CEBU INSTITUTE OF TECHNOLOGY

UNIVERSITY
COLLEGE OF ENGINEERING AND ARCHITECTURE
Chemical Engineering Department

Project Report
PROCESS CONTROL OF THE DYNAMIC SYSTEM: WATER TANK

AUTHORS
Degollacion, Plutarch Romiel A.
Mondejar, Ma. Theresa B.
Pasasadaba, June Vernon B.
Rubi, Ma. Lourdes C.

ABSTRACT

This project explores the implementation of feedback control strategies, specifically PI

controllers, for regulating water level and temperature in a dynamic system, focusing on a water

tank. It integrates theoretical models with practical implementations to maintain precise control

over system variables. Through simulation setups and hardware descriptions, the study

demonstrates the effectiveness of the control system in achieving desired setpoints. Control

tuning processes optimize PID controller parameters, ensuring stability and responsiveness.

The project concludes by highlighting future directions for enhancing control strategies and

system optimization.

Keywords: closed-loop feedback control, PI controller, water level, temperature, dynamic

system, PID controller parameters, stability, responsiveness, optimization,

I. Introduction
This section demonstrates the objectives, review of related literature, and the
theoretical concepts about the dynamic system being controlled.

A. Objective
The control aims to maintain the water level (measured by transmitter LT) and
temperature (measured by transmitter TT) at desired set points using closed-loop
feedback strategies using PI controllers (LC and TC, respectively) in the ΔV distributed
control system.

B. Background of the Study

Process control is an important part of automation technology. In recent years,

process control technology and its application field have developed rapidly. A large
number of engineering skills with automation expertise is currently urgently needed.

With the needs of research and technology development, water tank testing
systems are becoming the mainstream of process control testing equipment. With a
water tank system containing typical process variables such as liquid level, flow rate,
pressure and temperature, it is possible to simulate systems of different orders, linear or
nonlinear, single or multi-capacitive and with large time constants. Control devices can
be PLC, computer or distributed control system or field control system. And the
experimental platform is more open and convenient to achieve various traditional or
advanced management strategies.

The water tank system is widely used in industrial applications, especially in

chemical process systems. Controlling the water level in the tanks and the flow between
the tanks is a problem in process technologies. The process industry needs liquids to be
pumped, stored in tanks, and then pumped to another tank systematically. In crucial
industries such as petro-chemical industries, paper industries, water treatment
industries, the tanks have affected each other where the processes of chemical or
mixing movement takes important place in the process tanks. Thus, the liquid level
control system has attracted attention in the literature (Altun, Y. 2016).

Theoretical Dynamic Models are based on relevant balance equations. The

important condition of the Theoretical Dynamic Models is to have a good understanding
of the principles of the production process. It is useful for exploring a wide range of
operating conditions. Studies using theoretical models can be performed quickly, safely
and inexpensively. They can also form the basis of a training simulator. First-principles
(theoretical) dynamic models result from conservation equations. Conserved variables
include mass and energy (Li, X. et al. 2018).

Balances are created by defining a boundary around the process and then
computing the following.

Accumulation = In - Out + Generation – Consumption

Figure 1. Model of Linear Water Tank

(Source: Li, X. et al. 2018)

The constant volumetric flow rate 𝑄1 is controlled by the control valve opening

coefficient ∆µ and 𝐾µ is the valve flow coefficient. Then,

𝑄1 = 𝐾µ∆µ eq.1

According to the mass balance, the difference between the liquid inflow and
outflow of the tank within the unit time should be equal to the rate of change of the liquid
accumulated in the tank. Thus,

𝑑𝑉
𝑑𝑡
= 𝑄1 − 𝑄2 eq.2

𝑉 = 𝐴ℎ(𝑡) eq.3

Dynamic system models describe how system variables evolve over time in
response to inputs, disturbances, and control actions. In the context of a water tank,
relevant variables may include water level, inflow rate, outflow rate, temperature, and
pressure.
II. Theory, Methods, and Based Modeling
This section serves as the foundational framework for understanding the
principles, methodologies, and models used in the project. It typically encompasses
theoretical concepts, mathematical models, and analytical methods employed to design
and analyze the control system.

