SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

1.0 INTRODUCTION

The Gas Temperature Process Control Training System (Model: SE 124) has been
designed for students’ demonstration and to provide them with hands on experience on how a
temperature loop for an exchanger can be controlled using a microprocessor based controller.
The equipment consists of industrial graded instrumentation to exhibit a realistic working
environment of standard industrial temperature control loop. The unit can also be
interconnected with Air Flow Control Trainer Model: 120 and Air Pressure Control Trainer
Model: SE 121 to form a bigger plant.

The equipment is self contained and constructed on a stainless steel frame with four lockable
castor wheels. The tank, instrumentation and valves are strategically located for easy access.
For safety reasons, the control panel is protected against water splashes. The process piping is
made of industrial pipes. Electrical wiring is in flexible PVC conduit and all instrument cables are
screened. A mimic diagram is included showing the flow of the process.

1.1 Process Description

The SOLTEQ Model: SE 124 Gas Temperature Process Control Training

System is an air process where 6 bar(g) compressed air is charged into the air
receiver tank V-101 and regulated to about 4 bar(g) by the air regulator PCV-
102. Air from V-101 flows through the process line into the air heater E-101,
where it is heated up to 1500C and is then discharged to the atmosphere.

1.2 Control Strategy

Various types of instrumentations are installed in the process line. An RTD

Temperature Transmitter, TT-102 monitors the product temperature and feeds
the signal to a PID loop TIC-102 in the process controller. Another
thermocouple temperature transmitter TT-101 monitors the surface temperature
of the air heater and also feeds the signal to 2 PID loops TIC-101 & TIC-102 in
separate process controller. In TIC-102, temperature signal TT101 TT102 is
used as input for single loop control or auto selector control via a switch at
panel. When in auto selector control, product temperature TT102 is used as
input to TIC-102 with TT101 cut in (use as input) when TT101>170oC. Output is
then used to regulate the energy in the air heater via a thyristor controller, TY-
102. This high/low signal selection is often used in industry to protect
equipment, for eg in this case can be used to prevent heater burnout. Once the
product temperature TT-102 reaches steady state, hand valve HV118 is
manipulated to simulate load changes for the purpose of observation of the
effectiveness of the controller in use.

1.3 Safety Features

There is another temperature controller TIC-101 that is used to cut off the
electrical supply to the air heater in the event of over-temperature, which is set
at 3000C. This is also to protect heater burnout. An airflow switch FSL-101 also
cuts off the electrical supply to the air heater in the event of no airflow. Pressure

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

Relief Valves PSV-101 and PSV-102 are installed to prevent over pressure
during the course of the experiments.

1.4 Faults Simulations

Solenoid valves have been installed for the purpose of faults simulation in
various sections of the process line. Fault simulation switches have been
installed to simulate these faults, which will create errors in the process line
similar to those experienced in the industry. This unit comes with 3 different
fault simulations.

1.5 Experimental Capabilities

 Air Temperature Measurement using RTD and Thermocouple

 ON/OFF Control
 Proportional Control
 Proportional + Integral Control
 PID Control
 Loop Tuning
 Fault Simulation
• Loss of Instrument Air
• Leakage at Heater Tank (K-101)
• Heater Burnout
 Auto Selector Control

