Practical No : 01

Aim : Perform the operation of Level Process Trainer and determine process dynamic and its
characteristics.

Relevant CO: CO3

Competency and Practical Skills: Basic of control and precss

Objectives:

1. To understand process dynamics

2. To understand about process variables

Equipment/Instruments:
Level Process Trainer

Fig : Level Process Trainer with WebAccess SCADA Software

Theory :

Controlled variable: The controlled variables of the process should be that variable which
must directly indicate the desired form or state of product the variance most indicative of the
process is the temp. of water at heater outlet and that is selected as controlled variable.

Manipulated variable: The manipulated variable of the process is that variable which is
selected for adjustment by automatic controller so as to maintain the controlled variable at desired
value.

Load variable: The load variables of the process are all other independent variable except
the controlled variable and manipulated variable.
Process:
A process in the science of automatic control denotes an operation on series of operation on fluid or
solid material during which the materials are placed in more useful state. This condition may be
expressed in terms of process variables such as temp., level, Press. Etc.
This process may be controlled by measuring a variable representing the desired state of product
and automatically adjusted one or the other variance of process.
Process variable:

PROCESS CONTROL (3151705) Page 1

 Controlled variable: The controlled variables of the process should be that variable which must
directly indicate the desired form or state of product the variance most indicative of the process is the
temp. of water at heater outlet and that is selected as controlled variable.

Manipulated variable: The manipulated variable of the process is that variable which is selected
for adjustment by automatic controller so as to maintain the controlled variable at desired value.

Load variable: The load variables of the process are all other independent variable except the
controlled variable and manipulated variable
Transmission lag:
It is the infinite the taken by any sensor or any sharing element to response to a change in process
parameter it is an inherient property of sensor. It is also a measurement lag.
Process lag:
The process controlled loop respond to ensure that some infinite time, the variable returns to the set
point value.
Self regulation:
A significant characteristic of some process is that tendency to adopt a specific value of controlled
variable for nominal load with number of controlled operation. The controlled operation may be
significantly affected by such self regulation.
An example of a process without self regulation is the tank from which liquid is pumped .If
increased slightly the level rises until the tank overload.

Variable range:
Generally the variables under controlled have a range of valve within which it can be controlled and
maintained. The range can be expressed in minimum and maximum value of variance of above the
nominal value is standard 4 to 20 mm transmission that represents for minimum value of 20%
maximum value.
Controlled parameter range:
The range is associated with the control output. Final control elements has some maximum and
minimum effect on process .This range is also expressed as percentage, 0% for minimum and 100%
for maximum.
Control lag: The control system has a lag associated with it operation that must be compared to be
process lag when control variable is experience a sudden change .The process control loop reacts
with output putting the command to final control element to adopt a new value to detect changes.
PROCESS CONTROL (3151705) Page 2
Dead time:
This is the elapsed time between instant a destination over and when co-reactive first curve an
example of the dead time occurs in a control of chemical reaction by varying a reactance flow rate
through long pipe when deviation is defected. Control system quickly changes value setting to
adjust the flow rate it also due finite time after change of input respond in output.

Task: Identify and discuss any two examples of process control system around you. Classify its
process variables with block diagram.

Task to perform:
1. Draw the P & I diagram for level process trainer

2. List out various Instrumentation used in trainer

 LT : Level Transmitter
 E/P : Electric to Pneumatic Converter
 V : Bypass Valve
 CV: Pneumatic Control Valve
 F: Rotameter
 R: Air Pressure Regulator
 S : Supply Pressure Gauge (I/P)
 LIC : Level Indicator Controller

PROCESS CONTROL (3151705) Page 3

 3. Draw the closed loop diagram for level process trainer

The control system shown in Figurev is called a closed loop system or a feedback system because
the measured value of the controlled variable is returned to of “fed back” to a device called the
comparator. In the comparator, the controlled variable is compared with thedesired value or set
point. If there is any difference between the measured variable and the set point, an error is
generated; this error enters a controller, which in turn adjusts the final control element in order to
return the controlled variable to the set point.

Fig : Closed Loop Block diagram of Level control System

4. Prepare start up and shut down procedure for Level Process Trainer

Start up Procedure:
 Connect the air compressor line to the experimental control trainer. Shut off the air
supply valve to the trainer.
 Start the air compressor by providing electric supply to the compressor. Close the air
discharge valve while the compressor is started. Fill the air inside the compressor
cylinder.
 Fill the water supply tank at the behind of the trainer full with the fresh clean water.
 Make sure the drain valve is closed.
 After pressure of air inside compressor has built up sufficient (around 6 – 7 Kg/cm 2)
open the discharge valve of the compressor and valve to the trainer.
 Apply 20 psi (or 1.4 Kg/cm2) to the E/P converter by regulating pressure from air filter
cum regulator. Lock the regulator by pressing ring of it.