A. Conceptual Framework, Methods or Control Strategies

The conceptual framework for the water tank system centers on a
closed-loop control system, integrating diverse components to regulate water
level and temperature. Illustrated in Figure 1, the schematic diagram depicts the
dynamic system under examination in this project. At its core lies a water tank
system designed to regulate water temperature, featuring a tank for water
storage. A pump facilitates water circulation, with a heating coil responsible for
temperature adjustment before water returns to the tank. Integral to the system
are sensors monitoring water level (LT) and temperature (TT), triggering
automatic adjustments through the activation of the pump and heater to maintain
desired levels. This adaptable system finds wide-ranging applications, from
industrial process control to domestic hot water systems. The Level Transmitter
(LT) and Temperature Transmitter (TT) serve as key sensors, while controllers
such as the Level Controller (LC) operate within a closed-loop control
mechanism, guided by the Proportional-Integral (PI) principle. These controllers,
along with other components, are seamlessly orchestrated within the ΔV
distributed control system, providing a robust platform for implementing control
algorithms and coordinating control actions with precision and efficiency.
 Figure 2. Schematic Diagram of a Water Tank System
Source: Tzouanas, V. et al. 2013

This project utilizes an automatic controller to maintain the water level.

There are a few methods in controlling the water level of a tank. Firstly, an
adjustable On/Off control for flexibility could improve the efficiency of the pump,
while being at an optimum condition. Secondly, the modulating level control
where it uses a sensor that continuously monitors the water level and sends a
proportional signal to a control unit. The control unit then adjusts the pump speed
or valve opening to maintain the desired water level. This method is often used in
industrial applications where consistent and accurate water level is critical.
Pressure sensors or ultrasonic sensors are commonly used for this type of
control. Among these two methods, the optimal choice for this project centered in
a closed-loop control system is the modulating level control. This method aligns
seamlessly with the project's objectives of maintaining precise water levels in the
tank. By utilizing sensors to continuously monitor water level and transmitting
proportional signals to the control unit, the system can dynamically adjust pump
speed or valve opening to uphold the desired water level. This approach offers
greater accuracy and responsiveness compared to adjustable On/Off control,
making it well-suited for applications where consistent and precise water level
regulation is paramount, such as in industrial settings. Pressure sensors or
ultrasonic sensors commonly serve as reliable means for monitoring water levels
 in this type of control system, ensuring robust performance and efficiency in
maintaining optimal water levels within the tank.

B. Modeling Approach and Parameter Estimations

Table 1. Variables and Identified Parameters

PARAMETERS

Symbol Description and Units

Qi Tank Inflow Rate, m3/h

Qi, ss Tank Inflow Rate at Steady State, m3/h

Qo Tank Outflow Rate, m3/h

𝜌 Water Density, kg/m3

Cp Water Specific Heat, J/kg-K

Hss Water Level at Steady State, m

H Water Level, m

h Residual (h = H - Hss), m

ds Tank Diameter, m

A Tank Cross-Sectional Area, m2

Tss Tank Temperature at Steady State, oC

Ti Water Inflow Temperature, oC

To Water Outflow Temperature, oC

ΔP Pressure Loss, Pa or N/m2

g Acceleration due to gravity, m/s2

Mass Balance:
The change in water level (ΔH) over time is determined by the difference
between the inflow rate, Qi, and outflow rate, Qo, of water to and from the tank.

𝑑𝐻 𝑄𝑖−𝑄𝑜
𝑑𝑡
= 𝐴
 To derive the equation, the determined values from Table 1 is substituted, arriving
to the equation as follows:

𝑑𝐻 0.008−𝑄𝑜
𝑑𝑡
= 0.041
(1)

Energy Balance:
The change in water temperature (ΔT) over time is determined by the energy
balance, taking into account the heat transferred through inflow and outflow, where V is
the volume of water in the tank in m3, T is the temperature, Ti is the inflow temperature,
and To is the outflow temperature.

