27 03 2015100V2 E7 026

Research Paper
Volume 2 Issue 7 March 2015
International Journal of Informative & Futuristic Research ISSN (Online): 2347-1697
PID Based Flow Loop Control

Paper ID IJIFR/ V2/ E7/ 026 Page No. 2166-2173 Instrumentation &
Subject Area
Control Engg.
Key Words PID Controller, Rotameter, I-P Convertor, Control Valve, Final Control element
Assistant Professor
1 Department of Instrumentation & Control Engg.
Jadhav Vilas K.
Pravara Rural Engineering College, Loni
Ahmednagar - Maharashtra
B. E. Student
2 Department of Instrumentation & Control Engg.
Anap Tushar
B. E. Student
Department of Instrumentation & Control Engg.
Gadakh Sachin 3
B. E. Student
Department of Instrumentation & Control Engg.
Dighe Sandip B. 4
Abstract
In this paper we have proposed to design an PID controller which is used for
controlling the flow rate and design PID controller using OPAMP. The
closed loop flow control system is basically a feedback control system.
Process loop control which used in chemical and petrochemical plants, oil
refineries, steel plants, cement kilns, paper mills and pharmaceuticals,
waste water treatment plants and the like. The early production process
was natural scale up version of the traditional manual practices. In flow
control loop various component are used which perform accurately
according their function .In flow control loop flow which is to be controlled
is passes from tank to rotameter through pipe differential pressure of this
flow is sensed through venturimeter or orifice meter .
www.ijifr.com
Copyright © IJIFR 2015 2166
ISSN (Online): 2347-1697
International Journal of Informative & Futuristic Research (IJIFR)
Volume - 2, Issue - 7, March 2015
19th Edition, Page No: 2166-2173
1. Introduction
The closed loop flow control system is basically a feedback control system. Process loop control
which used in chemical and petrochemical plants, oil refineries, steel plants, cement kilns, paper
mills and pharmaceuticals, waste water treatment plants and the like. The early production process
was natural scale up version of the traditional manual practices. In flow control loop various
component are used which perform accurately according their function .In flow control loop flow
which is to be controlled is passes from tank to rotameter through pipe differential pressure of this
flow is sensed through venturimeter or orifice meter .This differential pressure converted into
corresponding electrical signal by differential pressure transmitter, the output of transmitter is given
to through a square root extractor to the PID controller. The controller compares the input signal
with the desired flow signal and generates a corrective output signal in the process control industries
is the control valve. The control valve manipulates a flowing fluid, such as gas, steam, water, or
chemical compounds, to compensate for the load disturbance and keep the regulated process variable
as close as possible to the desired set point. The control valve assembly typically consists of the
valve body, the internal trim parts, an actuator to provide the motive power to operate the valve, and
a variety of additional valve accessories, which can include transducers, supply pressure regulators,
manual operators, Snubber, or limit switches. In our project we are going to use the control valve of
globe type to control the flow as a final control element. The project deals with the flow parameter
which is to be control with given set point, and the controller action by PID controller. The flow
transmitter sends the signal information of flow to PID controller. This is to be passing to control
valve acting as final control element.
To optimize control value, the instruments used in process should be properly installed, like Flow
transmitter used in process is DPT which generate nonlinear output and affects the performance of
system. To increase the performance of DPT we will introduce the square root extractor in the loop
which will generate the linear output. The PID block used as feedback controller which generates the
controlled output and minimizes the error between set point and actual flow from steam. In flow
control loop pneumatic control valve is two way, single seated type. Body of this valve is made of
pneumatic control loop; the output of the controller is given to a current to pressure converter which
gives a corresponding corrective signal to the pneumatic control valve which controls the flow. In
stainless steel, Plug of this valve is of Equal percentage type. In this electric loop, output of
controller is given to the auto manual station that generates 230v pulses to operate the electrical
control valve, which controls the flow. In flow control loop electrically operated control valve is two
way, single seated type. Body of this valve is made of stainless steel. Plug of this valve is Equal
percentage type. Actuator is electric motor. Signal for this is 230v ac. A solenoid valve is controlled
by electrical current, which is run through a coil. When the coil is energized, a magnetic field is
created, causing a plunger inside the coil to move. Depending on the design of the valve, the plunger
will either open or close the valve. When electrical current is removed from the coil, the valve will
return to its de-energized state which controls the flow stream..
2. Flow Loop Control

