Experiment 5

Level Control Trainer

Valves Specification

V1 Suction Valve of Pump

V2 Bypass Valve of Pump
V3 Outlet Valve of Process Tank
V4 Drain Valve of Sump Tank
AIM: STUDY OF FEEDBACK LEVEL USING PID SOFTWARE

THEORY:
Feedback is the most basic and commonly used control strategy. Through feedback control a
desired process condition is achieved & maintained by measuring the process condition with
respect to the desired condition, (set point), and initiating a corrective action based on their
difference. It is a relatively simple process where control is achieved by acting on change in
the controlled variable that was induced by a change in load.

Let us understand this system by taking an example of feedback Level Control as a

loop. Level is the controlled variable. Level in the tank is measured by the
sensor/transmitter & signal is transmitted to PID controller. In this case the PID
Controller is the software in the PC. Set point is given through the PID controller &
depending onthe error between the set point & the measured variable a corrective signal
is given to the control valve. Control valve, through the E/P converter. The valve opens
or closes according to the signal and theflow of water into the tank is adjusted. This in
turn adjusts the level in the level tank till the level that is controlled variable equals the
set-point.

Thus here PID is acting as feedback controller where the controlled variable is the
output from level transmitter & the manipulated variable is the flow into the tank.
FEEDBACK LEVEL CONTROL SYSTEM:

The level is sensed by the level sensor transmitter. This signal is fed to PID Controller
which compares this value with the set point. Depending on the error (Difference
between measured variable and set point) and the PID settings, the PID controller
gives out output signal. The Control Valve opens or closes depending on this signal
value the measured variable is adjusted to match the set point.

What Is PID Controller?

PID stands for Proportional, Integral, and Derivative. Controllers are designed to eliminate the
need for continuous operator attention. Cruise control in a car and a house thermostat are
common examples of how controllers are used to automatically adjust some variable to hold
the measurement (or process variable) at the set-point.

The set-point is where you would like the measurement to be. Error is defined as the difference
between set-point and measurement.

(Error) = (set-point) - (measurement)

The variable being adjusted is called the manipulated variable which usually is equal to the
output of the controller. The output of PID controllers will change in response to a change in
measurement or set-point. Manufacturers of PID controllers use different names to identify the
three modes. These equations show the relationships:

P Proportional Band = 100/gain

I Integral = 1/reset (units of time)

D Derivative = rate = pre-act (units of time)

Depending on the manufacturer, integral or reset action is set in either time/repeat or

repeat/time. One is just the reciprocal of the other. Note that manufacturers are not consistent
and often use reset in units of time/repeat or integral in units of repeats/time. Derivative and
rate are the same.

Proportional Band

With proportional band, the controller output is proportional to the error or a change in
measurement (depending on the controller).

𝑒
controller output = PB X 100

With proportional controller, offset (deviation from set-point) is present. Increasing the
controller gain will make the loop go unstable. Integral action is included in controllers to
eliminate this offset.

Integral

With integral action, the controller output is proportional to the amount of time the error is
present. Integral action eliminates offset.

1
controller output = It ∫ 𝑒 𝑑𝑡
Notice that the offset (deviation from set-point) in the time response plots is now gone. Integral
action has eliminated the offset. The response is somewhat oscillatory and can be stabilized
some by adding derivative action. Integral action gives the controller a large gain at low
frequencies that results in eliminating offset and "beating down" load disturbances. The
controller phase starts out at -90 degrees and increases to near 0 degrees at the break frequency.
This additional phase lag is what you give up by adding integral action. Derivative action adds
phase lead and is used to compensate for the lag introduced by integral action.

Derivative

With derivative action, the controller output is proportional to the rate of change of the
measurement or error. The controller output is calculated by the rate of change of the
measurement with time.

𝑑(𝑒)
controller output = 𝐷𝑡 𝑑𝑡

Some manufacturers use the term rate or pre-act instead of derivative. Derivative, rate and pre-
act are the same thing.