PROCESS CONTROL (3151705) Page 4

  Give the supply of 230 V AC to the trainer by three plugs pin provided. Switch ON the
power supply.
 Switch on the pump by the toggle switch provided with indicating lamp.
 Now adjust the set point of the PID controller to the 250 mm WC and also make
necessary P, I, D. Setting as per shown in the manual of PID Controller.
 Make sure the needle valve of Rotameter is fully open during whole operation. Also,
slight open the ball valve (drain/disturbance valve) provided on the bottom of the level
tank so that excess water can drain out from the valve to the water supply tank.
 Apply the new set point to the PID Controller and read the behaviors of the loop. Adjust
the drain valve of the level tank according to the set point
 Do the experiment as indicated in the level control trainer experiment manual.
 Choose the Mode of Operation or Control action of interest, apply the disturbance/
change of set point and log the data to the computer and analyze it.
Shut Down Procedure:
 Switch off the PID and Pump.
 Close the air supply to the E/P Converter/Control valve.
 Now shut off the pressure regulator provided for the I/P converter (fitted on the front
panel) until the pressure gauge fitted along with it indicates 0 kg/ cm 2 (g) pressure.
 Switch off the air compressor and shut off the discharge valve of it. Drain the filled air
from the Cylinder of compressor by opening the drain coke at the bottom of the
compressor. Close the air supply valve to the control trainer.
Switch off the power supply to the trainer.

5. Suggest Major five Precaution taken during operation of Level trainer

 Do not apply very high set point to the PID Controller, as it may damage the level tank /
transmitter after long time though the tank is tested to higher level.
 Do not apply higher pressure to E/P Converter (greater than 1.4 Kg/cm2) as it may
damage it. Also the lesser Pressure (lesser than 1.4 Kg/cm 2) may not give accurate
functioning of it.
 Do not change the link position of the control panel terminals.

PROCESS CONTROL (3151705) Page 5

  Do not open input and output wiring t to terminal ( Capacitive transmitter and I/P
Converter to controller from panel)
 Follow the standard Operating Procedure and safety rules during online mode
6. Given the Control variable, Manipulated variable, range of control variable and disturbances for
level process trainer.

PROCESS CONTROL (3151705) Page 6

 Practical No : 02
Aim : To perform ON-OFF control in Level Process Trainer
Relevant CO: CO3
Competency and Practical Skills: Knowledge of process and Process dynamics

Objectives:
(a) To understand the concept of ON/OFF controller.
(b) To understand the importance of neutral zone in ON/OFF controller.

Equipment/Instruments:
Level Process Trainer, SCADA Operator Panel

Fig : Level Process Trainer with WebAccess SCADA Software

Theory :
ON/OFF controller: The ON/OFF controller is the simplest and the discontinuous controller, which
switches ON when the error is positive and switches OFF when the error is zero or negative. It does not
have any intermidiate states.
Neutral zone: Neutral zone is a band of input values in the domain of transfer function where the
system output is zero.
1. Practically, in designing of two position controller, whenever the controller output has to change
from 0% to 100% or vice versa, there is a differential gap around zero error point where no controller
output results, this gap is known as neutral zone.

PROCESS CONTROL (3151705) Page 7

2. As the range of neutral zone increases, the switching of controller decreases but the deviation
from the set point will also increase.

P = 0% , ep < 0
= 100% , ep > 0

Fig.1: Output of ON-OFF Controller with Neutral Zone

APPLICATIONS

Generally, the two-position control mode is best adapted to large-scale systems with relatively slow
process rates. Thus, in the example of either a room heating or air-conditioning system, the capacity
of the system is very large in terms of air volume, and the overall effect of the heater or cooler is
relatively slow. Sudden, large-scale changes are not common to such systems. Other examples of
two-position control applications are liquid bath-temperature control and level control in large-
volume tanks. The process under two-position control must allow continued oscillation in the
controlled variable because, by its very nature, this mode of control always produces such
oscillation. For large systems, these oscillations are of long duration, which is partly a function of
the neutral-zone size. To illustrate this, consider the following example.

