Lab 2 Process Control

Computer-based Control Systems Flow Control

1. Aims
To operate PC-based instrumentation and control systems
To get familiar with open-loop control, ON-OFF, and PID control systems
To explain P, PI, PD, and PID control actions
To transfer MAN mode to AUTO smoothly.
2. Apparatus
Process/Plant: Flow Control Bench consists I/P Converter, Pneumatic Control Valve,
Orifice and D/P Cell Transmitters, Pipes and Pump, and Rotameter
Computer, LabVIEW 8.6, NI DAQ 6036E Card, Current-to-Voltage converter (4mA-20mA
to 1 to 5V) and Voltage-to-Current converter (-10V/+10V to 4mA-20mA).
Multimeter, mAmeter
3 Connection Diagram
The connection diagram for control systems is shown in Fig. 1.
Pneumatic
supply

Water
supply
MI
Valve

I/P
kPa
Actuator

CS 4-20mA

PV

Process
(Plant)

MV 4-20mA

Sensor/s

I/V

V/I

PC, DAQ PCI 6036E and LabVIEW

PC-based controller
Figure 1 Connection diagram
Schematic diagram for flow control system is shown in Fig. 2 (a & b).

4. Further Information
Refer to Chapters 7, 8, 9 (Pressure, Flow and Level), Chapter 12 Actuators and Chapter 13 Basic
Control Theory (Direct Acting On-Off Control, PID Control)

4-20mA

COMPUTER
LABView
DAQ 6036E
I/V & V/I

mA

Pneumatic
supply

Rotameter

Globe valve

kPa

mA
I/P Converter

Output
current

Q (lpm)

Actuator
Control valve

24V
DC

Valve
(Open) Gauge 1

D/P Cell

Orifice
plate

Gauge 2

Valve
(Closed)

Valve
(Closed)

Pump

Water tank

Figure 2a Schematic diagram of Flow Control System (Flow Control Bench)

DC 24V

AI channel 10
250R

D/P
Cell

Current 4-20mA
(0-30kPa)

1-5V

COMPUTER
DAQ 6036E and
LabVIEW

Control signal
10V to +10V

V-to-I
Orifice plate
Control signal
4-20mA

Flow Bench
kPa

I/P
converter
Current 4-20mA

Pneumatic
supply

20-100 kPa (designed)

Flow

Figure 2b Connection diagram of the Flow Control System

2

Methods
1. Connection and turning on the power
Connect the computer, I/V converters, and V/I converter to the process (sensor/s and
actuators) by referring to the above scheme/connection diagrams
Supply control air (or confirm if the pneumatic supply is done)
Turn on the power
Log on to the computer
2. Identification of Components and Variables
Identify all components and their variable of the process control system (that you have
selected) and complete Table 1.
Table 1 Components and variables
Process system:
No

Component / Model Code

(where applicable)
Example: Controller (PC)

Input (variable, unit)

Output (variable, unit)

Process variable: flow [mm, Control signal [V, mA]

mA, V]
Set point [mm, mA, V]

1
2
3
4
5
6
7
3. Hands-on Exercises
3.1 Hands-On Exercise 1: Getting Started with Open-Loop Flow Control System
Purpose: The purpose of this hands-on exercise is to get familiar with a control system and its
components, variables and signals.
In the Open Loop Control System there is no comparison of feedback signal to the Set Point. In
almost controllers MAN mode is an Open Loop mode.
Learning Objectives:
Operate the open loop control system
Understand components of the control system and their signals
3

Explain the principles and functions of the components including process, measurement
devices (flow transmitters, pressure gauges), actuators, valves and valve positioners.

Procedure
Run the LabVIEW On-Off controller program
Flow:
C:\Documents and Settings\All Users\LabVIEW Data\JEE326_2009\Lab 2\OnOffFlowControlSys\
OnOffFlowControlSys.exe
The On-Off controller program looks like...

(from D/P cell)

SP, PV and CS in mA

Manual Controller

P and PV in litre/min
Diagram

Figure 3 On-Off controller program (for flow control)

to run the On-Off Controller Program.

The program is running. If not, click
Make sure that the Auto/Man mode switch is in Man position)
Make sure that the Write to File is at Write position and change the path for data files if
necessary
Enter a minimum value of voltage (Manual Controller), i.e. -10V, write down in Table 2
and Table 3.
Change the value of voltage with a step of 2.5 volts and complete Table 2 and Table 3.

