Users Manual

For
MULTIPROCESS CONTROL
TRAINER

TRI-ANGLE SIMULATION PVT. LTD.

PRINTED IN INDIA * SEPTEMBER 2014

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TRI-ANGLE SIMULATION PVT LTD

Office : 2/64, Darshan, Ground Floor,

R.A. Kidwai Road,
King’s Circle, Mumbai – 400019

Factory : Antop Hill Warehousing Co. Ltd

B-28/29, Acme Rd. Salt Pan Rd.
Near Krishna Steel Industries,
Opp. Indian Hume Co. Ltd.
Wadala (East), Mumbai – 400037.

Phone : (Office) +91 - 22 - 2409 56 82

(Factory) +91 - 22 - 3291 18 11

FAX : +91 - 22 - 2409 5682

Email : [email protected]
 Table of Contents
1. MULTIPROCESS CONTROL TRAINER ..........................................................................3
ACTUAL PHOTOGRAPH OF THE SYSTEM ......................................................................4
2. FEEDBACK CONTROL FOR FLOW ................................................................................5
2.1 PROCESS DESCRIPTION: ........................................................................................5
2.2 PRECAUTIONS: ...........................................................................................................7
2.3 STARTUP PROCEDURE: ..........................................................................................7
2.4 SHUT DOWN PROCEDURE .....................................................................................8
3. FFEDBACK CONTROL FOR LEVEL ...............................................................................9
3.1 PROCESS DESCRIPTION: ........................................................................................9
3.2 PRECAUTIONS: ......................................................................................................... 10
3.3 STARTUP PROCEDURE: ........................................................................................ 10
3.4 SHUTDOWN PROCEDURE: ................................................................................... 11
4. FFEDBACK CONTROL FOR TEMPERATURE ............................................................ 12
4.1 PROCESS DESCRIPTION: ...................................................................................... 12
4.2 PRECAUTIONS: ......................................................................................................... 15
4.3 STARTUP PROCEDURE: ........................................................................................ 16
4.4 SHUTDOWN PROCEDURE .................................................................................... 16
5. CASCADE CONTROL FOR FLOW AND LEVEL.......................................................... 18
5.1 PROCESS DESCRIPTION: ...................................................................................... 18
5.2 PRECAUTIONS: ......................................................................................................... 20
5.3 STARTUP PROCEDURE: ........................................................................................ 21
5.4 SHUT DOWN PROCEDURE:.................................................................................. 22
6. RATIO CONTROL............................................................................................................. 23
6.1 PROCESS DESCRIPTION: ...................................................................................... 23
6.2 PRECAUTIONS: ......................................................................................................... 24
6.3 STARTUP & PROCESS OPERATION PROCEDURE : ...................................... 24
6.4 SHUTDOWN PROCEDURE: ................................................................................... 24
 Preface

With an overwhelming sense of exhilaration, we would like to express our

gratitude for availing Digital PID Based Process Control Trainers in your institution.
Imparting students with the wisdom of PID based Digital Controllers ` has become the
need of hour in constantly growing automation of manufacturing industries and it is
ingenuity of the institutions to have Digital Control trainers as they facilitate students to
comprehend the operational realm of the controllers used widely in the industries. These
trainers help students to expedite the learning of several aspects of process controls and
provide them the feel of their usages and limitations.

In contrast to PID based Digital controller is employed more comprehensively for

its inexpensive and unsophisticated usage. They are mainly utilized where process
parameters are allowed to deviate in certain extents and are to be maintained in a user-
specified range. In PLCs, sensing elements and final control elements both are of switch-
type, operating within used-defined range.

The Digital PID based Controllers are used for prompt, acute and precise
controls of process parameters. They are used where parameters are to be maintained at
constant values. Thus, Digital PID based controllers find their applications where
process is sensitive to these parameters. In Digital PID Control Systems, we have used
continuous monitoring type sensing elements and variable type final control elements.
With our state-of-art HMI software, students can control and visualize recorded Trends
of the parameters and alter these parameters to see the response of Digital PID based
controller for its corrective action. Students will also learn about PID tuning for different
process parameters like pH, pressure, level, flow and temperature.

The User’s Manual incorporates Operating Procedures and Exercises for students
for guided training on these systems. We are positive that these systems will sharpen the
skills of aspiring engineers of tomorrow.

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 1. MULTIPROCESS CONTROL TRAINER
Multi process Trainer is designed such that using only one equipment one can learn about
flow control loop, level control loop, cascade control loop, temperature control loop, ratio
control loop, etc. To execute any of the loop one is required to open, close or divert the flows to
proper direction using hand valves and operations. This equipment is very much helpful to teach
plant operations.

