Design Electronical control system

Level_5

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 What is process control
• Process as used in the terms process control and process
industry, refers to the methods of changing or refining raw
materials to create end products. The raw materials, which
either pass through or remain in a liquid, gaseous, or slurry
(a mix of solids and liquids) state during the process, are
transferred, measured, mixed, heated or cooled, filtered,
stored, or handled in some other way to produce the end
product.
• Process industries include the chemical industry, the oil and
gas industry, the food and beverage industry, the
pharmaceutical industry, the water treatment industry, and
the power industry.
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 What is process control
• Control in process industries refers to the
regulation of all aspects of the process. Precise
control of level, temperature, pressure and
flow is important in many process
applications.

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 What is process control
• Process control is the ability to monitor and
adjust a process to give a desired output. It
is used in industry to maintain quality and
improve performance. An example of a simple
process that is controlled is keeping the
temperature of a room at a certain temperature
using a heater and a thermostat.

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 PROCESS CONTROL
• Process control refers to the methods that are used to control
process variables when manufacturing a product. For example,
factors such as the proportion of one ingredient to another, the
temperature of the materials, how well the ingredients are
mixed, and the pressure under which the materials are held can
significantly impact the quality of an end product.
Manufacturers control the production process for three
reasons:
– Reduce variability
– Increase efficiency
– Ensure safety

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 Reduce Variability

• Process control can reduce variability in the end product,

which ensures a consistently high-quality product.
Manufacturers can also save money by reducing variability.
• For example, in a gasoline blending process, as many as 12
or more different components may be blended to make a
specific grade of gasoline. If the refinery does not have
precise control over the flow of the separate components, the
gasoline may get too much of the high-octane components.
As a result, customers would receive a higher grade and
more expensive gasoline than they paid for, and the refinery
would lose money. The opposite situation would be
customers receiving a lower grade at a higher price.

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 Reduce Variability

• Reducing variability can also save money by reducing the

need for Activities product padding to meet required product
specifications.
• Padding refers to the process of making a product of higher-
quality than it needs to be to meet specifications. When there
is variability in the end product (i.e., when process control is
poor), manufacturers are forced to pad the product to ensure
that specifications are met, which adds to the cost. With
accurate, dependable process control, the set-point (desired or
optimal point) can be moved closer to the actual product
specification and thus save the manufacturer money.

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 Increase Efficiency

• Some processes need to be maintained at a

specific point to maximize efficiency. For
example, a control point might be the
temperature at which a chemical reaction takes
place. Accurate control of temperature ensures
process efficiency. Manufacturers save money
by minimizing the resources required to
produce the end product.

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 Ensure Safety

• A run-away process, such as an out-of-control nuclear or

chemical reaction, may result if manufacturers do not maintain
precise control of all of the processing variables. The
consequences of a run-away process can be catastrophic.
• Precise process control may also be required to ensure safety.
For example, maintaining proper boiler pressure by controlling
the inflow of air used in combustion and the outflow of
exhaust gases is crucial in preventing boiler implosions that
can clearly threaten the safety of workers.

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 The Control Loop
• Imagine you are sitting in a cabin in front of a small fire on a
cold winter evening. You feel uncomfortably cold, so you
throw another log on the fire. This is an example of a control
loop. In the control loop, a variable (temperature) fell below
the set-point (your comfort level), and you took action to bring
the process back into the desired condition by adding fuel to
the fire. The control loop will now remain static until the
temperature again rises above or falls below your comfort
level.

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 THREE TASKS
• Control loops in the process control industry work in the same way,
requiring three tasks to occur:
– Measurement
– Comparison
– Adjustment
• In Figure 7.1, a level transmitter (LT) measures the level in the tank and
transmits a signal associated with the level reading to a controller (LIC).
The controller compares the reading to a predetermined value, in this case,
the maximum tank level established by the plant operator, and finds that
the values are equal. The controller then sends a signal to the device that
can bring the tank level back to a lower level—a valve at the bottom of the
tank. The valve opens to let some liquid out of the tank. Many different
instruments and devices may or may not be used in control loops (e.g.,
transmitters, sensors, controllers, valves, pumps), but the three tasks of
measurement, comparison, and adjustment are always present.