Table 2 Data collection for components and variables of open loop system
No

Component and/or
variable [unit]

Examples: Controller
(PC), control signal:
V:
mA
Volt-to-Curr Converter,
control signal [mA]

I/P converter
Output (pressure) kPa

Control valve
Upstream kPa
Downstream kPa
Control valve
Output (flowrate) [l/m]

D/P Cell
Measured flowrate [mA]

Symbol

uc
uc

-10
4

uc2

4.12

Pc

P1
P2

5
0

-7.5

-5.0

-2.5

2.5

7.5

10

220

20.12

In PC:
Meas flowrate [V]
Meas flowrate [mA]
Meas flowrate [l/m]

4.999
19.99
221

Table 3 Ranges of variables

Input (range, unit)
No

Component / Instrument
Open-loop (MAN)
Controller

Min

Max

Min

Max

-10V

10V

4 mA

20mA

Flowrate
0

Output (range, unit)

Reading of flowrate on scale

Example: Rotameter
20 l/min

220 l/min

20 l/min

220 l/min

Label the components, variables and their ranges in the following block diagram.
Air supply

S2

S1

S3

V/I
converter

S7
Indicators (Virtual Instruments)

Disturbances

C1

S5

S4
C2

C3

S6

PC + Controller
C4
Figure 4 Block diagram of the open-loop control system (for flow control)

QUESTION 1
What type is the pneumatic control valve?

QUESTION 2
When the Controller Output changes from 0% (4mA) to 50% (12mA) (of span)
How much (%) does the Valve Opening change?.............................................
How much (%) does the Process Variable change?..........................................

Return the Controller Output to the minimum value.

Stop the Open-Loop Control System by clicking

button.

Important: Dont forget to copy data files to your USB flash memory stick!

Notes for Hands-on Exercise 1 (Open Loop Control System)

3.2 Hands-on Exercise 2: Operation of On-Off Flow Control System

Purpose
The purpose of this hands-on exercise is to get familiar with an On-Off Flow Control System.
Learning Objectives
To operate the On-Off Flow Control System
To perform settings of ON and OFF values to optimize the system response.
Introduction
The On-Off flow control system is based on the following principle:
Error (E) = PV SP
SP

Error

If E > 0 then OFF (large) CLOSE

If E < 0 then ON (small) OPEN

Controller Output

PV
Figure 5 On-Off control algorithm for the flow control system
The CLOSE and OPEN values of the valve can be set at different values:
Fully close: +10 V (in PC) or 20 mA
Fully open: -10 V (in PC) or 4 mA

SP, PV and CS in mA

Manual Controller

P and PV in litre/min
Diagram

Figure 6 On-Off flow control program (Front Panel)

8

Procedure
(It is supposed that this exercise is started after Exercise 3.1, the On-Off Flow Controller Program
is still open).
Run the On-Off Flow Controller Program
In MAN mode, confirm SP at 220 litre/min (fully open) and the valve is fully opened.
Confirm the OPEN value at -10V, and the CLOSE value (fully open) at +10V (fully close).
Switch to AUTO mode. The controller is working in the On-Off control mode.
Observe the change in PV.
Change the SP to 50% of the span, i.e. 120 lit/min (or 12mA), observe the change in PV.
Change the OPEN value to -8V and the CLOSE value to +8V, and observe the change in PV.
QUESTION 1
How is the system response changing?

Select an OPEN value and a CLOSE value so that the system response hunts the set-point
with the least oscillation. You may execute several trials to select appropriate valves.

QUESTION 2
What are the best values?

To stop the On-Off Controller Program click

Close the On-Off Controller Program.

button.

Notes: Dont forget to copy data files to your USB flash memory stick!
Notes for Hands-on Exercise 3.2

3.3 Hands-On Exercise 3: Operation of PID Control System

Introduction
The PID control system is based on the following principle:
Error (E) = SP PV or PV SP

SP

Error

u PID = K P e + K I edt + K D

de
dt

Controller Output

PV
The PID controller program has the MAN mode similar to that of the On-Off controller program.
In AUTO (closed-loop) mode, the PID controller can work in the following control actions:
P only control by setting Ki = 0 and Kd = 0
I only control by setting Kp = 0 and Kd = 0 (rarely used for this flow system because I
control action makes the system unstable)
PI control by setting Kd = 0
PD control by setting Ki = 0