Instrumentation and Control point of view one can learn about,

 PID control operation,

 Flow measurement by Differential Pressure Measurement across orifice meter,
 Temperature transmitters,
 Capacitance type Level Transmitter,
 Pneumatic Control Valves,
 Triac Triggering Based Heater Control (Temperature Control System),
 Ratio Control System,
 Cascade Control System,
 Level Control System,
 Flow Control System.

Before the user actually starts with the control loops, he is strongly advised to refer
back to the fundamentals of P, I and D as well as the explanation regarding the working of
the different loops.

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 ACTUAL PHOTOGRAPH OF THE SYSTEM

Figure 1.1
Multiprocess Control Trainer

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 2. FEEDBACK CONTROL FOR FLOW
2.1 PROCESS DESCRIPTION:

The feedback control for flow loop consists of the following Major elements of the Multiprocess
equipments as shown in figure 2.1:

1. Cooling Water tank, Level Tank

2. Cold Water Pump(P-01)
3. Pneumatic Control Valve(PCV-01, PCV-01)
4. Differential Pressure Transmitter, FT-01.
5. Rotameter RM-1
6. Compressor for supplying air to Pneumatic Control valves.

Figure 2.1

FEEDBACK CONTROL ESSENTIALLY, CONSISTS OF PROVIDING A

COMPENSATORY SIGNAL AFTER A DISTURBANCE HAS OCCURRED IN THE
PROCESS.

The cold water tank is filled up about 60% with water.

Keep Recalculation Valve (HV-01) at least 60% (This is done to prevent damage to the pump, in
case, if the PCV-01 closes down completely, when the system is running in the AUTO Mode).

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Switch on Rocker SW for level indicator & Cold Water Pump-01 from the panel board.

The pump P-01 is switched ON. The flow passes through the FT-02. Some of the liquid is
pumped back into the cooling water tank via Recalculation Valve (HV-01). FT-02 senses the
flow and sends out the signal to the controller FIC-01. The output signal from the FT-02 to the
FIC-01 is in the range of 4-20mA. The FT-02 is calibrated in a manner, such that, the input flow
range of 0-200 LPH corresponds to an output signal of 4-20mA.

The controller FIC-01 compares this value, which is known as the MEASURED
VARIABLE or MV with the set point (SP). (The set point is the value, which the user has
MANUALLY fixed through the KEYBOARD in the bar graph page.) The difference in the two
values known as the ERROR is sent to the final Control element i.e. Pneumatic Control Valve. In
this case, the final control element is PCV-01. Corresponding to this signal the control valve
opens or closes to limit the flow to the desired value. If the flow is higher than that which is
desired (i.e. MV > SP), the controller FIC-01 will send a signal such that the output of the PCV-
01 decreases, so that the flow through it reduces.
In the reverse case, if the flow is less than the desired (i.e. MV, < SP) the output of the
controller is increased such that the flow through PCV-2 is increased.

Please note that the output of the controller is the signal given to the Pneumatic Control
Valve. So when we say that the output of the controller is increasing or decreasing, we also mean
that the Control Valve opening is increasing and decreasing respectively.

NOTE: The level tank is used in the operation then it is advisable to keep a watch on the level in
the tank

All this is done in the MANUAL mode. A certain value of the output is reached, whereby
the Measured Variable approximates to the set point. At this juncture, certain ‘P’, ‘I’ and ‘D’
values are inserted.
The controller is now placed in the AUTO mode. In the auto mode, the controller FIC-01
takes in the PID values and tries to control the output such that the measured variable stabilizes
near the set point. (In the MANUAL mode, the PID values are not activated, since all the
variables are changed MANUALLY).

Using a few permutations and combinations of the PID values, the flow can be accurately
controlled.

In Brief:
Initially, the flow (MV) may be higher or lower than the desired value (SP). This value is sensed
by the FT-02 transmitted to the controller FIC-01; comparison is done between MV and the SP,
and an output signal is given to the final control element PCV-01 to limit the flow. This is how
the feedback loop is established.

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2.2 PRECAUTIONS:

The following steps have to be taken before, the system can actually be put into operation
otherwise, and there may be unnecessary damage to any part of the system, particularly the
pumps.

a. The Recalculation Valve (HV-01) is to be kept open to at least 40%.

b. When the level tank is to be filled up, it is strongly advised to keep track of the
level in the upper tank. This can be measured by the Level Capacitance Probe (LI-
01) to ensure that the tank does not get filled up and overflows. In any case, it is
advised to OPEN PCV-02 so that the water from the tank continuously flows out
back in the cooling water tank.
c. The particular switches from the PANEL, which are to be used for the respective
loops, should be switch to the ‘ON’ position to ensure the electrical signal
transmission.

2.3 STARTUP PROCEDURE:

1. Switch on the PC.

2. Run the Software.
3. Fill up the cooling water tank T-2 with water to at least 60% of its full capacity.
4. Start air supply to pneumatic control valves (PCVs) by switching on the
compressor and setting a pressure of 30 psig by tuning the regulator and adjust the
air regulator in the actual system to a pressure of 20 psig.

