Experiment no 9

PRESSURE PROCESS MODULE

Evaluation Table:

Organization and Analysis of

Components / Conclusion Total
Content Results
Weightage (3) (10)
(3) (4)

Obtained marks

Objective:

• To verify the effects of the gain on the dynamic response of the system
• To draw the curve of dynamic response of the system

Apparatus:

Figure 1 Temperature Process Rig

List of Equipment:
1. Digital Multimeter
2. Set of Leads
3. Temperature Process Rig
4. Choronometer

Working Principle:

Related Theory:

Introduction to Control Systems

Control systems play a pivotal role in regulating various processes and ensuring desired outcomes
in a wide range of applications. These systems are employed to maintain a specific condition or
variable within a desired range by manipulating input parameters. Temperature control is one of
the fundamental applications of control systems, with diverse uses in industries such as
manufacturing, food processing, and environmental control.

Control Loops

Control loops are closed-loop systems designed to maintain or adjust a process variable to meet a
desired setpoint. They are classified into three main types: open-loop, closed-loop (feedback
control), and feedforward control.

Open Loop Control: In an open-loop control system, the control action is predetermined and
not adjusted based on feedback. These systems lack the ability to self-correct, making them less
common for critical applications.
Closed-Loop (Feedback) Control: Closed-loop control systems, often simply referred to as
control loops, are the most widely used. These systems continuously measure the actual process
variable, compare it to the desired setpoint, and adjust the control action to minimize any
deviations. Closed-loop control is highly adaptable and accurate.

Feedforward Control: Feedforward control is used in combination with closed-loop control. It

anticipates disturbances and adjusts the control input before they can affect the process variable.
It is particularly effective in situations where process variations can be predicted.
Types of Control Systems:

• ON/OFF Control Systems: ON/OFF control switches a system between two discrete
states (ON and OFF) based on a predefined setpoint, maintaining the variable being
controlled as close to the setpoint as possible.
• Proportional Control (P-Control): In a proportional control system, the control output is
directly proportional to the error between the desired setpoint and the actual process
variable. The controller adjusts the output in proportion to the error, which helps reduce
steady-state errors but may still lead to oscillations.
• Integral Control (I-Control): Integral control eliminates steady-state errors by
continuously summing the error over time and adjusting the control output accordingly. It
focuses on reducing the accumulated error, which can be particularly useful for systems
with offset.
• Derivative Control (D-Control): Derivative control anticipates future errors by looking
at the rate of change of the error. It provides rapid corrections when the error is changing
quickly, helping to dampen oscillations and improve system stability.
• Proportional-Integral (PI) Control: PI control combines proportional and integral
control actions to eliminate both steady-state errors and oscillations. It is a commonly used
control strategy in various industrial processes.
• Proportional-Integral-Derivative (PID) Control: PID control combines proportional,
integral, and derivative control actions to achieve precise and responsive control. It is one
of the most widely used control algorithms and is effective in many applications.

Proportional Control

Proportional control, one of the fundamental building blocks of control systems, is a subset of
closed-loop control. It adjusts the control output in proportion to the error between the setpoint
and the process variable. This control action is governed by a proportional gain, often denoted as

Kp. The mathematical expression for proportional control is:

Pout=Kp⋅e(t)

Where:
Pout is the proportional control output.

Kp is the proportional gain.

e(t) is the current error (setpoint - process variable).

The proportional control action seeks to reduce the error by amplifying it through the gain. As a
result, proportional control provides a linear response to the error signal.

Advantages of Proportional Control

Proportional control offers several advantages that make it a valuable choice in many applications:

• Stability: Proportional control helps maintain system stability by continuously adjusting

the control output in response to deviations from the setpoint.
• Simplicity: It is relatively straightforward to implement and tune, making it a practical
choice for many control applications.
• Linear Response: The linear relationship between the error and control output simplifies
system analysis and tuning.
• Reduced Offset: Proportional control reduces the steady-state error, ensuring that the
system approaches and remains close to the desired setpoint.
• Compatibility: Proportional control can be used in conjunction with other control actions
(integral and derivative control) to form PID control, a widely used and versatile control
strategy.

