EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

1. INTRODUCTION
Pressure control (PC) is a mode of mechanical ventilation alone and a variable within
other modes of mechanical ventilation. Pressure control is used to regulate
pressures applied during mechanical ventilation, instrumentation systems measure the
variable then control the variable to keep the variable within the given limits.

In today‘s modern plants, processes are controlled to achieve desired objectives. The
term control means method or means used to force parameters in the environment to
have specific or desired values. To achieve control, several elements are coordinated
together to achieve the control objective

Control can be either manual or automatic. Manual control involves human intervention
and it often entails forcing a given parameter to specific value with the human factor
actually carrying out the control function Pressure, Temperature, Flow are the main
three process variables in industries. The level is an another process variable in
industries.

1.1Pressure Control:

Pressure is a term used to describe the amount of force applied to a specific unit area.

Fig 1.1 Pressure control

1
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

If you open the block valve, air is released to the atmosphere, so the pressure inside the
receiver decreases. If you close the control valve, you keep the air inside the receiver
and the pressure increases. The process variable that we are controlling is called
PRESSURE

1.2 Automatic Control System

An automatic control system is a preset closed-loop control system that requires
no operator action. An automatic control system has two process variables
associated with it.

 Controlled variable: A controlled variable is the process variable that is

maintained at a specified value or within a specified range.
 Manipulated variable : A manipulated variable is the process variable that is
acted on by the control system to maintain the controlled variable at the
specified value or within the specified range.

1.3 Functions of Automatic Control

In any automatic control system, the four basic functions that occur are:

 Measurement
 Comparison
 Computation
 Correction

In the water tank level control system, the level transmitter measures the level within the
tank. The level transmitter sends a signal representing the tank level to the level control
device, where it is compared to a desired tank level. The level control device then
computes how far to open the supply valve to correct any difference between actual and
desired tank levels.

1.4 Working of Process Control Loop:

The first point of interest for any process control endeavour is the process variable, PV.
It is the variable we have to send to control or maintained at a given reference point or
setpoint. So as shown in the process control loop, the process variable, PV is measured
with the aid of sensor/transducers. This message signal is then fade into a controller
incorporating an error detector device. Here, the process variable, PV is compared with
the desired value of the process variable or the setpoint, SP and an error signal with a
specific magnitude and polarity generated and further process within the controller.
Based on the process error signal, the controller initiate a control action with the shape

2
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

of the control element or final control element as it is often known. The final control
element change in the process by changing the manipulated variable, MV, which then
alters the process until it settled at the setpoint. In this way,the process variable is taken
back to its desired value or setpoint. This is essentially a process control loop works.
Most complex process plants are operated with this simple underlying principle of
process control.

Fig 1.2 Working of process control loop

1.5 Proportional controller

Proportional control, in engineering and process control, is a type of linear feedback
control system in which a correction is applied to the controlled variable which is
proportional to the difference between the desired value (set point, SP) and the
measured value (process value, PV).Proportional control modulating the output to the
controlling device, such as a control valve at a level which avoids instability, but applies
correction as fast as practicable by applying the optimum quantity of proportional gain.

3
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

Proportional control dictates . From the block diagram shown, assume that r, the
setpoint, is the flowrate into a tank and e is error, which is the difference between
setpoint and measured process output. is process transfer function; the input into the
block is flow rate and output is tank level.
The output as a function of the setpoint, r, is known as the closed-loop transfer
function.

4
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

Fig 1.3 step response of p controller

1.6 Proportional band

The proportional band is the band of controller output over which the final control
element (a control valve, for instance) will move from one extreme to another.

So if , the proportional gain, is very high, the proportionnal band is very small, which
means that the band of controller output over which the final control element will go from
minimum to maximum (or vice versa) is very small. This is the case with on–off
controllers, where is very high and hence, for even a small error, the controller output is
driven from one extreme to another.

5
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

1.7OFF SET ERROR

Proportional control cannot eliminate the offset error, which is the difference between
the desired value and the actual value, SP − PV error, as it requires an error to generate
an output. When a disturbance (deviation from existing state) occurs in the process
value being controlled, any corrective control action, based purely on Proportional
Control, will always leave out the error between the next steady state and the
desired setpoint, and result in a residual error called the offset error. This error will
increase as greater process demand is put on the system, or by increasing the set
point.

1.8 Proportional derivative controller

The control actions of the proportional or integral controllers are based on the current
error or past errors. In derivative control the controller output is proportionalto the rate of
change of the error. The idea behind derivative control is that the controller should react
immediately to a large change in the control error in essence, predicting that the error
will continue to increase (or decrease) andact accordingly. Although this quick reaction
can result in fast response times,it can also result in undesirable overreaction,
especially if the system output has significant stochastics.

Where, the derivative control gain KD defines the ratio of the input magnitude to the
change in the error Since the derivative controller adjusts the control input according to
the speed of error variation, it is able to make an adjustment prior to the appearance of
even larger errors. Practically, the derivative controller is never used by itself since if the
error remains constant, the output of the derivative controller would be zero.