From The Mimic Page:

5. Put the controller FIC-01 in the MANUAL Mode. (The default values of all the
controllers are in the MANUAL mode. If by chance, the controller is switched to
the AUTO Mode, the user should switch it back to the MANUAL mode).
6. Put the controller FIC-01 in the REVERSE Mode. (Normally the controller is in
the REVERSE mode by default.
7. Initially keep the control valve PCV-01 50% open. The user can change this value
at any other desired value. Fix a particular Set Point on the controller FIC-01 say
100 LPM. Fix some P, I and D values on the Controller. (By default, the values of
P, I and D fixed are 0.3,25 and 0 respectively). The user can try these values out
or change them to suit the process.

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From the actual system:

8. Switch on the pump P-01.

From the bar graph page1:

9. If the flow if higher than the Set Point, manually decrease the output of the
control valve. If the flow is lower than that desired, increase the opening of
PCV-01.

After a few manuals opening and closing of the PCV-01, a particular value of the opening
will be reached whereby the flow will be nearly up to the desired value.
Then:
10. Switch the controller from the Manual to the AUTO Mode.

NOTE: Initially, when the controller is switched from the MANAUL Mode to the AUTO Mode,
the flow may not be automatically controlled due to the preset P, I and D values. In such a case,
change these values. After some permutations and combinations correct values can be inserted
and the flow can be accurately controlled.

2.4 SHUT DOWN PROCEDURE

1. Shut down cold water pump P-01.

2. Open PCV-02 fully and make level tank fully empty.
3. The switches on the Panel should be switched ‘OFF’ and then the main switch
should be turned ‘OFF’.

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 3. FFEDBACK CONTROL FOR LEVEL
3.1 PROCESS DESCRIPTION:

Feedback for level consists of the following equipments in the loop:

1. Level Tank, Cold Water Tank.

2. Pumps P-01.
3. Differential Pressure Transmitter FT-02.
4. Level Indicator, LIC-01 & HIC-01.
5. Pneumatic Control Valves, PCV-01 and 02.
6. Recirculation Valve HV-01, T-01 and T-02.
7. Compressor for supplying air to Pneumatic Control valves.

The Cold water tank is filled up with water. Recirculation Valve HV-01is kept open to say 40%
to prevent any damage to the pump P-01. The pneumatic control valve PCV–01 is kept open to at
least 20% to allow for the passage of the liquid.. The controller LIC-01 is put in the DIRECT
Mode and a Set Point of say 50% is fixed on LIC-01 controller. When the pump P-01 is switched
‘ON’ the liquid flows through the FT-02, the 3-Way Valve T-01 into the Level Tank. A Level
Capacitance Probe (LIC-01) senses the level of the tank. A probe connecting to this transmits the
signal. The effective level of the tank is 0-100%. For this head, the output signal range of the
Level Capacitance Probe is 4-20mA. Corresponding to the level in the tank, an electrical signal
is transmitted to the Level Indicator Controller (LIC-01) (ex: if the level in the tank is 50%, then
a signal of 12mA is transmitted). The controller LIC-01 reads this value (which is known as the
measured variable or MV), compares it with the set point (SP) value. The difference of these two
values; known as the ERROR, is fed to the controller. The output of which is transmitted to the
final Control Element.

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In this case the Final Control Element is PCV-02. In this period, the Pump P-01 is switched
‘ON’. The liquid is sucked into the Pump P-01 from Cold water Tank discharged to Level Tank
through Orifice meter (FT-02). If the level in the Level Tank is low then PCV-02 will closed
down further to decrease the amount of flow out of it, thereby increasing the level and vice-
versa.

PCV-01 is used as Manual Station to introduce an error in the system, either by

increasing or decreasing the water flow through it.

After a few manual opening and closing of the PCV-2, (i.e. the Level Indicator Controller
LIC-01 is in the MANAUL mode), the measured variable will approximate to the Set Point. The
user then inserts PID values and the controller LIC-01 is placed in the Auto mode. In the AUTO
Mode, PID values are activated and the controller functions using these values. (In the
MANUAL Mode, the PID values are out of operation). The PID values set in by the user may or
may not be suitable to stabilize the level. The PID values are frequently changed and using a few
permutations and combinations, the correct PID values are found and the controller is tuned to a
fine degree.

3.2 PRECAUTIONS:

The following steps have to be taken before the system can actually be put into operation.
Otherwise, there may be unnecessary damage to any part of the system, particularly to the
pumps.

a. Recirculation Valve HV-01has to be kept open to at least 40%.

b. The particular switches from the PANEL that are to be used for the respective
loops should be switched to the ‘ON’ position to ensure the electrical signal
transmission.