𝑑(𝑇·𝑉)
𝑑𝑡
=𝑄𝑖 · (𝑇𝑖 − 𝑇) − 𝑄𝑜(𝑇 − 𝑇𝑜)

To derive the equation, the determined values from Table 1 is substituted, arriving
to the equation as follows:

𝑑(𝑇·𝑉)
𝑑𝑡
= 0. 008 · (27 − 𝑇) − 𝑄𝑜(𝑇 − 𝑇𝑜) (2)

This system of differential equations represents the dynamic behavior of the

water tank system, where Qo is the variable to be determined through control strategies
to maintain desired water level and temperature. By solving these equations
numerically or applying control strategies such as PID (Proportional-Integral-Derivative)
control, one can effectively regulate the system to achieve desired performance.

To obtain the pressure loss due to friction and other factors, empirical formulas
such as the Darcy-Weisbach or Hazen-Williams equations are used. Recalling the
mass and energy balance equations and incorporating pressure loss by integrating
hydrostatic pressure and pressure loss terms in the balance equations.

Hydrostatic Pressure:

The hydrostatic pressure exerted by the water column in the tank depends on the
height of the water level (H) and the density of water, as shown:
𝑃𝐻𝑦𝑑𝑟∆𝑜𝑠𝑡𝑎𝑡𝑖𝑐 = ρ · 𝑔 · 𝐻 (3)
 𝑑𝐻 𝑄𝑖−𝑄𝑜 ∆𝑃
Mass balance: 𝑑𝑡
= 𝐴
− ρ·𝑔
(4)

𝑑(𝑇·𝑉) ∆𝑃·𝑄𝑜
Energy Balance: 𝑑𝑡
=𝑄𝑖 · (𝑇𝑖 − 𝑇) − 𝑄𝑜(𝑇 − 𝑇𝑜) − ρ·𝐴
(5)

These equations account for the influence of pressure on the dynamics of the
water tank system, considering both hydrostatic pressure and pressure losses within
the system. The addition of these pressure terms enhances the accuracy of the
mathematical model, especially when a controller is applied to regulate the system.

III. Simulation and Hardware Description

This section provides crucial information about the implementation and
performance of the control system in both simulated and physical environments.

A. Simulation Set-up

DWSIM Simulation:

Figure 3.1 Process Flowsheet of the Water Tank

 Figure 3.2 Flow DIagram of PID Controller on the Tank’s Water Level

The process involves regulating the water level within a tank using a PID
controller, which operates in tandem with two control valves. Initially, the operator
or control system sets a desired water level, known as the setpoint. This setpoint
serves as the target level that the system aims to achieve and maintain within the
tank.

A level transmitter continuously measures the actual water level within the
tank, providing real-time feedback to the control system. This measurement is
crucial for assessing the current state of the system relative to the desired
setpoint. The measured level is then compared with the setpoint to determine the
error, representing the deviation between the desired level and the actual level.

The PID controller operates based on three main terms: proportional,

integral, and derivative. The proportional term adjusts the control signal based on
the present error. If the measured level falls below the setpoint, the controller
signals the first valve, located before the tank, to adjust its opening, allowing
more water into the tank to increase the water level. Meanwhile, the integral term
integrates the error over time to eliminate any persistent deviations between the
actual and desired levels. The derivative term predicts the future trend of the
error, aiding in damping oscillations and enhancing system stability.

The PID controller computes a control signal that reflects the corrective
action required to regulate the water level. This signal is transmitted to the
 actuation system, which consists of two control valves. If the measured level
exceeds the setpoint, indicating an overfill condition, the second valve, located
after the tank, either drains excess water or adjusts its opening to reduce the
water level to the desired setpoint.

The process functions as a continuous feedback loop, with a level sensor

consistently measuring the actual water level and relaying this information to the
PID controller. The controller then adapts the control signal in real-time to keep
the water level within the desired range, ensuring accurate regulation regardless
of changing conditions. By coordinating the setpoint determination, level
measurement, PID control computation, actuation, and feedback, the system
achieves automated and precise control of the water level in the tank.

B. Control System Evaluation

The evaluation process involved analyzing the closed-loop response of

the control system. Screenshots of the simulation were utilized to visualize how
the system effectively maintained the desired water level despite disturbances.
Various performance metrics, including rise time, settling time, and overshoot,
were examined based on the simulated data to assess the transient response
characteristics and overall system stability. Through visual inspection of the
simulation results, the system's ability to respond to changes in the setpoint and
disturbances was evaluated, providing insights into its dynamic behavior and
performance under varying conditions.