Control gains (Kp, Ki and Kd) are adjusted by

on the following formula of the PID Control Algorithm:
de
VPID = K P e + K I edt + K D
dt

Proportional Band is PB =

Integral Time: TI =

. The control signal is computed based

100%
KP

KP
KI

Derivative Time: TD =

KD
KP

10

Figure 7 PID flow control program (Front Panel)

Purpose
The purpose of this hands-on exercise is to get familiar with the PID Flow Control System.
Learning Objectives
Operate the PID flow control system with different control actions:
o P control
o PI control
o PD control
o PID control
Explain the effects of P, I, D, PI, PD and PID on the system response.
Switch between the AUTO and MAN modes smoothly.
Procedures
(It is suggested that you have closed the On-Off Controller Program.)
Run the PID Controller Program
Confirm the PID Controller Program in MAN mode.
Observe the SP, PV, Controller Output and confirm the following values (if not adjust
accordingly):
Setpoint: 220 lit/min
Kp = 2, Ki = 0, Kd = 0 (Proportional Only Control)
Controller Output: -10V (4 mA)
PV: 20 mA (220 lit/min)
11

Switch to the AUTO mode. The controller is working with Proportional Only Control.

Proportional Only Control and Effects of Proportional Gains on System Response and Offset

Wait until the system response is stable, fill in Table 1

Execute the Trials 1-10 and fill in Table 1.

Table 1 Proportional Band Effect on OFFSET

PB

SETPOINT

TRIAL

KP

2.0

220

2.0

200

2.0

180

3.5

180

4.0

180

4.0

160

5.0

160

6.0

160

7.0

160

2.0

180

10

2.0

220

MEAS.
(PV)

+ OR ERROR

OUTPUT
(Control Signal)

QUESTION 1
How does the system response change when the Proportional Gain changes?

Proportional and Integral Control

Switch to the MAN and confirm the following value:
Setpoint: 220 lit/min
Kp = 2, Ki = 0, Kd = 0 (Proportional Only Control)
Controller Output: 2V (4 mA)
PV: 20 mA (220 lit/min)
Change the SP to 180 lit/min
What is the error?___________________(mA, lit/min)
12

What is the P action?________________ (mA)

Change Ki to 0.01.
What is the I action?_________________ (mA)
How is the PI action changing? (You can draw a diagram for I action)

Stop the PID Controller Program.

Start the PID Controller Program.
What is the P action?__________________(mA)
How is the I action changing? (You can draw a diagram for I action)

Change SP to 220 lit/min and Ki = 0 (confirm Kp = 2.0).

Switch to the AUTO mode. Confirm the system is stable at SP of 220 l/min.
Change SP to 180 lit/min. Wait until the system is stable.
What is offset value?_______________ (mA, lit/min)

Change Ki to 0.01. Observe the system response (PV).

How does the PV change?
Is the offset compensated?

Change SP to 160 lit/min. Observe the system response (PV).

How does the PV change?

Change SP to 180 lit/min. Observe the system response (PV).

How does the PV change?

Change Ki to 0.5. Observe the system response (PV).

Change SP to 160 lit/min. Observe the system response (PV).
How does the PV change?

Change the following value:

SP to 220 lit/min
13

Ki to 0.0
Kp to 2.0
Switch to the MAN mode. Stop the PID Control Program.

Proportional and Derivative Control

Run the PID Control Program in MAN mode.
Confirm the following:
Kp = 2
Ki = 0.0
Kd = 0.0
SP = 220 lit/min
Change Kd to 2 and SP to 180 lit/min.
Change SP to 160 lit/min
How does the D action change? (You may change the Sampling Interval to 1 to observe the
D action). Draw a diagram showing the D action.

Change Kd to 2 and SP to 220 lit/min. Wait until the system response is stable.
Switch to AUTO Mode PD control
Change the SP to 180 l/min, wait until the system response is stable.
Change the SP to 160 l/min, wait until the system response is stable.
Is the OFFSET compensated by PD control action?

Stop the PID Control Program.

