Basrah University

College of Engineering
CHEMICAL ENGINEERING DEPARTMENT
Process control lab.
Asst. Prof. Abdulwahid Al-Hajjaj
EXPERIMENT NO. 2

PCT50 Level control process

Objective:
The objective of this experiment is:

➢ To control the level of water in the process vessel using an on/off controller to
automatically start and stop the feed pump as required to maintain the required
level in the process vessel (inflow control).
➢ To determine the variations in water level due to the dead band inherent in an
on/off controller.
➢ To change the level inside the process vessel by changing the set point on the
on/off controller and to determine the effect of disturbances to the process.
➢ To investigate the effect of different ranges of inflow and outflow to / from the
process vessel.
➢ To control the level of water in the process vessel using a proportional controller
to automatically vary the speed of the feed pump (inflow control).
➢ To determine the response of a level process when using a P only controller to
vary the pump speed.
➢ To determine the response of a level process when using a P+I controller to vary
the pump speed.
➢ To change the level inside the process vessel by changing the set point on the P or
P+I controller and to determine the effect of disturbances to the process.
➢ To investigate the effect of different ranges of inflow and outflow to / from the
process vessel.

Introduction:

The PCT50 Level Control Process consists of a combined sump tank / level vessel
assembly together with an electrical connection box, mounted on a common base plate.
The process is free standing, without the need for a permanent water supply or drain
connection, and suitable for locating on a work bench alongside a PC. The process
incorporates an electronic interface with sensor conditioning, drive circuits and integrated

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USB connection. This means that the user only needs to fill the process with water (where
appropriate), connect the mains adaptor and connect the supplied USB cable to a suitable
PC for the equipment to be operational. The use of transparent materials gives clear
visibility of the process in operation and the location of control components such as sensors
and control elements. The facility to vary the operating characteristics to allow
optimization of the PID settings to suit the characteristics and to demonstrate the differing
responses of both optimum and non-optimum controller configuration. Supplied with
software and USB lead allowing control and data acquisition using a PC. Disturbances
(step changes) can be applied to the process, remotely from the PC, to test the stability of
the system with the controller settings under investigation. The magnitude of the
disturbance can be changed in fixed steps for repeatability or varied continuously to
achieve a specific response in the system. Manual operation via the PC will allow open
loop testing of each process to determine the system response prior to assigning appropriate
values for the P, I and D terms, cycle time etc in a closed loop configuration. In addition to
control of the process and initiation of step changes, the software supplied will also allow
recording of the responses, graphing etc. when testing any of the control loops. The
electrical interface, mounted alongside the process, incorporates additional front panel
connectors that allow the input and output signals to be connected to an alternative PID
controller, Programmable Logic Controller or similar control equipment if required by the
end user. The electrical supply is provided by a universal 24V DC in-line adaptor with
interchangeable leads to suit the local electrical supply.

Theory

1) On/off control

An on/off controller is a simple and effective way of controlling many processes but does
have disadvantages because its output can only be on or off. In the case of the level process
in this exercise the pump is started and stopped.

An on/off controller incorporates a dead band to avoid rapid switching of the controlled
variable when at the setpoint i.e. in this case the level must rise above the setpoint by a
fixed amount before the pump switches off and the level must fall below the setpoint by a
fixed amount before the pump starts again.

Note: On PCT50 an On/off controller with fixed dead band is created by setting the
Proportional Band to 0 % in the PID controller. In a commercial On/off controller the dead
band can be varied to suit the process. This allows the choice of less frequent switching but
larger variations in the process variable or closer control of the process variable but more
frequent switching with attendant wear etc. of the components.

2) Proportional term (P)

The Proportional Band setting on a process controller makes a change to the output (pump
speed on PCT50) that is proportional to the current error value (the difference between the
measured level and the set point on the controller). The proportional response can be

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adjusted by multiplying the error by a constant Kp, called the Proportional Gain. This is
related to the Proportional Band setting on the controller as follows:

Proportional Gain (Kp) = 100 % / Proportional Band %

i.e. 100 % PB means unity gain (change in controller output = error at input)

and 50 % PB means a gain of 2 (change in controller output = 2x error at input)

A low setting of the Proportional Band (large gain) results in a large change in the output
for a given change in the error. If the Proportional Band is too low, the system can become
unstable. In contrast, a large setting of the Proportional Band (low gain) results in a small
output response to a large input error, and a less responsive or less sensitive controller. If
the Proportional Band is too high, the control action may be too small when responding to
system disturbances resulting in slow response and offsets of the resulting process variable
from the set point.