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

2.0 INSTRUMENT FUNCTION AND CAPABILITIES

No. Instrument Tag No. Description Range
Microprocessor based PID controller,
1 PID Controller TIC-102 -
heater, temperature
On/Off controller, turns off heater when
2 Temperature Controller TIC-101 heater surface temperature exceeds 0 – 4000C
preset limit
3 Recorder TR-102 Paper Recorder (2 channel) -
Signal type PT 100, for product line, 4 –
4 RTD Transmitter TT-102 0 – 2000C
20 mA
Temperature transmitter for heater
5 T/C Transmitter TT-101 0 – 4000C
element, 4 to 20 mA
0 – 50 kg/hr @
6 Rotameter FI-101 Air flow rate control and load changes
2bar
Controls amount of energy input to the
7 Thyristor TY-102 0 – 25 A
heater
PI-101 0 – 7 bar
Dial gauge pressure indicator for local
8 Pressure Indicator PI-102 0 – 4 bar
pressure indication
PI-103 0 – 4 bar
TI-101 0 – 4000C
9 Temperature Indicator TI-102 For local temperature indication 0 – 2000C
TI-103 0 – 1000C
V-101 Receiver tank 250 L
10 Process Tank
E-101 Air Heater
FAL-101 Process line detecting alarm low
11 Alarm Annunciator TAH-101 Control tank temperature alarm high -
TAH-102 Product temperature alarm high
Mechanically activated device, spring
PSV-101 loaded normally closed valve. Opens
12 Pressure Relief Valve -
PSV-102 and purges air to atmosphere in case
of over pressure in tank.
HV101
13 Solenoid Valves HV102 Solenoid valves for fault simulation -
HV103
Input/output isolation valves.
HV111-
14 Hand Valves Determine the direction of airflow and -
HV121
load changes
HS-101F Loss of process air
Fault Simulation
15 HS-102F Leakage at heater tank -
Switches
HS-103F Heater burn out
Regulates the air supply to the process
16 Air Regulator PCV-101 -
receiver tank (V-101)
17 Air Flow Switch FSL-101 Flow sensor -
Mounting/installation of controller, alarm
annunciator, recorder, push button,
18 Control Panel - -
power supply switch and changeover
switch between IOT and local control

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

3.0 THEORETICAL BACKGROUND

3.1 Process control

A fundamental component of any industrial process control system is the

feedback control loop. It consists of the process, the measurement, the
controller, and the final control element, as shown in figure 1. If all these
elements are interconnected, that is, if information can be passed continuously
around the loop, this is closed-loop control and automatic feedback generally
exists.

Figure 1: A Closed Loop Control Loop

This information flow provides the means for control, which allows efficient
utilization of raw materials and energy, if a loop is interrupted for any reason,
such as when the controller is placed on manual control, as seen in figure 2, it
is considered to be open-loop control and automatic control no longer exists.

Figure 2: An Open Control Loop

The concept of automatic feedback control is not new. The first such industrial
application occurred in 1774 when James Watt used a fly-ball governor to
control the speed of his steam engine. Understanding of automatic feedback
control loops developed slowly at first. Pneumatic transmission systems did not

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

become common until the 1940s, but past few decades have seen extensive
study and development in the theory and application of those concepts.

Automatic feedback control is not used universally. In figure 2, parts of the

system are disconnected, creating open-loop control. Open-loop control does
not feed information from the process back to the controller. A familiar example
is the domestic washing machine, which may be programmed to control a
series of operations necessary to wash a load of clothing, it runs through its
cycle and, since no information is fed back to the control device regarding the
condition of the wash, it shuts down. Only a human agent inspection the load,
and finding it unsatisfactory, can institute corrective action. Open-loop control is
seldom encountered in industrial processes and will be given no further
consideration.

As stated before, automatic control requires some sort of signal system to close
the loop and provide the means for information flow. This means that the
controller must be able to move the valve, the valve must be able to affect the
measurement, and the measurement signal must be reported to the controller.
Without this feedback, you do not have automatic control.

3.2 On/off Control

On/off control is generally both the simplest and the least expensive type of
process control and has wide application in industry. A process controlled by an
on/off controller almost always has some error in it; in fact, the controller turns
on or off only at those times there is no error in the measurement, when the
measurement crosses the set point on its way from one extreme error to
another. At that point, the valve goes either fully open (on) or closed (off),
depending on the direction of the error. The size of the error is not recognized.

No attempt is made to balanced the inflow with the outflow; therefore. The
energy or material supplied to the process is always either too much or not
enough. The measured variable cycles continuously. However, when on/off
control is applied to the right type of process, the effect of the cycling is small
and acceptable.

On/off control best applied to a large capacity process that has relatively little
dead time and a small mass or energy inflow with respect to the capacity of the
system.

A common example would be a typical domestic heating system. A

house gets colder than the desired temperature (set point) and the thermostat
turns the heater on. The heater supplies enough heat to warm the house to the
desired temperature, and the thermostat turns the heater off.

However, there is still enough heat stored in the mass of the house to keep it
warm for a while. When the temperature returns to the set point, the thermostat

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

turns the heater on again, but the temperature drops a little more before the
heater starts to take effect and warm the house again (dead time).

This cycling is illustrated in Figure 3, which shows the relationship between the
temperature of the house (the controlled variable) and the action of the heater
(the manipulated variable). Because the mass of the house constitutes a large
capacity, the variation in temperature caused by the cyclic effect is so small that
it goes unnoticed by the people in the house.