Limitations of Proportional Control:

Despite its advantages, proportional control has limitations that need to be considered:

• Limited Ability to Eliminate Steady-State Error: While proportional control reduces

steady-state error, it may not entirely eliminate it. In situations where minimizing error is
critical, additional control actions, such as integral control, may be required.
• Susceptibility to Oscillations: Depending on the control loop's characteristics and the
tuning of the proportional gain, proportional control can lead to oscillations, which can be
detrimental in some applications.
 • Tuning Sensitivity: The performance of proportional control is highly dependent on the
correct choice of the proportional gain. Tuning can be challenging, and improper settings
can lead to inadequate control or instability.
• Limited Response to Changing Dynamics: Proportional control does not adapt to
changing process dynamics. It can be less effective in situations where the process itself
varies significantly.
• No Predictive Capability: Proportional control is reactive and does not anticipate future
disturbances or changes in the process variable.

The Necessity of Temperature Control

Temperature control is an essential aspect of process control in numerous industries, including

chemical manufacturing, pharmaceuticals, food production, HVAC systems, and research
laboratories. Maintaining precise temperature levels is vital for several reasons:

• Product Quality: Many chemical reactions and industrial processes are highly
temperature-sensitive. Precise temperature control is essential to ensure product quality
and consistency.
• Safety: In some processes, temperature control is critical to prevent hazardous reactions or
equipment failures. Deviations from safe temperature limits can result in accidents and
damage.
• Energy Efficiency: Effective temperature control helps in minimizing energy
consumption. Energy-intensive processes often require careful management of temperature
to optimize efficiency.
• Process Efficiency: Temperature control enhances the efficiency of various processes by
ensuring that they operate within specified temperature ranges, minimizing waste and
resource consumption.
• Regulatory Compliance: Many industries must adhere to strict regulations and quality
standards. Temperature control is often a regulatory requirement to meet these standards.
• Biological and Scientific Research: In laboratories, precise temperature control is
necessary for conducting experiments, growing cultures, and maintaining equipment.
Applications of Temperature Control

Temperature control is employed in a wide range of applications:

• Industrial Processes: Chemical, petrochemical, and food processing industries use

temperature control to optimize reactions and product quality.
• HVAC Systems: Heating, ventilation, and air conditioning systems regulate indoor
temperature for comfort and energy efficiency.
• Pharmaceuticals: Temperature control ensures the stability of drugs and vaccines during
manufacturing and storage.
• Environmental Chambers: Environmental chambers create controlled temperature and
humidity conditions for testing and research.
• Biotechnology: Biotech processes, including fermentation and cell culture, rely on precise
temperature control.
• Electronics Cooling: Temperature control is essential in cooling electronic components to
prevent overheating.
• Agriculture: Controlled environment agriculture employs temperature control for plant
growth and crop yield optimization.

Procedure:
1. Connect, through leads, bush No. 11 of the HEATER DRIVER to bush No. 11 and bush
No. 12 to bush No. 12.

2. Connect bushes No. 1 and 2 of the temperature sensor to bushes No. 1 and 2 of the
relevant interface.

3. Check if the water level in the tank is 18 cm; otherwise fill process tank from water Inlet
Valve until the water level has reached 18 cm.

4. Press the main switch (ON).

5. Connect the bush of SET POINT 2 to bush No. 4 of the PID controller and bush No. 3 of
the temperature interface to bush No. 3 of the PID controller

6. Insert one terminal of the digital voltmeter, set in dc, to bush No. 3 of the temperature
interface and the other one in the earth bush (Sheet 5.1): read and write down the voltage
value which corresponds, multiplied by 10, to the starting temperature.

7. Move the terminal of the digital voltmeter from bush No. 3 to the bush of SET POINT 2
and regulate the voltage at 4V (40°C).

8. Move the terminal of the digital voltmeter to bush X2 of the PID controller; the voltage
value, which represents the reference step, must be equal to the difference between the
voltage applied to bush No. 4 and that applied to bush No. 3.

9. Set the PROPORTIONAL knob at 25%.

10. Connect bush No. 5 of the PID controller to bush No. 5.

11. Move the terminal of the digital voltmeter to bush No. 3 of the PID controller: write
down in Table 5.1 the voltage value after conversion in °C.

