CHE381 – Process Control and Dynamics

Lab Report

Experiment no. 2
Name of Experiment PID Controller

Date of Experiment 28-8-24

Date of Submission 18-10-24

Group no. 14

TA Name Vimal Singh

Student 1 Mosham 220671

Student 2 Moni Dutt 220668

Student 3 Supriya 221107

Student 4 Nikhil Gupta 220708

Student 5 Prabhat Mishra 220775

Objective:
To study the characteristics of PID controller.

Introduction:
Most of the process industries are equipped with advanced control systems to
improve the productivity of the plant. For design and operation of process control in
the age of rational technology change, engineers & technicians must have training of
control systems.

Theory:
The different types of combinations of controller actions used in industrial process
are:
• Proportional Controller
• Proportional – Integral Controller
• Proportional – Derivative Controller
• Proportional – Integral - Derivative Controller

Proportional controller:
𝑃(𝑡) = 𝐾𝑐𝜖(𝑡) + 𝑃𝑠
where 𝑃 is the output signal from the controller, 𝐾𝑐 is the proportional controller gain, 𝜖 is the
error, and 𝑃𝑠 is the steady state value.

Proportional integral (PI) controller:

𝑃(𝑡) = 𝐾𝑐𝜖(𝑡) + 𝐾𝑐𝜏𝐼∫ 𝜖(𝑡′)𝑑𝑡′𝑡0+ 𝑃𝑠

Where 𝜏𝐼 is the integral time. Integral action combined with proportional control gives
us a controller, which will always act to maintain the controlled variable at its set point i.e. eliminates
offset.

Proportional derivative (PD) controller:

𝑃(𝑡) = 𝐾𝑐𝜖(𝑡) + 𝐾𝑐𝜏𝐷𝑑𝜖𝑑𝑡 + 𝑃𝑠

where 𝜏𝐷 is derivative time. Derivative action combined with proportional gives a controller which is
good on process containing appreciable lag. The derivative (anticipatory or rate) control gives a faster
response with less oscillations.
 Proportional integral derivative (PID) controller:

𝑃(𝑡) = 𝐾𝑐𝜖(𝑡) + 𝐾𝑐𝜏𝐼∫ 𝜖(𝑡′)𝑑𝑡′𝑡0+ 𝐾𝑐𝜏𝐷𝑑𝜖𝑑𝑡+𝑃𝑠

When all the three control effects are combined together, we obtain the benefits of each control
action.

Equations:

DESCRIPTION:
The experiment offers hands-on experience with key control strategies commonly
used in industrial processes, focusing on Proportional (P), Proportional-Integral (PI),
and Proportional-Integral-Derivative (PID) controllers. These controllers play a
crucial role in regulating process variables such as temperature, flow, and pressure,
ensuring they remain at desired set points in various chemical engineering
applications. By adjusting controller settings and observing their impact on system
stability and response time, students gain valuable insights into the functioning of
these controllers and how they can be optimized for different processes.
The experimental setup features a stirred tank equipped with a heater, where water
is heated to a set temperature. P, PI, and PID controllers regulate the temperature by
controlling the power supplied to the heater, based on the difference between the set
point and the actual water temperature. Students manually adjust the P, I, and D
parameters to explore different control modes. Data is recorded throughout the
experiment, allowing for further analysis of the system's dynamic response under
various control configurations.

Understanding the theory behind P, PI, and PID control is essential for interpreting
the results. A Proportional Controller adjusts the output based on the size of the
error, while the Integral action addresses steady-state error (offset) by accounting for
cumulative error over time. The Derivative action anticipates future errors by
analyzing the rate of change, providing a damping effect to minimize oscillations.
Together in a PID controller, these three actions create a balanced approach that
enhances system stability, speeds up response times, and minimizes oscillations,
making PID control highly effective in industrial settings.

Observations:
P Variable:
PI Variable:
Calculations:
Plots:

Rise Time 660 sec

Time of Peak 1080 sec

Over Shoot 0.309

Percent Overshoot 30.9%

Decay Ratio 0.076

Time period 1860 sec

Angular Frequency 0.0033 sec^(-1)

Rise time 630 sec

Time of peak 1080 sec

Overshoot 0.269

Percent of overshoot 26.9%

SUMMARY:
In our experiment, we observed the expected behaviour of the P, PI, and PID
controllers as follows:

● The proportional controller (P) reduces the error between the desired setpoint
and the actual output, but a steady-state offset may remain. With a proportional
constant (Kc) set at 100/4, we observed that the temperature did not reach the set
point of 36°C even after 30 minutes, as shown in the graph.

● Adding integral action (PI controller) eliminates the steady-state offset but can
introduce oscillations and overshoot. We implemented an integral constant (τI =
240 sec) to the P controller, resulting in a rapid change in the process variable,
with the temperature reaching the set point within 11 minutes for the first time (i.e.,
rise time).

● Incorporating derivative action (PID controller) helps reduce both the frequency
of oscillations and overshoot. After adding a derivative constant to the PI
controller, as illustrated in the comparison graph, we observed a significant
decrease in the overshoot seen with the PI controller alone.
Precaution & Maintenance Instructions:
● Use the stabilize A.C. Single Phase supply only.
● Never switch on the mains power supply before ensuring that all the ON/OFF
switches given on the panel are at OFF position.
● Never run the apparatus if the power supply is less than 180 volts and above
than 240 volts.
● Always keep the apparatus free from dust.