3.3 STARTUP PROCEDURE:

1. Switch on the PC.

2. Start the software.
3. Start air supply to pneumatic control valves (PCVs) by switching on the
compressor and setting a pressure of 30 psig by tuning the regulator and adjust the
air regulator in the actual system to a pressure of 20 psig.
4. Fill up the cooling water Tank-2 with water to at least 80% of its full capacity. .
5. Open up the control valve PCV-01 to 20%.
6. Place the controller LIC-01 in MANUAL and DIRECT Modes of operation.
7. Fix a set point say 50% on the LIC-01.
8. Set some PID values on the Level Indicator Controller (LIC-01).
9. Start the Pump P-01. After a few minutes, the level in the tank will approach the
set point value. Then,
10. When the level in the tank rises beyond 50%, manually decrease the output of
PCV-01 to bring the level back to 50%. If the level decreases beyond the set point

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 value, SET the opening of the controller LIC-01 to stabilize the level to the
desired value.
11. Repeat the above procedure a few times until the Measured Variable is
maintained at the Set Point in the Manual Mode. Then,
12. Switch the controller from the MANUAL to the AUTO Mode.

NOTE: When the controller is switched from the MANUAL to the AUTO Mode, the control
action will be most probably not accurate. This is due to the randomly set PID values. In such a
case, the user is asked to change the PID values. By trial and error correct values can be inserted
and the level can be controlled accurately.

3.4 SHUTDOWN PROCEDURE:

1. Switch off the Pumps.

2. Empty the level tank.
3. The switches on the Panel should be switched back to ‘OFF’ position and then the
main switch should be turned ‘OFF’.

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 4. FFEDBACK CONTROL FOR TEMPERATURE
4.1 PROCESS DESCRIPTION:

The temperature loop encompasses the following elements of the control system viz:

1. Cold water, Hot water Tanks, Level Tanks.

2. Pumps, P-01, P-02.
3. Recirculation Valves, HV-01 and HV-04.
4. Pneumatic Control valves, PCV-01, PCV-02 and PCV-03.
5. Resistance Temperature Detectors (RTDs), T-01, T-02 and T-03, T-04
6. Heat Exchanger, HE.
7. Differential Pressure Transmitters FT-01, FT-02.
8. Heater, TTC-01.
9. Hand Valves, HV-02, HV-03.
10. Compressor for supplying air to Pneumatic Control valves.

AIM: The aim over here is to control the outlet temperature of the cold water by
controlling the inlet flow of hot water.

The PC is switched ON and the user enters the feedback loop by running software. The
required panel switches are put in the ON position.. The hot water tank should be filled 30%
and the cooling water tank should be filled up with at least 80% of water. The user is then
asked to switch on the heaters.

Put Heater in ON condition at least 10 minutes before switching ON the pump P-01. So that
effective temperature difference can be created between hot water and cold water.

Recirculation Valves, HV-01 and HV-04 are kept open to at least 40% to prevent damage
to the pumps.

Hot water enters in shell side of Heat Exchanger through PCV-01, T-01. The temperature
of the heated cold water is sensed by a RTD T-01 that is just placed at the outlet of shell side
of H.E. This outlet flow is sent back to the Hot Water Tank.

Cold water enters in tube side of Heat Exchanger through PCV-02, T-02, and HV-03 to
Level Tank and back to cold water tank to OUT TO DRAIN. The temperature of the heated cold
water is sensed by a RTD T-02 that is just placed at the outlet of tube side of H.E. This outlet
flow is sent back to the Hot Water Tank.

The USER is ensuring that temperature of water in cooling water tank is remains constant

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 Initially, after the hot water has reached a particular temperature, then the Pump
P-01 is switched ON. When the pump P-1 is switched ON, the hot water will pass through
the HE-01.

Now, pump P-02 is switched ON. Some of the liquid flows back into the cooling water
Tank by Recirculation Valve HV-04 while the remaining flows through the Differential
Pressure Transmitter FT-02.

Because of the flow of the hot and the cold water through the inner and the outer pipes of
the H.E., a certain amount of heat transfer will take place. The flow of hot water through
shell side and the flow of cold water through tube side are such that countercurrent the
transfer of heat is from the hot liquid to the cold liquid. Hence, the temperature of the hot
liquid will decrease when it discharges from the HE and correspondingly the temperature of
the cold liquid will increase when this liquid is discharged from the HE. Now, the
thermocouple T-03 placed at the tube side outlet of the HE will sense the temperature of cold
the water and transmit this analog signal to the Temperature Controller TC-02 (This
controller is not a physical instrument, but a software program. This controller can be viewed
on the Mimic & Bar graph page.

The controller T-02 will compare the value (which is known as the MEASURED
VARIABLE or MV), with its Set Point. The difference of these values (known as the
ERROR) is transmitted to the final control element- control valve PCV-01.

