Temperature Control Demonstration Unit: Experimental Setup

Temperature control demonstration unit
Introduction
Temperature process rig uses
water as both a process fluid
and a secondary cooling circuit.
Rig comprises of a benchmounted temperature rig with
temperature
sensors,
process
interface and controllers.
Experimental setup
The system comprises two water
circuits. Named primary and
secondary, in the secondary circuit
fresh water from the tab is heated
up by a heat exchanger. The
temperature is measured by a
temperature sensor at the fresh
water outlet. The primary circuit
comprises an electrically heated
tank,
a
pump
and
an
electromagnetic proportional valve
as the actuator. Both circuits
include rotameters. The controller
used is a state-of-the-art digital industrial controller. A ball valve in the secondary
circuit enables defined disturbance variables to be generated. The outlet
temperature of the fresh water is controlled by the flow rate of warm water in the
primary circuit.
Theory
Proportional controller
In this control method, the control system acts in a way that the control effort is
proportional to the error. There is always a certain error in this controller type, called
steady state error
Integral Control.
In this control method, the control systems acts in a way that the control effort is
proportional to the integral of the error. The proportional controller amplifies the
error and applies a control effort to the system that is proportional to the error. In
integral control, the control effort is proportional to the integral of the error so the
controller now needs to be an integrator.
Proportional Integral Control

Integral control combined with proportional control gives us a controller which will
always act to maintain the controlled variable at its desired value. The proportional
control mode provides a stabilizing influence while the integral mode will
help to overcome the offset. Integral controller will provide corrective action as
long as there is a deviation in the controlled variable from the set point value.
Proportional Derivative Control

Derivative control action combined with proportional gives us a controller which is
good on processes containing appreciable lag. Because the process lag can be
compensated by the anticipatory nature of derivative action (i.e.) derivative action
provides the boost necessary to counter act the time delay associated with such
control systems. This is due to the fact that derivative control leads proportional
control by 90 deg. Since this controller combination is most effective where the
system lags are high, it could be used on most multi capacity process applications.
Proportional Integral Derivative Control

When all three control effects are combined together, we obtain the benefits of each
control action and moreover the effect duplicates the action of a good human
operator on a control application. A three mode controller contains the stability
to eliminate offset because of reset control and the ability to provide an
immediate correction for the magnitude of a disturbance because of rate control.
Differential Gap
Differential gap is the region in which the control causes the manipulated
variable to maintain its pervious value until the controlled variable has moved
slightly beyond the set point.
Time Delay
The delay given to the controller between successive corrective actions
Proportional Control
It is a controller action in which there is a continuous linear relation between value
of the controlled variable and position of the final control element with in the
proportional band.
Proportional Band
Proportional band or throttling range is defined as the percent deviation in
measurement of its full scale required to give 100% valve deviation.
Proportional Gain
It is the proportional control factor which is used to determine the proportional
band.
Proportional Band=100 of full scale valve/ proportional gain(Kp)
Experimental procedure
Turn on demonstration unit via main switch
Make sure cold(fresh) water circuit is off

Set a desired set point on controller
Using heater rise the temperature of water in tank up to a certain value
Open valve on cool water circuit to allow water to run into exchanger
Observe the value of outlet temperature of cool water after a certain interval
of time
Calculate inlet temperature of cool water by energy balance
Calculate area of heat exchanger

Temperature Control Demonstration Unit: Experimental Setup

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Temperature Control Demonstration Unit: Experimental Setup

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Temperature control demonstration unit

Proportional Integral Control

Proportional Derivative Control

Proportional Integral Derivative Control

Proportional Band=100 of full scale valve/ proportional gain(Kp)

Turn on demonstration unit via main switch

Make sure cold(fresh) water circuit is off

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