P6

TEMPERATURE CONTROL

TEMPERATURE CONTROL

Description of the experimental set-up:

Temperature control trainer is designed for understanding the basic temperature control principles. The process setup consists of a heating tank fitted with

an SSR controlled heater for on-line heating of the water. The flow of water can be manipulated and measured by rotameter. Temperature sensor (RTD) is

used for temperature sensing. The process parameter (Temperature) is controlled by a microprocessor based digital indicating controller which

manipulates heat input to the process. These units along with necessary piping and fitting are mounted on a support frame designed for tabletop mounting.

The controller can be connected to the computer through a USB port for monitoring the process in SCADA mode.

Rotameter Electric Supply Set Point

Drain
Heating Tank
Heater
Theory:

In an automatic controlled process the parameter to be controlled is measured and compared with the set point by the process controller. The difference

between the measured signal and the set point is error. The controller performs on-line calculations based on error and other setting parameters and

generates an output signal. The output signal drives the final control elements like control valve or a damper to control the process to the set point.

On-Off Controller

A special case of proportional control is On-Off control. If the proportional band of the controller is made very low (=0) the controller output will move

from one extreme position to another for slight deviation of process value from the set point. This very sensitive action is called On-Off control because

the final control element is either open (On) or close (Off) i.e. operates like a switch. These are the simplest controllers. These controllers incorporate a

dead band to keep the output from cycling rapidly between on and off. The controller will not turn on or off until the error signal moves the process

controllers out of the dead band. The process variable controlled by an on/off controller always cycles back and forth about the set point as shown in the

Fig.1 Red line and blue line shows process parameter and reference values respectively. Hysteresis is a value set in the vicinity of an on-off operating

point. Upper hysteresis is value or band in which process value is allowed to operate above the set point and lower hysteresis is value or band in which

process value is allowed to operate below the set point.

Proportional (P) controllers

In a proportional controller the control algorithm generates a linear control output proportional to deviation. In proportional action the amount of change in

the measured value (or deviation) is expressed in percent of span that is required to cause the control output to change from 0 to 100 % is called the

proportional band.

The controller output is given by:

100
OP=b+ e
PB
Where, OP is the output, PB is proportional band in %, b is the bias value, and e is the error signal. If there is no biasing, output OP will become zero

when error is zero. Hence bias value decides the value of output when error is zero. The proportional controllers usually show some difference between the

set point and process variable called offset. The offset can be reduced by decreasing proportional band or by readjusting the bias. With decrease in

proportional band the process becomes oscillatory. There are two types of controller actions:

1) Increase-increase in which output increases as measurement increases. (error e = measurement – set point)

2) Increase-decrease in which output decreases as measurement increases. (error e = set point –measurement)

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Fig.2 Showing the behavior of P controller

Proportional- Integral (PI) controllers

The offset in the proportional controller can be overcome by adding integral action. The control algorithm that applies changes in output as long as

deviation exists, so as to bring the deviation to zero, is called integral action. Output of proportional-Integral controllers is given by:

100 1
OP=b+ (e+ ∫ edt )
PB Ti
Where OP is the output, b is the bias, PB is the proportional band in %, e is the error signal, Ti is integral time; this is the time required to repeat

proportional action.

Fig.2 Showing the behavior of PI controller

Proportional–Integral–Derivative (PID) controllers

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PID controllers are used for controlling almost all process variables like temperature, flow, level, pressure etc. in a continuous or batch process. The output

of a PID controller is given by:

100 1 de
OP=b+ (e+ ∫ edt +T d )
PB Ti dt
Where OP is the output, b is the bias, PB is the proportional band in %, e is the error signal, Ti is the integral time and Td is derivative time. Selection of

proportional band, integral time and derivative time to achieve desired process response to load changes is called tuning of controller.

Fig.2 Showing the behavior of PID controller

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 Experiment - A

Aim of the experiment: Study of open loop response (Manual control)

Experimental procedure

1. Start water supply to the heater by opening the valve in the supply line

2.
Open the rotameter valve and circulate the water. Adjust water flow rate to 40 LPH.

3.
Switch on the supply for both connections and switch on “Mains”.

4.
Set the Digital indicating controller to auto mode by pressing the A/M key.

5. Initialize Modbus communication on the computer i.e.Start| All programs | Wonderware FactorySite | IO Servers | Modicon MODBUS.