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 Now the TIC will function in this manner:

If the Measured variable is less than the set point, (MV < SP), it means, that the temperature
of the cold liquid OUTLET is below then that desired. It means that the amount of heat
transfer from the hot water to the cold liquid is less than that desired. There may be two
reasons for that:

1) The temperature of the Hot water may be less, or

2) The flow of cold water may be more.
3) The flow of the hot water may be less.

The heater is continuously in the ON position and hence the condition one will sooner or
later be taken care.

For meeting the second the condition, valve PCV-02 has to close down further, so that lesser
amount of cold water passes through it and hence through the H.E. and greater amount of heat
transfer takes place. Even after decreasing the opening of PCV-02, if the cold water temperature
is less than that desired, the T-02 will further INCREASE the opening of PCV-01, until the
desired temperature is attained.

Now, if the MV is less than SP, then controller TC-02 will transmit a Reverse Signal. It
will increase the opening of the control valve PCV-01, so that more amount of hot water passes
through it, and hence the amount of heat transfer to the cold liquid is decreased, thereby bringing
the measured variable to the desired value.

This opening and closing of PCV-01 will continue until the desired value is reached.
Once the desired value is attained, the controller TC-02 is switched to the AUTO Mode.

If the AUTO Mode, the controller will control the output of the final control element by
taking in the PID values set by the user. In the MANUAL mode, the PID values DO NOT
COME INTO OPERATION, since the user is changing the output by entering the values from
the keyboard.

The PID values inserted may or may not be suitable to tune the controller. Hence, the real
test lies is setting the correct PID values.

Also, since the valve PCV-02 is a Manual Station, its output can be changed by the user
so that greater or lesser amount of hot liquid than that assumed for the above process can be
pumped into the HE.

Also, the cold liquids from the discharge ends of the HE is transferred to the level tank,
the user is advised to keep a watch on the level tank. If the tank is filled up, the user can open
PCV-03. Or can put LIC-01 in auto mode giving some set-point to prevent overflow of level tank
with some PID values.

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 The response of the various variables with respect to time can be visualized on the Trend
Page. The various alarms can be seen and acknowledged from the Alarm Page.

STARTPUP PROCEDURE:

Before starting the unit all input and output connections must be thoroughly checked and if loose
connections detected should be tightened up for prevention of leakage.

NOTE: Pneumatic valve PCV-01 will be used as final control element to maintain the desired
temperature. The mode of the controller should be in the REVERSE, since when the MV
increases beyond the Set Point, the output of the Control Valve has to be DECRESED to
increase the flow of the hot water to bring down the Temperature of cold water. Also, if the
Measured Variable is less than the Set Point (MV<SP) then the output of the controllers has be
INCREASED.

4.2 PRECAUTIONS:

The following steps have to be taken before the system can actually be put into operation.
Otherwise, there may be unnecessary damage to any part of the system, particularly to the
pumps.

a. Recirculation Valve HV-01has to be kept open to at least 40%.

b. The particular switches from the PANEL that are to be used for the respective
loops should be switched to the ‘ON’ position to ensure the electrical signal
transmission.

a) Here Hot Water is passed through the PCV-01, T-01, H.E., and T-01; again back
to hot water tank. If the hot water is to be passed through the Heat Exchanger and
recycled back to the original tank, then the 3-way Bypass T-01 located at the inlet
of the shell side of the HE has to be rotated such that the flow leading to the level
tank is bypassed totally by closing HV-02.

b) When the level tank is to be filled up, it is strongly advised to keep track of the
level in the upper tank. To ensure that the tank does not get filled up and
overflow. In any case, it is advised to open up the control valve PCV-3, so that the
water continuously flows out back in the cooling water tank.

c) The particular switches from the PANEL, which are to be used for the respective
loops, should be switched to the ‘ON’ position to ensure the electrical signal
transmission.

d) The heaters used in this system are immersion heaters. They will get burnt out if
they are switched on without being completely immersed in water. Hence,
whenever the heaters are to be used, care should be taken that adequate quantity

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 of the liquid is filled in the tank and the heaters are completely immersed in the
liquid.
e) The level of the hot water should not be more as the larger amount of water will
take more time to heat it and more will be the chances of accidents that may be
caused by hot water spillage.

4.3 STARTUP PROCEDURE:

1. Switch on the PC.

2. Run the software.
3. Start air supply to pneumatic control valves (PCVs) by switching on the
compressor and setting a pressure of 50 psig by tuning the regulator and adjust the
air regulator in the actual system to a pressure of 20 psig.
4. Fill up the hot water 30% and cold water tanks to at least 60-65% of its capacity.
5. Ensure that the Controller TT-02 is in the MANUAL and REVERSE MODES.
6. Ensure that the control valve PCV-01 is kept open to 50% of its full capacity.
7. The 3 way valves T-01, 02 and 03 are rotated in such a manner so that the liquid
can be transferred to the desired location.
8. Fix some PID values and a particular Set point on the PID controller (TC-02)
9. Start the cold water pump P-02 thus allowing the circulation of cold water in the
heat exchanger (The temperature indicator controller TIC on the mimic or bar
graph page, indicates the temperature of the cooling water at the outlet of the tube
side of the heat exchanger).
10. Start the hot water pump P-01.
11. Observe the outlet temperature of the cold water. Subsequently increase or
decrease the output of T-02 depending on whether the temperature of the outlet
stream is below or above the set point respectively.
12. Gradually, the M.V. will approach the set point and stabilize. Switch the mode of
the controller from the MANUAL to the AUTO.
13. If in the AUTO mode the MV overshoots or undershoots the set point, then
change the P, I and D values until the system stabilize.