A Proportional-only controller will not always settle at the set point, but may retain a
steady-state offset. Offset can be reduced in Proportional-only control by reducing the
Proportional Band setting. However, if the PB is set too small then hunting or oscillating
will occur. The offset can be minimised by adding a bias to the set point (setting the set
point above or below the required value to compensate for the offset) but this technique is
only appropriate if the system characteristics are known and fixed. A better solution is to
remove the offset by adding Integral action to the controller (P+I) as described below.

3) Integral term (I)

The contribution from the integral term is proportional to magnitude and duration of the
error. The Integral term in a PID controller is the sum of the instantaneous error over time
and gives the accumulated offset that should have been corrected previously. The resulting
controller output is the sum of the contribution from the Integral term and the contribution
from the P term.

When the I term is correctly adjusted any residual offset in the process variable due to the
P term will be gradually reduced by the Integral term until the offset is eliminated. If the
time setting of the I term is too long then correction to any offset will be very slow.

However, since the integral term responds to accumulated errors from the past, it can cause
the present value to overshoot the setpoint value or to make the process completely unstable
if the time setting of the I term is too short. If this occurs the I term makes adjustments to
the controller output faster than the process can respond. I.e. the I term winds up the
controller output so that the process overshoots considerably, hence the term Integral
Wind-up or Integral saturation.

Careful selection of the I term in combination with the P term will give efficient response
to changes in the system.

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Apparatus

Refer to the equipment diagram for details about the PCT50 Level Process, Figures (1 and
2), the front view shows the layout of the PCT50 and the circuit diagrams show the process
in operation with inflow to the process vessel (controlled by varying pump speed) or
outflow from the process vessel (controlled by opening and closing a solenoid valve on a
time cycle). These alternatives are described in detail later.

PCT50 is a level control process using water as the working fluid for safety and
convenience in use.

Water stored in the lower sump tank is transferred to the upper process vessel via a
submerged, variable speed centrifugal pump (10). A quick release connector (9) allows the
flexible pump outlet tube to be disconnected to aid priming of the pump after filling the
sump tank with water. A vertical inlet arrangement in the process vessel allows
visualisation of the water entering the vessel, independent of water level and an integral
non-return valve (8) prevents water from draining back into the sump vessel when the
pump speed is reduced or stopped. An inline ball valve (CV1) above the quick release
connector allows the flow of water entering the process vessel to be varied to suit a
particular demonstration.

The water level inside the process vessel is measured using an electronic pressure sensor
(2) mounted through the floor of the vessel. One side of the pressure sensor is connected
to the inside of the process vessel and the other is open to atmosphere, allowing the pressure
in the process vessel to be measured relative to atmosphere. This sensor therefore measures
the level of water inside the process vessel. The level is indicated (1) on the scale on the
side of process vessel.

Water drains from the process vessel back into the lower sump tank via two outlets in the
floor of the process vessel. Flow through the main outlet is continuous. Flow through the
second outlet can be started and stopped by a solenoid valve (SOL) under remote control.
Both outlets incorporate a hand operated ball valves (CV2 and CV3) that allows the flow
of water to be varied continuously to suit a particular demonstration. Both outlets also
incorporate an interchangeable orifice (3 and 5) that allows the flow to be fixed at
predetermined values, varying only with the size of the orifice and the head in the process
vessel. The orifice size is changed by unscrewing the plastic fitting containing the orifice
and replacing it with the required alternative. The fitting incorporates an ‘O’ ring seal and
only requires hand tightening. The alternative sizes of orifice (12) are stored in threaded
holes at the front of the base plate when not in use.

An overflow (6) in the process vessel returns water to the sump tank, preventing the process
vessel from flooding in use.

The pressure sensor measuring the level, the centrifugal pump and the solenoid valve are
connected to an electrical interface (4) that incorporates the necessary signal conditioning,
allowing the process to be operated directly from a PC using a single USB port.

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Alternatively the process can be operated using a controller such as PCT54 (PID
Controller) or PCT55 (Programmable Logic Controller) connected to the electrical
interface.