Figure 3.3 Process Flowsheet of the Water Tank - Different Set Point
 Figure 3.4 DWSIM Dynamics Manager - Changed Amount Variables

Figure 3.5 PID Controller History

A critical aspect of the assessment involved evaluating the effectiveness

of the actuation system, which encompasses two control valves. This
examination primarily focused on the system's responsiveness and accuracy in
executing the control signal generated by the PID controller. Through meticulous
analysis, the performance of the valves in adjusting flow rates, particularly in
scenarios of overfill or underfill conditions, was thoroughly inspected. This
evaluation provided valuable insights into the actuation system's capacity to
maintain the desired water level by regulating the flow into and out of the tank,
underscoring its crucial role in ensuring precise control and system stability.
C. Sensitivity Analysis
Sensitivity analysis of a control system is an essential process that
examines how the output of the system is affected by varying input parameters.
This analysis is crucial for ensuring the robustness, stability, and performance of
the control system under different operating conditions. For a PID (Proportional,
Integral, Derivative) control system managing water levels, key parameters like
the PID gains are pivotal. Adjusting the proportional, integral, and derivative
gains helps optimize response time, overshoot, and steady-state error. By
methodically tuning these parameters, the aim is to achieve minimal deviation
from the desired water level while maintaining system stability.

Sensor accuracy plays a significant role in the performance of control

systems. The precision and accuracy of sensors directly impact the system's
response time and stability. Any variations in sensor measurements can lead to
discrepancies in how the system perceives and reacts to changes in water level.
Thus, assessing the impact of sensor accuracy is critical for ensuring that the
system can reliably maintain control under varying conditions. Additionally, the
characteristics of the valve response, such as its timing and accuracy, are
examined to determine their effects on both the transient and steady-state
responses of the system.

Another aspect of the sensitivity analysis is understanding how the

system manages changes in the setpoint, which is the desired water level, and its
ability to reject external disturbances. This part of the analysis helps in evaluating
the system’s stability and responsiveness under dynamic conditions. It’s crucial
for the system to respond effectively to both planned adjustments in the water
level and unplanned disturbances that may affect the system's operation,
ensuring that performance remains consistent and predictable.

The dynamics of the actuators, particularly those controlling the valves,

are also a significant factor in system performance. Factors like valve size and
the speed of response can greatly influence how well the system can control the
water level. An optimal selection and tuning of actuator parameters are vital for
improving the responsiveness and efficiency of the control system. By exploring
 different configurations and settings, the best possible performance can be
achieved while also minimizing potential issues like delays or overshoots.

Finally, a comprehensive sensitivity analysis encompasses all these

elements to enhance the control system's effectiveness in maintaining the
precise water level in the tank. By systematically examining each component and
parameter, from PID gains to actuator dynamics, the analysis aims to refine and
optimize the system. This holistic approach ensures that the system is not only
stable and robust under a variety of conditions but also capable of achieving high
performance and reliability in controlling the water level. Through careful testing
and adjustment, the control system can be fine-tuned to deliver optimal results
consistently.

D. Hardware Set-up

For the water level control system using a PID controller and two control valves,
the hardware set-up would contain the following to ensure precise regulation of
the water level within the tank:

Tank Configuration: The central component of the system is the tank which
stores the water. This tank must be equipped with adequate inlet and outlet
provisions that are controlled by the two control valves. It should be designed to
accommodate the specific volume and pressure conditions of the application and
constructed from materials compatible with the water quality and environmental
conditions.

Level Transmitter: Continuous and accurate measurement of the water level is

crucial and is facilitated by a level transmitter installed within the tank. This
device must be capable of delivering real-time and precise water level data to the
control system, ensuring that the feedback loop is reliable and the system's
response to water level changes is prompt and accurate.

PID Controller: The core of the control system is the PID controller, which
calculates the necessary adjustments to maintain the water level at a
predetermined setpoint. The controller's effectiveness hinges on the precise
tuning of its proportional, integral, and derivative gains, which must be optimized
according to the dynamic characteristics of the specific application to minimize
error and enhance response time and stability.

Control Valves: The system incorporates two strategically placed control valves
to manage water flow: one valve controls the inflow by adjusting its opening
based on the PID controller's signals, while the other manages the outflow, either
draining excess water or modulating the discharge to maintain the setpoint.
These valves must be selected based on their capacity to handle the expected
flow rates and pressures and should feature rapid response times to changes in
the control signal.