In industry, a typical application for on/off control is the temperature of a large

tank or bath. These also have large thermal capacities, with a small source of
heat (the energy inflow) warming the liquid in them (the controlled variable) to
the desired temperature (the set point).

In either example, the rate of rise (or fall) of the controlled variable is small
because the energy inflow is small compared to the large capacity of the
system.

Figure 3: System Response to a Process Upset with ON/OFF Control

3.3 Proportional Control

On/off control works best on processes with large capacities, which change
slowly. When a process has small capacity, it usually responds quickly to
upsets. Therefore, precise continuous regulation of the manipulated variable is
needed. Proportional control attempts to stabilize the system and avoid
fluctuations by responding to the magnitude as well as the direction of the error.

The type of process that benefits most from proportional control has a large
mass or energy inflow with respect to the capacity and very little dead time. A
bathroom shower is an example of a small capacity process. On/off control of
water temperature is useless here because turning the controls fully on or fully
off causes too radical a change in output. The energy inflow is large with
respect to the capacity of the process. So, we established a proportion of hot
water to cold, which can be maintained continuously.

In the shower, as in most process control systems, the final control element is a
valve, which partially opens or closes to regulate the mass or energy inflow. To
provide the appropriate output, the valve travels between fully open and fully

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

closed as positioned by the controller. This valve travel is called the valve
stroke.

The relationship between the output and the width of the measurement span is
called the proportional band. Sometimes call PB or P Band, it is expressed in
percent. For example, a 20 percent proportional band is narrow; it provides
sensitive control because 100 percent output change is produced by only 20
percent measurement change. Conversely, a 500 percent proportional band is
very wide with only 20percent of the possible output produced by 100 percent
change in measurement.

In operation, the proportional controller calculates the amount of error between

the measurement and set point, amplifies it, and positions the final control
element to reduce the error. The magnitude of the corrective action is
proportional to the error. Generally, the measurement of proportional-only
controller can completely eliminate offset at only one load condition.

When there is a process upset, such as when flow is suddenly reduced, the
valve must change position to keep the controlled variable at a constant level
(maintain the set point). The output from the controller (which controls the valve
position) must assume a new value, different from the original (the set point),
before equilibrium can again be reached.

This new value of the controlled variable is offset from the set point. Figure 4,
Curve C, shows system response when the proportional band in which the
oscillations settle out quickly.

If the proportional band is too wide (insensitive), the offset will be much larger,
reducing the amount of control over the process. Narrowing the proportional
band (increasing the gain) can reduce the amount of offset, but too narrow a
band creates cycling. The most important limitation of proportional-only control
is that it can accommodate only one fixed relationship between input and
output, one control load where input error is zero and one output signal which
positions the control valve in the position required to make the error zero.

Pure proportional action is generally adequate for a process that is stable using
a narrow proportional band and where a small offset is not detrimental to the
operation of the system. For example, non-critical temperature level control
loops with long time constants are good applications for proportional-only
control.

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

Figure 4: Proportional Only System Response to a Process Upset with Different Proportional
Band (PB) Widths

3.4 Integral Control

Integral action avoids the offset created in proportional only control by bringing
the output back to the set point. It is an automatic rebalancing of the system,
which operates as long as an error exists. Therefore, integral control responds
to the duration of the error as well as its magnitude and direction. Integral
control is almost never used alone; rather, it is combined with proportional
control.

At one time, the system rebalancing had to be done manually; this was called
"manual reset." The term "reset" is occasionally still used, although a complete
definition of the function includes the mathematical concept of integrating the
error until it reaches zero.

Proportional-plus-integral (PI) control is generally used on processes where no

amount of offset can be tolerated. Other applications include those where such
a wide proportional band would be required for stability that the amount of
offset created would be unacceptable.

PI control is applied to almost all processes. When a process upset occurs, the
proportional controller registers an error and responds to it as shown in Figure
5. The integral control mode detects the offset error in the proportional mode
and tries to eliminate the error.

In a proportional-plus-integral controller, integral action can be expressed in

terms of minutes per repeat—the amount of time necessary for the integral

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

controller to repeat the open-loop response caused by the proportional mode

for a step change in error. The smaller the time value, the faster the integral
action. (Some controller manufactures express integral action in repeats per
minute, which is the reciprocal of minutes per repeat.)