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A Simple Control Loop

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 Process Control Terms
• As in any field, process control has its own set of
common terms that you should be familiar with and that
you will use when talking about control technology.

PROCESS VARIABLE
• A process variable is a condition of the process fluid (a
liquid or gas) that can change the manufacturing process
in some way. In the example of you sitting by the fire,
the process variable was temperature. In the example of
the tank in Figure 7.1, the process variable is level.
Common process variables include:
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 Common process variables include:
• Pressure
• Flow
• Level
• Temperature
• Density
• Ph (acidity or alkalinity)
• Liquid interface (the relative amounts of different liquids
that are combined in a vessel)
• Mass
• Conductivity
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 Process Control Terms
• The set-point is a value for a process variable that is desired to be
maintained. For example, if a process temperature needs to kept within 5
°C of 100 °C, then the set-point is 100 °C.
• A temperature sensor can be used to help maintain the temperature at set-
point.
• The sensor is inserted into the process, and a controller compares the
• temperature reading from the sensor to the set-point. If the temperature
• reading is 110 °C, then the controller determines that the process is
• above set-point and signals the fuel valve of the burner to close slightly
• until the process cools to 100 °C. Set points can also be maximum or
• minimum values. For example, level in tank cannot exceed 20 feet.

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 Process Control Terms
• Controlled variables (Measured variables) - The
measured variable is the condition of the process fluid
that must be kept at the designed set-point., which are
also called output variables.
• Manipulated variables - these input variables are
adjusted dynamically to keep the controlled variables at
their set-points.
• Disturbance variables - these are also called "load"
variables and represent input variables that can cause the
controlled variables to deviate from their respective set
points.
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Specify the shower example with above
process control terms

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 Process Control Terms
• In the temperature control loop example, the measured variable is
temperature, example which must be held close to 100 °C.
• In this example and in most instances, the measured variable is also the
process variable.
• Sometimes the measured variable is not the same as the process variable.
For example, a manufacturer may measure flow into and out of a storage
tank to determine tank level. In this scenario, flow is the measured
variable, and the process fluid level is the process variable.
• The factor that is changed to keep the measured variable at set-point is
called the manipulated variable.

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 ERROR
• Error is the difference between the measured
variable and the set-point and can be either
positive or negative. In the temperature control
loop example, the error is the difference
between the 110 °C measured variable and the
100 °C set-point—that is, the error is +10°C.
• The objective of any control scheme is to
minimize or eliminate error.

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Level control system

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Level control system

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The material and equipment to control level
in the tank
• Level sensor, level transmitter (from sensor to
the controller)
• Solenoid valve
• Level controller (PLC, PID, Ardinou, . . .)
• Cable and related accessories

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Another configuration of tank level control

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Control the tank temperature
at constant value

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 Control the tank temperature
at constant value
• The controlled variable is temperature
• The manipulated variable is heat
• The disturbance variable is tank inlet cold
water

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Control the tank temperature
at constant value

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Control the tank temperature
at constant value

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Jacketed tank temperature control system

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 MANUAL AND AUTOMATIC CONTROL
• Before process automation, people, rather than machines,
performed many of the process control tasks. For example, a
human operator might have watched a level gauge and closed a
valve when the level reached the set-point.
• Control operations that involve human action to make an
adjustment are called manual control systems.
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• Conversely, control operations in which no human intervention
is required, such as an automatic valve actuator that responds to
a level controller, are called automatic control systems.
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 CLOSED AND OPEN CONTROL LOOPS
• A closed control loop exists where a process variable is
measured, compared to a set-point, and action is taken to
correct any deviation from set-point.
• An open control loop exists where the process variable is not
compared, and action is taken not in response to feedback on
the condition of the process variable, but is instead taken
without regard to process variable conditions. For example, a
water valve may be opened to add cooling water to a process
to prevent the process fluid from getting too hot, based on a
pre-set time interval, regardless of the actual temperature of
the process fluid.