Actuation System: This system includes the control valves and their associated
actuators, which physically open or close the valves in response to commands
from the PID controller. The actuators must be robust and reliable, capable of
precise movements and quick adjustments to valve positions to accurately match
the controller's demands.

Sensor Interface: An integral part of the system, the sensor interface, links the
level transmitter with the PID controller. This interface must ensure seamless and
error-free transmission of water level data to the controller, enabling accurate and
timely adjustments to the control signals sent to the actuation system.

Power Supply: A stable and reliable power supply is essential for the
uninterrupted operation of the PID controller, actuation system, and other
electronic components of the water level control system. The power supply
should be designed to handle fluctuations and provide consistent power to all
components.

Communication Interface (Optional): For advanced applications requiring

remote monitoring or control, integrating a communication interface such as
Ethernet, RS-485, or Wi-Fi can provide significant advantages. This interface
allows for real-time data exchange between the control system and external
devices or monitoring stations, enhancing the system's flexibility and
responsiveness to operational changes.

Safety Mechanisms: To ensure operational safety and prevent damage or

hazards due to malfunctions, the system may include safety mechanisms such
 as overflow preventers or emergency shutdown features. These mechanisms are
crucial for automatically halting the system in adverse conditions, thus
safeguarding both the equipment and the environment.

Instrumentation and Control Panel: For effective management and

maintenance of the water level control system, an instrumentation and control
panel is typically installed. This panel houses the PID controller, communication
interfaces, and other monitoring instruments, allowing for centralized control and
easy access during both routine operations and troubleshooting scenarios.

IV. Mathematical Modeling

For the water tank with a consistent cross-sectional area, labeled as A, and a valve
connected to the output flow with a resistance constant denoted as R:
ℎ(ℎ𝑒𝑎𝑑)
Where 𝑞0(𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒) = 𝑅(𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒)

Note: q(t) represents the time-varying volumetric flow rate under constant density
conditions.

Transfer Function Derivation:

Mass Balance: mass in – mass out = accumulation
𝑑(𝑣ρ)
𝑞ρ − 𝑞0ρ = 𝑑𝑡

𝑑(𝐴ℎ) 𝑑ℎ
ρ(𝑞 − 𝑞0) = ρ 𝑑𝑡
→ 𝑞 − 𝑞0 = 𝐴 𝑑𝑡

ℎ 𝑑ℎ
𝑞− 𝑅
=𝐴 𝑑𝑡

ℎ𝑆
Steady State condition: 𝑞𝑠 − 𝑅
=0

Subtracting both conditions:

ℎ−ℎ𝑆 𝑑𝐻
(𝑞 − 𝑞𝑠) − 𝑅
=𝐴 𝑑𝑡

Note: 𝐻 = ℎ − ℎ𝑠
𝐻 𝑑𝐻 𝑑𝐻
𝑄− 𝑅
=𝐴 𝑑𝑡
→ 𝐴𝑅 𝑑𝑡
+ 𝐻 = 𝑅𝑄
𝑑𝐻
𝐴𝑅 𝑑𝑡
+ 𝐻 = 𝑅𝑄

Taking the Laplace Transform:

𝐴𝑅[𝑠𝐻(𝑠) − 𝐻(0)] + 𝐻(𝑠) = 𝑅 𝑄(𝑠)
 𝐴𝑅𝑠 𝐻(𝑠) + 𝐻(𝑠) = 𝑅 𝑄(𝑠)
𝐻(𝑠)[𝐴𝑅𝑠 + 1 = 𝑅 𝑄(𝑠)
𝐻(𝑠) 𝑅 𝐾
𝑄(𝑠)
= 𝐴𝑅𝑠+1
→ τ𝑠+1
; τ = 𝐴𝑅, 𝐾 = 𝑅
1
Steady-state gain: 𝑄(𝑠) = 𝑠

𝑅 1
𝐻(𝑠) = τ𝑠+1
(𝑠)

Using Final Value Theorem:

𝑅
lim 𝐻(𝑡) = lim 𝑠𝐻(𝑠) = lim τ𝑠+1
=𝑅
𝑡→∞ 𝑠→0 𝑠→0

V. Model Fitting Results

In this section, the outcomes of model fitting procedures are presented and
analyzed. The primary goal is to assess the adequacy of the proposed mathematical
model in representing the behavior of the system under study. This section typically
follows the development and validation of the mathematical model in earlier sections.

