Instrumentation and process control April 16, 2024

EXPERIMENT# 1
Objective:
To analyze the effect of proportional action on the automatic feedback flow control system.

• Control the value in the range of 4 lit/min to 18 lit/min, calculate the time constant, dead
time, and Kp, plot graph between time v/s process value, and plot graph between time
v/s controller outputs.

Instruments:
• Console
• Display unit
• Computer
• Turbine flow sensor (2-30 L/ min, working pressure: 14bar, Accuracy: +/- 3% of reading)
• Control unit
• Solenoid valve (Model: 2W-160-15, 5-80 oC, 0-7 kg/cm2)
• Motorized valve (Model: SR03GC22032A1-E, 24 AC, 50/60Hz, 3.5 VA)
• Pump (Padrollo Motor to flow water 220V/50Hz, 4L/min to 22L/min)
• Manual Valve

Theory:
In feedback control, the variable being controlled is measured and compared with a target
value. This difference between the actual and desired value is called the error. Feedback
control manipulates an input to the system to minimize this error. Figure. 10.1 shows an
overview of a basic feedback control loop. The error in the system would be the Output –
Desired Output. Feedback control reacts to the system and works to minimize this error. The
desired output is generally entered into the system through a user interface. The output of the
system is measured (by a flow meter, thermometer or similar instrument) and the difference is
calculated. This difference is used to control the system inputs to reduce the error in the
system. [Lee, Newell, and Cameron et. al]

Fig. 1.1. feedback control loop diagram

Turbine flowmeters are precision instruments that measure the volumetric flow rate of a fluid
within a pipeline. They operate on the principle of angular momentum transfer, where the
Instrumentation and process control April 16, 2024

flowing fluid imparts rotational energy to a turbine rotor, the angular velocity of which is
directly proportional to the fluid velocity. [Wan et.al]
f = K⋅Q
PI controller mode, proportional control mode provides a stabilizing influence while the
Integral mode will help to overcome OFFSET. Integral controller will provide corrective action as
long as there is a deviation in the controlled Variable from the set point value. [Richardson and
coulson et. al]

Flow control system, In a storage tank or other piece of equipment, flow control is typically
linked to inventory control. A reservoir is required to accommodate variations in flow rate. A
by-pass control would be used to offer flow control on a compressor or pump that is operating

at a fixed speed and producing an output that is almost constant in volume as shown in fig.1.1
[Richardson and coulson. Et. Al]
Fig. 1.2 (a) Flow control for a reciprocating pump (b) Alternative scheme for a centrifugal
compressor or pump
Dead Time (td) is the between the change in an input variable and when the output variable
begins. Dead time is important because it effects the controllability of the control system. A
change in set point is not immediate because of this parameter. Dead time must be considered
in tuning and modeling processes. [Leland, George and Arthur Rubenstein. Et. al]
Time Constant: The time constant of a system is the time required for the transient response to
reach 63.2% of its final steady-state value. [Leland, George and Arthur Rubenstein. Et. al]
Instrumentation and process control April 16, 2024

Fig. 1.3. Process Flow Diagram of Feedback Flow Control System

Methodology:
The Purpose of this experiment was to analyze the effect of proportional action on automatic
feedback flow control system.

• Turned on the power supply.

• After the system was started, wait for some instance to run safety check.
• Turned on the computer and run application software.
• The outlet flow valve was set in the opening position.
• The set values for the desired process were provided.
• Different values of time, controller output and rotameter were observed with respect to
the set values provided.
• After the observations were completed, the software was disconnected.
• Pressed the stop button, pressed emergency stop and turned off the system
Instrumentation and process control April 16, 2024

Working Formula:
Time Constant Δτ = ti + 0.632 Δt
Proportional gain = Kp = ΔPV/ ΔCO

Observations:
Dead time = 8 sec
Table. 1.1: Experimental values based on flow control system at set point 4 lit/min

S.No Time PV Controller

(Sec) (L/min) Output

1 10 18 615
2 16 15 408
3 20 15 276
4 25 13 130
5 28 7 55
6 30 4 51

Calculation:
• Time constant:
Δτ = ti + 0.632 Δt
Δτ = 10+ 0.63 (30-10)
Δτ = 22.64 sec

• Proportional gain:
Kp = ΔPV/ΔC0
Kp = 14/564
Kp = 0.024
Instrumentation and process control April 16, 2024

20 700
18
615
18
600
16 15 15

14 13 500
408
12
400

CO
PV

10
276
7 300
8

6 200
130 4
4
55 51 100
2

0 0
0 5 10 15 20 25 30 35
TIME in sec

Fig. 1.4. Graphical representation of Time vs PV vs Controller output for table 1.1
Table 1.2: Experimental values based on flow control system at set point 18 lit/min
Dead time: 8 sec

S.NO Time PV Controller

(Sec) (L/min) Output
1 11 3 1020
2 15 9 1020
3 21 11 1020
4 40 15 1020
5 44 17 1020
6 58 18 0

Calculation:
Time constant:
Δτ = ti + 0.632 Δt
Δτ = 11+ 0.63 (58-11)
Δτ = 40.74 sec
Instrumentation and process control April 16, 2024

Proportional gain:
Kp = ΔPV/ΔC0
Kp = 14/1020
Kp = 0.013

20 1200

18 18
10201020 1020 10201020
17 1000
16
15
14
800
12
11

CO
PV

10 600
9
8
400
6

4
3 200
2

0 0 0
0 10 20 30 40 50 60 70
Time in sec

Fig. 1.5: Graphical representation of Time vs PV vs Controller output for table 1.2

Result and Discussion:

The experiment’s findings on the effect of PI action on an automatic feedback flow control system
reveal a distinct relationship between the set point and the system’s dynamic response. At a set
point of 4 L/min, the time constant is relatively high at 69.648 seconds, and the proportional gain
(Kp) is set at 0.042, indicating a slower system response to changes in flow rate. Conversely, at a
higher set point of 18 L/min, the time constant decreases to 53.44 seconds, and the Kp is reduced
to 0.032, suggesting a quicker response and a more stable system with less propensity for
oscillation. These results align with control system principles that suggest a system’s
responsiveness increases with flow rate, and a lower Kp at higher flow rates can mitigate
overshoot and enhance stability. Where time constants and Kp values are tailored to balance
responsiveness against stability, with variations accounted for by the unique characteristics of
each system. Turbine flowmeter, it is chosen for its accuracy, reliability, and suitability for the
fluid’s properties and flow range in the experiment, the turbine flowmeter’s ability to provide
Instrumentation and process control April 16, 2024

precise measurements over a wide range of flow rates makes it an ideal choice for this
experiment, ensuring accurate data for the PI controller to act upon.

References:
[1] Richardson and coulson introduction chemical engineering volume’3 and third Edition
[2] Wan, G., Wu, Y., Wu, C., Xiao, Y., Lin, J., & Zhang, S. (2023). Research progress and
challenges of the gas turbine flowmeter in energy measurement. Frontiers in Energy Research,
10. https://doi.org/10.3389/fenrg.2022.977140
[3] Lee, Newell, and Cameron 1998: 6 FEEDBACK LOOP CONTROL SYSTEM (Peter Woolf et al.
University of Michigan)
[4] Leland Beckwith, George Lienhard, and Arthur Rubenstein Feedback Systems