12. Connect bush No. 8 of the PID controller to bush No. 8 of the HEATER DRIVER and at
the same time start the chronometer.

13. Write down in Table 5.1 the voltage value, after conversion in °C, at equal time intervals
up to the end of the transitory (for example every minute).

14. Move the terminal of the digital voltmeter to bush X2 of the PID controller: write down
the voltage value which represents the steady state error.

15. Remove temporarily the lead from bush No. 3 of the PID controller.

16. Drain the tank by opening the DRAIN VALVE.

 17. Close the valve DRAIN VALVE and bring the level in the tank back to 18 cm.

18. Move the terminal of the digital voltmeter to bush No. 3 of the PID controller: write
down in Table 5.1 the voltage value after conversion in °C.

19. Set the PROPORTIONAL knob at 50% and repeat the procedure from step 12.

20. Repeat the procedure with the PROPORTIONAL knob at 75% and at 100%.

21. Switch OFF the main switch.

22. Draw the curves of the closed loop dynamic response for each value of the
PROPORTIONAL knob position.

23. Analyze the results.

Laboratory Precautions:

● Turn on the main switch after cables have been connected.

● Do not touch the apparatus with wet hands as it might result in electric shock.
● Connect the wires carefully.
● Perform experiment carefully and with responsibility.

Circuit Diagram:
Observations and Calculations:
Gain=25% Gain=50% Gain=75%
Time
Voltage Temperature Voltage Temperature Voltage Temperature Setpoint
sec mV °C mV °C mV °C °C
0 3.4 34 3.4 34 3.4 34 40
30 3.44 34.4 3.45 34.5 3.5 35 40
60 3.44 34.4 3.45 34.5 3.5 35 40
90 3.44 34.4 3.46 34.6 3.51 35.1 40
120 3.44 34.4 3.46 34.6 3.53 35.3 40
150 3.44 34.4 3.47 34.7 3.54 35.4 40
180 3.44 34.4 3.48 34.8 3.57 35.7 40
210 3.44 34.4 3.49 34.9 3.59 35.9 40
240 3.44 34.4 3.51 35.1 3.62 36.2 40
270 3.44 34.4 3.54 35.4 3.65 36.5 40
300 3.44 34.4 3.57 35.7 3.69 36.9 40
330 3.44 34.4 3.59 35.9 3.72 37.2 40
360 3.44 34.4 3.62 36.2 3.76 37.6 40
390 3.44 34.4 3.64 36.4 3.8 38 40
420 3.44 34.4 3.67 36.7 3.83 38.3 40
 Proportional Controller
41
40
Temperature (°C ) 39
38
37
36
35
34
33
32
0 100 200 300 400 500
Time(s)

Temperature Setpoint Temperature Temperature

Discussion:

For each value of gain we observed the response of the system for 7 minutes. As Process Gain is
defined as how far the measured Process Variable moves to a change in Controller Output.

25% Gain:

When the value of gain was kept at 25% the response of the system in achieving the setpoint is so
slow that within 7 minutes no change in temperature of the system was observed. The temperature
remained at 34.4 °C. If the readings were observed for a longer interval we may have observed a
change in the response of the system.

50% Gain:

When the gain was set to 50% we could observe a faster response of the system and the final value
of process variable reached was 36.7°C. We can observe from the graph as well that the response
of the system was rapid and the set point would be achieved much faster than when the gain was
25%.

75% Gain:
When the gain was set to 75% we could observe a faster response of the system and the final value
of process variable reached was 38.3°C. The set point was 40°C. We can observe from the graph
as well that the response of the system was even more rapid and the set point would be achieved
much faster than when the gain was 50%.

So from the results of the experiment it is clear that the higher the gain, the faster will be the
dynamic response of the system.

In my opinion we should have let the experiment to continue for a longer time. It would have given
us a better idea of how much time it will take to reach the set point.

References:

▪ "Principles of Industrial Instrumentation" by D. Patranabis, Publisher: Prentice-Hall, Year:

1997.
▪ "Instrumentation and Control Systems" by William Bolton, Publisher: Newnes, Year:
2006.
▪ "Flow Measurement: Principles and Methods" by Henry V. Moyer, Publisher: Wiley, Year:
2015.