Ideally, the minutes per repeat chosen for the integral mode of the controller
should bring the control point back to the set point quickly. (The proportional
band is specified separately.) If the integral time is too long, the system will not
perform at maximum efficiency. If the time is too short, it will overshoot the set
point; in fact, if the integral time is too short for the process being controlled, a
continuous cycle may result. There relationships are shown in Figure 5.

Figure 5: Proportional-Integral (PI) System Response to a Process Upset with Different

Integral Times

One problem with integral control can occur when a deviation cannot be
eliminated over a period of time (as with batch processes when a tank is
empty). The controller continues to see an error and tries to correct for it,
saturating it and driving the output to its maximum value. This is called integral
windup. When the situation causing the error is corrected, the controller does
not immediately return to normal operation; it holds the output—and the valve -
at the extreme for a period of time after the deviation has reversed sign.

3.5 PID

Each of the three basic control modes and the combinations discussed so far,
proportional (P), proportional-plus-integral (PI) have limitations which may not
be significant if the process and controller are carefully matched.

However, some processes are so difficult to control or so critical to maintain at

set point, that the use of all three modes will be helpful in maintaining desired
control. PID control responds to all aspects of process error—direction,

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

magnitude, duration, and rate of change. The output of a PID controller is a

linear combination of P, I, and D modes of control.
PID control can be advantageous on many processes. However, its application
should be considered carefully because it has limitations with some processes.
Processes that benefit most from PID control have rapid and large disturbances
in which derivative action can respond to the rapidity of the changes, and
integral action can respond to the duration of them.

Derivative and integral action are complementary. Derivative action permits an

increase in proportional gain, offsetting the decrease necessitated by integral
action; where integral action tends to increase the period of cycling of a loop,
derivative action tends to reduce it, thereby producing the same speed of
response as with proportional action but without offset.

Temperature processes, such as the heat exchanger, typical of those

applications, which can benefit from PID control.

Figure 6 shows the effect of the addition of derivative action to a properly

adjusted PI controller. The period (time to complete a cycle) is shorter than with
proportional-plus- integral control.

Figure 6: Comparison of System Response to a Process Upset With PI Control and with PID
Control

Figure 7 shows the response of a system to a process upset in the primary

analogue control mode: proportional, integral, and PID. The uncontrolled
response is shown for the sake of comparison.

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

Figure 7: System Response to a Process Upset with Different Modes of Analogue Control

Figure 8 shows the response of a system to a change in set point (as would happen in
tuning a controller) using the same analogue control modes.

Figure 8: System Response to a Change in Set Point with Different Modes of Analogue
Control

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

3.6 Loop Tuning

The closed-loop control system attempts to achieve a balance between supply

and demand by comparing the controlled variable to the set point and
regulating the supply to an amount, which will maintain the desired balance.
Tuning the controller adjusts it so it can achieve that balance as quickly as
possible. This is done when the instrument is first put in service and, later, on a
periodic basis as part of preventive maintenance. When tuning, remember that
each controller is part of a closed loop: all the parts of the loop are interactive,
behaviour of other devices in that loop. The controller response must be
matched to that of the process. There are several procedures for doing this,
some mathematical, most using trial and error.

A simple three-step method for tuning most three-mode controllers follows.

(Batch controllers and one-through processes are special cases discussed after
the three-mode and two-mode controllers.) This three-step procedure is based
on a simple test to determine the nature period of oscillation of the process.

Step 1: Set the integral time of the controller at its maximum and the derivative
time at its minimum, thereby providing proportional-only control. Then
reduce the proportional band until oscillation begins. Measure the
period of this oscillation (also called the natural period) as the time
between two successive crests or valleys (see Figure 9).

Figure 9: Period of Oscillation with Proportional-Only Controller after First Tuning Step

Step 2: Set the derivative time at 0.15 times the natural period, and the integral
time at 0.4 times the natural period. Observe the new period of
oscillation; there should be a 25 percent decrease (see Figure 10). If
the new period of oscillation is shorter than this, reduce the derivative
time; if the period is longer, increase the integral time.

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

Figure 10: Period of Oscillation for Correctly Tuned PID Controller after Second Tuning Step

Step 3: Finally, readjust the proportional band to achieve the desired degree of
damping (the amount of correction to a process upset which, when too
much or too little, shows up as either overshoot or sluggishness
respectively).