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Control Loop Equipment and Technology

• The previous section described the basic elements of

control as measurement, comparison, and adjustment.
• In practice, there are instruments and strategies to
accomplish each of these essential tasks.
• In some cases, a single process control instrument,
such as a modern pressure transmitter, may perform
more than one of the basic control functions.
• Other technologies have been developed so that
communication can occur among the components that
measure, compare, and adjust.
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 Process control loops
• In this section, you will learn about how control
components and control algorithms are
integrated to create a process control system.
• Because in some processes many variables must
be controlled, and each variable can have an
impact on the entire system, control systems
must be designed to respond to disturbances at
any point in the system and to mitigate the effect
of those disturbances throughout the system.

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 1. FEEDBACK CONTROL

• A feedback loop measures a process variable and

sends the measurement to a controller for
comparison to set-point.
• If the process variable is not at set-point, control
action is taken to return the process variable to
set-point.
• Figure 7.18 illustrates a feedback loop in which a
transmitter measures the temperature of a fluid
and, if necessary, opens or closes a hot steam
valve to adjust the fluid’s temperature.
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 FEEDBACK CONTROL
Temperature control loop FEEDBACK CONTROL
• Temperature control system time required
to change the temperature of a process
fluid, it tend to be relatively slow.
• RTDs or thermocouples are typical
temperature sensors.
• Temperature transmitters and controllers
are used, although it is not uncommon to
see temperature sensors wired directly to
the input interface of a controller.
• The final control element for a
temperature loop is usually the fuel valve
to a burner or a valve to some kind of heat
exchanger.

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 FEEDBACK CONTROL
LEVEL CONTROL LOOPS A Level Loop

• The speed of changes in a level control loop

largely depends on the size and shape of
the process vessel (e.g., larger vessels take
longer to fill than smaller ones) and the
flow rate of the input and outflow pipes.
• Manufacturers may use one of many
different measurement technologies to
determine level, including radar, ultrasonic,
float gauge, and pressure measurement.
• The final control element in a level control
loop is usually a valve on the input and/or
outflow connections to the tank (Figure
7.23).
• Because it is often critical to avoid tank
overflow, redundant level control systems
are sometimes employed.

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 FEEDBACK CONTROL

A Pressure Loop
PRESSURE CONTROL LOOPS
• Pressure control loops vary in
speed—that is, they can
respond to changes in load or to
control action slowly or quickly.
• The speed required in a
pressure control loop may be
dictated by the volume of the
process fluid.
• High-volume systems (e.g., large
natural gas storage facilities)
tend to change more slowly
than low-volume systems
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 FEEDBACK CONTROL
FLOW CONTROL LOOPS A Flow Loop
• Generally, flow control loops are regarded as fast
loops that respond to changes quickly.
• Therefore, flow control equipment must have fast
sampling and response times.
• Because flow transmitters tend to be rather sensitive
devices, they can produce rapid fluctuations or noise
in the control signal.
• To compensate for noise, many flow transmitters have
a damping function that filters out noise.
• Sometimes, filters are added between the transmitter
and the control system.
• Because the temperature of the process fluid affects
its density, temperature measurements are often
taken with flow measurements and compensation for
temperature is accounted for in the flow calculation.
• Typically, a flow sensor, a transmitter, a controller, and
a valve or pump are used in flow control loops

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 2. FEEDFORWARD CONTROL
• Feedforward control is a control
system that anticipates load
disturbances and controls them
before they can impact the process
variable.
• For feedforward control to work, the
user must have a mathematical
understanding of how the
manipulated variables will impact the
process variable.
• Figure shows a feedforward loop in
which a flow transmitter opens or
closes a hot steam valve based on
how much cold fluid passes through
the flow sensor.

