Process Control

Aim: Controlling the temperature, level, pressure, and flow using manual and automatic
controller (PID).

Key facts

• For each model an individual experiment is available.

• Every experiment covers the impact of controller design on the process and
disturbance response, assessing the stability of the control loop and optimising the
controller.

Introduction

Process control refers to principles involved in controlling industrial processes to achieve a

desired outcome. Process control involves monitoring and manipulating a various variable
such as temperature, flow rate, level within a system. Control systems are designed to regulate
process variables within desired ranges. They consist of sensors to measure variables,
actuators to manipulate process conditions, and controllers to make decisions and adjust the
actuators based on measured values. The controller receives feedback from sensors,
compares it to a desired setpoint, and takes corrective actions to maintain the process variable
at the setpoint.

Types of controllers that could be used are P, PI and PID controllers:

• P (Proportional): This is the simplest controller and bases its response on the
difference between the measured variable and set point.
• PI (Proportional/Integral): An integral time constant is introduced to the P controller
which gives a stronger signal built up over the time from the disturbance to now.
• PID (Proportional/Integral/ Derivative): This introduces a derivative time constant
which covers the immediate future response and incorporates this in the signal for the
controller.

Experimental Set-up

The system handles typical control loops, including liquid level, flow, pressure, and
temperature. The system diagram shows the schematic view of the loop for the selected
control system. The selection field has the options of manual mode, continuous control, step
control, Three- point control, and programmer. In the manual mode, the control dial is used to
select the manual regulations ratio from 0 to 100% or the valued can be entered manually in
the field below the control dial using the keyboard keys. In the PID selection field the input
parameters proportional gain (Kp), integral action time (Tn), and derivative time (Tv) are used
to enter the control parameters. There is a display to illustrate the current values including
reference variable (W in %), control variable (X in %), regulation ratio in (Y in %), and
disturbance variable (Z in %).

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 Outline of Experimental Procedure

Liquid Level Control, RT 010

Figure 1. Layout of level control system; 1. Supply tank, 2. Pump, 3. Liquid level tank, 4. Pressure hose for
level measurement, 5. Overflow, 6. Bleeder valve, 7. Pump switch, 8. Master switch, 9. Pump signal lamp, 10.
Bleeder valve signal pump, 11. Button for complete opening of bleed valve (Z=100%).

Manual control of level:

Determination of loop type:
The loop behaviour is determined by a step in the reference variable and observations of the
resulting transient response.
1. Perform step in manual regulation ratio Y= 0 %, Z= 0 %, to Y= 50 %, Z= 0 % and wait
for the overflow of liquid level tank.
2. Then perform step in manual regulation ratio Y= 50 %, Z= 0 %, to Y= 0 %, Z= 50 %
and allow the liquid level tank to drain. Operating points are Y=0…… 60 %, Z=40 %.
3. Discuss the results.
Continuous Control:
P control: In the following experiment the effect of P components of different levels on the
control of the reference variable is initially observed.
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=10, Tn=0, Tv=0, Z=40% and W= 10 cm.
3. Wait for steady state and then set the proportional gain (Kp) value of 25, 40,50, and
100. Wait for steady state after entering each value.
4. Discuss the results.

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 PI control: In the following experiment, the effect of an additional I parameter on the control
of the reference variable (W) is investigated.
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=25, Tn=10, Tv=0, Z=50% and W= 8 cm.
3. Wait for steady state and then perform step in reference variable by selecting W=12
cm. Wait for steady state.
4. Perform step in reference variable by selecting W=8 cm. Wait for steady state.
5. Set the parameters as follows: Kp=25, Tn=5 s, and W= 8 cm.
6. Wait for steady state and then perform step in reference variable by selecting W=12
cm. Wait for steady state.
7. Perform step in reference variable by selecting W=8 cm. Wait for steady state.
8. Set the parameters as follows: Kp=35, Tn=5 s, and W= 8 cm.
9. Wait for steady state and then perform step in reference variable by selecting W=12
cm. Wait for steady state.
10. Perform step in reference variable by selecting W=8 cm. Wait for steady state.
11. Discuss the results.

PID control of disturbance variable: The following experiment observes compensation

for a disturbance variable.
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=28, Tn=9, Tv=0.5 s, Z=10% and W= 12 cm.
3. Wait for steady state.
5. Connect the disturbance, Z=80% and observe the progression of the control variable
and the manipulated variable.
6. Disconnect disturbance, Z=10% and observe the progression of the control variable
and the manipulated variable.
7. Discuss the results.

Flow Control, RT 020

Figure 2. Layout of flow control system; 1. Immersion pump, 2. Water tank, 3. Rotameter, 4. Control valve,
5. Turbine wheel flow sensor, 6. Signal lamp, control valve, 7. Signal lamp, pump, 8. On/off switch pump, 9.
Master switch.
Control loop:

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Manual control of flow:
Determination of loop type:
1. Select the Manual operating mode.
2. Set the disturbance Z=0%
3. Set the manual regulation ratio Y=20%, wait until a steady stated is reached.
4. Perform step in manual regulation ratio, Y=20% to Y=80%.
5. Discuss the results.