Proportional plus Integral plus Derivative Control and AUTO/MAN Transfer

From previous trial, change the following values:
SP = 220 lit/min
Kp = 2
Ki = 0.025
Kd = 2
AUTO/MAN = MAN
Run the PID Control Program. Wait until the system is stable.
Switch to the AUTO Mode PID Control Action. At this point, you have experienced
with the effects of P, I, PI, PD actions. In this section, please do several trials in order to find
some values of Kp, Ki and Kd such that the system response has less oscillation and reaches
the SP quickly.
Change SP to 160 lit/min. How does the PV change?

You can do several trials with different sets of Kp, Ki and Kd.
14

You can also do several trials with transfer between AUTO/MAN modes when:
o SP = PV
o SP is different from PV

Describe your observations:

Conclusion
At this point the following LOs have been met:
Operate the PID flow control system with different control actions:
o P control
o PI control
o PD control
o PID control
Explain the effects of P, I, D, PI, PD and PID on the system response.
Switch between the AUTO and MAN modes smoothly.
Notes: Dont forget to copy data files to your USB flash memory stick!
4. Calculation and Report
In your report, do the following tasks (but not restricted to):
Introduction
Relevant theory on On-Off control
Relevant theory on PID control
Relevant theories related to level or flow transmitters/sensors and actuators
Using AS Standard Drawing Symbols, draw a flow diagram for the above control system
you have selected.
Draw a block diagram for the closed-loop control system you have selected.
Find transfer functions/sensitivities for all components of the systems. Hints:
For the level control system the ODE for the tank is
Ah& + k v h = q in or Ah& + k v h = q in
For the flow control system the ODE for the piping system (flow dynamics) is
Qout
K Td s
=
e
Qin Ts + 1
Find the total feedback transfer function (refer to Chapter 15)
Plot sketches and graphs (from data files)
Discussions, evaluations and conclusions

15

Appendix 1 Flow Control Bench

Control Valve

Global Valve

Rotameter

D/P Cell

I/O Converter

Appendix 2 Block Diagram for On-Off Controller Program (flow control)

16

Appendix 3 Block Diagram of the PID Controller Program (flow control)

17

Lab 2 Process Control

Computer-based Control Systems Level Control
1. Aims
To operate PC-based instrumentation and control systems
To get familiar with open-loop control, ON-OFF, and PID control systems
To explain P, PI, PD, and PID control actions
To transfer MAN mode to AUTO smoothly.
2. Apparatus
Process/Plant: Process Control Trainer Cart with Level Control Mode of I/P Converter
consists of a tank, a pneumatic control valve (with a pneumatic positioned), a D/P level
transmitter, an orifice plate and D/P flow transmitter, pipes and pump, and a D/P pressure
transmitter (not used in this experiment).
Computer, LabVIEW 8.6, NI DAQ 6036E Card, Signal Conditioning SC-2345 (for level
control) including a current-to-voltage converter (4mA-20mA to 1 to 5V, with two
channels) and a voltage-to-current converter (0V-+10V to 0mA-20mA).
A multimeter.
3 Connection Diagram
The connection diagram for control systems is shown in Fig. 1 and Fig. 2b.
Pneumatic
supply

Water
supply
MI
Valve

I/P
kPa
Actuator

CS 4-20mA

PV

Process
(Plant)

MV 4-20mA

Sensor/s

I/V

V/I

PC, DAQ PCI 6036E and LabVIEW

PC-based controller
Figure 1 Connection diagram
Scheme diagram for level control system is shown in Fig. 2 (also see Appendix 1).
4. Further Information
Refer to Chapters 7, 8, 9 (Pressure, Flow and Level), Chapter 12 Actuators and Chapter 13 Basic
Control Theory (Direct Acting On-Off Control, PID Control)

I/P converter
Air supply
20-100 kPa

0-20mA

Flow transmitter
Positioner
Supply
liquid

0-10V

Orifice Pneumatic
plate control valve

AO-0
4-20mA
1-5V
AI-12
1-5V

qin (0-85% square root)

Level transmitter
Level
0-0.4 m

4-20mA

AI-10
SC-2345

Isolation
valve

DAQ PCI 6036E,

PC and LabVIEW

Valve 1
qout1

Valve 2
qout2

Figure 2a Schematic diagram for level control system

I/P converter
Air supply
20-100 kPa (desired)

0-20mA

FT
Supply
liquid

0-10V

qin (0-85% square root)