Flow control loop system is basically a feedback control system. Differential pressure is sensed
through a venture meter or orifice meter .This differential pressure is converted into a corresponding
electrical signal by a differential pressure transmitter.
Jadhav V.K., Anap Tushar, Gadakh Sachin, Dighe Sandip B:: PID Based
Flow Loop Control 2167
Figure 2.1: Process Flow Diagram
Elements of Flow control loop using PID controller:

A. Rotameter
B. Orifice
C. Venturi meter
D. Differential pressure transmitter
E. PID controller
F. I/P converter
G. Control valve
As shown in fig.2.1 flow control loop system is basically a feedback control system. Differential
pressure is sensed through a venture meter or orifice meter .This differential pressure is converted
into a corresponding electrical signal by a differential pressure transmitter. The output of the
transmitter is given through a square root extractor to the PID controller. The controller compares
the input with the desired flow and generates an corrective output signal. In the pneumatic loop, the
output of the controller is given to a current to pressure converter which gives a corresponding
corrective signal to the pneumatic control valve, which controls the flow. In the electrical loop, the
output of the controller is given to the auto manual station that generates 230 v pulses to operate the
electrical control valve, which control the flow.
In solenoid valve operation are also shown when the flow goes out of limits. The controller can be
tuned by varying the values of proportion band width, integral and derivation times. an I/P converter
is used to convert a 4-20 mA signal to 3-15 psi .This is mainly used for operating control valve by
using PID controller. I/P converter is force balance device in which a coil is suspended in the field of
magnet by flexure .In this flow control loop control valve is used is pneumatically operated
diaphragm valve ,type of this valve is two way single seated and equal percentage type. Electrically
operated control valve is also two way single seated and equal percentage types.
3. Hardware Configuration:
Under this topic we discuss about the devices used by us in the loop, their construction details,
operational features and safety considerations.
A. Orifice Plate
The orifice plate is the most common form of restriction that is used in flow measurement. An
orifice plate is basically a thin metal plate with a hole bored in the centre. It has a tab on one side
where figure 3.1 shows a representative orifice plate. The specification of the plate is stamped. The
upstream side of the orifice plate usually has a sharp, edge when an orifice plate is installed in a flow
line (usually clamped between a pair of flanges), increase of fluid flow velocity through the reduced
area at the orifice develops a differential pressure across the orifice. With an orifice plate in the pipe
work, static pressure increases slightly upstream of the orifice (due to back pressure effect) and then
decreases sharply as the flow passes through the orifice, reaching a minimum at a point called the
vena contract where the velocity of the flow is at a maximum. Beyond this point, static pressure
starts to recover as the flow slows down.
Figure 3.1. Cross-Section of Orifice Plate

However, with an orifice plate, static pressure downstream is always considerably lower than the
upstream pressure.
B. Flow Transmitter
Figure 3.2. Flow Transmitters
It helps to transmit the signal containing the necessary information of flow towards control
station. Differential pressure transmitter (DPT) is vastly used in process industries as flow
transmitter. DPT works on the principle, when fluid flow through pipe the orifice plates
generates pressure difference which bends diaphragm towards low pressure. This displacement
is measured with the help of LVDT and amplified to standard signal range of 4 to 20 mA using
conditioning circuit. ROSEMOUNT 3051 pressure transmitter is having time tested reliability,
the ROSEMOUNT 3051 is the industry standard.
C. Square Root Extractor
Figure 3.3. Connections for Square Root Extractor
Up to now, our flow measurement loop can be represented by the installation shown in Figure 9. The
high and low-pressure taps of the primary device (orifice type shown) are fed by sensing lines to a
differential pressure (D/P) cell. The output of the D/P cell acts on a pressure to mili-amp transducer,
Figure: Connections for Square Root Extractor which transmits a variable 4-20 ma signal. The D/P
cell and transmitter are shown together as a flow transmitter (FT).
D. PID Controller:
The P stands for proportional control, I for integral control and D for derivative control. This is also
what is called a three term controller. The basic function of a controller is to execute an algorithm
(electronic controller) based on the control engineer's input (tuning constants), the operators desired
operating value (set point) and the current plant process value. In most cases, the requirement is for
the controller to act so that the process value is as close to the setpoint as possible. In a basic process
control loop, the control engineer utilizes the PID algorithms to achieve this. The PID control
algorithm is used for the control of almost all loops in the process industries, and is also the basis for
many advanced control algorithms and strategies. In order for control loops to work properly, the
PID loop must be properly tuned. Standard methods for tuning loops and criteria for judging the loop
tuning have been used for many years, but should be reevaluated for use on modern digital control
systems.
While the basic algorithm has been unchanged for many years and is used in all distributed control
systems, the actual digital implementation of the algorithm has changed and differs from one system
to another. Controllers are designed to eliminate the need for continuous operator attention. Cruise
control in a car and a house thermostat are common examples Error is defined as the difference
between set-point and measurement. (error) = (set-point) - (measurement).The output of PID
controller will change in response to the error
Figure 3.4: Working Diagram of PID Controller

