3/10/2020

EE312: CONTROL
SYSTEM
ENGINEERING
LAB 3: PROCESS CHARACTERISTICS

Objective
Sohail Ali – S11159789
Meshach Kumar – S11159787
Nimish Prakash – S11157048
Avishek Prasad – S11144291
  To understand what are single and multiple- capacity processes.
 To be able to characterize a process using the process response curve method.

Introduction
The Process Control Timer
The process control timer is a portable, bench – top component designed to enable students to
grasp the concepts regarding Instrumentation and process control [2]. The unit uses temperature
cycle whose values and features can be altered to get a stable and damped output. As a reason
various experiments can be performed using this unit. Some of the experiments include, study of
open loop (manual control), Gain knowledge of on/off controller and of open and closed loop
methods. It can also provide basic knowledge regarding PID controller, relative and fundamental
controllers, as well as auto controllers [2].

Figure 1: Shows the Process control timer unit.

The key features include:

One of its main features is that it can be connected to PC through USB and the control console
can be either be controlled by PC or PLC [3].
There is various application of process control timer unit. Some of the applications are;
Digitizing the control of flow control system, calibration of transmitter, stability of flow control
system and of single loop PID [2].
There are many types of process control timers, but the most important ones are the;
 Level/ Flow Process Control unit = has two common types of process control system that is flow
and liquid level. This unit allows students to adjust, operate, calibrate and connect systems [4].

Figure 2: Shows Level process control unit.

 Temperature process control unit = this allows the students to adjust, operate, calibrate
and tune thermal process control systems. Major elements include temperature control, loop
control, temperature sensors and transmitters [4].

Figure 3: Shows the Temperature process control unit.

 Analytical process control unit = enables students to control and modify the chemical properties
of a substances. Some major topics covered include: pH electrodes, pH meters, transmitters and
theoretical process control knowledge [4].
 Figure 4: Shows the Analytical process control unit.

 Pressure process control unit = allows students to control the liquid level and tank pressure at
once. The major topics include: HMI panel operation, pressure control systems, pressure system
alarms and open/close loop tuning [4].

Figure 5: Shows the Pressure process control unit.


Methodology
Setting up the circuit
It was made sure that the POWER switch of the Process Control Trainer was set to the O (OFF)
position. Appropriate connections were then made to obtain the circuit shown below.

Figure 6: Shows the experimental circuit diagram.

The required settings were made on the Process Control Trainer and the power switch of the
process control trainer was set to I (ON) position. Initial temperature transmitter output voltage
was recorded.
The DC source-1 level control was turned fully counterclockwise (MIN.) and the process control
trainer was let to operate so that the radiator cools down. The relationship between temperature
transmitter output voltage and time was plotted.
The dead time td of the temperature process was determined using the curve plotted. Then the
temperature transmitter output voltage at 63.2% of the voltage excursion was determined. Later,
the time constant of the temperature process was determined using the response curve plotted
previously. The time constant of the temperature process to the time constant of the temperature
transmitter was compared.
Results
Table 1: Temperature Transmitter output voltage for first 2 minutes at 15 seconds interval
Time Temperature Transmitter
(sec) Output Voltage (V)

0 3.2
15 3.2
30 3.23
45 3.25
60 3.3
75 3.4
90 3.6
105 3.7
120 3.8

Table 2: Temperature Transmitter output voltage for next 18 minutes at 1 minute interval
Time Temperature Transmitter
(mins) Output Voltage (V)

3 4.1
4 4.3
5 4.45
6 4.6
7 4.7
8 4.8
9 4.85
10 4.9
11 4.95
12 4.98
13 5
14 5
15 5
16 5
17 5
18 5
19 5
20 5
 Temperature Transmitter Output Voltage (V) Vs Time (mins)
5
Temperature Transmitter output voltage (V)

4.8

4.6

4.4

4.2

3.8

3.6

3.4

3.2

0 2 4 6 8 10 12 14 16 18 20
Time (mins)
Figure 7: Shows relationship between temperature output voltage and time.

The above graph shows the relationship between temperature transmitter output voltage and
time. This graph is a representation of the temperature process response curve of the Process
Control Trainer. It can be observed that after 30 seconds there is a step change and after 12
minutes approximately the graph reaches its final steady state.
Analysis
1) Dead Time td (s) = 30 seconds

2) Temperature Transmitter Output Voltage at 63.2%:

63.2
x (5 – 3.2) = 1.1377 Vdc
100
At 63.2%, Output Voltage = 3.2 + 1.1377 = 4.34 Vdc

3) Time constant = 3 minutes 20 seconds

Temperature Transmitter Output Voltage (V) Vs Time (mins)

4.8

4.6

4.4

4.2

3.8

3.6
Time Constant
3.4

3.2

0 2 4 6 8 10 12 14 16 18 20
Time (mins)

4) Initial voltage = 3.2 Vdc

5)
 2V = 5V
3V = X
X = 7.5V
Change in voltage = 7.5 – 5 = 2.5V
Thus, Change span expressed in percentage:
2.5
x 100 = 50%
5

6) Change in power supply as input changes from 0 – 2V as percentage

2−0
x100 = 40%
5

Therefore,
Control variable
K=
Manipulated variable
40
K=
50
K = 0.8

Experimental Setup
 Figure 8: Lab setup for process control trainer.