AO-0
Controller

Positioner

4-20mA

Pneumatic
control valve

1-5V
DC 24V

AI-12
1-5V

4-20mA

Level
0-0.4 m

LT

AI-10
SC-2345
PC, DAQ PCI 6036E,
and LabVIEW

Isolation
valve
DC 24V

Valve 1
qout1

Valve 2
qout2

Figure 2b Connection diagram for level control system

2

Methods
1. Connection and turning on the power
Connect the computer, I/V converters, and V/I converter to the process (sensor/s and
actuators) by referring to the above scheme/connection diagrams
Supply control air (or confirm if the pneumatic supply is done)
Turn on the power
Log on to the computer
2. Identification of Components and Variables
Identify all components and their variable of the process control system (that you have
selected) and complete the following table.
Table 1 Components and variables
Process system:
No

Component / Model Code

Input (variable, unit)
Output (variable, unit)
(where applicable)
Example: PC-based controller Setpoint level [mA, V, mm] Control signal: [V]
(Manual Controller)
Measured level [mA, V,
mm]
V/I converter (SC-2345)

Control signal: [V]

Control signal: [mA]

3
4
5
6
7
3. Hands-on Exercises
3.1 Hands-On Exercise 1: Getting Started with Open-Loop Level Control System
Purpose: The purpose of this hands-on exercise is to get familiar with a control system and its
components, variables and signals.
In the Open Loop Control System there is no comparison of feedback signal to the Set Point. In
almost controllers MAN mode is an Open Loop mode.
Learning Objectives:
Operate the open loop control system
Understand components of the control system and their signals

Explain the principles and functions of the components including process, measurement
devices (flow transmitters, level transmitter, pressure gauges), actuators, valves and valve
positioner.

Procedure
Run the LabVIEW On-Off controller program
C:\Documents and Settings\All Users\LabVIEW Data\JEE326_2009\Lab 2\OnOffLevelControl\
OnOffLevelControl01.exe

The controller program is running. If not, click

MAN (open-loop) mode.

to run the On-Off Controller Program in

The controller program looks like...

Process variable: level

Manual controller

Flow rate

Diagram

Drain valves
Figure 3 On-Off controller program in the Manual mode (for level control)

Make sure that the Auto/Man mode switch is in Man position.

Make sure that the Write to File is at Write position and change the path for data files if
necessary
Enter a minimum value of voltage, i.e. 0V, write down in Table 2 and Table 3.
Change the value of voltage to 2V and then with a step of 1 volt and complete Table 2 and
Table 3.

Table 2 Data collection for components and variables of open loop system
No
0
1
2
3
4
5
6

Component and/or
variable [unit]
Examples: Controller
(PC), control signal:
V:
mA
Volt-to-Curr Converter,
control signal [mA]
I/P converter
Air supply pressure kPa
Output (pressure) kPa
Positioner
Instrument pressure
Air supply pressure
Output pressure
Control valve

Sym

uc
uc

0
0

uc2

10

0
P1
P2
P3
Pc

Flow transmitter
Tank

Table 3 Ranges of variables

Input (range, unit)
No

Open-loop (MAN)
Controller

Min

Max

Min

Max

0V

10V

0 mA

20mA

Control signal
0

Output (range, unit)

Component / Instrument

Control pressure

Example: I/P converter

0

20 mA

0 bar

1.2 bar

Label the components, variables and their ranges in the following block diagram.
Air supply

S2

S1

S3

V/I
converter

S7
Indicators (Virtual Instruments)

Disturbances

C1

S5

S4
C2

C3

S6

PC + Controller
C4
Figure 4 Block diagram of the open-loop control system (for level control)

QUESTION 1
What type is the pneumatic control valve?

QUESTION 2
When the Controller Output changes from 0% (4mA) to 50% (12mA) (of span)
How much (%) does the Valve Opening change?.............................................
How much (%) does the Process Variable change?..........................................

Return the Controller Output to the minimum value.

Stop the Open-Loop Control System by clicking

button.

Important: Dont forget to copy data files to your USB flash memory stick!