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 Feedforward Control

• An advantage of feedforward control is that error is prevented,

rather than corrected.
• However, it is difficult to account for all possible load disturbances in
a system through feedforward control.
• Factors such as outside temperature, buildup in pipes, consistency
of raw materials, humidity, and moisture content can all become
load disturbances and cannot always be effectively accounted for in
a feedforward system.
• In general, feedforward systems should be used in cases where the
controlled variable has the potential of being a major load
disturbance on the process variable ultimately being controlled.
• The added complexity and expense of feedforward control may not
be equal to the benefits of increased control in the case of a
variable that causes only a small load disturbance.

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 4. FEEDFORWARD PLUS FEEDBACK
• Because of the difficulty of
accounting for every possible load
disturbance in a feedforward
system, feedforward systems are
often combined with feedback
systems.
• Controllers with summing functions
are used in these combined
systems to total the input from
both the feedforward loop and the
feedback loop, and send a unified
signal to the final control element.
• Figure shows a feedforward-plus-
feedback loop in which both a flow
transmitter and a temperature
transmitter provide information for
controlling a hot steam valve.
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 Comparison of Feedback and Feedforward Control

1) Feedback (FB) Control

– Advantages:
• Corrective action occurs regardless of the source and type
of disturbances.
• Requires little knowledge about the process (For example, a process model is
not necessary).
• Versatile and robust (Conditions change? May have to re-tune controller).

– Disadvantages:
• FB control takes no corrective action until a deviation in the controlled variable
occurs.
• FB control is incapable of correcting a deviation from set point at the time of its
detection.
• Theoretically not capable of achieving “perfect control.”
• For frequent and severe disturbances, process may not settle out.

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 Comparison of Feedback and Feedforward Control
2) Feedforward (FF) Control

– Advantages:
• Takes corrective action before the process is upset (cf. FB control.)
• Theoretically capable of "perfect control"
• Does not affect system stability

– Disadvantages:
• Disturbance must be measured (capital, operating costs)
• Requires more knowledge of the process to be controlled (process model)
• Ideal controllers that result in "perfect control”: may be physically unrealizable. Use
practical controllers such as lead-lag units

3) Feedforward Plus Feedback Control

– FF Control
• Attempts to eliminate the effects of measurable disturbances.
– FB Control
• Corrects for unmeasurable disturbances, modeling errors, etc.
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 5. BATCH CONTROL
• Batch processes are those processes that are taken from start to finish in
batches.
• For example, mixing the ingredients for a juice drinks is often a batch process.
• Typically, a limited amount of one flavor (e.g., orange drink or apple drink) is
mixed at a time.
• For these reasons, it is not practical to have a continuous process running.
• Batch processes often involve getting the correct proportion of ingredients
into the batch.
• Level, flow, pressure, temperature, and often mass measurements are used at
various stages of batch processes.
• A disadvantage of batch control is that the process must be frequently
restarted.
• Start-up presents control problems because, typically, all measurements in
the system are below setpoint at start-up.
• Another disadvantage is that as recipes change, control instruments may
need to be recalibrated.
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 6. SELECTIVE CONTROL
• Selective control refers to a control system in which
the more important of two variables will be
maintained.
• For example, in a boiler control system, if fuel flow
outpaces air flow, then uncombusted fuel can build
up in the boiler and cause an explosion.
• Selective control is used to allow for an air-rich
mixture, but never a fuel-rich mixture. Selective
control is most often used when equipment must be
protected or safety maintained, even at the cost of
not maintaining an optimal process variable setpoint.
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 PRIMARY ELEMENTS/SENSORS
• In all cases, some kind of instrument is
measuring changes in the process and
reporting a process variable measurement.
• Some of the greatest useful in the process
control field is apparent in sensing devices.
• Because sensing devices are the first element
in the control loop to measure the process
variable, they are also called primary elements.