NOTE: In case the system is being run for a long period of time and the heater is ON in that
period, the cooling water temperature will rise gradually. With the passage of time, the
difference in the temperatures of the cooling and hot water decreases further and further and the
heat transfer become more and more difficult, with the result that the MV may never be able to
stabilize near the set point. In such a case, fill in fresh cooling water in tank. Simultaneously,
open the drain valve of COLD WATER TANK and drain out some of the warm water. Or
Directly drain out heated cold water out of the system by rotating the 3-way valve as shown in
figure.

4.4 SHUTDOWN PROCEDURE

1. Switch off the current to the heaters by placing the switch-heaters-from the main
panel to OFF position. Continue circulation of both the hot water and the cooling

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 water until the temperature as indicated by TT-01, TT-02 drops down to the room
temperature.
2. When the temperature of the Hot water drops down to Room temperature. Switch
OFF the Centrifugal Pumps P-01 and P-02. (This condition is not mandatory; the
user can simply shut off both the pumps without being concerned about the
temperature of the two liquids.
3. The switches on the panel should be switched back to OFF position and then the
main switch should be turned ‘OFF’.
4. Quit from the program.

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 5. CASCADE CONTROL FOR FLOW AND LEVEL
5.1 PROCESS DESCRIPTION:

The elements used in experiment are:

1. Cold Water Tank, Level Tank.

2. Pumps P-01.
3. Recirculation Valve (HV-01), 3-way valves(T-01, T-02)
4. Controllers, LIC-01 and FIC-01.
5. Differential Pressure Transmitter (FT-02).
6. Pneumatic Control Valves, PCV-01 and PCV-02.
7. Compressor for supplying air to Pneumatic Control valves.
8. Rotameter (RM-1).

The cold water tank is filled up with water. Recirculation Valve (HV-01) is always kept
open such that Rotameter shows 200LPH on 100% opening of PCV-01.It also prevents any
damage to cold water pump while PCV-01 is fully closed. The necessary switches from the Panel
are switched ON. The PC is then switched ON and after selecting the required loop; the user
enters the Mimic page. Puts system on RUN mode. On entering the Mimic, the user observes,
that the valves HIC-01 output is 24% it means that PCV-02 is 24% open to let water flow out
from level tank. PCV-01 is by default set to a value of 60%. PCV-02 is closed down to
completely in the initial stages-so that the level tank fills up. A certain set point is fixed on both
the controllers LIC-01. FIC-01 should be kept in the remote mode of operation, which means
that the output of level controller is fed as remote set point to the flow controller. Initially, both

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these controllers are placed in the MANUAL Modes, so that the flow and hence the level can be
controlled INDIVIDUALLY.

The level in the tank to be controlled is of primary importance. When the pump P-01 is
switched ON the liquid passes through the FT-02, Rotameter into the level tank. As the level in
the tank builds up it will be sensed and displayed measured variable on the LIC-01. The FT-02
senses the flow and transmits this signal to the FIC-01 controller. This signal is the Measured
Variable (MV) for the FIC-01. The controller FIC-01 will compare this value (MV), with the
Remote Set Point (RSP), which is directly coupled to the output of the Level Controller (LIC-
01). If the level in the tank is higher than the Set Point (MV>SP) the user manually, decrease the
opening of PCV-01. On doing this, the output of PCV-01 deceases and hence the flow through it
reduces. If on doing this, the flow decreases and level of the tank falls below the SP (i.e. if
MV<SP), then the output of PCV-01 is increased to accommodate greater flow. After a few
increments and decrements, the flow will approximate to the Remote Set Point. Some PID values
are inserted and the controller is then switched from the MANUAL to the AUTO Mode.

The controller FIC-01 will take in these PID values and control the flow to the desired
Remote Set Point. If these values are insufficient, then the user has to replace them with some
new values to achieve the desired results.

Meanwhile, the level tank is being filled up. The control valve PCV-02 is opened up
MANUALLY, so that the liquid flows out form the Level Tank to Cold Water Tank. A particular
set point is fixed on the LIC-01 Controller. The Level Capacitance Probe senses the level in the
tank. The level probe is calibrated such that the level range of 0-100% of the level tank
corresponds to an output signal of 4-20 mA. So, if the level in the tank is 50%, then the LT
transmits an output signal of 12 mA.