Notes for Hands-on Exercise 1 (Open Loop Control System)

3.2 Hands-on Exercise 2: Operation of On-Off Level Control System

Purpose
The purpose of this hands-on exercise is to get familiar with an On-Off Control System.
Learning Objectives
To operate the On-Off Control System
To perform settings of ON and OFF values to optimize the system response.
Introduction
The On-Off level control system is based on the following principle:
Error (E) = SP PV
SP

Error

Controller Output
If E > 0 then ON (large) OPEN
If E < 0 then OFF (small) CLOSE

PV
Figure 5 On-Off control algorithm for level control system
Confirm ON (OPEN) and OFF (CLOSE) values of the control valve for your control system:
ON (OPEN) Fully open: 10 V or 20 mA
OFF (CLOSE) Fully close: 0 V or 0 mA

Figure 6 Level controller program (Front Panel)

8

Procedure
(It is supposed that this exercise is started after Exercise 3.1, the On-Off Level Controller Program
is still open).
Run the On-Off Level Controller Program
In MAN mode, confirm SP at 400 mm and the valve is fully opened. If not, adjust the
Manual Control to 10 V to fill water in the tank up to 400 mm. (Notes: There are two drain
valves. One is fully closed, the other is half opened. If the tank is empty you may need to
closed the half-opened valve, and then return it back to the half opening position when the
water reaches 400 mm.)
Confirm the OFF (CLOSE) value (fully close) at 0V, and the ON (OPEN) value (fully open)
at 10V.
Switch to AUTO mode. The controller is working in the On-Off control mode.
Observe the change in PV.
Change the SP to 50% of the span, i.e. 200 mm (or 12 mA), observe the change in PV.
Change the OFF value to 2V (4 mA) and the ON value to 6V (12 mA), and observe the
change in PV.

QUESTION 1
How is the system response changing?

Select an OPEN value and a CLOSE value so that the system response hunts the set-point
with the least oscillation. You may execute several trials to select appropriate valves.

QUESTION 2
What are the best values?

To stop the On-Off Controller Program click

Close the On-Off Controller Program.

button.

Important: Dot not forget to copy data files to your USB flash memory stick!
Conclusion
At this point, the learning objectives have been met. You are able to
To operate the On-Off Control System
To perform settings of ON and OFF values to optimize the system response.
Notes for Hands-on Exercise 2

3.3 Hands-On Exercise 3: Operation of PID Control System

Introduction
The PID control system is based on the following principle:
Error (E) = SP PV

SP

Error

u PID = K P e + K I edt + K D

de
dt

Controller Output

PV

Figure 7 PID control algorithm for the level control system

The PID controller program has the MAN mode similar to that of the On-Off controller program.
In AUTO (closed-loop) mode, the PID controller can work in the following control actions:
P only control by setting Ki = 0 and Kd = 0
I only control by setting Kp = 0 and Kd = 0 (rarely used for this level system because I
control action makes the system unstable)
PI control by setting Kd = 0
PD control by setting Ki = 0

Control gains (Kp, Ki and Kd) are adjusted by

on the following formula of the PID Control Algorithm:
de
VPID = K P e + K I edt + K D
dt

Proportional Band is PB =

Integral Time: TI =

. The control signal is computed based

100%
KP

KP
KI

Derivative Time: TD =

KD
KP

Purpose
The purpose of this hands-on exercise is to get familiar with the PID Control System.
Learning Objectives
Operate the PID level control system with different control actions:
o P control
o PI control
o PD control
o PID control
Explain the effects of P, I, D, PI, PD and PID on the system response.
Switch between the AUTO and MAN modes smoothly.
10

Figure 8 PID controller program (Front Panel)

Procedures
(It is suggested that you have closed the On-Off Controller Program.)
Run the PID Controller Program
Confirm the PID Controller Program in MAN mode.
Observe the SP, PV, Controller Output and confirm the following values (if not, adjust
accordingly):
Setpoint: 200 mm
Kp = 2, Ki = 0, Kd = 0 (Proportional Only Control)
Controller Output: 0V (0 mA)
PV: 12 mA (200 mm)
Switch to the AUTO mode. The controller is working with Proportional Only Control.
Proportional Only Control and Effects of Proportional Gains on System Response and Offset

Wait until the system response is stable, fill in Table 4.

Execute the Trials 1-10 and fill in Table 4.

11

Table 4 Proportional Band Effect on OFFSET

TRIAL

KP

PB

SETPOINT

2.0

200

2.0

180

10

160

15

160

40

160

40

140

50

140

60

140

70

140

20

140

10

2.0

200

MEAS.
(PV)

+ OR ERROR

OUTPUT
(Control Signal)

QUESTION 1
How does the system response change when the Proportional Gain changes?