PROCESS CONTROL (3151705) Page 8

Task:
To Perform ON/OFF control in Level Process Trainer and observe control on SCADA on operator panel

Procedure:
1. Connect the air compressor line to the experimental control trainer and start air
compressor.
2. Fill the water supply tank at the behind of the trainer full with the fresh clean
water. Make sure the drain valve is closed.
3. Switch on the Power supply of panel and start SCADA window
4. Open parameter setting screen and adjust ON/OFF Parameter
5. Observe controller performance on P&I window and on Trend display.
6. Take necessary reading and analysis of trend for given controller.
7. Shut down the process trainer as per Standard operating procedure manual.
8. Derive the conclusion as per your reading and trend analysis.

 Open the P&I diagram process window for monitor complete control of trainer

Fig 2: On/OFF control P&I diagram on SCADA Trainer

 Set the parameter for ON/OFF controller for Level Process trainer

PROCESS CONTROL (3151705) Page 9

 Fig 3 : Parameter Setting of On/OFF Controller
 Observe the control in trend display and note result for conclusion

Observations/Result:

Fig 4 : Trend display for ON/OFF control

Conclusion:

PROCESS CONTROL (3151705) Page 10

 Practical No : 03

Aim : To perform Proportional control in Level Process Trainer

Relevant CO: CO3

Competency and Practical Skills: Knowledge of process and Process dynamics

Objectives:
(a) To understand the concept of Proportional controller.
(b) To understand the importance Proportional gain and Proportional band in controller.

Equipment/Instruments:
Level Process Trainer, SCADA Operator Panel

Fig : Level Process Trainer with WebAccess SCADA Software

Theory :

Proportional Controller:
 Proportional controller can be defined as extension of ON/OFF controller, because it
overcomes the drawbacks of ON/OFF controller.

 In this mode, for every value of error there is a unique vale of controller output, called band
of errors.

PROCESS CONTROL (3151705) Page 11

  This band of errors is known as Proportional Band(PB) and is between two threshold values
i.e. 100% ON and 100% OFF.

 𝑃𝐵=100𝐾𝑃 where, Kp is proportionality constant

 If we make PB=0 it will become ON/OFF controller.

 In case error signal is present, the proportional controller output signal needs a correction of
Kp % for every 1% error. There an error band about zero having a magnitude equal to
proportional band within which output is not saturated at 0% or 100%.

Fig.1: Response of Proportional Controller

saturation
100
c
o gain G1
n
t
r
o
l
l
e 50
r
o
u
t gain G2<G1
p
u
t
%
0
saturation
(-) O (+) Error (%)
Narrow Band

Wide Band

Fig : PB/GAIN in Proportional controller

PROCESS CONTROL (3151705) Page 12

• P= Kp* ep + Po

Where, P= controller output

Kp=proportional gain (%/%)
Po=controller o/p when error is zero
• For transfer function:

P = Kp * E(s)
E(s)/ P(s) = Kp
Characteristics of P Controller:
• One of the main disadvantage of proportional controller is it produces a permanent residual
error in the controlled variable. When a process load change results in error. This is called Offset.
• For proportional controller ess = 11+𝐾𝑝. This error is offset error.
Application :
The offset error limits use of the proportional mode to only a few cases,particularly those where a
manual reset of the operating point is possible to eliminate offset.Proportional control is generally
used in processes where large load changes are likely or with moderate to small process lag
times.Thus,if the process lag time is small,the proportional band can be made very small(large
Kp),which reduces offset error.Figure A shows that if Kp is made very large,the PB becomes very
small,and the proportional mode just acts like an ON/OFF mode.Remembered that the ON/OFF
mode exhibited oscillations about the set point.From these statements it is clear that,for high
gain,the proportional mode causes oscillations of the error.

Task:
To Perform Proportional control in Level Process Trainer and observe control on SCADA on
operator panel

Procedure:
9. Connect the air compressor line to the experimental control trainer and start air
compressor.
10. Fill the water supply tank at the behind of the trainer full with the fresh clean
water. Make sure the drain valve is closed.
11. Switch on the Power supply of panel and start SCADA window

PROCESS CONTROL (3151705) Page 13

 12. Open parameter setting screen and adjust PROPORTIONAL Parameter
13. Observe controller performance on P&I window and on Trend display.
14. Take necessary reading and analysis of trend for given controller.
15. Shut down the process trainer as per Standard operating procedure manual.
16. Derive the conclusion as per your reading and trend analysis.