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 Examples of primary elements include:
• Pressure sensing diaphragms, strain gauges, capacitance cells
• Resistance temperature detectors (RTDs)
• Thermocouples
• Orifice plates- An orifice plate is a device used for measuring flow rate,
for reducing pressure or for restricting flow (in the latter two cases it is
often called a restriction plate ).
• Pitot tubes- instrument for measuring the velocity (speed) of a flowing
fluid. Pitot tubes are used in anemometers to measure airspeed in wind
tunnels and aboard aircraft in flight; they are also used to measure the
flow of liquids (see flow meter).
• Venturi tubes- A venturi works by measuring the difference in pressure at
two different locations. The pressure difference is created by reducing the
diameter of the pipe causing the fluid to flow faster. The fast moving fluid
has a lower pressure than the slower fluid in the larger section of the
venturi.
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 Examples of primary elements include
• Magnetic flow tubes- Magnetic flow meters measure the velocity of conductive liquids
in pipes, such as water, acids, caustic, and slurries. Magnetic flow meters can measure
properly when the electrical conductivity of the liquid.
• Coriolis flow tubes- Coriolis mass flow meters are used predominately in scientific
applications where they measure both corrosive and clean gases and liquids. They are also
used in: Pulp and paper processing. Petroleum and oil.
• Radar emitters and receivers- A radar system has a transmitter that emits radio
waves known as radar signals in predetermined directions. When these signals contact an
object they are usually reflected or scattered in many directions, although some of them
will be absorbed and penetrate into the target.
• Ultrasonic emitters and receivers- are designed to detect and transmit high frequency
sound waves, respectively. They are characterized by frequency, rated voltage, and beam
angle.
• Annubar flow elements- the Annubar primary flow element is a device that is used to
measure the flow of a liquid, gas or vapor that flows through a pipeline. It allows flow
measurement by creating a differential pressure (DP) that is proportional to the square of
the fluid velocity in the pipeline, according to Bernoulli's theorem.

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 Primary elements
• Primary elements are devices that cause some change in their
property with changes in process fluid conditions that can then be
measured.
• For example, when a conductive fluid passes through the magnetic
field in a magnetic flow tube, the fluid generates a voltage that is
directly proportional to the velocity of the process fluid.
• The primary element (magnetic flow tube) outputs a voltage that can
be measured and used to calculate the fluid’s flow rate.
• With an RTD, as the temperature of a process fluid surrounding the
RTD rises or falls, the electrical resistance of the RTD increases or
decreases a proportional amount.
• The resistance is measured, and from this measurement, temperature
is determined.
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TRANSDUCERS AND CONVERTERS
• A transducer is a device that translates a mechanical signal into
an electrical signal.
• For example, inside a capacitance pressure device, a transducer
converts changes in pressure into a proportional change in
capacitance.
• A converter is a device that converts one type of signal into
another type of signal.
• For example, a converter may convert current into voltage or an
analog signal into a digital signal.
• In process control, a converter used to convert a 4–20 mA current
signal into a 3–15 psig pneumatic signal (commonly used by
valve actuators) is called a current-to-pressure converter.
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 TRANSMITTERS
• A transmitter is a device that converts a reading
from a sensor or transducer into a standard signal
and transmits that signal to a monitor or controller.
Transmitter types include:
– Pressure transmitters
– Flow transmitters
– Temperature transmitters
– Level transmitters
– Analytic (O2 [oxygen], CO [carbon monoxide], and pH)
transmitters
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 TRANSMITTERS
• A pressure transducer, often called a pressure transmitter, is a transducer that
converts pressure into an analog electrical signal. Pressure applied to the
pressure transducer produces a deflection of the diaphragm which introduces
strain to the gages.
• Flow transmitters provide electrical outputs that are proportional to flow
inputs. They use flow meters to measure the flow of liquids and gases. Flow
transmitters use three basic types of meters: mass, volumetric, and velocity.
• Temperature transmitter is an electrical instrument, which interfaces the
temperature sensor to isolate, amplify, filter noise and convert the signal from the
sensor to send it to the control device. It is a tool to help measure and alert
temperature changes.
• Level transmitters provide continuous level measurement over the range of
the system rather than at a single point and produce an output signal that
directly correlates to the level within a vessel. The output signal generated can
be used to display the depth or to actuate control functions.