Proportional and Integral Control

Switch to the MAN and confirm the following value:
Set-point: 200 mm
Kp = 2, Ki = 0, Kd = 0 (Proportional Only Control)
PV: 12 mA (200 mm) (if not, adjust the Manual Control to 10V to fill water up to 200 mm.
Switch to the Auto Mode. Wait until the level is stable.
What is the error?___________________(V, mA, mm)
What is the P action?________________ (V, mA)
Change the SP to 180 mm
What is the error?___________________(V, mA, mm)
What is the P action?________________ (V, mA)
Change Ki to 0.01.
What is the P action?__________________(mA)
How is the PI action changing? (You can draw a diagram for I action)
12

Stop the PID Controller Program.

Start the PID Controller Program.
What is the P action?__________________(mA)
How is the I action changing? (You can draw a diagram for I action)

Change SP to 200 mm and Ki = 0 (confirm Kp = 2.0).

Switch to the AUTO mode. Wait until the system is stable.
Change SP to 180 mm. Wait until the system is stable.
What is offset value?_______________ (mA, mm)

Change Ki to 0.01. Observe the system response (PV).

How does the PV change?
Is the offset compensated?

Change SP to 160 mm. Observe the system response (PV).

How does the PV change?

Change SP to 180 mm. Observe the system response (PV).

How does the PV change?

Change Ki to 0.5. Observe the system response (PV).

Change SP to 160 mm. Observe the system response (PV).
How does the PV change?

Change the following value:

SP to 200 mm
Ki to 0.0
Kp to 2.0
Switch to the MAN mode. Stop the PID Control Program.

13

Proportional and Derivative Control

Run the PID Control Program in MAN mode.
Confirm the following:
Kp = 2
Ki = 0.0
Kd = 0.0
SP = 200 mm
Change Kd to 2 and SP to 180 mm.
Change SP to 160 mm
How does the D action change? (You may change the Sampling Interval to 1 to observe the
D action). Draw a diagram showing the D action.

Change Kd to 2 and SP to 200 mm. Wait until the system response is stable.
Switch to AUTO Mode PD control
Change the SP to 180 mm, wait until the system response is stable.
Change the SP to 160 mm, wait until the system response is stable.
Is the OFFSET compensated by PD control action?

Stop the PID Control Program.

Proportional plus Integral plus Derivative Control and AUTO/MAN Transfer

From previous trial, change the following values:
SP = 200 mm
Kp = 2
Ki = 0.025
Kd = 2
AUTO/MAN = MAN
Run the PID Control Program. Wait until the system is stable.
Switch to the AUTO Mode PID Control Action. At this point, you have experienced
with the effects of P, I, PI, PD actions. In this section, please do several trials in order to find
some values of Kp, Ki and Kd such that the system response has less oscillation and reaches
the SP quickly.
Change SP to 160 mm. How does the PV change?

You can do several trials with different sets of Kp, Ki and Kd.
You can also do several trials with transfer between AUTO/MAN modes when:
o SP = PV
o SP is different from PV

14

Describe your observations:

Conclusion

Operate the PID level control system with different control actions:
o P control
o PI control
o PD control
o PID control
Explain the effects of P, I, D, PI, PD and PID on the system response.
Switch between the AUTO and MAN modes smoothly.

Notes: Dont forget to copy data files to your USB flash memory stick!
4. Calculation and Report
In your report, do the following tasks (but not restricted to):
Introduction
Relevant theory on On-Off control
Relevant theory on PID control
Relevant theories related to level or level transmitters/sensors and actuators
Using AS Standard Drawing Symbols, draw a level diagram for the above control system
you have selected.
Draw a block diagram for the closed-loop control system you have selected.
Find transfer functions/sensitivities for all components of the systems. Hints:
For the level control system the ODE for the tank is
Ah& + k v h = q in
For the flow control system the ODE for the piping system (flow dynamics) is
Qout
K Td s
=
e
Qin Ts + 1
Find the total feedback transfer function (refer to Chapter 15)
Plot sketches and graphs (from data files)
Discussions, evaluations and conclusions

15

Appendix 1 Process Control Trainer Cart

Tank
Control valve
Microprocessor-based
controllers and chart
recorders

Valve positioner
Pressure
transmitter

Level transmitter

Flow
transmitter

I/P converter
Process Control Trainer Cart

Appendix 2 Block Diagram for On-Off Controller Program (level control)

16

Appendix 3 Block Diagram of the PID Controller Program (level control)

17