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Design of PID Controller for Level Loop

Research · April 2017

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International Journal of Engineering& Scientific Research
Vol.5 Issue 4, April 2017,
ISSN: 2347-6532 Impact Factor: 6.660
JournalHomepage:http://www.ijmra.us,Email:[email protected]
Double-Blind Peer Reviewed Refereed Open Access International Journal - Included in the International Serial
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Design of PID Controller for Level Loop

Vikas L. Karade
Sagar S. Sutar
Ambadas B. Shinde
Vijay R. Bhanuse 
Abstract
Liquid level control is most widely used in diverse processes industries. The key issue in level
control system is liquid level control mechanism. In this paper control of liquid level using PID
controller is presented. We have developed a system which adjusts the liquid level without
human intervention, according to set point. The parameters of PID controller were adjusted
automatically. The model presented here meets the precise demand of liquid level system; the
accuracy of model is 87.84 %. It is more accurate for controlling the liquid level.

Keywords:PID controller, Tuning of PID, Water level control,Level loop control


Assistant Professor, Instrumentation Engineering, PVPIT, Sangli, MS, India

Assistant Professor, Instrumentation Engineering, MPCOE, Velneshwar, MS, India

Assistant Professor, Electronics Engineering, PVPIT, Sangli, MS, India

Assistant Professor, Instrumentation Engineering, VIT, Pune, MS, India

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 ISSN: 2347-6532Impact Factor: 6.660

1. Introduction
Controlling the liquid level is a significant parameter in most process industries. The PID
algorithm is most frequently used to control various types of the processes. Concerning the
safety in production and quality of products, efficiently and timed control of liquid level is
necessary. Objective of the proposed system is to control the liquid level of water tank at
preferred set point. The liquid level control of tank is major problem in process industries.
Normally process industries pumps and stores the liquid in tank; which is then used for further
processing. Hence, it becomes necessary to control the liquid level of tank.
Proportional Derivative Integral controller is influencing controller mode. In 1910 the PID
Controller was invented and the Ziegler-Nichols (Z-N) tuning method was invented in 1942 [1].
Now days PID controller is most frequently used in chemical and several manufacturing
industries to control various processes. PID plays vital role in liquid level control mechanism.
PID controls level according to preferred set point. One can change the set point on the fly
during level loop. This paper considers design of PID controller for liquid level tank.

The paper is organized as follows.The related work is presented in section 2. The

mathematical model for level loop is mentioned in section 3. Section 4 presents with the
designing of PID controller and its mathematical model. The experimental results are shown in
section 5.

2. Literature Survey
There are various methods used to tune the PID controller to find appropriate values of the
parameters.

Our system objective is to design PID controller to maintain the level in tank according to the set
point value. The model considered to develop the system is as shown in figure 1. Mostafa A.
Fellani [6] et. al. has used PID, P, PI controller to manage/maintain the liquid level at one
specific level. They used MATLAB for the simulation, and they compared the dynamic
characteristics like Rise time, settling time, steady state error and overshoot of each controller
with PID. Miral Changela, Ankit Kumar [7] in their paper presented water level control for two
tank model. They mentioned that the liquid level in tank and flow between the tanks is more

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 ISSN: 2347-6532Impact Factor: 6.660

important in the process modelling. They compared the performance of PID controller with
fuzzy controller for their systems. PID controller and fractional order PID controller is used by S.
Janarthanan [8] et. al. in their work. They presented different tunning methods to find the
parameters of PID. Anca Maxim [9] et. al. proposed model based on multivariable process.
Internal Model Controller (IMC) controller is used for Multiple Input Multiple Output (MIMO)
system. Hur Abbas [12] et. al. proposed operational model for coupled tanks. A non linear model
of SISO system is developed and simulated using MATLAB.

3. Mathematical Model of System

Figure 1 show the liquid level system which contains following parameters.
Process Parameters:
A = Cross sectional area of tank (cm2)
h = Water level (cm)
Qin= Inlet flow rate
Qout = Outlet flow rate

Figure 1. Liquid level loop

Modelling Process:
Time Rate of
Change Rate of Rate of
= −
Mass in flow Mass Out flow
of Mass into the system

dh
ρA = ρQin − ρQout
dt

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 ISSN: 2347-6532Impact Factor: 6.660

dh
A = Qin − Qout … … … (1)
dt

Since
h
Qout = R

dh
R = RQin − h
dt
Put T = AR

dh
T dt = RQin − h

Taking Laplace transform

TSH S + H S = RQin (S)

H(s) R
= … … … (2)
Qin (s) 1 + TS

Equation (2) gives model equations.