Table 4.1. In-Out Results of the Simulation

IN-OUT

Object Outlet Inlet Units

Temperature 298.153 298.152 K

Pressure 109909 130000 Pa

Mass Flow 10.0019 10 kg/s

Molar Flow 555.192 555.084 mol/s

Volumetric Flow 0.0100315 0.0100295 m3/s

Density (Mixture) 997.051 997.06 kg/m3

Specific Enthalpy (Mixture) 104.951 104.966 kJ/kg

Specific Entropy (Mixture) 0.367276 0.367257 kJ/[kg.K]

Thermal Conductivity 0.607205 0.607212 W/[m.K]

The table presents comprehensive data comparing inlet and outlet parameters
obtained from the simulation, offering valuable insights into the system's behavior.
While the temperature differential between inlet and outlet is minimal, suggesting
limited heat exchange, a notable pressure drop hints at significant resistance within the
system. Although mass and molar flows show consistency, minor fluctuations imply
potential variations in fluid dynamics. Similarly, slight deviations in volumetric flow and
density underscore system stability.
Table 4.2. Valves Setting Values

Valves Setting

Object Valve - 02 Valve - 01

Actuator Delay 0 0 s

Pressure Drop 9003.89 12998.2 Pa

Outlet Pressure 109909 117002 Pa

Temperature Drop 0.00157288 0.00288076 K

Kv(max) 400 100

Opening 30.0428 50

Characteristic Parameter 50 50

Actual Flow Coefficient 120.174 100

Table 4.2 provides crucial insights into the setting values of valves within the
system. Valve 02 exhibits a higher pressure drop and a marginally lower outlet
pressure compared to Valve 01, indicating potentially different flow control capabilities.

Table 4.3. Tank Settings

Tank Settings

Object Tank

Liquid Level 1.80003 m

Height 2 m

Initialize using Inlet 1

Stream

Pressure Drop 0 Pa
 Volume 2 m3

Residence Time 199.411 s

Table 4.3 outlines the settings pertaining to the tank within the system. It
indicates a liquid level of 1.80003 meters within the tank, with a total height of 2 meters.
The tank is initialized using the inlet stream with no pressure drop observed. With a
volume of 2 cubic meters, the tank has a residence time of 199.411 seconds, reflecting
the duration for which fluid remains within the tank before exiting.

Table 4.4. PID Results

PID

Object PID Controller

Last Error 2.00415E-05

Current Error 1.38919E-05

Cumulative Error 23.5256

Set Point Abs 1.8

Kp 119.455

Ki 4.52784

Kd 16.3382

Output 15.6905

OutputMin -1000

OutputMax 1000

OutputAbs 30.0428

Table 4.4 presents the results of a PID (Proportional-Integral-Derivative)

controller applied within the system. It indicates the last error, current error, and
cumulative error values, which are essential for understanding the controller's
performance in minimizing deviations from the set point. The table offers tuning
parameters (Kp, Ki, Kd) for adjusting the PID controller's response to error signals,
crucial for optimizing system performance. It also provides insights into the controller's
action and limitations through its output, minimum, and maximum permissible values.

Figure 4.1 PID Controller History

This graph shows the behavior of a system controlled by a

Proportional-Integral-Derivative (PID) controller over time, as measured. The graph
presents the performance of a PID controller over discrete time steps, illustrating the
relationship between the Process Variable (PV) in green, which tracks the system's
current state; the Set Point (SP) in yellow, representing the desired system state; and
the Manipulated Variable (MV) in red, reflecting the controller's efforts to align the PV
with the SP. Time progresses along the x-axis in steps, while the y-axis is dual-scaled,
with the left side showing the SP/PV range from 0 to 1.5, and the right side denoting
the MV range from 0 to -100, effectively displaying how the PID controller adjusts the
system's output to reach and maintain the target condition.
VI. Control Tuning and Stability Analysis

In this section, the focus is on optimizing the parameters of the control system
and assessing its stability to ensure robust and effective performance in regulating the
system's behavior. This section typically follows the development and validation of the
control algorithm and the integration of the controller with the system hardware.