6
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

2. EXPERIMENTAL SETUP
2.1 Aim:
To control pressure in a closed head tank using P and PD controller.

2.2 Apparatus required:

Pressure control trainer kit

2.3 Circuit Diagram:

7
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

2.4 Procedure:

2.4.1 Study of open loop response(manual control):

1. Start the setup, adjust the vent valve.

2. Select open loop experiment (click on “change experiment” button, click on
“change”, click on “open loop button”).
3. Close the control valve by increasing the controller output and wait to 100 %.
Note down the steady state process value.
4. Apply the step change by 10% to controller output and wait for the process value
to reach the steady state value. Note down the process variable.
5. Repeat the above steps until the controller output reaches to minimum 0%
6. From the above data, note the output required for maintaining the process at
desired set points (for particular vent valve opening).
7. Set the output of controller to the noted value and at steady state apply the load
change to the process. Load changes can be given by slightly varying the vent
valve. Observe the steady state process variable.

2.4.2 Study of proportional controller:

1. Start the setup, adjust the vent valve.

2. Select P mode option for control from software (click on “change experiment”
button, click on “change”, click on “P mode” button)
3. Keep the set point to 50%. Change the output mode to manual. Adjust output
valve so as to match the process value with set point and apply this output value
s bias value to the controller. Adjust the proportional band to 50%
4. Switch the controller to auto mode.
5. Apply the step change of 10% to set point and observe the response.
6. Switch the controller to manual mode. Decrease proportional band to half the
previous value and then shift controller to auto mode. With the set point changes
are around the same operating point.

8
EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

7. Using trial and error method, find a values 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 system
to reach steady state.

2.4.3 Study of Proportional Derivative controller:

1. Start the setup, adjust the vent valve.

2. Select PD mode option for control from software (click on “change experiment”
button, click on “change”, click on “PD mode” button).
3. Select PD controller. Set the proportional band estimated from proportional
control (P Only). Start with derivative time t=0s and integral time t=30s which
derivative action and widen the effect of integral action.
4. Switch ON the controller to manual mode. Increase the derivative time by 1s.
switch to auto mode and apply step change to the set point by 2 to 5%. Note the
response of system.

Increase derivative time gradually and observe the process response for step change.

9
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

3. RESULTS AND OBSERVATION

3.1 Tabulation:

Table 3.1 Controller response.

Process variable PV (%)

P mode PD mode
S.No Time(s) PB=20% PB=60% PB=20%, PB=60%
DT=1s DT=4s
1 10 49.1 44.6 50.6 56.3
2 20 53.7 52.3 55 55.3
3 30 53.9 53.9 55.2 54.9
4 40 53.6 54.2 55.2 42.6
5 50 53.6 54.2 55.2 47.2
6 60 53.7 54.2 55.2 53.2
7 70 54 54.3 55.2 54.8
8 80 54 54.3 55.2 55.4
9 90 54.1 54.3 55.2 55.6
10 100 54.1 54.3 55.2 55.6
11 110 54.1 54.4 55.2 55.6
12 120 54.1 54.4 55.2 55.6
13 130 54.2 54.4 55.2 55.6
14 140 54.2 54.5 55.2 55.6
15 150 54.2 54.5 55.2 55.6
16 160 54.3 54.5 55.2 55.6
17 170 54.3 54.5 55.2 55.6
18 180 54.3 54.5 55.2 55.6

10
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

3.2 Graph:

Comparison of P and PD controller for PB=20%

56
55
54
53
Process variable(%) 52
Series1
51
Series2
50
49
48
0 50 100 150 200
Time(sec)

Fig 3.1 Comparison graph between P and PD controller with PB=20%

Comparison of P and PD controller of PB=60%

60

50

40
Process variable
30 Series1
(%)
20 Series2

10

0
0 50 100 150 200
Time(sec)

Fig 3.2 Comparison graph between P and PD controller with PB=60%

11
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

PROPORTIONAL BAND 20% (P Mode)

Fig 3.3 Response of P controller with PB=20%

PROPORTIONAL BAND 20% (PD Mode)

Fig 3.4 Response of PD controller with PB=20%

12
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

PROPORTIONAL BAND 60%(P MODE)

Fig 3.5 Response of P controller with PB=60%

PROPORTIONAL BAND 60%(PD Mode)

Fig 3.6 Response of PD controller with PB=60%

13
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

PROPORTIONAL BAND 20% WITH DISTURBANCE(P Mode)

Fig 3.7 Response of P controller with disturbance PB=20%

PROPORTIONAL BAND 20%WITH DISTURBANCE (PD Mode)

14
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

Fig 3.8 Response of PD controller with disturbance PB=20%

PROPORTIONAL BAND 60% WITH DISTURBANCE (P Mode)

Fig 3.9 Response of P controller with disturbance PB=60%

15
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

PROPORTIONAL BAND 60% WITH DISTURBANCE(PD Mode)

Fig 3.10 Response of PD controller with disturbance PB=60%

16
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

4. INFERENCES
It could be inferred that in proportional controller when the proportional band is
increased, the offset is reduced. A similar case is observed in proportional derivative
controller where the error is positive. It is also observed that set point is achieved
quickly in proportional derivative controller, hence proving its stability.

In P mode for PB=20%, the offset is 0.7%

In p mode for pb=60%, the offset is 0.5%

In PD mode for PB=20%, the offset is -0.2%

In PD mode for PB=20%, the offset is -0.5%

17
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

5. CONCLUSION
Thus, an experimental study of controller response and analysis on pressure loop is
accomplished using different controllers and the response is plotted in the graph.

18
 EXPERIMENTALSTUDY OF CONTROLLER RESPONSE AND ANALYSIS ON PRESSURE LOOP

6. REFERENCES
[1] https://www.instrumentationtoolbox.com/2012/01/how-process-control-loop-works-
in_24.html

[2] https://en.wikipedia.org/wiki/Pressure_control

19