PIDC Lab

Experiment-
DEPARTMENT OF CHEMICAL LEVEL CONTROL TRAINER
ENGINEERING

Level Control Trainer

Name: Gaytri Sachdeva
Entry number: 2021uch0008

Exp 2 Lab 1

DOE: 04/09/2024
DOS: 06/11/2024
Aim: - To study the level control experiment

Description

Level control trainer is designed for understanding the basic principles of level control. The process setup
consists of supply water tank fitted with pump for water circulation and rotameter for indication of flow
rate. The level transmitter used for level sensing is fitted on transparent process tank. The process
parameter (level) is controlled by microprocessor based digital indicating controller which controls the
pump characteristics. A digital indicating controller adjusts the water flow in to the tank. One drain valve
for manual adjustment of drain fitted at the back of setup. These units along with necessary piping are
fitted on support housing designed for tabletop mounting.

SPECIFICATIONS:-
Level transmitter :- Type Electronic, two wire, Range 0–300 mm, Output 4–20mA
Rotameter :- 0.1 - 1 LPM
Pump :- Centrifugal pump
Process tank :- Transparent, Acrylic, with 0 - 340 mm graduated scale

UTILITIES REQUIRED:-

Electric supply
Provide 230 VAC single phase electric supply with proper earthing. (Neutral – Earth voltage less than 5
VAC)
5A, three pin socket with switch (1 No.)
constant (ie a fast response) while the other lag has a gain of larger magnitude and opposite sign with a
much larger time constant (i.e. a slow response in the opposite direction). Figure below illustrates this
concept.

References:

http://nptel.ac.in/courses/103104049/2
 EXPERIMENT - Study of proportional integral derivative controller for level control trainer
1. Select Experiment, click PID level then experiment screen opens.
2. Adjust the tank drain valve such that the tank level shall remain between 90 and 100%
3. Put the integral (I) and derivate(D) values to 0 (zero)
4. Keep the value of P as 100 % (maximum) and observe behavior of controller
5. Now keep the value of P as 0.1 (as low as minimum) and observe the behavior of controller
6. Based on the observation of behavior of the controller output select the optimum value of P such
that it should have minimum offset and
7. To minimize the offset introduce the I value ( trial and error) which introduces few oscillation from
the mean value (set point)
8. To reduce the oscillations, introduce the D value (trial and error) 9.
9. When steady state is achieved then give step input to the set point.
10. Accordingly change the proportional band, integral time, derivative time and observe the response
of the process for step change for each change in setting.

Observations
1. Compare the steady state response of the PID controller with P, PI and PD controller obtained in
the previous experiments.
2. Apply a setpoint change (say 50% to 60%).
3. Adjust the P, I and D values using trial and error approach to obtain a better response.
4. Achieve a step response with at most one overshoot and one undershoot. Plot the response.
5. Compare the response with previous experiment responses.
6. After the experiment is over click on the save report button.
7. Now go to main page by click on Go to homepage
GRAPH:

Set Point = 40.000000

P = 0.100000
I = 0.000000
D = 0.000000

Set Point = 40.000000

P = 90.000000
I = 0.000000
D = 0.000000
Set Point = 40.000000
P = 15.000000
I = 1.000000
D = 0.000000
Set Point = 40.000000
P = 15.000000
I = 1.000000
D = 1.000000
Results:

Graph 1 (Set Point = 40, P = 0.1, I = 0, D = 0):

The system reacts sluggishly, showing a slow approach toward the set point with a noticeable delay. There’s no
overshoot or undershoot, but due to the low proportional gain, it takes a prolonged period to reach the desired level.
Graph 2 (Set Point = 40, P = 90, I = 0, D = 0):

Here, the high proportional gain drives a much faster response. However, this quick response comes with a significant
overshoot, initially making the system unstable until it begins to settle. No integral or derivative adjustments are made
here.
Graph 3 (Set Point = 40, P = 15, I = 0, D = 0):

With a moderate proportional gain, the system reaches the set point more efficiently, showing a relatively rapid
response and minimal overshoot, but there remains a slight offset.
Graph 4 (Set Point = 40, P = 15, I = 1, D = 0):

Adding an integral term helps reduce the offset seen in Graph 3. The system oscillates a bit around the set point before
it stabilizes, showing improved performance over using only proportional control.
Graph 5 (Set Point = 40, P = 15, I = 1, D = 1):

Introducing a derivative term decreases the oscillations present in Graph 4, leading to faster stabilization and a more
direct transition to the set point, with little to no overshoot.

Using only Proportional (P) control cannot entirely eliminate offset and leads to varying response speeds depending
on the gain level. Proportional-Integral (PI) control reduces the steady-state error but can introduce oscillations if
improperly tuned. The Proportional-Integral-Derivative (PID) configuration combines the advantages of both P and I
actions, with the derivative term effectively minimizing oscillations and enhancing stability. As shown in the final
graph, a well-tuned PID controller results in minimal overshoot, fewer oscillations, and a quicker settling time.

Discussion:

This experiment illustrates the need for fine-tuning P, I, and D parameters to achieve optimal system performance in
level control. High proportional gain (Graph 2) yields a rapid response but compromises stability, causing overshoot
and oscillations. Adding an integral component (Graph 4) reduces the steady-state error; however, an excessive
integral effect can lead to ongoing oscillations. The derivative term (Graph 5) is critical for damping these
oscillations, allowing the system to settle smoothly and swiftly.

Through testing, it becomes clear that finding the right balance among PID settings is essential for achieving both a
fast and stable response, as shown by the performance in the final graph. This experiment highlights the vital role of
PID tuning in process control, where precise adjustments lead to effective and stable system behavior in practical
applications.