A. Control Tuning
Proportional-Integral-Derivative (PID) control is a widely used feedback
control technique that adjusts control actions based on error, integral of error,
and derivative of error. PID controllers are effective for regulating water level by
adjusting valve openings or pump speeds. It is a crucial step in designing an
effective control system, especially for dynamic systems like water tanks.

a.1. Feedback Control

The success of feedback control is due to the system
making everything faster, more accurate and less susceptible to
interference. Because of its simplicity, open-loop control is only
recommended in a system where the outputs and inputs are known
and do not cause interference.

Figure 4. PID Controller Structure

(Source: Rodrigues, M.J.M 2011)

The basic structure of conventional feedback control

systems is shown in figure above. The purpose is to make the
variable y follow the Set-point r. For that, the variable u is manipulated
at the command of the controller. The variable d is considered as
disturbances. The disturbance may be any factor that influences the
process variable.
a.2. PID Controller
A PID controller is a controller that includes the
proportional element, “P element”, the integral element, “I element”
and the derivative element, “D element”.
Defining u(t) as the controller output, the final form of the
PID algorithm is:
𝑡
𝑑
𝑢(𝑡) = 𝑀𝑉(𝑡) = 𝐾𝑝𝑒(𝑡) + 𝐾𝑖 ∫ 𝑒(τ)𝑑τ + 𝐾𝑑 𝑑𝑡
𝑒(𝑡) eq.5.1
0

Where:
𝑃𝑜𝑢𝑡: Proportional term of output

𝐾𝑝: Proportional gain, a tuning parameter

𝐾𝑖: Integral gain, a tuning parameter

𝐾𝑑: Derivative gain, a tuning parameter

𝑒: Error = SP − PV
𝑡: Time or instantaneous time (the present)
𝑀𝑉: Manipulated variable

● Proportional term − The proportional influence is proportional to

the generated error and it is given by:
𝑃𝑜𝑢𝑡 = 𝐾𝑝𝑒(𝑡) eq.5.2

The higher the error the higher the proportional control which
leads us to another one that is that: the proportional control leads
the system to a fast SetPoint.

● Integral term − The integral influence is proportional to the

variation of the error on time, this is given by the equation:
𝑡
𝐼𝑜𝑢𝑡 = 𝐾𝑖 ∫ 𝑒(τ)𝑑τ eq.5.3
0

● Derivative term − The derivative term is proportional to the rate

of change of the error, as we can see on the equation below. The
derivative term is given by:
𝑑
𝐷𝑜𝑢𝑡 = 𝐾𝑑 𝑑𝑡
𝑒(𝑡) eq.5.4
 This term makes an estimation of the future error and by that it
can increase or decrease the speed of correction, because it can
work in an early way when there are detected any changes on the
error. This term is very sensitive to disturbances.

Stability analysis is an essential part of controller design,

especially when PID (proportional integral-derivative) controllers
are used in various industrial processes. PID controllers are widely
used in control systems because of their simplicity and efficiency.
Adjust the PID controller parameters, if the closed-loop system is
unstable or slightly unstable, adjust the PID controller parameters
to improve stability. This can include increasing or decreasing
proportional (P), integral (I), and derivative (D) gain..

VII. Scilab Xcos Tuning and Console

VIII. Discussion
This section discusses, interprets, and analyzes the findings, results, and
implications of the project.

The process control simulation project aimed at optimizing the management of a

water tank system through closed-loop feedback strategies using PI controllers has
successfully met its intended goals. The project demonstrated its efficacy through
detailed model fitting, comprehensive simulation results, and the effective
implementation of tailored control strategies. These elements worked in concert to
maintain precise control over water level and temperature, two critical variables in the
dynamic environment of the water tank system. The success of this project is rooted in
its meticulous approach to simulating real-world scenarios, thereby allowing the
theoretical models to be tested and refined based on empirical data.