With proportional band, the controller output is proportional to the error or a change in
measurement. Drawbacks -with a proportional controller offset is present. Increasing the controller
gain will make the loop go unstable. Integral action was included in controllers to eliminate this
offset. With integral action, the controller output is proportional to the amount of time the error is
present. Integral action eliminates offset. Integral action gives the controller a large gain at low
frequencies,
4. Tunning Of Controller
Setting of control parameters to Ziegler/Nichols Determine the operating point Set the controller to
‘Manual’ and determine the possible control range by means of changing the correcting variable.
Select the operating point so that the controller has sufficient "reserve" in both modulation
directions, (e. g. in the Centre of the control range Configure the controller as a P controller: To do
this, set Tn at the highest possible value (9999.) and TV at 0.Determine the critical amplification Kr
(stability limit, closed control loop is in the process of carrying out continuous oscillation), by
analyzing small set point step-changes around the operating point after each newly set amplification.
This determines the critical amplification factor KKR and the period of oscillation Tk of this
continuous oscillation.
There are three method of tuning:
a) Ziegler-Nichols Method
b) Frequency Response Method
c) Open loop transient Method
5. I To P Convertor:
In this project the pneumatically operated control valve is connected to the current to pneumatic
convertor. This Ito P convertor connect the control valve to the process the main advantage of this
instrument is to operate the valve with current signal which is generated by the controller i.e. PLC
and it separates the hazardous and non-hazardous area. The basic construction detail of I-P convertor
is, it has two types of connection one from electronic controller and other from storage pressure tank
with constant pressure 20psi.
6. Final Control Element:

Final control element used in the flow loop control is control valve .Most of the time control
designer prefers use of control valve rather than the variable speed pump. Because in a liquid
system, inertia is significant; flow cannot be started or stopped without accelerating or decelerating.
To decompensate the dynamic character of inertia i.e. by reducing the time constant therefore, flow
controlled by speed variation will always have a higher time lag than the same flow controlled by a
valve.
Figure 6.1: Final Control Valve
7. Implementation
Figure 7.1:Connection Diagram of Flow Loop Control
An orifice plate is basically a thin metal plate with a hole bored in the center. It has a tab on one side
where the specification of the plate is stamped. The upstream side of the orifice plate usually has a
sharp, edge. An orifice plate generates pressure difference. Differential pressure transmitter (DPT) is
vastly used in process industries as flow transmitter.
8. Conclusion
We have studied the working of differential flow meter, DPT, PID controller, control valve etc. We
have understood the tuning of PID controller. Learn the electrical wiring and connection of control
panel. Thus we had controlled the flow loop system by using PID Controller.
References
[1] Liptak, Bela. Instrument Engineers' Handbook: Process Control. Radnor, Pennsylvania: Chilton
Book Company. pp. 20–29. ISBN 0-8019-8242-1, 1995
[2] Curtis D. Johnson‘Process control and instrumentation technology’ PHI publication
[3] K. Astrom and T HagglundPID Controllers: ‘Theory, Design, and Tuning’, 2nd Edition Publisher:
Instrument Society of America ISBN 1-55617-516-7
[4] Douglas M. Considine ‘Process / Industrial Instruments & Controls Handbook’
Fourth Edition Publisher: McGraw-Hill, Inc.ISBN 0--07--012445--0

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Research Paper

Volume 2 Issue 7 March 2015

International Journal of Informative & Futuristic Research ISSN (Online): 2347-1697

PID Based Flow Loop Control

2. Flow Loop Control

Figure 2.1: Process Flow Diagram

Elements of Flow control loop using PID controller:

Figure 3.1. Cross-Section of Orifice Plate

Figure 3.2. Flow Transmitters

Figure 3.3. Connections for Square Root Extractor

Figure 3.4: Working Diagram of PID Controller

6. Final Control Element:

Figure 6.1: Final Control Valve

Figure 7.1:Connection Diagram of Flow Loop Control

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