6. Execute Programs | Wonderware | InTouch for Temperature control. Select All in Windows to open and Click “Runtime”.

7. Select Open loop Experiment (click on “Change Expt.” Button, click on “Change”, Click on “Open Loop” button.)

8. Decrease the controller output to 10%. Note down steady state process value.

9. Apply the step change by 10% to controller output and wait for the temperature to reach the steady state value. Note down the process value.

10. Repeat the above step until the controller output reaches to maximum i.e. 50% and for each change, note steady state process value.

Observation

Table1:

0
Controller out put in % Process value in C

10

20

30

40

50

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 Experiment - B

Aim of the experiment: Study of on/off controller

Experimental procedure

1. Follow steps 1 to 6 from Experiment A

2. Select On-Off Mode Experiment (click on “Change Expt.” Button, click on “Change”, Click on “On-Off Mode” button.).

3. Change Hysteresis value to 1% (Range 0.1-10%).

4. Change the values of the set point and observe the On-Off control operation.

Observations

Observe that if process value exceeds the set point and increases than the value of (0.5x Hysteresis), controller switches off the SSR and if process value

decreases below the set point by (0.5 x Hysteresis), SSR switches on i.e. controller operates like On/Off switch.

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 Experiment - C

Aim of the experiment: Study of Proportional (P) controller

Experimental procedure:

1. Follow steps 1 to 6 from Experiment A

2. Select P Mode Experiment (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.

4. Adjust output value to match the process value with set point and apply this output value as bias value to the controller.

5. Adjust the proportional band to 30%.

6. Switch the controller to Auto mode.

7. Apply step change to set point, step change should be of 2 to 3 % and observe the response.

8. Switch off the controller.

9. Repeat steps 1 to 8. Adjust the proportional band to 50%. Ensure that the set point changes are around the same operating point (@ 2-3%

only).

10. 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.

11. Set the controller to the settings obtained in the above step and wait for the system to reach a steady state.

Observation

●
Observe the variation in steady state error with the variation in proportional band.
●
Observe the effect of very low proportional band values.
●
Observe the response of the system to load change. Load change can be given by slightly varying the inlet flow rate.

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 Experiment - D

Aim of the experiment: Study of Proportional Integral (PI) controller

Experimental procedure

1. Follow steps 1 to 6 from Experiment A

2. Select PI Mode Experiment (click on “Change Expt.” Button, click on “Change”, Click on “PI Mode” button.).

3. Adjust the process value by changing the output of the controller in manual mode to a particular temperature (set point =40%).

4. Set the proportional band estimated from Proportional control (from previous experiment).

5. Start with derivative time=0 and integral time=30 sec., which will cut off the derivative action and widen the effect of integral action.

6. Set the set point to desired temperature (@40%). Allow the process to reach a steady state. Record the steady state error.

7. Repeat steps 1 to 8. Adjust the integral time to 50 sec. Ensure that the set point changes are around the same operating point (@ 2-3% only).

Note the response of the system.

8. Using trial and error, find out an integral time, which gives satisfactory response to the step change in set point.

Observations
Observe the effect of reducing integral time on offset and on the response of the process.

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 Experiment - E

Aim of the experiment: Study of Proportional Integral Derivative (PID) controller

Experimental procedure:

1. Follow steps 1 to 6 from Experiment A

2.
Select PID Mode Experiment (click on “Change Expt.” Button, click on “Change”, Click on “PID Mode” button.)

3. Adjust the process value by changing the output of the controller in manual mode to a particular temperature (set point =40%).

4. Set the proportional band estimated from Proportional control PB (from previous experiment).

5. Start with derivative time=2 sec and integral time=30 sec., which will cut off the derivative action and widen the effect of integral action.

6. Set the set point to desired temperature (@40%). Allow the process to reach at steady state. Record the steady state error.

7. Repeat steps 1 to 8. Adjust the derivative time to 5 sec. Ensure that the set point changes are around the same operating point (@ 2-3% only).

Note the response of the system.

9. Using trial and error, find out an integral time, which gives satisfactory response to the step change in set point.

10.
Change the proportional band, integral time, derivative time and observe the response of the process for step change for each change in

setting.

Observation

Compare the steady state response of the PID controller with P, PI and PD controller obtained in the previous experiments.