Model fitting played a crucial role in validating the accuracy of the mathematical
models used to represent the behavior of the water tank system. The process involved
comparing the predicted outputs of the models with actual data obtained from the
system under various operating conditions. This step was essential in ensuring that the
mass and energy balance equations used were capable of accurately capturing the
dynamics of water level, temperature, pressure, and flow rates within the tank. The high
degree of congruence between the simulated results and the actual data underscored
the model’s reliability and the effectiveness of the control strategies employed,
particularly in how the valve settings and tank configurations were adjusted to respond
adeptly to any changes in the process variables.

The performance of the PI controllers was another focal point of the analysis. In
the PID results section, the efficiency of these controllers was evident in their ability to
minimize deviations between the actual measurements and the desired setpoints for
water level and temperature. This was particularly highlighted through the controllers'
history graphs, which provided a visual representation of the controllers' performance
over time. The fine-tuning of the PID parameters, a critical aspect of the project, was
optimized to enhance the system's stability and responsiveness, thus achieving the
project's core objective of maintaining precise control over the dynamic variables within
the system.

The design and execution of the project were grounded in robust principles of
process control and automation technology. By integrating sensors, actuators, and
controllers within a well-thought-out system framework, the project not only
demonstrated a high level of technical proficiency but also showcased the practical
application of theoretical concepts in a controlled environment. This integration was
critical in facilitating the real-time monitoring and adjustment of the system parameters,
ensuring that the control strategies were both effective and efficient.

The project's success is a testament to the rigor and precision of modern control
engineering practices. From the initial model fitting and simulation phases to the final
implementation of control strategies, each component of the project was meticulously
planned and executed. The successful outcome not only validated the theoretical
models but also demonstrated the practical capabilities of PI controllers in managing
complex dynamic systems like water tanks. The project thus stands as an exemplary
model of how theoretical knowledge can be effectively applied in practical scenarios to
achieve precise and reliable control over critical system variables.
IX. Conclusion and Future Work

In conclusion, the water tank control system designed and analyzed in this
project showcases a robust approach to maintaining precise water levels and
temperatures within industrial processes. Beyond technical efficacy, the implications of
this control system extend to various non-technical factors, reflecting its broader
significance in societal, environmental, and economic contexts.

Public Health and Safety. Accurate water level control is paramount in industries
where processes rely on specific liquid levels for optimal operation. Maintaining precise
levels mitigates risks of equipment malfunction, spills, and potential hazards, thereby
enhancing workplace safety and minimizing health risks associated with industrial
accidents.

Public Welfare. Industries such as petrochemical, water treatment, and

pharmaceuticals heavily rely on controlled processes for product quality and public
safety. The successful implementation of this water tank control system contributes to
the overall welfare by ensuring consistent product quality and reliability in essential
services.

Global Factors. In a global context, efficient process control technologies contribute to

sustainable development goals by reducing resource wastage and environmental
impacts. By minimizing energy consumption and optimizing resource utilization,
industries can align with global initiatives for sustainability and environmental
stewardship.

Cultural Factors. The adoption of advanced process control technologies reflects a

commitment to innovation and efficiency, traits valued across cultures. By integrating
cutting-edge control systems, industries demonstrate a dedication to continuous
improvement and competitiveness in the global market, irrespective of cultural
differences.

Social Factors. Reliable water management systems play a vital role in community
well-being, ensuring access to clean water and sanitation. By enhancing control over
water levels and quality, industries indirectly contribute to social welfare by supporting
infrastructure development and resource conservation efforts.

Environmental Factors. Precise control over water levels minimizes wastage and
reduces environmental impacts associated with excessive resource consumption.
Additionally, optimized process control strategies can lead to lower emissions and
pollutants, contributing to environmental preservation and conservation efforts.

Economic Factors. Efficient process control systems translate into cost savings
through reduced energy consumption, minimized material wastage, and enhanced
productivity. By improving operational efficiency and product quality, industries can
remain competitive in global markets, fostering economic growth and sustainability.

The process control simulation not only achieved its goal of maintaining the water level
and temperature within the tank but also laid down a foundation for future exploration. It
highlighted the importance of an integrated approach involving theoretical
understanding, simulation validation, and practical implementation of control strategies.
Future directions could include refining the control algorithms, exploring advanced
control techniques, or incorporating additional sensors and actuaries to enhance
system monitoring and control capabilities, aiming for even greater efficiency and
optimization of the dynamic system.
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