TEMPERATURE CONTROL

TRAINER
 1. Study of open loop response (Manual control)
Aim: To study of open loop response in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup
including water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature
control principles. The process setup consists of heating tank fitted with SSR
controlled heater for on-line heating of the water. The flow of water can be
manipulated and measured by Rota-meter. Temperature sensor (RTD) is used for
temperature sensing. The process parameter (Temperature) is controlled by
microprocessor based digital indicating controller which manipulates heat input to
the process. These units along with necessary piping and fitting are mounted on
support frame designed for table top mounting. The controller can be connected to
computer through Ethernet port for monitoring the process in SCADA mode or Apex
process trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
 • Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select open loop Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “Open Loop” button.)
3. Close the control valve by increasing the controller output to 100%.
4. Apply the step change by 10% to controller output in manual mode, wait for the
level to reach the steady state value.
5. Repeat the above step until the controller output reaches to minimum i.e. 0%.
Table:
S. No. Controller output in % Process value in %
1 0
2 10
3 20
4 30
5 40
6 50
7 60
8 70
9 80
10 90
11 100
Observations:
1. From the above data, note the output required for maintaining the temperature
at desired set points. (For particular drain valve opening).
2. Set the output of the controller to the noted value and at steady state applies
the load change to the process. Load change can be given by slightly varying
the drain valve. Observe new steady state process value.
Result: The open loop responses in temperature control trainer were identified.
 2. Study of ON-OFF control in Temperature Control Trainer
Aim: To study of response of ON-OFF Control in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup
including water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature
control principles. The process setup consists of heating tank fitted with SSR
controlled heater for on-line heating of the water. The flow of water can be
manipulated and measured by Rota-meter. Temperature sensor (RTD) is used for
temperature sensing. The process parameter (Temperature) is controlled by
microprocessor based digital indicating controller which manipulates heat input to
the process. These units along with necessary piping and fitting are mounted on
support frame designed for tabletop mounting. The controller can be connected to
computer through Ethernet port for monitoring the process in SCADA mode or Apex
process control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select “On-Off mode” option for the control from software. (Click on “Change
Expt.” Button, click on “Change”, Click on “On-Off mode” button.)
3. Change Hysteresis value to 5%.(Range 0.1-10%)
4. Change the values of the set point and observe the On-Off control operation.
Table:

S. No. Set point value in % Process value in % Output value in %

1
2
3
4
5
6
7
8
9
10

Observations:
 Observe that if process value exceeds the set point and increases above the
value of (0.5x Hysteresis), control valve is fully closed and if process value
decreases below the set point by (0.5 x Hysteresis), the control valve opens
fully i.e. controller operates like On/Off switch.

Result: The responses of ON-OFF control in Temperature control trainer were

studied.
 3. Tuning of Controller in Temperature Control Trainer
Aim: To study the tuning of controller using auto tuning method in temperature
control trainer
Apparatus: Computer setup and Temperature control trainer equipment setup
including water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature
control principles. The process setup consists of heating tank fitted with SSR
controlled heater for on-line heating of the water. The flow of water can be
manipulated and measured by Rota-meter. Temperature sensor (RTD) is used for
temperature sensing. The process parameter (Temperature) is controlled by
microprocessor based digital indicating controller which manipulates heat input to
the process. These units along with necessary piping and fitting are mounted on
support frame designed for tabletop mounting. The controller can be connected to
computer through Ethernet port for monitoring the process in SCADA mode or Apex
process control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select Autotune option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “Autotune” button.)
3. Wait Till Autotune is complete. (Blinking of green LED stops).
4. Controller automatically finds the PB, IT & DT values.
5. Find out PID values at different set points /flow rates
Table:

Set point Process Output

S. Proportional Integral Derivative
value in value in value in
No. band time time
% % %
1
2
3
4
5
6
7
8
9
10

Observations:
 The controller has preprogrammed logic for finding “Auto tune” values.
Based on the response of the process the controller calculates PID values or
comes out without finding the “Auto tune” values.
Result: The tuning of controller in temperature control trainer using auto tuning
method at different set point values.
Set point = ____; Proportional band = ____; Integral Time = ___; Derivative time =___.
Set point = ____; Proportional band = ____; Integral Time = ___; Derivative time =___.
 4. Study of P-controller in Temperature Control Trainer
Aim: To study of response of P-controller in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup
including water and air supply.
Description:
Temperature control trainer is designed for understanding the basic
temperature control principles. The process setup consists of heating tank fitted with
SSR controlled heater for on-line heating of the water. The flow of water can be
manipulated and measured by Rota-meter. Temperature sensor (RTD) is used for
temperature sensing. The process parameter (Temperature) is controlled by
microprocessor based digital indicating controller which manipulates heat input to
the process. These units along with necessary piping and fitting are mounted on
support frame designed for tabletop mounting. The controller can be connected to
computer through Ethernet port for monitoring the process in SCADA mode or Apex
process control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Theory: The proportional controller produces an output signal (pressure in the case
of a pneumatic controller, current or voltage for an electronic controller) that is
proportional to the error E. This action may be expressed as
p=K ϵ+p
Where: p = output signal from controller, psig or ma; Kc= gain, or sensitivity;
є = error = (set point - measured variable); ps = constant.
 The error є, which is the difference between the set point and the signal from
the measuring element, may be in any suitable units. However, the units of set point
and measured variable must be the same, since the error is the difference between
these quantities.
In a controller having adjustable gain, the value of the gain Kc can be varied
by moving a knob in the controller. The value of ps is the value of the output signal
when E is zero, and in most controllers ps can be adjusted to obtain the required output
signal when the control system is at steady state and є = 0.
Proportional control produces an overshoot followed by an oscillatory
response, which levels out at a value that does not equal the set point; this ultimate
displacement from the set point is the offset.
Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
  Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select P Mode option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “P Mode” button.)
3. Keep the set point to 40%. Change output mode to Manual. Adjust output value so
as to match the process value with set point and apply this output value as bias value
to the controller. Adjust the proportional band to 50%.
4. Switch the controller to Auto mode.
5. Apply step change to set point, step change should be of 2 to 3 % and observe the
response.
6. Switch the controller to Manual mode. Decrease proportional band to half of the
previous value & then shift controller to Auto mode. With each decrease, obtain a new
response of the step change. Ensure that the set point changes are around the same
operating point (@ 2-3% only).
7. Using trial and error approach, find a value of proportional band so that the
response to a step change has at most one overshoot and one undershoot.
8. Set the controller to the settings obtained in the above step and wait for the system
to reach at steady state.

Table:
Set point Process Output
Proportional Integral Derivative
S. No. value in value in value in
band time time
% % %
1
2
3
4
5
6
7
8
9
10
Observations:
1. Observe steady state error decreases as proportional band decreases.
2. Observe the effect of very low proportional band values (system works in
oscillatory mode).
3. Observe the response of the system to load change. Load change can be given by
slightly varying the inlet flow-rate.

Result: The responses of P-controller in Temperature control trainer were studied.

 5. Study of PID-controller in Temperature Control Trainer
Aim: To study of response of PID-controller in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup
including water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature
control principles. The process setup consists of heating tank fitted with SSR
controlled heater for on-line heating of the water. The flow of water can be
manipulated and measured by Rota-meter. Temperature sensor (RTD) is used for
temperature sensing. The process parameter (Temperature) is controlled by
microprocessor based digital indicating controller which manipulates heat input to
the process. These units along with necessary piping and fitting are mounted on
support frame designed for tabletop mounting. The controller can be connected to
computer through Ethernet port for monitoring the process in SCADA mode or Apex
Control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Theory:
This mode of control is combination of the previous modes and is given by the
expression

dϵ K
p=K ϵ+K τ + ϵ dt + p
dt τ
 In this case, the controller contains three knobs for adjusting Kc, τI, and τD.
The transfer function for this controller can be obtained from the Laplace transform of
above equation; thus
P(s) 1
=K 1+τ s+
ϵ(s) τs
The use of PID control combines the beneficial features of PD and PI control.
Integral action, which is present in PI and PID controllers, eliminates offset. The
addition of derivative action speeds up the response by contributing to the controller
output a component of the signal that is proportional to the rate of change of the
process variable. PID control is needed to prevent large overshoot and long settling
time.
Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
  Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select PID Mode option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “PID Mode” button.)
3. Switch the controller to manual mode.
4. Change the proportional band to the value that estimated in proportional controller.
Set integral time and derivative time based on the responses in previous experiments.
5. Adjust the set point to @ 50 %. Switch the controller to auto mode. Apply step
change of 10%. Observe the process response.
6. Change the proportional band, integral time, derivative time and observe the
response of the process for step change for each change in setting.

Table:
Set point Process Output
Proportional Integral Derivative
S. No. value in value in value in
band time time
% % %
1
2
3
4
5
6
7
8
9
10

Observations: Compare the steady state response of the PID controller with P. PI and
PD controller obtained in the above experiment.