Computer Controlled Process

Control System Manual (UCP)

CHE 184-1P Process Dynamics and Control
Revision Date: Revision:
December 2018 1.0.b

Introduction:

The EDIBON UCP Process Control Systems Module is miniaturized process control trainer for students
and professional. The Unit itself consist of the process module (UCP-UB. Base Unit) and the control
panel (Control Interface Box) connected to a National Instruments Acquisition board to a computer. The
computer runs SCADA to acquire the data from the control interface box.
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

The SCADA software is the user interface for the automated control of the UCP. The software is based
on the striped-down version of the National Instruments LabVIEW (Laboratory Virtual Instrument
Engineering Workbench).

The program consists of different panel. The topmost left portion is the main operations panel
which has the “START”, “STOP” and “SAVE DATA” buttons.

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 1

Level Control – On/Off Control

Procedure:

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 2” tab.
4. Click the “ON-OFF 1” tab.
5. Select the “LEVEL” from the pull-down tab.
6. Set the set point at “200 mm”
7. Tick on the “Action AB-2” checkbox. Set the tolerance at 3
8. Tick off the “AVS-1”, “AVS-2”, “AVS-3” checkboxes
9. Tick on the “SN-1” at the graph panel
10. Set the “AR-1”, “AA-1”, “AB-1”, “AB-2” to “off” position.
11. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
12. Click the “Start” button and take note of the “SN-1” sensor during the run.
13. Make sure that all the tick boxes in procedure 5 to 11 are correct. If not, set the values as stated
in procedure 5 to 11 even if the unit is already processing.
14. Record the value of SN-1 every 10 seconds.
15. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SN-1 with respect to time.

Review Questions:

1. What is gain, what is offset?

2. What will happen if AB-2 is left unchecked in procedure no 8?
3. Will the level approach 56mm, how about 64mm? Explain.

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 2

Level Control – Proportional Control

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab
4. Click the “PID 1” tab.
5. Select the “LEVEL” from the pull-down tab.
6. Set the set point at “200 mm”
7. On the “PID constant” panel, set the proportional gain (Kc) to 1.0, the integral time (Ti) to 0 and
the derivative time to 0. Click the “PID1 ON” button until it turns green.
8. Tick on the “SN-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SN-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SN-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SN-1 with respect to time.

Review Questions:

1. What is a proportional control?

2. Will the level reach 60mm solely based on proportional control?
3. What is the steady-state value of the level sensor? What is the ultimate vale of the level
sensor? Did the sensor value approached 60mm?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 3

Level Control – Proportional-Integral Control

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “LEVEL” from the pull-down tab.
6. Set the set point at “200 mm”
7. On the “PID constant” panel, set the proportional gain (Kc) to 1.0, the integral time (Ti) to
2.0 and the derivative time to 0. Click the “PID1 ON” button until it turns green.
8. Tick on the “SN-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SN-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SN-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SN-1 with respect to time.

Review Questions:

1. What is a proportional-integral control?

2. What is the integral time?
3. Why should the integral time be greater than 1?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 4

Level Control – Proportional-Derivative Control

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “LEVEL” from the pull-down tab.
6. Set the set point at “200 mm”
7. On the “PID constant” panel, set the proportional gain (Kc) to 1.0, the integral time (Ti) to 0
and the derivative time to 0.01. Click the “PID1 ON” button until it turns green.
8. Tick on the “SN-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SN-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SN-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SN-1 with respect to time.

Review Questions:

1. What is a proportional-derivative control?

2. What is the derivative time?
3. Why should the derivative time be lesser than 1?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 5

Level Control – Proportional-Integral-Derivative Control

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “LEVEL” from the pull-down tab.
6. Set the set point at “60 mm”
7. On the “PID constant” panel, set the proportional gain (Kc) to 1.0, the integral time (Ti) to 1.0
and the derivative time to 0.01. Click the “PID1 ON” button until it turns green.
8. Tick on the “SN-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-1”, “AB-2” to “off” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SN-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SN-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SN-1 with respect to time.