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 SIGNALS
• There are three kinds of signals that exist for
the process industry to transmit the process
variable measurement from the instrument to
a centralized control system.
– Pneumatic signal
– Analog signal
– Digital signal

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 Pneumatic Signals
• Pneumatic signals are signals produced by changing the
air pressure in a signal pipe in proportion to the measured
change in a process variable.
• The common industry standard pneumatic signal range is
3–15 psig. The 3 corresponds to the lower range value
(LRV) and the 15 corresponds to the upper range value
(URV).
• Pneumatic signaling is still common.
• However, since the advent of electronic instruments in the
1960s, the lower costs involved in running electrical signal
wire through a plant as opposed to running pressurized air
tubes has made pneumatic signal technology less attractive.
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 Analog Signals
• The most common standard electrical signal is the 4–
20mA current signal.
• With this signal, a transmitter sends a small current
through a set of wires.
• The current signal is a kind of gauge in which 4mA
represents the lowest possible measurement, or zero,
and 20mA represents the highest possible
measurement.
• Other common standard electrical signals include
the 1–5 V (volts) signal and the pulse output.
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 Analog Signals
• For example, imagine a process that must be maintained at 100 °C.
• An RTD temperature sensor and transmitter are installed in the
process vessel, and the transmitter is set to produce a 4 mA signal
when the process temperature is at 95 °C and a 20 mA signal when
the process temperature is at 105 °C.
• The transmitter will transmit a 12 mA signal when the temperature
is at the 100 °C Set-point.
• As the sensor’s resistance property changes in response to changes
in temperature, the transmitter outputs a 4–20 mA signal that is
proportionate to the temperature changes.
• This signal can be converted to a temperature reading or an input to
a control device, such as a burner fuel valve.

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 Digital signals
• Digital signals are the most recent addition to
process control signal technology.
• Digital signals are discrete levels or values that
are combined in specific ways to represent
process variables and also carry other
information, such as diagnostic information.
• The methodology used to combine the digital
signals is referred to as protocol.

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 INDICATORS
• indicator is a human-readable device that
displays information about the process.
• Indicators may be as simple as a pressure or
temperature gauge or more complex, such as a
digital read-out device.
• Some indicators simply display the measured
variable, while others have control buttons that
enable operators to change settings in the field.

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 RECORDERS
• A recorder is a device that records the output of a measurement devices.
• Many process manufacturers are required by law to provide a process
history to regulatory agencies, and manufacturers use recorders to help
meet these regulatory requirements.
• In addition, manufacturers often use recorders to gather data for trend
analyses.
• By recording the readings of critical measurement points and comparing
those readings over time with the results of the process, the process can
be improved.
• Different recorders display the data they collect differently.
• Some recorders list a set of readings and the times the readings were
taken;
• others create a chart or graph of the readings.
• Recorders that create charts or graphs are called chart recorders.
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 CORRECTING ELEMENTS/FINAL CONTROL ELEMENTS
• The correcting or final control element is the part of the control system
that acts to physically change the manipulated variable.
• In most cases, the final control element is a valve used to restrict or cut
off fluid flow, but pump motors, louvers (typically used to regulate air
flow), solenoids, and other devices can also be final control elements.
• Final control elements are typically used to increase or decrease fluid
flow.
• For example, a final control element may regulate the flow of fuel to a
burner to control temperature, the flow of a catalyst into a reactor to
control a chemical reaction, or the flow of air into a boiler to control
boiler combustion.
• In any control loop, the speed with which a final control element reacts
to correct a variable that is out of setpoint is very important. Many of
the technological improvements in final control elements are related to
improving their response time.

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 ACTUATORS

• An actuator is the part of a final control device that

causes a physical change in the final control device
when signaled to do so.
• The most common example of an actuator is a valve
actuator, which opens or closes a valve in response to
control signals from a controller.
• Actuators are often powered pneumatically,
hydraulically, or electrically.
• Diaphragms, bellows, springs, gears, hydraulic pilot
valves, pistons, or electric motors are often parts of an
actuator system.
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 CONTROLLERS
• A controller is a device that receives data from
a measurement instrument, compares that data
to a programmed set-point, and, if necessary,
signals a control element to take corrective
action.
• Local controllers are usually one of the three
types: pneumatic, electronic or programmable.
• Controllers also commonly reside in a digital
control system.
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 CONTROLLERS
• Controllers may perform complex mathematical
functions to compare a set of data to set-point or
they may perform simple addition or subtraction
functions to make comparisons.
• Controllers always have an ability to receive
input, to perform a mathematical function with
the input, and to produce an output signal.
• ON/OFF controller (PLC), PID, Fuzzy
controller. . .are type of controller.