 Open the P&I diagram process window for monitor complete control of trainer

Fig 2: Proportional control P&I diagram on SCADA Trainer

 Set the parameter for Proportional controller for Level Process trainer

Fig 3 : Parameter Setting of On/OFF Controller

PROCESS CONTROL (3151705) Page 14

  Observe the control in trend display and note result for conclusion

Observations/Result:

Fig 4 : Trend display for Proportional control

Conclusion:

PROCESS CONTROL (3151705) Page 15

 Practical No :04

Aim : Understand and analyse non-interacting and interacting series tank system dynamics.

Relevant CO: CO2

Competency and Practical Skills: Control system, Process dynamic
Objectives:
(a) To understand the dynamics of Tank system
(b) Relation between non-interacting and interacting series tank system
Theory:
Non-Interacting System:
When neither one or more inputs or outputs of a system affect an output or more than one output of
the system, it is called a non-interacting system.
Interacting System:
A system is said to be interacting if each input of the system affects over one of its outputs.
Single Tank System:
In level process, firstly, a single-tank system is considered where the objective is to maintain the
process liquid at a desired level or change it at a pre-determined rate by controlling the manipulated
variables, firstly one at a time and then all of them being controlled simultaneously at the same time

Fig 1: Single Tank System

Transfer function of single tank system:

PROCESS CONTROL (3151705) Page 16

 Task-1: Take two tanks having same dimensions and connect them in non-interacting form. Find
step response of it. Compare single tank response and two non-interacting tank response.

Non-interacting tank system:

Fig 2: Non Interacting two tank system

PROCESS CONTROL (3151705) Page 17

Task-2: Take same dimensions as above and connect them in interacting way. Find step response of
it. Compare and analyze the responses

Interacting tank system:

Fig 3: Interacting two tank system

Where, 𝑇1=𝐴1𝑅1,2=𝐴2𝑅2

Here, we have assumed R1 = 1 and R2 = 1

Area of first tank (A1) = 3
Area of second tank (A2) = 3
For transfer function T1 = T2 = 3min

Therefore, step response:

Conclusion:

PROCESS CONTROL (3151705) Page 18

 Practical No : 05

Aim : To perform Proportional-Integral control in Level Process Trainer

Relevant CO: CO3

Competency and Practical Skills: Knowledge of process and Process dynamics

Objectives:
(a) To understand the concept of Proportional-Integral controller.
(b) To understand the importance Proportional gain, Integral time in controller.

Equipment/Instruments:
Level Process Trainer, SCADA Operator Panel

Fig : Level Process Trainer with WebAccess SCADA Software

Theory :

 To eliminate the limitations of individual proportional and integral controller composite PI

controller is used.
 PI control mode combines advantages of both individual modes and their disadvantages are
compensated at the same time.
 Proportional mode provides stability and rapid adjustment of manipulated variable but at the
same time there will be some offset error in the response.

PROCESS CONTROL (3151705) Page 19

  Integral mode is used to eliminate the offset error due to proportional mode.

Therefore PI mode have advantages of both modes that is stability, rapidity and no steady state
error.
P(t) = KpEp + KpKi ʃ Ep (t) dt + P0
Where,
P(t) = controller output at time t sec
Kp = proportional gain
Ep = error
Ki = Integral gain or repeats per minute
P0 = controller output at t = 0sec
This controller can be used in system with large and frequent load changes.

Let us summarize the characteristics of the PI mode and Equation.

1. When the error is zero, the controller output is fixed at the value that the integral had when
the error went to zero.
2. If the error is not zero, the proportional term contributes a correction, and the integral term
begins to increase or decrease the accumulated value

(+)
e
r
r 0 t
o t1

r
(-)

p%

100

c
o
n
t
r proportional
o
l integral
l
e
r 50

o
u
t
p composite
u
t

0 t

Fig : Proportional Integral control characteristic

PROCESS CONTROL (3151705) Page 20

Application

As noted, this composite proportional integral mode eliminates the offset problem of
proportional controllers. It follows that the mode can be used in systems with frequent or large load
change. Because of the integration time, however, the process must have relatively slow changes in
load to prevent oscillations induced by the integral overshoot.

Another disadvantage of this system is that during start up of a batch process, the
integral action causes a considerable overshoot of the error and output before settling to the
operation point.

Task:
To Perform Proportional-Integral control in Level Process Trainer and observe control on SCADA
on operator panel

Procedure:
17. Connect the air compressor line to the experimental control trainer and start air
compressor.
18. Fill the water supply tank at the behind of the trainer full with the fresh clean
water. Make sure the drain valve is closed.
19. Switch on the Power supply of panel and start SCADA window
20. Open parameter setting screen and adjust PI controller Parameter
21. Observe controller performance on P&I window and on Trend display.
22. Take necessary reading and analysis of trend for given controller.
23. Shut down the process trainer as per Standard operating procedure manual.
24. Derive the conclusion as per your reading and trend analysis.