Discussion:
While conducting this experiment, the objective was to understand the concept of single and
multiple capacity processes. The team was also expected to characterize a process based on its
response curve.
A single capacity model representation consists of a single element of capacity and resistance.
The capacity element describes the storage ability of the network while the resistance applies to
the network’s opposition to the flow of energy. In practice, there are few single capacity
processes. The multiple capacity processes are more widely used but generally require more
complex models.
When a single capacity process is subjected to a step change, the process responds immediately.
However, the process reaches steady state in a certain time. This time is known as the capacity
lag/dead time. A particular response also occurs when step changes are introduced to two
capacity process. The response seen after the first tank is same as for single capacity tanks and
the response for the second tanks are steadier. It is important to note that the delay in reaching
steady state is because the effects of the combined effects of resistance and capacity.

In control system definition, Dead time is the delay between the instant a controller issues an
output signal to the instant when the process variable begins to display a response.
According to the results of our experiment, the dead time for our process was found to be 30
seconds. This was obtained from the graph of Temperature Transmitter Output Voltage Vs
Time. The graph represents the response curve of our process. The graph also gives the output
voltage value at our first-time constant which was 63.2% of the steady state voltage. This value
was found to be 4.34V and hence, the corresponding time (Time constant) was found to be 200
seconds. It was also observed that the time constant for the Temperature Transmitter vs Time
and the Temperature Transmitter voltage Vs Time had the same time constant.

The team’s hypothesis that, a short timer constant would mean that the response curve
approaches steady state more quickly was also held true based on the results obtained. The gain
(K) value for our system was found to be 0.8. This was the steady state voltage as seen from the
graph of Temperature Transmitter Output voltage vs Time. By observing the response curve,
the team recognized it as a First Order Response curve. Hence, by substituting the final steady
state voltage (K) and the temperature time constant (T) into the first order transfer function below:

K
T(s) = Ts+1

We obtained the transfer function of the process as:

5
T(s) = 200 s+ 1
Hence, systems can be mathematically modelled based on their transfer functions which can
calculated from data obtained from the systems physical response.

Review Questions
1) A single capacity process consists of a single element of resistance and a single element
of capacity. Simply a representation of an analogy with electrical systems.
 2) Process gain is simply calculated by control variable divided by manipulated variable. It
the final steady state of a response curve.

3) The response curve obtained will be significant due to the fact the sensor time constant
doesn’t have much influence on the response curve. Only significant difference obtained
will be a steeper PV slope and the graph will reach its final steady state more quickly.

4) Dead time is simply the time required for a process to respond to change. It the delay
between the instant a controller issues an output signal to the instant when the process
variable begins to display a response.

5) Use of transfer function or in our case getting experimental data and plotting the graph.

Conclusion
By conducting this experiment, the team learnt that a process may have only single capacity or have
multiple capacities. The team was also able to characterize the process as a first order system by
analyzing its response curve. Moreover, the process gain K and the time constant T had to be obtained in
order to write the transfer function.
A challenge faced in this experiment was that due to some system error the temperature of the transmitter
tends to fluctuate a lot when the unit was turned on. It is recommended that, the set-up is given some time
to stabilize into run temperature before turning the voltage supply.
The transfer function obtained can be used to mathematically model Temperature Transmitter in
simulations.

References
[1] Anonymous "Procurement Of Pressure Control Process Trainer, Flow Control Process
Trainer, Programmable Logic Controller, Level Control Process Trainer, Temperature Control
 process Trainer [Tender documents: T37706250]," MENA Report, 2017. Available:
http://ezproxy.usp.ac.fj/login?url=https://search.proquest.com/docview/1890315725?
accountid=28103.
[2] Process Control - Temperature Datasheet, Canada: Festo Didactic Ltée/Ltd, 2014.
[3] Process Control Technology PCT-100. Datasheet, United Kingdom: Bytronic Limited.
[4] "Process Control Training | Level / Flow, Temperature, Analytical, Pressure," AMATROL
Inc., 2020. [Online]. Available: https://amatrol.com/product/process-control-training/.
[Accessed 12 March 2020]

Appendix

Temperature Vs Time
55
Temperature ( degree celsius)

50

45

40

35

30
0 2 4 6 8 10 12 14 16 18 20
Time (min)
Figure 9: Shows relationship of temperature Vs time.

We also took the temperature readings and plotted a graph of temperature VS time as shown
above. It can be observed that the relationship also represents a step response curve which is
similar to the output voltage VS time graph.