5 46.5 58.5

CALCULATION
Volumetric flowrate (with or without pressure and temperature compensation)
ℎ𝑃
With P//T compensation: Fvb = kvb √ 𝑇 where kvb = 1.356

h = differential pressure, mm H2O

P = absolute pressure, psia
T = temperature, K
ℎ𝑃
Based on perfect gas law: Fm = km √ 𝑇 where km = 1.753
Trial 1:
66.0
Fvb = 1.356 x 79.9 𝑥 √(28.4+273.15)

= 50.6873 Nm3/hr

66.0
Fm = 1.753 x 79.9 𝑥 √(28.4+273.15)

= 65.5271 kg/hr

Trial II:
98.7
Fvb = 1.356 x 52.8 𝑥 √(28.8+273.15)

= 40.9340 Nm3/hr

98.7
Fm = 1.753 x 52.8 𝑥 √(28.8+273.15)

= 52.9184 kg/hr
Trial III:
109.9
Fvb = 1.356 x 35.7 𝑥 √(28.9+273.15)

= 29.2003 Nm3/hr

109.9
Fm = 1.753 x 35.7 𝑥 √(28.9+273.15)

= 37.7494 kg/hr

Distance between two adjacent peaks

Tn = measured period in mm x 3600 = 1.0 x 3600 = 7.2

Chart speed eg 500mm/hr 500

TI = Tn = 7.2 = 6
1.2 1.2

So, the PB* = 2 x PB* = 2 x 60 = 120%

DISCUSSION

In this experiment, air flow process control experiment was done to identify the
important components of the air pressure control system and to mark them in the P&ID,
to carry out the start-up procedures systematically, to study gas volumetric flow rate
measurement by using orifice plate, to study gas mass flow rate measurement using
orifice plate and perfect gas law to complete the gas density from the pressure and
gas measurements, to study the gas mass flow rate (Fm) control using PID controller
and also to design a PID controller by using Ziegler Nichols closed loop method. In
order to detect the differential pressure throughout the flow the orifice plate was used,
and the differential pressure measurement was calculated. The volumetric flow rate
and mass flow rate was recorded in the chart by the air flow process control training
system, where the red colour in the chart showed the mass flow rate and the green
colour showed the volumetric flow rate throughout the experiment.

Based on the experiment, there are three different tests was done to observe
the process response. For the first experiment, gas mass flow rate control was
observed by using PID control mode with pulse load disturbance and set point
disturbance were applied to bother the process flow response. In manual (M) mode,
the SV value was set at its set point which is 25kg/hr and the control valve FCV91 was
fully open with MV was -6.3%. In this experiment, three different value of PB was tests
which are 200%, 100% and 150% with T1 at 6s and TD is 0s. The auto mode was set
and waited until the recorder response of the air flow (red pen) was fairly steady. Then,
a pulse disturbance was introduced by quickly opening and shutting fully the by-pass
valve around control valve FCV91.