 Open the P&I diagram process, parameter and trend window for monitor PI controller
performance of trainer.

PROCESS CONTROL (3151705) Page 21

 Fig 2: Proportional-Integral control P&I diagram on SCADA Trainer
 Set the parameter for Proportional controller for Level Process trainer

Fig 3 : Parameter Setting of Proportional-Integral Controller

PROCESS CONTROL (3151705) Page 22

  Observe the control in trend display and note result for conclusion

Observations/Result:

Fig 4 : Trend display for Proportional-Integral control

Conclusion:

PROCESS CONTROL (3151705) Page 23

 Practical No : 06

Aim : To perform Proportional-Derivative control in Level Process Trainer

Relevant CO: CO3

Competency and Practical Skills: Knowledge of process and Process dynamics

Objectives:
(a) To understand the concept of Proportional-Derivative controller.
(b) To understand the importance Proportional gain, Derivative time in controller.

Equipment/Instruments:
Level Process Trainer, SCADA Operator Panel

Fig : Level Process Trainer with WebAccess SCADA Software

Theory :

By combining all the three modes ( PROPORTIONAL, DERIVATIVE mode ), optimum

performance can be achieved.
So, there are 2 basic actions in PID.
1. Proportional

2. Derivative

PROCESS CONTROL (3151705) Page 24

Proportional mode:
In this mode the controller output varies linearly with respect to the error i.e. the controller output is
proportional to the error.
The equation for P mode is: P = Kp*ep + P0
Where,
• P is the controller output
• Kp is the proportional gain between error and controller output
• ep is the error in %
• P0 is the controller output when error is zero (%)

As the gain Kp is increased, the band to control (PB) decreases.

Derivative mode:
This action is used to increase the speed of response of slow processes. It anticipates the rate of
change of error and takes the control action. Equation for Derivative mode is: (𝑡)=𝐾𝑑ⅆ𝐸𝑃ⅆ𝑡+𝑃0
Where,
• P(t) is the controller output at time t

• Kd is the derivative gain constant in % / (%/sec)

• 𝑑𝐸𝑃𝑑𝑡 is the rate of change of error in %/sec

Set Point can be achieved quickly by using D mode.

In noisy environment, this action is not used as the output goes into saturated condition.
Even for constant error D action provides no correction, hence not preferred alone. It is always
combined with P action.
PD controller
A second combination of control modes has many industrial applications. It involves the serial
(cascades) use of the proportional and derivative modes. The analytic expression for this mode is found a
combination of Equations.

P = Kpep + KpKd dep/dt + po . . . . . . . . (1)

Where, the terms are all defined in terms given by previous equations.

It is clear that this system cannot eliminate the offset of proportional controllers. It can , however ,
handle fast process load changes as long as the load change offset error is acceptable. An example of the

PROCESS CONTROL (3151705) Page 25

operation of this mode for a hypothetical load change is shown in Figure. Note the effect of derivative
action in moving the controller output in relation to the error rate change.

Fig : Proportional-derivative(PD) action showing the offset error from the proportional mode .

Task:
To Perform Proportional-Derivative control in Level Process Trainer and observe control on
SCADA on operator panel

Procedure:
25. Connect the air compressor line to the experimental control trainer and start air
compressor.
26. Fill the water supply tank at the behind of the trainer full with the fresh clean
water. Make sure the drain valve is closed.
27. Switch on the Power supply of panel and start SCADA window
28. Open parameter setting screen and adjust PD controller Parameter
29. Observe controller performance on P&I window and on Trend display.

PROCESS CONTROL (3151705) Page 26

 30. Take necessary reading and analysis of trend for given controller.
31. Shut down the process trainer as per Standard operating procedure manual.
32. Derive the conclusion as per your reading and trend analysis.
 Open the P&I diagram process, parameter and trend window for monitor PI controller
performance of trainer.

Fig 2: PD control P&I diagram on SCADA Trainer

 Set the parameter for PD controller for Level Process trainer

Fig 3 : Parameter Setting of PD Controller

PROCESS CONTROL (3151705) Page 27
  Observe the control in trend display and note result for conclusion

Observations/Result:

Fig 4 : Trend display for Proportional-Derivative control

Conclusion:

PROCESS CONTROL (3151705) Page 28

 Practical No : 07

Aim : To perform Proportional-Integral-Derivative control in Level Process Trainer

Relevant CO: CO3

Competency and Practical Skills: Knowledge of process and Process dynamics

Objectives:
(a) To understand the concept of Proportional-Integral-Derivative controller.
(b) To understand the importance Proportional gain, Integral time, Derivative time in controller.