The computer software supplied with PCT50 allows control of the level process and data
logging of the responses using a PC. Alternatively the software allows data logging only
while operating the process remotely using a PID controller or PLC.

When filled with water, the PCT50 is self contained requiring only a mains electrical
supply to the in-line DC converter and connection to either a PC via the USB port or to a
process controller such as PCT54 (PID Controller) or PCT55 (PLC with PID controller).

The unit is drained using the ball valve (11) located at the rear.

Figure 1: Photographic image of the apparatus

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 Figure 2: Schematic diagram of the PCT50 Level Control Process

Experimental procedure
a. On-off control

1. Choose the PID box on the mimic diagram, set the Proportional Band, Integral Time
and Derivation time to 0 then set the Set Point to 75 mm (default at start up). Click
Apply to enter the changes to the settings as shown in Figure (3).
2. Choose the Automatic Mode of Operation.
3. Select the icon to begin data logging.
4. The pump will switch on, the level will gradually rise and water will drain from the
vessel via outlet valve CV2. The level will continue to rise until it reaches the level
set on the controller I.e. the setpoint of 75 mm. When the level rises above the
setpoint by a fixed amount (the dead band) the pump will switch off and the level
will fall as water drains via outlet valve CV2. When the level falls below the
setpoint by a fixed amount (the dead band) the pump will switch on again and the
cycle will continue.

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 5. In the PID controller adjust the set point to 50 mm, click Apply then observe the
pump remains off until the level falls to the new set point then switch on and off as
before to maintain the new level.
6. Adjust the set point to 1000 mm and observe the response of the process.

Effect of Disturbances

1. Open the solenoid valve by clicking the button on the mimic diagram (1 indicates
that the valve is open). Observe that the level falls faster due to the additional
outflow via the solenoid valve then the controller switches on the pump to restore
the original level.
2. Close the solenoid valve by clicking the button on the mimic diagram (0 indicates
that the valve is closed). Observe that the process returns to the original
characteristics.

Effect of differences in Inflow Rate and Outflow rate

1. Close inlet valve CV1 so that the level only just rises when the pump is running.
Allow the level to rise and fall through several cycles then open the solenoid valve
to disturb the process. If the combined outflow exceeds the inflow then the level
will continue to fall with the pump operating and the required level cannot be
maintained. Close the solenoid valve again.
2. Open inlet valve CV1 so that the level rises rapidly when the pump is running.
Allow the level to rise and fall through several cycles then open the solenoid valve
to disturb the process.
3. Choose the icon to finish data logging.
4. If time permits repeat the exercise with different sizes of orifice fitted to the outlet
valve CV2 and solenoid valve, E.g. 2 mm at CV2 and 4 mm at the solenoid valve
(smaller outflow with larger disturbance). The filling characteristics with different
settings of CV1 could also be investigated.
5. Create a new results sheet for each run by selecting the icon in the tool bar of
the software.

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 Figure (3) PID controller

b. P only controller

1. Choose the PID box on the mimic diagram, set the Proportional Band P to 200%,
the Integral Time I to 0 and the Derivation time D to 0 then set the Set Point to 75
mm (default at start up). Click Apply to enter the changes to the settings.
2. Choose the Automatic Mode of Operation.
3. Select the icon to begin data logging.
4. The pump will start, the level will gradually rise and water will drain from the vessel
via outlet valve CV2. The level will continue to rise until it reaches a steady level
but this will not correspond with the setpoint of 75 mm on the controller because
of the offset inherent in a P only controller.
5. Open the solenoid valve by clicking the button on the mimic diagram (1 indicates
that the valve is open) to disturb the process. Observe that the level falls slightly,
the pump speeds up slightly due to the increased error but a large offset remains.
When the level has settled close the solenoid valve and allow the level to settle.
6. Adjust the set point to 100 mm then click apply and observe the response to a
requested increase in water level. When the level has settled, return the set point to
75 mm and observe the response.
7. Adjust the P term to 100 % in the PID controller then click Apply. Observe that the
pump speeds up and the offset reduces slightly. Open then close the solenoid valve
as before to disturb the process and observe the response, the stability of the level
and any reduction in offset.