Review Questions:

1. What is a proportional-integral-derivative control?

2. Why is the PID control the widely used control operations for processes?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 6

Pressure Control – On/Off Control

Procedure:

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 2” tab.
4. Click the “ON-OFF 1” tab.
5. Select the “PRESSURE” from the pull-down tab.
6. Set the set point at “200 mmH2O”
7. Tick on the “Action AB-2” checkbox. Set the tolerance at 5
8. Tick off the “AVS-1”, “AVS-2”, “AVS-3” checkboxes
9. Tick on the “SP-1” at the graph panel
10. Set the “AR-1”, “AA-1”, “AB-1”, “AB-2” to “off” position.
11. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
12. Click the “Start” button and take note of the “SP-1” sensor during the run.
13. Make sure that all the tick boxes in procedure 5 to 11 are correct. If not, set the values as stated
in procedure 5 to 11 even if the unit is already processing.
14. Record the value of SP-1 every 10 seconds.
15. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SP-1 with respect to time.

Review Questions:

1. From the schematic, where is the pressure sensor located? Is the pressure of the
tank proportional to the water level of the tank?
2. Is the pressure in SP-1 is absolute or relative? Explain.

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 7

Pressure Control – Proportional Control

Procedure:

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “PRESSURE” from the pull-down tab.
6. Set the set point at “200 mmH2O”
7. On the “PID constant” panel, set the proportional gain (Kc) to 1.0, the integral time (Ti) to 0 and
the derivative time to 0. Click the “PID1 ON” button until it turns green.
8. Tick on the “SP-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SP-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 10 are correct. If not, set the
values as stated in procedure 5 to 10 even if the unit is already processing.
13. Record the value of SP-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SP-1 with respect to time.

Review Questions:

1. Why is there a need to use proportional control for pressure systems?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 8

Pressure Control – Proportional-Integral Control

Procedure:

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “PRESSURE” from the pull-down tab.
6. Set the set point at “200 mmH2O”
7. On the “PID constant” panel, set the proportional gain (Kc) to 2.0, the integral time (Ti) to
1.0 and the derivative time to 0. Click the “PID1 ON” button until it turns green.
8. Tick on the “SP-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SP-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SP-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SP-1 with respect to time.

Review Questions:

1. Why is there NO “derivative” control only in pressure systems?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 9

Pressure Control – Proportional-Derivative Control

Procedure:

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “PRESSURE” from the pull-down tab.
6. Set the set point at “200 mmH2O”
7. On the “PID constant” panel, set the proportional gain (Kc) to 2.0, the integral time (Ti) to 0 and
the derivative time to 0.05. Click the “PID1 ON” button until it turns green.
8. Tick on the “SP-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SP-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SP-1 every 10 seconds.
14. Click the “STOP” button after 3 minutes.

Data:

Graph the value of SP-1 with respect to time.

Review Questions:

1. What is the effect of the integral time on the response of the pressure sensor?

Laboratory Manual
EDIBON UCP Computer Controlled Process Control System CHE 184 – 1P

Experiment 10

Pressure Control – Proportional-Integral-Derivative Control

Procedure:

1. Turn on the UCP panel

2. Click the SCADA icon in the desktop of the computer
3. Click the “CONTROL 3” tab.
4. Click the “PID 1” tab.
5. Select the “PRESSURE” from the pull-down tab.
6. Set the set point at “200 mmH2O”
7. On the “PID constant” panel, set the proportional gain (Kc) to 2.0, the integral time (Ti) to 1.0
and the derivative time to 0.05. Click the “PID1 ON” button until it turns green.
8. Tick on the “SP-1” at the graph panel
9. Set the “AR-1”, “AA-1”, “AB-2” to “off” position. Set “AB-1” to “on” position.
10. Set the “AVS1”, “AVS2” to opened and “AVS3” to closed.
11. Click the “START” button and take note of the “SP-1” sensor during the run.
12. Make sure that all the tick boxes and the values in procedure 5 to 11 are correct. If not, set the
values as stated in procedure 5 to 11 even if the unit is already processing.
13. Record the value of SP-1 every 10 seconds.

Click the “STOP” button after 3 minutes.

Data:

Graph the value of SP-1 with respect to time.

Review Questions:

1. What is the most effective control strategy: P, PI, PD or PID? Explain why.

Laboratory Manual