Equipment/Instruments:
Level Process Trainer, SCADA Operator Panel

Fig : Level Process Trainer with WebAccess SCADA Software

Theory :

By combining all the three modes ( PROPORTIONAL, INTEGRAL, DERIVATIVE mode ),

optimum performance can be achieved.
So, there are 3 basic actions in PID.
1. Proportional

2. Integral and

3. Derivative

PROCESS CONTROL (3151705) Page 29

Proportional mode:
In this mode the controller output varies linearly with respect to the error i.e. the controller output is
proportional to the error.
The equation for P mode is: P = Kp*ep + P0
Where,
• P is the controller output
• Kp is the proportional gain between error and controller output
• ep is the error in %
• P0 is the controller output when error is zero (%)

As the gain Kp is increased, the band to control (PB) decreases.

Integral mode:
Integral mode is used to remove the offset produced due to P mode. Offset can either be positive
and negative
Equation for Integral mode is (𝑡)=𝐾𝑖∫𝐸𝑃(𝑡)ⅆ𝑡+𝑃(0)
• P(t) is the controller output at time t

• Ki is the integral gain in sec-1

• Ep is the error

• P(0) is the controller output at time t=0

When this action is used alone due to integral effect the action becomes too slow.
When combined with Proportional, this mode combines the advantages of both controller types,
stability and fast response of P mode and no steady state error of I mode.
Derivative mode:
This action is used to increase the speed of response of slow processes. It anticipates the rate of
change of error and takes the control action. Equation for Derivative mode is: (𝑡)=𝐾𝑑ⅆ𝐸𝑃ⅆ𝑡+𝑃0
Where,
• P(t) is the controller output at time t

• Kd is the derivative gain constant in % / (%/sec)

• 𝑑𝐸𝑃𝑑𝑡 is the rate of change of error in %/sec

PROCESS CONTROL (3151705) Page 30

Set Point can be achieved quickly by using D mode.
In noisy environment, this action is not used as the output goes into saturated condition.
Even for constant error D action provides no correction, hence not preferred alone. It is always
combined with P action.
Composite controller
Composite controller is . P, I and D adds advantages of all the three modes. The Equation for the
combined PID controller: (𝑡)=𝐾𝑝𝑒𝑃+𝐾𝑃𝐾𝑖∫𝑒𝑝ⅆ𝑡+𝐾𝑃𝐾𝑑ⅆ𝑒𝑃ⅆ𝑡+𝑃𝑖(0)

Where, all terms have been defined earlier.

One of the most powerful but complex controller mode operation combines the proportional,
integral, and derivative modes. This system can be used for virtually any process condition.

This mode eliminates the offset of the proportional mode and still provides fast response. In
Figure, the response of the three-mode systems to an error is shown to an error is shown.

Fig: The three-mode controller action exhibits proportional, integral and derivative action.

PROCESS CONTROL (3151705) Page 31

Task:
To Perform Proportional-Integral-Derivative control in Level Process Trainer and observe control
on SCADA on operator panel

Procedure:
33. Connect the air compressor line to the experimental control trainer and start air
compressor.
34. Fill the water supply tank at the behind of the trainer full with the fresh clean
water. Make sure the drain valve is closed.
35. Switch on the Power supply of panel and start SCADA window
36. Open parameter setting screen and adjust PID controller Parameter
37. Observe controller performance on P&I window and on Trend display.
38. Take necessary reading and analysis of trend for given controller.
39. Shut down the process trainer as per Standard operating procedure manual.
40. Derive the conclusion as per your reading and trend analysis.

 Open the P&I diagram process, parameter and trend window for monitor PI controller
performance of trainer.

Fig 2: PID control P&I diagram on SCADA Trainer

 Set the parameter for Proportional controller for Level Process trainer

PROCESS CONTROL (3151705) Page 32

 Fig 3 : Parameter Setting of PID Controller

 Observe the control in trend display and note result for conclusion

Observations/Result:

Fig 4 : Trend display for Proportional-Integral-Derivative control

Conclusion:

PROCESS CONTROL (3151705) Page 33

 Practical No : 08

AIM :
To study behavior of cascade control loop.