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 CONTROLLER DESIGN

Programmable Logic Controller for

Process Control System

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 Design PLC controller for automatic liquid
level control system
Instruction
• The plant wants to turn ON when the level of
tank is at high level point and turn OFF when
the tank level is at low level point of tank.

Prepared by Shimels Chekol 69

 Logic Description :
• When the water level reaches low level then pump will be stopped.
• if the level of the water reaches high point, the pump will started so
that the water can be drained and thus lowering the level.
• Indication Panel : This panel contains LED’s to show the status of the
water level control. It has Pump Running, Low Level & High Level
Signals
• If pump is running then the Pump Running status lamp will be ON.
• then, if Low Level Switch activated then Low Level Status lamp will
be ON.
• if High Level Switch activated then High Level Status lamp will be
ON.

Prepared by Shimels Chekol 70

 Controller; Programmable Logic Controller (PLC)
Hardware

1. Input device of controller 2. Output device of controller

Stop push button =I1  Pump motor =Q1
Start push button=I2  Pump running indicator
lamp=Q2
Low level sensor=I3
 Low level indicator lamp=Q3
High level sensor=I4  High level indicator lamp=Q4

Prepared by Shimels Chekol 71

Design PLC controller for automatic water
level control system

Prepared by Shimels Chekol 72

Design ladder program to execute the
above instruction

Prepared by Shimels Chekol 73

Level Sensors

Prepared by Shimels Chekol 74

 Liquid temperature control using PLC
• Problem Description
• Controlling heating process for the liquid in
the tank. Implement PLC program for this
application using ladder diagram language.

Prepared by Shimels Chekol 75

Problem Diagram

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 Problem Solution
• In this system we will consider S7-300 PLC and TIA portal
software for programming.
• In this system two sensors are used for level measurement in
the tank, heater is used for material heating purpose in the
tank.
• We used temperature sensor (it can be RTD or thermocouple)
also for temperature measurement in the tank.
• Two valves are used for material inlet and outlet.
• Inlet valve is used for feeding the tank and outlet valve for
discharging the tank.
• If system detects low level, system will start to feed the tank.
Feeding cycle will be OFF when tank will detect high level. After
high level system will start heating process till set temperature.

Prepared by Shimels Chekol 77

 List of Inputs/Outputs of PLC
Input devices Output devices
– START PB :- I0.0 – Inlet valve :- Q0.0
– STOP PB :- I0.1 – Heater :- Q0.1
– Low level switch :- I0.4 – Outlet valve :- Q0.2
– High level switch :- I0.3 • Memory List
– Master coil :- M0.0
– Actual temperature :- MW12
– Set temperature :- MW14

Prepared by Shimels Chekol 78

PLC Program for heating liquid in the tank
by heater

Prepared by Shimels Chekol 79

Prepared by Shimels Chekol 80
Prepared by Shimels Chekol 81
Prepared by Shimels Chekol 82
 Logic Description
• Network 1 :-
– Master coil (M0.0) will start when START PB (I0.0) will be
pressed and cycle can be stopped by pressing STOP PB (I0.1).
• Network 2 :-
– When low level switch (I0.4) is detected, inlet valve (Q0.0) will
be ON.
• Network 3 :-
– When high level switch (I0.3) is detected, heater (Q0.1) will be
ON.
• Network 4 :-
– If actual temperature (MW12) is greater than set temperature
(MW14), outlet valve (Q0.2) of the tank will be ON.
Prepared by Shimels Chekol 83
 Arduino Controller design
• Level control system
• Process temperature control
• ,,,

Prepared by Shimels Chekol 84

PID controller design

Prepared by Shimels Chekol 85