When adjusting a two-mode (proportional-plus-integral) controller, a slightly

different method should be used since integral mode introduces phase lag that
is not counteracted by derivative. The procedure follows:

Step 1: Set the integral time of the two-mode controller at its maximum and the
derivative time at its minimum, thereby providing proportional-only
control, just as with the three-mode controller. Then reduce the
proportional band until oscillation begins and measure this period.

Step 2: Set the integral time to the natural period. The period of oscillation
should increase about 40 percent (ideally, 43 percent). If the period is
longer than this, increase the integral time (see Figure 11).

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

Figure 11: Period of Oscillation for Correctly Tuned PI Controller after Second Tuning Step

Step 3: Finally, adjust the proportional band until the desired degree of damping
is achieved. Adding integral will always increase the proportional band
required for stable control.

Some consideration must be given to processes with variable dynamic

characteristics. Once-through processes such as tubular heat exchangers
exhibit a natural period that varies inversely with flow. In such situations, one
combination of controller settings cannot be ideal for all flow rates. Integral time
should be set according to the lowest anticipated flow rate, and derivative time
according to the highest.

Some batch controllers, because of their mechanical arrangement, will become

unstable if equal values of integral and derivative time are used. Always keep
their integral time at least twice the derivative time.

3.7 Auto Selector Control

The auto selector, or selective, control system monitors several variables on a

process and manipulates one final actuator necessary to keep the variables
within safe operating limits. Any variable may be included in the loop (e.g.
pressure, temperature), but all must be affected by the operation of the one
valve.

Each variable has an associated controller whose output goes to a device that
compares two values, selecting the lowest or highest one (a low selector or
high selector, respectively) to direct the valve to respond in such a way that the
variable returns to a safe range. However, if another variable exceeds or fall
below its set point, that variable’s controller output takes over control of the
valve.

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.0 EXPERIMENTAL PROCEDURE

4.1 Start-up Procedure

1. Start compressor and wait for sufficient air pressure to build up in receiver
tank.
2. Ensure that all valves are set according to the Initial Valve Positions
outlined in Table 1.
3. Fill up air receiver tank V-101 to approximate 6 bar(g) by regulating PCV-
101.
4. Switch on the panel.
5. Regulate PCV-102 to allow 2bar(g) of compressed air flow through the
process line.
6. Regulate HV118 to set flow indicator FI-101 to approximate 25kg/hr.
7. Use selector switch to select TT101, TT102 or auto selector control.
8. Set controller TIC-102 to “MANUAL” mode with set point 1000C.
9. You are now ready to proceed with the experiment.

Table 1: Temperature Control Initial Valve Positions

Open Close Manipulating Valve
HV111 HV113 HV119
HV112 HV114 HV120
HV115 HV117
HV116
HV118
HV119
HV120

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.2 Air Temperature Measurement using RTD and Thermocouple

Air temperature can be measured using RTD and thermocouple, as per given
experiment. This requires the observation of the temperature readings from TT-
101 and TT-102 during all the experimental runs, following the start-up.

4.3 ON/OFF Control

Objective: To demonstrate the characteristic of On/Off Control

Procedure:
1. Enter PB value of 2, I value of 9999 seconds, and D value of 0 second.
2. While the control loop TIC-102 is in “MANUAL” mode, adjust the set point
to 100oC.
3. Tune the output (MV) gradually so that the temperature measurement
matches the set point at 100oC.
4. Turn on the paper recorder recording function and set the control loop into
“AUTO” mode.
5. Simulate a load change by opening HV118 so that FI-101 reads 50 kg/hr
for approximately 60 seconds.
6. Restore HV118 to its original position and observe the measurement for
about 5 minutes.
7. Once the measurement stabilizes, stimulate a set point change by
increasing the set point to 150oC.
8. Observe the response of the system for another 5 minutes.

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.4 Closed Loop Proportional Only Temperature Control

Objective: To demonstrate the characteristic of Proportional Only Control

Procedure:
1. Enter PB value of 100, I value of 9999 seconds, and D value of 0 second.
2. While the control loop TIC-102 is in “MANUAL” mode, adjust the set point
to 100oC.
3. Tune the output (MV) gradually so that the temperature measurement
matches the set point at 100oC.
4. Turn on the paper recorder recording function and set the control loop into
“AUTO” mode.
5. Simulate a load change by opening HV118 so that FI-101 reads 50 kg/hr
for approximately 60 seconds.
6. Restore HV118 to its original position and observe the measurement for
about 5 minutes.
7. Once the measurement stabilizes, stimulate a set point change by
increasing the set point to 150oC.
8. Observe the response of the system for another 5 minutes.
9. With the I and D values maintained, repeat steps 2 through 8 for the
following PB values:

PB Offset Value
10
2

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.5 Closed Loop Proportional and Integral Temperature Control

Objective: To demonstrate the characteristic of PB (Proportional Band) + I

(Integral Action) on a temperature process control loop.

