UniKL MICET

LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

REVISION NO:

1
1
29 SEPT
2014

AMENDMENT
DATE:

SECTION OF CHEMICAL ENGINEERING TECHNOLOGY

MALAYSIAN INSTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

PROCESS CONTROL LABORATORY

LABORATORY INSTRUCTION SHEETS

COURSE CODE
EXPERIMENT NO.
EXPERIMENT TITLE

CPB 30004 / CPD 20302 / CKB 20003

EXPERIMENT 5
Heat Exchanger Process Control

DATE
GROUP NO.
LECTURER/INSTRUCTOR/TUTOR

1)
2)

DATE OF REPORT SUBMISSION

DISTRIBUTION OF MARKS FOR

LABORATORY REPORT:

ATTENDANCE/PARTICIPATION/DISIPLINE:

/5%

INTRODUCTION:

/5%

PROCEDURE:

/5%

RESULTS& CALCULATIONS
ANALYSIS
DISCUSSIONS:
ADDITIONAL QUESTIONS
CONCLUSION

/15%
/20%
/15%
/10%

SUGGESTIONS& RECOMMENDATIONS

/5%

REFERENCES:

/5%

TOTAL:
EXAMINER COMMENTS:

/15%

RECEIVED DATE AND STAMP:

/100%

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

1
1

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

STUDENT CODE OF ETHICS

SECTION OF CHEMICAL ENGINEERING TECHNOLOGY

MALAYSIAN INSTITUTE OF CHEMICAL &

BIOENGINEERING TECHNOLOGY
I hereby declare that I have prepared this report with my own efforts. I also admit to
not accept or provide any assistance in preparing this report and anything
that is in it is true.
1) Group Leader: ..
Name
: __________________________________
Matrix No. : __________________________________

(Signature)

2) Group Member 1: .
Name
: __________________________________
Matrix No
: __________________________________

(Signature)

3) Group Member 2:..

Name
:__________________________________
Matrix No. : __________________________________

(Signature)

4) Group Member 3:..

Name
:__________________________________
Matrix No. : __________________________________

(Signature)

1.0

2.0

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

OBJECTIVES
a)

To study On/Off temperature control of electric heaters

b)

To study temperature control in heat exchanger using PID controller

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
3.0

training system
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

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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
4.2

4.3

INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

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

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
3. Learn to use the PID Controller TIC61

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

Display TIC61 in Manual (M) mode. Set MV = 100% to open the

control valve. Check the control valve is open (at the plant)
Set the SV to 40oc
Access the PID tuning page PID1 and change the PID values to

the first(I) trial values

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 pressing ON the RCD pushbutton.
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

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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. during this
time, STOP the recorder, by push the RCD button and proceeds

to steps (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
PO1:
PO2:
PO3:
PO4:

High temperature limit and Dead Band of controller TIC62

High temperature limit = 55oc
Dead Band = 0.5oc
High limit for annunciator TAH62.(Same as PO1)
Dead Band for annunciator TAH61.(Same as PO2)

Access to menu and select I/O Data button and note the

following data:
X2 : TE62/TIT62, % of 0-100oc, input variable to the controller
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
following check list:
TE62/TIT62 rise and exceeds the High limit (55oc)
The heater is Off
The annunciator TAH62 is activated

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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) but the heater is still

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

Continue the observation to get a full cycle, i.e; 2 temperature

peaks or bottom
Note the oscillatory nature of On/Off control at the Green pen

of the recorder
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. Set the controller TIC as follow:
Endure the setpoint SV = 40oc
With TIC61 in Manual(M) mode, set the output MV=100%
Check that the PID value are set to the (I) trial value
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
Shut the by-pass B61.

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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 40oc or it continues to oscillates

eve after 3 cycle

5. Test Disturbance Setpoint Change
Set the PID values of the controller TIC61 to the second (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

continues to oscillates even after 3 cycle

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

result in the report

7. Retrieve the relevant portions of the chart paper and attach to the
results in the report.

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

6.0

RESULTS & CALCULATIONS

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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
High Temp
Dead Band
Limit

I/O Data
Status

TIC62, Controller

PO1 =_____oc

PO2 = ____oc

DO1:

TAH62, Annunciator

PO3 =_____oc

PO4 =____oc

DO2:

Table: On/Off temperature control of the electric heaters

4. Study and compare the different response with different PID value. Submit
relevant portions of the recorder chart response with the following data
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. Decay ratio etc.
Prepare the results of the PID controller test is a results sheet table below
PID temperature control of the heat exchanger
TE61 TIT61 TIC61 TCY61/TCV61
Controller parameter value: TIC61 (PID)
PB1 = ______%

TI1 = _______secs

Setpoint (SV) = _______ oc

Product flow rate (FI61) = __________ m3/Hr

TD1 = _________secs

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

Test disturbance:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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 the discussion section. It also relates to the objectives stated earlier.

UniKL MICET
LABORATORY: PROCESS
CONTROL

EDITION:

EXPERIMENT: HEAT
EXCHANGER PROCESS
CONTROL

EFFECTIVE DATE:

1
1

REVISION NO:

29 SEPT
2014

AMENDMENT
DATE:

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)