Now, the flow is being controlled in the AUTO Mode by the controller FIC-01. Also the
controller LIC-01 in the MANUAL mode is controlling the level.

The PID values inserted may or may not be suitable to tune the controller. By trial and
error, the correct PID values can be inserted and the controller can be tuned to a fine degree.

Once the LIC-01 controller has been fine tuned, the next step would be to run the system
in the CASCADE Mode. For running this experiment is the CASCADE mode, put FIC-01
controller in the mimic page and switch FIC-01 controller switches from the LOCAL Mode, to
the REMOTE mode. The L alphabet in the FIC-01 area changes to R.

In the CASCADE Mode, there exists a master and slave relation between two controllers.
The Master in this case is the LIC-01 controller and the Slave is the FIC-01 controller. The LIC-
01 is called the Master controller, because it is the LEVEL which is of prime importance. The
flow controller will obey the command issued out from the LIC-01 controller. The FIC-01
controller will vary the flow such that the level is maintained to its set point value.

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 In this operation, the CASCADE mode works in this fashion: Before we start with the
cascade operation, it is necessary to mention in which MODE, the controllers will function when
running in CASCADE.

Normally, in the feedback control (the feedback loops for level and flow), both the
controllers are in REVERSE mode. For cascade control, both the controllers will also function in
the REVERSE mode. The reason is simple: When the level in the tank increases beyond the set
point (MV>SP), the output will decrease. Since the output decreases, the |Remote Set Point to
the FIC-01 decreases. This means that the MV (flow) of the FIC-01 controller is greater than its
RSP. Because of this decrement, the output of FIC-01 controller will decrease, so that lesser
amount of water passes through it into the level tank. Gradually, the level in the tank will
stabilize. Now the opposite case, if the level in the tank (MV) is less than the set point, the output
of the LIC-01 controller will INCREASE, the RSP of the FIC-01 controller INCREASES. That
is its Remote set point. Consequently, the output i.e. opening (OP) of the FIC-01 controller will
increase to accommodate a greater amount of flow. Thereafter, the level will gradually increase.

SO WHILE RUNNING THE CASCADE CONTROL FOR LEVEL AND FLOW,

BOTH THE CONTROLLERS SHOULD BE KEPT IN THE REVERSE MODE.

The output of the LIC-01 controller is fed in as the REMOTE SET POINT to the FIC-01
controller. This means that the Controller LIC-01 is functioning in the SERVO mode and the FI
controller is functioning in the REGULATORY mode.

As the output of the LIC-01 controller varies, the Remote set point of the FIC-01 will
vary. The user has to set PID values on the LIC-01 controller in such a manner, that the output
changes in a very narrow range. Consequently, the Remote Set Point on the FIC-01 controller
will vary within this range. Hence, the control action would be easier.

NOTE: In all our previous experiments, the Set point of any controller was constant and the
Measured Variable and the output were changing to stabilize the process. In this case, the Set
point is also changing.

5.2 PRECAUTIONS:

The following steps have to be taken before the system can actually be put into operation
otherwise, there may be unnecessary damage to any part of the system, particularly the pumps.

a. The Recirculation valve HV-01 has to be kept open to such that

b. When the level tank is to be filled up, it is strongly advised to keep track of the
level in the upper tank-this can be measured by the Capacitance level based
transmitter to ensure that the tank does not get filled up and overflow. In any case,
it is advised to open up the control valve PCV-02, so that the water from the tank
continuously flows out back in the cooling water tank.
c. The particular switches from the PANEL, which are to be used for the respective
loops, should be switched to the ‘ON’ position to ensure the electrical signal
transmission.

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5.3 STARTUP PROCEDURE:

1. Switch on the PC.

2. Run the Software.
3. Start air supply to pneumatic control valves (PCVs) by switching on the
compressor and setting a pressure of 30 psig by tuning the regulator and adjust the
air regulator in the actual system to a pressure of 20 psig.
4. The 3-way valve T-01 & T-02 is rotated such that the flow passes into the level
tank by bypassing the Heat Exchanger line and again from level tank to cold
water tank.
5. Put both the controllers in the MANUAL Mode.
6. Put LIC-01 and FIC-01 in the REVERSE Mode.

NOTE: We have kept the mode of LIC-01 in the REVERSE Mode, whereas, in the feedback
control system for level, the mode on LIC-01 was in DIRECT Mode. The reason is, the control
element in the Feedback Level Mode was PCV-02, (kept at the outlet of the level tank), whereas,
the control valve in this experiment is PCV-01 (placed at the inlet).