DERIVATIVE = RATE = PRE ACT

Derivative action can compensate for a changing measurement. Thus, derivative takes action
to inhibit more rapid changes of the measurement than proportional action. When a load or set-
point change occurs, the derivative action causes the controller gain to move the "wrong" way
when the measurement gets near the set-point. Derivative is often used to avoid overshoot.

Derivative action can stabilize loops since it adds phase lead. Generally, if you use derivative
action, more controller gain and reset can be used.

With a PID controller the amplitude ratio now has a dip near the center of the frequency
response. Integral action gives the controller high gain at low frequencies, and derivative action
causes the gain to start rising after the "dip". At higher frequencies the filter on derivative action
limits the derivative action. At very high frequencies (above 314 radians/time; the Nyquist
frequency) the controller phase and amplitude ratio increase and decrease quite a bit because
of discrete sampling. If the controller had no filter the controller amplitude ratio would steadily
increase at high frequencies up to the Nyquist frequency (1/2 the sampling frequency). The
controller phase now has a hump due to the derivative lead action and filtering. The time
response is less oscillatory than with the PI controller. Derivative action has helped stabilize
the loop.
Procedure:

1. Keep the structure on a plane even & rigid groundsurface.

2. Ensure that drain valve V4 of Process Tank is crackly open
3. Give 230 V AC power supply to the PC and Compressor separately.
4. Ensure that the valve positions are as follows,

Valve/Switch Position
V1 Open
V2 Partially open
V3 Partially Open
V4 Close

5. Switch ON the Mains ON-OFF switch on the controlpanel.

6. Switch ON the supply of Compressor. (Compressor issupplied by us only if you

have specifically ordered it)

7. Switch OFF the MODE switch to control pressure loop using PID Software.

8. Rotate the knob of regulator on the control panel fullyanticlockwise.

9. Connect the output of the compressor to the “Filter” onthe equipment using
pipe provided.

10. Start the pneumatic supply to the equipment.

11. Observe the pressure on the pressure gauge marked E/P IN. This should be
zero. Gradually rotate the knob of regulator on the control panel clockwise.
You will observe that the pressure starts increasing on the pressure gauge
marked E/P IN. Let the pressure reach 20 psi.
12. Give set point to PID Controller in such a way that set point value should be
more than the value of process variable

13. Take the PID controller in 'Auto Mode'.

• Press the A/M key of PID Controller.

• Then press UP or DOWN key to change thestatus of mode.

14. Make following settings,

▪ Setpoint: 4 kg/cm2

▪ PB: 100 %
▪ It: 40 sec -1
Range of the Set point is between 200-600 mm.
15. Switch on the Pump using the switch provided on the panel marked as
“Pump”.
16. Water level in the Level Tank will start rising.
17. Take the PID controller in 'Auto Mode'.
18. Check the Level on the PC. It should approximatelymatch with the physical
level in the Level tank.

19. See the graphical trend display where you will observe graphs of Level v/s
time, Set point v/s time, Output v/s time, etc. Observe if the level comes under
control. Noteif there are any oscillations or offset, note if the response time is
faster or slower. Depending on this data, tune the PID controller. (Refer to
“Tips for Tuningof PID Controller" given below.) To save the data enter the
DAQ interval, so that the data will get logged after that particular interval. For
example refer to the following figure:

20. Set the different PID values and Set Point for example refer to the following
figure:
21. Exit from the software. Switch Off the PC.
22. Empty the process Tank by opening the Outlet valve of Pressure Tank i.e. valve
V3
23. If you want to see the saved data, open the experiment you have saved. Refer
to the section “How to Operate the Software” for details.

TIPS FOR TUNING OF PID CONTROLLER

1. Observe the temperature fluctuations for three minutes. If it is not within +/- 5%
of the set point increase proportional band gradually till the level becomes steady
and equal to the set point.
2. Observe the output for three minutes. If the response is very sluggish decrease
proportional band.
3. When actual temperature value comes close to the Set Point value reduce the
Integral time gradually till sufficiently fast response is obtained.