Continuous Control:
P control:
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=0.1, Tn=0, Tv=0, Z=0 and W1= 120 1/h.
3. Wait for steady state.
4. Set the proportional gain (Kp) value of 0.2, 0.4,0.6, and 0.8. Wait for steady state
after entering each value.
5. Discuss the results.

PI control:
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=0.1, Tn=0.5 s, Tv=0, Z=0 and W1= 120 1/h.
3. Wait for steady state.
4. Perform step in reference variable by selecting W2=160 1/h. Wait for steady state.
5. Set the parameters as follows: Kp=0.2, Tn=0.5 s, Tv=0, Z=0 and W1= 120 1/h.
6. Wait for steady state.
7. Perform step in reference variable by selecting W2=160 1/h. Wait for steady state.
8. Set the parameters as follows: Kp=0.2, Tn=0.6 s, Tv=0, Z=0 and W1= 120 1/h.
9. Wait for steady state.
10. Perform step in reference variable by selecting W2=160 1/h. Wait for steady state.
11. Discuss the results.

PI control of disturbance variable: the following experiment is designed to

investigate if the obtained variables to control reference variable are also suitable to
compensate for a disturbance variable.

1. Select the continuous control operating mode.

2. Set the parameters as follows: Kp=0.2, Tn=0.6 s, Tv=0, Z=0 and W= 120 1/h.
3. Wait for steady state.
4. Connect the disturbance, Z=20% and observe the progression of the control variable
and the manipulated variable.
5. Disconnect disturbance, Z=0% and observe the progression of the control variable
and the manipulated variable.
6.
7. Discuss the results.
8. Set the parameters as follows: Kp=0.4, Tn=0.3 s, Tv=0 s, Z=0% and W= 120 l/h

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 9. Wait for steady state.
10. Connect the disturbance, Z=20% and observe the progression of the control variable
and the manipulated variable.
11. Disconnect disturbance, Z=0% and observe the progression of the control variable
and the manipulated variable.
12. Discuss the results.

Pressure Control, RT 030

Figure 3. Layout of pressure control system; 1. Compressor, 2. Pressure vessel, 3. Pressure sensor, 4.
Manual control of flow:
Manometer, 5. Bleeder valve, 6. Disturbance valve, 7. Master switch, 8. Compressor switch, 9. Compressor
signal lamp, 10. Disturbance
Determination valve signal lamp.
of loop type:
1. Select the Manual operating mode.
2. Set the manual regulation ratio Y=40%, wait until the pressure reaches the steady
stated is reached.
3. Perform step in manual regulation ratio, Y=40% to Y=60%.
4. Discuss the results.

Continuous Control:
P control:
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=200, Tn=0, Tv=0, Ymin=48% and W1= 0.7 bar.
3. Wait for steady state (~0.5 bar).
4. Perform step in reference variable by selecting W2=0.8 bar. Wait for steady state.
5. Perform step in reference variable by selecting W3=0.9 bar. Wait for steady state.
6. Discuss the results.

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 PI control:
1. Select the continuous control operating mode.
2. Set the parameters as follows: Kp=750, Tn=5 s, Tv=0, and W1= 0.7 bar.
3. Wait for steady state (~0.5 bar).
4. Perform step in reference variable by selecting W2=0.9 bar Wait for steady state.
5. Wait for steady state.
6. Perform step in reference variable by selecting W3=0.8 bar. Wait for steady state.
7. Perform step in reference variable by selecting W4=0.9bar. Wait for steady state.
8. Discuss the results.

PI control of disturbance variable:

1. Select the continuous control operating mode.

9. Set the parameters as follows: Kp=750, Tn=5 s, Tv=0, and W1= 0.8 bar.
10. Wait for steady state pressure.
2. Connect the disturbance and observe the progression of the control variable and the
manipulated variable.
3. Discuss the results.

Temperature Control, RT 040

Figure 4. Layout of temperature control system; 1. Fan, 2. Heater and cooler, 3. Bar in cladding tube, 4.
Control thermometer, 5. Temperature measuring points T1, T2 and T3, 6. Heater switch, 7. Master switch, 8.
Heating signal lamp, 9. Cooling signal lamp, 10. Fan signal lamp.

Determination of loop type:

1. Select the Manual operating mode.

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 2. Set the manual regulation ratio Y=+100% (heating), wait until the temperature
reaches the steady stated is reached.
3. Discuss the results.

Continuous Control:
P control:
1. Select the continuous control operating mode.
2. In “System Diagram” select measuring point T3.
3. Set the parameters as follows: Kp=10, Tn=0 s, Tv=0, and W1= 25 0C
4. Perform step in reference variable by selecting W2=35 0C.
5. Discuss the results.
PID control of reference variable
1. Select the continuous control operating mode.
2. In “System Diagram” select measuring point T3.
3. Set the parameters as follows: Kp=1.1, Tn=750 s, Tv=75 s, and W1= 20 0C
4. Perform step in reference variable by selecting W2=35 0C.
5. Discuss the results.