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 8. Adjust the P term to 50 % and repeat the above steps.
9. Adjust the P term to 20 % and repeat the above steps.
10. Adjust the P term to 10 % and repeat the above steps
11. Adjust the P term to 5 % and repeat the above steps
12. Adjust the P term to 2 % and repeat the above steps.
13. Choose the icon to finish data logging.

c. P + I controller

1. Create a new results sheet for this run by selecting the icon in the tool bar of the
software.
2. Choose the PID box on the mimic diagram, set the Proportional Band P to the value
selected above, the Integral Time I to 0 seconds and the Derivation time D to 0 then
set the Set Point to 75 mm. Click Apply.
3. Select the icon to begin data logging.
4. Choose the Automatic mode of operation and allow the water level to stabilise.
5. Adjust the I term to 100 seconds in the PID controller then click Apply. Observe
that the pump speed varies to reduce the offset. When the level is settled at the set
point open the solenoid valve to disturb the process. Observe that the level falls
slightly, the pump speed varies and the level gradually returns to the set point.
When the level has settled close the solenoid valve and allow the level to settle.
6. Adjust the set point to 100 mm then click Apply and observe the response to a
requested increase in water level. When the level has settled return the set point to
75 mm and observe the response.
7. Adjust the I term to 50 seconds in the PID controller then click Apply. Observe that
the level returns to the set point faster than before. When the level is settled at the
set point open then close the solenoid valve as before to disturb the process.
8. Adjust the set point to 100 mm then click Apply and observe the response to a
requested increase in water level. When the level has settled return the set point to
75 mm and observe the response.
9. Continue reducing the Integral time setting and repeating the disturbance and set
point changes until the level becomes unstable.

Results:

a. On-off control

1. Choose the icon (or View \ Graph) to display a graph of the responses obtained.
Observe the rising and falling water level about each of the set points as the pump
starts and stops to maintain the required level. Observe the change in the rate of
filling when the solenoid valve is opened to disturb the process and when the inflow
is reduced by partly closing valve CV1.
2. From the graph or table of results ( icon or View\Table) determine the variation
in level about the set point to determine the dead band of the controller. In a
commercial controller the dead band would usually be adjustable to suit the process

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 but too small a variation would lead to wear of components switching rapidly on
and off.
3. From the graph observe that the rate of filling when the pump is on is not necessarily
the same as the rate of emptying when the pump is stopped.

b. P only controller

1. Choose the icon (or View \ Graph) to display a graph of the responses obtained.
2. Choose Format \ Graph Data and Plot Level L1 and Set point on 1 axis, and
Controller Output on the second axis.
3. Observe the changes in water level and the stability of the responses for each
change in P setting with a disturbance or change in set point.
4. Choose a setting for P that gives stable control with a reasonably small offset that
can be used in the next part of the exercise introducing Integral action.

c. P + I controller

1. Choose the icon (or View \ Graph) to display a graph of the responses obtained.
2. Choose Format \ Graph Data and Plot Level L1 and Set point on 1 axis, and
Controller output on the second axis.
3. Observe the changes in water level and the stability of the responses for each
change in I setting with a disturbance or change in set point.
4. Choose a setting for I that gives stable control and reduces any offset swiftly
without causing the system to become unstable.
5. Since the effect of Integral Action is related to the Proportional Band setting
(reduced PB gives greater effect for any setting of I) the above exercise should be
repeated at a completely different value of PB to determine the necessary change
in I for effective control of the level and to demonstrate the relationship between P
and I.
6. If time permits repeat the exercise with different sizes of orifice fitted to the outlet
valve CV2 and solenoid valve, E.g. 2 mm at CV2 and 4 mm at the solenoid valve
(smaller outflow with larger disturbance). The filling characteristics with different
settings of CV1 could also be investigated e.g. partly closing valve CV1 to reduce
the flow or increasing the flow by opening the valve.

References

1. D.R. Coughanowr and S.E. LeBlanc, Process System Analysis and Control, 3rd
edition, McGraw-Hill, 2007.
2. D.E. Seborg, T.F. Edgar, D.A. Mellichamp and F.J. Doyle III, Process Dynamics
and Control, 4th edition, John Wiley, 2017.
3. W.L. Luyben, Process Modeling, Simulation, and Control for Chemical Engineers,
2nd edition, McGraw-Hill 1999

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4. P.K. Sarkar, Process Dynamics and Control, Delhi, 2014.

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