7. Put the knob indicating LOCAL/REMOTE on FIC-01 in the LOCAL Mode.

8. Fix a set point say 100 on the FIC-01 controller and 50 on the LIC-01 controller.
9. Switch on the pump P-01.
10. Let the level approximates to the set point.
11. If the flow is higher than the set point on the FI controller, manually, reduce the
opening of the valve PCV-2. If the flow is lower, increase the opening. Gradually,
the flow will stabilize near the set point.
Then:
12. Switch the controller FIC-01 from the MANUAL to the AUTO mode.
13. Change the PID values, so that the FIC-01 is fine-tuned, meaning that the flow
has stabilized near the set point.

Gradually, the level in the level tank will stabilize. Then:

14. Switch the controller LIC-01 from the MANUAL to the AUTO mode.
15. Change the PID values to fine tune the LIC-01 controller.

Once both the controllers are working independently and in the AUTO Mode, then:

16. Switch the controller from the LOCAL to the REMOTE mode.
17. Adjust PID values of both the controllers, to bring the system under stability

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5.4 SHUT DOWN PROCEDURE:

In actual System:
1. Switch OFF the Pump P-01.
2. Switch the LOCAL/REMOTE knob on FIC-01 to the LOCAL Mode.
3. Open up the Drain valve to empty the tank.
4. The panel switches should be placed back to position ‘OFF’ and then the main
switch should be turned ‘OFF’.
In Software:
5. Quit the current loop and go to the main menu.
6. Quit the entire program and return to Windows.
7. Switch off the PC and the mains.

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 6. RATIO CONTROL
6.1 PROCESS DESCRIPTION:

As the name implies, ratio control is maintaining a fixed ratio between two variables. The
most common application for ratio control is maintaining a fixed relationship between two flows,
such as air-fuel ratio in furnaces, feed and catalyst ratio in reactors and mixture of two or more
material in a blending operation. There are several variations of flow control schemes used to
obtain the ratio of two variables. The most common method of ratio control and the method we
are using in this loop consist of separate units to provide the ratio control. The measurement of
an uncontrolled flow is transmitted to ratio unit where it is multiplied by a ratio factor and the
output of the ratio unit becomes the set point of the secondary controller. Ratio Control Scheme
is shown in figure 6.1 below.

Figure 6.1

Ratio controller involves two variables - one is uncontrolled or primary variable or wild
flow and the other is controlled or secondary variable. In our case, flow through FT-02 will be
primary controller and flow through FT-01 will be secondary controller.

The ratio, which can be maintained in between these two, will be in the range of 0.0 to
1.0. So, e.g. if a set point of say 0.5 is given to ratio controller, then for a flow of 20 lpm through
FT-02, the flow through FIC-01 will be maintained at 10 lpm which will act as Remote Set Point
from Ratio Controller.

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6.2 PRECAUTIONS:

The following steps have to be taken before the system can actually be put into operation.
Otherwise, there may be unnecessary damage to any part of the system, particularly to the
pumps.

a) The particular switches from the PANEL that are to be used for the respective
loops should be switched to the ‘ON’ position to ensure the electrical signal
transmission.
b) The Recirculation valves must be kept open such that at 100% opening of both
PCV-01 & PCV-02 we can have flow through FT-01 & FT-02 is 200LPH. It will
ensure pump protection also.

6.3 STARTUP & PROCESS OPERATION PROCEDURE :

1. Switch on the PC.

2. Start the software.
3. Set Hand-Valves (HV-02 & HV-03) .
4. Start air supply to pneumatic control valves (PCVs) by switching on the
compressor and setting a pressure of 30 psig by tuning the regulator and adjust the
air regulator in the actual system to a pressure of 40 psig.
5. Open PCV-01 & PCV-02 by 100% in MANUAL mode.
6. Start both pumps from panel.
7. Observe flow by FT-02 & FT-01; adjust both recirculation valves HV-01 & HV-
04 so that flow is 200 LPH.
8. Give HIC-01 output to 100%. So that we can have flow from FT-02 is 200LPH if
not done so previously.
9. Now Put FIC-01 in AUTO, LOCAL, REVERSE mode. Set RC-01(Ratio
Controller) in LOCAL, AUTO Mode and set particular ratio say 0.5 in Ratio
Controller on from page. (so that we can have sp of FIC-01 to 100LPH)
10. Now Put FIC -01 in AUTO, REMOTE, REVERSE so that it can receive SP from
RC-01.
11. Set some OPTIMUM PID values on FIC-01. Observe Trends.

NOTE: When the controller is switched from the MANUAL to the AUTO Mode, the control
action will be most probably not accurate. This is due to the randomly set PID values. In such a
case, the user is asked to change the PID values. By trial and error correct values can be inserted
and the level can be controlled accurately.

6.4 SHUTDOWN PROCEDURE:

1. Switch off the Pumps.

2. The switches on the Panel should be switched back to ‘OFF’ position and then the
main switch should be turned ‘OFF’.
3. To Exit software, got to session menu. Click on Quit to Windows.

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