THEORY:
In cascade control configuration there is one manipulated variable & more than one measurement.
Consider a process consisting of two process 1&2.Process1 has output variable that we have to
control. Process 2 has output variable that affect the control variable.
In cascade control there are two loops, primary & secondary. In secondary loop the secondary
variable is measured & controlled by feedback.
In primary loop the controlled variable is measured & gives it to the primary controller which act as
a setpoint for the secondary controller.
DEFINATION :
In control system the output of one controller is used to change the setpoint of another controller is
known as cascade controller. For master (primary) controller proportional while for slave
(secondary) controller integral controller modes are used.
In cascade control, the selection of the secondary variable is important, ideally the process should
be split in half by the cascade loop i.e. the secondary loop should be closed around half of the time
lag in the process.
(1) If the secondary variable were to respond instantly to the manipulated variable, the secondary
controller would accomplish nothing.

(2) If the secondary loop were closed around the entire process, the primary controller would have
no function.
Types of the secondary loop:-
(1) Valve position:-

The position assume by the plug of a control valve is affected by forces other then the control
signal, principally friction & line pressure. Change in line pressure can cause a change in position &
thereby upset a primary variable, and stem friction has an even more pronounced effect. Friction
produce square loop hysteresis between the action of the control signal & its effects on the valve
position whose phase & gain vary with amplitude of the control signal.

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(2) Flow control:-
A cascade flow loop can overcome of valve hysteresis. As well as positioned cam. It also ensures
that line pressure or undesirable valve characteristics will not affect the primary loop. For this
reason, in composite control systems, the proportional band & reset tin=me of the primary
controller may be low down.
(3) Temperature control:-
Chemical reactions are so sensitive to temperature that special consideration must be given to
controlling the rate of the heat transfer. Adding cascade control to any temperature variation of the
system, the proportional band & reset time of the primary controller may be lowered down.

SECONDARY CONTROL MODES

Valve Petitioners are proportional controller, usually with a fixed band of about 5%. Flow controller
invariably has both proportional & integral modes. In temperature- on temperature systems, the
proportional band of the secondary temperature controller is usually as narrow as 10 to 15 %. A
secondary flow controller, however, with its proportional band exceeding 100% does definitely
require an integral mode.

INSTABILITY IN CASCADE LOOPS

Adding cascade control to a system can destabilize the primary loop if most of the process
dynamics are within the secondary loop. The most common example is the practice of using a valve
positioned in a flow control loop. Closing the loop around the valve increases its

dynamics gain so much that the proportional band of the flow controller may have to be increased
by a factor of 4 to maintain stability.

ADVANTAGES:
➢ The change in load variable of secondary loop are compensated by secondary controller before
they can affect the primary loop.

➢ The secondary loop minimize the phase lag and increase the speed of response of primary loop.

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DISADVANTAGES:

 Can not be employed indiscriminately find suitable intermediate variable which measurable.
 Sec. loop always faster than primary loop.
APPLICATIONS :
➢ CSTR
➢ Heat exchanger
➢ Boiler control
➢ Furnace control
➢ Flow control
➢ Distillation column reboiler
➢ Temp. Control

Conclusion:

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 Practical No : 09

Aim :
To study behavior of ratio control loop.

Theory :
Ratio control systems are installed to maintain the relationship between two variables to control a third
variable. Ratio control systems actually are the most elementary form of feed forward control.

The system load is called the wild flow and it may be uncontrolled, controlled independently or controlled by
another controller that responds to variables of pressure, level, etc. Ratio control is applied almost
exclusively to flows, and there are correct and incorrect methods of implementation, both of which will be

addressed

Ratio calculation of controlled flow B to wild flow A outside closed loop

Correct Implement of Ratio control

Consider in this first example, a control system designed to maintain a certain ratio R of ingredient B and
ingredient A:

R=

The more common and correct way to accomplish this means manipulating the set point of the flow
controller controlling the flow of ingredient B (controlled flow) as a function of the desired ratio and the
measured flow of ingredient A (wild flow). The set point of flow controller B is calculated:

PROCESS CONTROL (3151705) Page 37

 B = R*A

Figure illustrates such a system. In this example, the ratio of the two ingredients is maintained by adjusting
the set point of the flow controller FIC-B, using an adjustable gain device known as a ratio station. The input
to the ratio station is the measurement of the wild flow A, which is multiplied by a constant. The output of
the ratio station is then the set point to FIC-B to maintain the desired ratio for the two ingredients.

Since the ratio calculation is done outside the control loop, it does not interfere with the loop response.