4. Design of PID controller

Process Parameters
A = 7.5 m2
R=1
T = AR = 7.5
1
G s =
1 + 7.5S

Ziegler Nichols Method is used for controller setting which is based on adjusting closed loop
until steady state oscillations occur [3]. By Using Z-N Method

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 ISSN: 2347-6532Impact Factor: 6.660

Kp
G s =
7.5S + 1 + K p
And
Wcp = 7.5
Following are the parameters of PID controller

K p = 0.6, Ti = 0.41, Td = 0.10

5. Results and Analysis

Figure 2. Simulink model of system

The Simulink model of single tank water level control system using PID controller for obtaining
the step response is mentioned in figure 2. Here the Z-N method is used find the PID parameters.
Transfer function in this system represents the mathematical model of single tank system.

Figure 3. Model by parameter estimation

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 ISSN: 2347-6532Impact Factor: 6.660

Simulation results of liquid level control system with PID controller are shown in figure 3.

Mathamatical model of level loop is calculated by using MATLAB.

Figure 4. PID Controller parameters for Sp=250

Figure 4 shows tunned and block parameters of PID controller for the set point 250. The
performance parameters like rise time, settling time, overshoot, gain margin and closed loop
stability etc were also mentioned in figure 4.

Figure 6. PID Controller parameters for Sp=300

For single tank system set point is 300 & flow rate is 600 LPH. Response time 8.4 Sec. The
figure 6, Shows controller parameters for set point 300 of actual level system.

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 ISSN: 2347-6532Impact Factor: 6.660

Figure 7. Measured & Simulated output

Figure 7 shows response of best fit for designed system. This is obtained by using MATLAB
identification tool box. The obtained best fit results are obtained from practical values.

6. Conclusion
The Theoretical model for liquid level control system is obtained by mass balance equation. PID
controller designed for the same system and for tunning Zeigler Nicholas method is used.
Simulated model parameters obtained by MATLAB. Results are obtained for various set points.
The parameters by simulation and by calculation are nearly same. Hence for varying set point
PID controller is most efficient which provides good response time. The model gave us 87.84 %
best fit.

References
[1] J. Swder, G. Wszoek, W. Carvalho, “Programmable Controller Design Electro pneumatic
systems”, Journal of Material Processing Technology 164-1655 (2005) 14659-1465
[2] William L. Luyben, “Process Modelling, Simulation and Control for Chemical
Engineers”, Second Edition, Mc-Graw Hill publication
[3] C. D. Johnson, “Process Control Instrumentation Technology”, Seventh Edition, Pearson
Education, New Delhi 2003.

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 ISSN: 2347-6532Impact Factor: 6.660

[4] Dale E. Seborg, Thomas F. Edgar, Duncan A. Mellichamp, “Process Dynamics and
Control”, Second Edition, Willey Publication. Manual: ECON DT 9812.
[5] G. Stepnopoulos, “Chemical Process Control: An Introduction to Theory & Practice”,
Prentice Hall Of India.
[6] Mostafa A. Fellani, Aboubaker M. Gabaj, “PID Controller Design for two tanks liquid
level control system using MATLAB”, International journal of Electrical and Computer
Engineering, Vol. 5 No.3 June 2015,pp, 436-442.
[7] Miral Changela, Ankit Kumar, “Designing of controller for two tank system”,
International Journal of Science and Research., ISSN 2319-7064.
[8] S.Janarthanan, K.N.Thirukkuralkani, S.Vijayachitra, “Performance Analysis of Non-
Integer Order PID Controller for Liquid Level Control of Conical Tank System”, IEEE , ISBN
No.978-1-4799-3834-6/14
[9] Anca Maxim, Clara M.Ionescu, Cosmin Copot, Robin De Keyser “Multivariable Model-
Based Control Strategies for Level Control in a Quadruple Tank Process”, IEEE, 978-1-4799-
2228-4/13.
[10] W. Bequette, “Process Control: Modeling, Design and Simulation”, Prentice Hall
Professional, 2003.
[11] K. Ogata ,“Modern Control Engineering” Fourth Edition, Pearson Publication.
[12] Hur Abbas, Sajjad Asghar, Shahid Qamar, “Sliding Mode Control For Coupled-Tank
Liquid Level Control System” 2012 10th International Conference on Frontiers of Information
Technology, IEEE, 978-0-7695-4927-9/12

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