Procedure:
1. Enter PB value of 50, I value of 180 seconds, and D value of 0 second.
2. While the control loop TIC-102 is in “MANUAL” mode, adjust the set point
to 100oC.
3. Tune the output (MV) gradually so that the temperature measurement
matches the set point at 100oC.
4. Turn on the paper recorder recording function and set the control loop into
“AUTO” mode.
5. Simulate a load change by opening HV118 so that FI-101 reads 50 kg/hr
for approximately 60 seconds.
6. Restore HV118 to its original position and observe the measurement for
about 5 minutes.
7. Once the measurement stabilizes, stimulate a set point change by
increasing the set point to 150oC.
8. Observe the response of the system for another 5 minutes.
With the PB and D values maintained, repeat steps 2 through 8 for the
following I values:

I
60s
10s

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.6 Closed Loop PID Temperature Control

Objective: To demonstrate the characteristic of PB (Proportional Band) + I

(Integral Action) +D (Derivative Action) on a temperature process
control loop

Procedure:
1. Enter PB value of 100, I value of 180 seconds, and D value of 60 second.
2. While the control loop TIC-102 is in “MANUAL” mode, adjust the set point
to 100oC.
3. Tune the output (MV) gradually so that the temperature measurement
matches the set point at 100oC.
4. Turn on the paper recorder recording function and set the control loop into
“AUTO” mode.
5. Simulate a load change by opening HV118 so that FI-101 reads 50 kg/hr
for approximately 60 seconds.
6. Restore HV118 to its original position and observe the measurement for
about 5 minutes.
7. Once the measurement stabilizes, stimulate a set point change by
increasing the set point to 150oC.
8. Observe the response of the system for another 5 minutes.
9. With the PB and I value maintained, repeat steps 2 through 8 for the
following D values:

D
30
10

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.7 PID Temperature Control Loop Tuning

Objective: To demonstrate the loop tuning procedure on a temperature process

control loop

Procedure:
1. Enter a PB value of 100, I value of 9999 seconds and D value of 0 second.
(Setting the I to its maximum and D to its minimum provides proportional
only control)
2. Put the control loop into “MANUAL” mode, adjust the set point to 100oC
and tune the output (MV) gradually so that the temperature measurement
matches the set point at 100oC.
3. Turn on the paper recorder recording function, and put the control loop into
“AUTO” mode. Stimulate a load change by opening HV118 so that FI-101
reads 50 kg/hr for approximately 60 seconds. Restore HV118 to its original
position and observe the measurement for about 5 minutes.
4. While maintaining the value of I and D values, gradually reduce PB until
the measurement oscillates about the set point. Repeat step 1 to step 3
with the following PB values:

PB
50
10
2
5. Determine the natural period using the following method:
D
Natural Period , T = × 60 min
Trend Speed
Where;
D = Distance in mm between successive crests or valleys

Note: Another way of measuring the natural period is by using a timer

to record the time travelled for successive crests or valleys.

6. Set the Integral Time to the natural period, T that was calculated, and
repeat steps 4 to 7. The period of oscillation should decrease by 40%. If
the period is longer than this, increase the integral time.
7. Finally, adjust the PB until the desired degree of damping is achieved.

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

4.8 Faults Simulation

Objective: To develop error detection and problem solving skills.

During the run of the experiments, various faults can be simulated by the unit,
to create errors similar to those that can be experienced in the industry. This
can be done with switches that have been installed for this purpose. Students
will be required to detect the error, its location and solve the error.
Switch HS-101F: Loss of Instrument Air Supply
Switch HS-102F: Leakage at Heater Tank (E-101)
Switch HS-103F: Heater Burnout

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SOLTEQ GAS TEMPERATURE PROCESS CONTROL TRAINING SYSTEM (MODEL: SE 124)

5.0 REFERENCES

1. Introduction to Process Control, Foxboro, USA.

2. Rys, R.A. August 20, 1984. Advanced Control Methods, Chemical Engineering.
pp 49.

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