Cascade Ratio Control

This example illustrates two combinations of cascade and ratio control to illustrate both the design of more
complex ratio control systems, and the proper use of the Protuner for analyzing the control system dynamics.
Figure illustrates a control system where a level controller manipulates the wild flow and a composition
controller manipulates the flow ratio.

In this system, the two flows A and B, are mixed to control a precise composition of the combined flow C
feeding into a storage vessel, used as feed to another process. Liquid level in the tank is affected by total
flow, hence the level controller LIC sets the setpoint of the wild flow controller FIC-A, which in turn sets
the setpoint of the controlled flow controller FIC-B proportionately. Composition on the other hand is not
affected by absolute value of either flow, but only by their ratio. Therefore, to make a change in composition
(ratio), the composition controller AIC adjusts the multiplier of the ratio station.

Conclusion:

PROCESS CONTROL (3151705) Page 38

 Practical No : 10

Aim : To perform vlab “To understand working of PID function block “

(https://plc-coep.vlabs.ac.in/exp/pid-controller/index.html)
Relevant CO:

Competency and Practical Skills: Knowledge of process and controller

Objectives:
1. To understand proportional, integral and derivative control actions.
2. To study working of PID instruction using PLC simulator.
3. Observe the effect of change in Proporotional Band, Integral gain and Derivative gain values
on PID performance

.
Equipment/Instruments:
Computer with internet

Fig : v lab of Programmable logic Controller

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Theory :

Programmable logic controller were originally designed to implement discrete or logical control.
But it has limited capability of handling analog input and outputs as well as analog control. PID
control is available in PLC as a function. The theory behind PID control is discussed here. In this
experiment students are expected to study all features of the PID block available in PLC, in
simulation mode without considering any process application. As the name suggests this
strategy is preferred for on - off type applications. This is a simplest form of control. Chattering of
contacts for final control element is major problem but it can be avoided by addition of dead zone.
Precise control is not possible due to addition of dead zone.
Mostly all domestic applications as Water Geyser, Electric iron, Electric Ovens are controlled using
on-off control strategy.

PID: Continuous Control

There are 3 basic actions in PID.

 Proportional
 Integral
 Derivative
Proportional mode:- In this mode the controller output varies linearly with respect to the error.
The equation for P mode is
m = Kp * e + Po

Where:
m is the controller output.
Kp is the gain of controller
e is the error in %
Po is the proportional Bias. (Value of m at e =0)

Due to addition of proportional bias, positive as well as negative errors are handled. Generally Po is
set at 50% to handle equal positive and negative error range. Higher is the gain lower is the band to
control.

Integral mode:- Integral mode is used to remove the offset produced due to P mode. Offset can
either be positive and negative. Equation for Integral mode is

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Where,
Ti is the integral time setting and t is the time.
When this action is used alone due to integral effect the action becomes too slow. When combined
with Proportional, the action may go into saturation which is called as Reset Windup. To overcome
this, controller output is limited at lower and higher end. This is called as Anti reset windup. But
due to addition of Integral action Offset is nullified.

Derivative mode:- This action is used to increase the speed of response of slow processes. It
anticipates the rate of change of error and takes the control action. Equation for Derivative mode is

Where,
Td is the derivative time.
Set Point can be achieved quickly by using D mode. In noisy environment. this action is not used as
the output goes into saturated condition. Even for constant error D action provides no correction,
hence not preferred alone. It is always combined with P action. Composite controller, i.e. P, I and D
adds advantages of all the three modes. The Equation for the combined controller depends on how
P, I, D blocks are combined. There are two commonly used configurations, Non-interacting and
Parallel.

Non-interacting PID controller algorithm:

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The equation for non-interacting controller is:

Parallel PID controller algorithm:

The equation for parallel algorithm is:

Loop tuning time can be optimized by using proper combination of PB, Ti and Td. The process
parameter analog value (PV) is given as input to the block. Various settings such direct or reverse
action, Proportional band setting, Set point value, Proportional band, Proportional gain, Derivative
gain, Integral gain etc. are configurable parameters available in PID function.

Click on simulator link to understand PID opeartion.

1. Add a new to rung.

2. Click on PID tab to insert PID function block in the rung.
3. The screen will appear as follows.

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 4. Now right click anywhere on PID function block to configure the bolck.

5. Once you configure the tags , You can set the action, PID mode, type of PID etc. The screen
will be as follows:

6. Click on Configure tab. Now you can set the tuning parameters and submit the same. See the
following screen shot.

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 7. Now go to run mode and observe the PID output.

Repeat steps 3 to 7 for various configurations and different tuning parameters

Conclusion:

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