LAB MANUAL

PROCESS CONTROL LABORATORY

ELECTRONICS AND INSTRUMENTATION
ENGINEERING
MIT,ANNA UNIVERSITY
 LIST OF EXPERIMENTS
S.NO. NAME OF THE EXPERIMENT

1. DESIGN OF CONTROLLER IN MATLAB

2. CONTROL VALVE CHARACTERISTICS

3. MODELLING OF A SINGLE TANK SYSTEM

4. FLOW CONTROL IN PLINT SETUP

5. REAL PROCESS SIMULATION

6. DESIGN OF FEEDFORWARD AND CASCADE

CONTROL
7. PID IMPLEMENTATION ISSUES

8. SPEED CONTROL SYSTEM OF DC SERVO MOTOR

9. CASCADE LEVEL CONTROLLER FOR PLINT SETUP

USING DCS
10. IMPLEMENTATION OF GAIN SCHEDULED PID FOR
CONICAL TANK SYSTEM
TABULATION :
P P+I P+I+D
METHOD KP KP KI KP KI KD

ZN OPEN
LOOP
METHOD
ZN CLOSED
LOOP
METHOD

COHENCOON
METHOD

ZN CLOSED LOOP :
ZN OPEN LOOP METHOD:
CONTROLLER PEAK OVERSHOOT SETTLING TIME FINAL VALUE

P+I

P+I+D

ZN CLOSED LOOP METHOD:

CONTROLLER PEAK OVERSHOOT SETTLING TIME FINAL VALUE

P+I

P+I+D

COHEN-COON METHOD:
CONTROLLER PEAK OVERSHOOT SETTLING TIME FINAL VALUE

P+I

P+I+D
ZN OPEN LOOP AND COHEN-COON :
 DESIGN OF CONTROLLER IN MATLAB

AIM:

To design PID controllers using different tuning methods and study

their response characteristics.

SIMULATION NEEDS:

 Software- MATLAB
 Tool- SIMULINK

FORMULA:

ZEIGLAR-NICHOL’S OPEN LOOP METHOD:

CONTROLLER FORMULA

i=
PI

i=

PID
d=
d
ZEIGLAR-NICHOL’S CLOSED LOOP METHOD:

CONTROLLER FORMULA
P

i=
PI

i=

PID
d=

ZEIGLAR-NICHOL’S OPEN LOOP METHOD:

CONTROLLER FORMULA

PI
i=L
 i= L
PID

d=L d

PROCEDURE:
 Using Simulink in MATLAB, place a PID block in a model

 Change the parameters in the PID controller block and observe

the response in slope.

 Repeat the step for three methods

 Find the response for P, PI and PID for each method

 For ZN closed method take 3 rd order Transfer function and find response

 Compare response of PID controllers for all three methods

 Draw a graph and find the difference in settling of three controllers

 CONTROL VALVE CHARACTERISTICS
AIM:

To plot the characteristics of the spring and diaphragm actuator

and the characteristics of the control valve and actuated by the
actuator.

APPARATUS REQUIRED:

 Control Valve
 Spring and Diaphragm actuator
 Continuous water supply
 5ml measuring jar

PROCEDURE:
 The actuator control valve assembly is connected with water
supply.
 The actuator is activated by supplying air pressure of (3 -15)psi.
 The air pressure is varied from (3-15)psi and the stem position or
the actuator is noted.
 The flow rate through the valve is calculated by the process of
collecting fixed amount of water and recording the time.
 The actuator characteristics are obtained by plotting flow rate
stem position or actuator.
CONTROL VALVE WITHOUT POSITIONER :

CONTROL VALVE WITH POSITIONER :

TABULATION:

INPUT STEM POSITION FLOW RATE FLOW RATE

PRESSURE (%) (%) (lph)
(bar)
TABULATION

TIME(S) LEVEL LEVEL (CM)

TRANSMITTER(mA)
 MODELLING OF A SINGLE TANK SYSTEM
AIM:

To model a single tank system and to find out the system

sensitivity and the time constant and to plot the response of level to
the changing inflow rate.

APPARATUS REQUIRED:

 Tank with level sensor

 Orifice plate with flow meter
 Loop Calibrator(FLUKE 105)
 Digital Multimeter
 I/P Convertor
 Control valve with pressure gauge
 Hand valves and Pump

PROCEDURE:

 Switch on the compressor which gives 15psi supply pressure

 Switch on the pump and partially open the bypass valve.
 The output flow rate should be constant throughout.
 The loop calibrator is set to source mode, current is given so that
the restrictor can be adjusted to 50% to 75% in pneumatic control
valve.
 The level of tank is remained by tabulating values of current in mA
from multimeter and time for the every next 5 seconds.
 The graph is drawn which gives the response and the time
constant and sensitivity are calculated.
SETUP DIAGRAM
BLOCK OF A SINGLE TANK SYSTEM
 FLOW CONTROL IN PLINT SETUP USING DCS
AIM:

To control the flow rate in the PLINT setup using yokogawa DCS and to
study about the proportional and integral action of the PID controller.

COMPONENTS REQUIRED:

 Yokogawa DCS (centum CS3000)

 PLINT setup
PROCEDURE:

SAFETY PRECAUTIONS:

 Check whether the pneumatic supply to the valves is in ON

condition.
 Check whether the valves are in AUTOMATIC mode and the
controller is in MANUAL mode.

PROCEDURE:
 Switch ON the PLINT setup and HS64 of the DCS unit.
 Open the PLINT setup in the DCS graphics page.
 Select the flow control loop and flow control graphics page.
 Set the set point of the flow controller only between 8 and 18 lpm
and switch ON the pump
 After attaining the steady state, change the controller mode to
AUTOMATIC.
 Tune the controller in only P mode and note down the readings
after changing the set point.
 Tune the controller in P+I mode and vary the set point.
 Tune the controller. Note down the readings and from the graph
infer the action of the P+I controller.
SCHEMATIC DIAGRAM OF FLOW CONTROL LOOP
TABULATION :
PROPORTIONAL : PROPORTIONAL+INTEGRAL :

SP= P= I= SP= P= I=

TIME(S) PV TIME(S) PV
PROPORTIONAL+INTEGRAL: PROPORTIONAL+INTEGRAL :

SP= P= I= SP= P= I=

TIME(S) PV TIME(S) PV
TABULATION :
FIN h

LEVEL PROCESS :

BLOCK DIAGRAM:
OPERATING POINT SELECTION : SS CURVE

FIN h

REFERENCE STEP

POSITIVE STEP

NEGATIVE STEP

TABULATION :

1.POSITIVE STEP:

TIME(S) FIN h
2.NEGATIVE STEP:

TIME(S) FIN h
 VALIDATION OF TRANSFER FUNCTION AND MODEL

TABULATION:

SIMULATION MODEL OUTPUT TRANSFER FUNCTION

TIME(t) OUTPUT
 REALTIME PROCESS SIMULATION

AIM:

To estimate the transfer function model of a process from its real

time model and compare the response.

SIMULATION NEEDS:

 Software – MATLAB 8.5

 Tool – Simulink

DESIGN:

For a pure capacitive level process

PROCEDURE:

 First the real time process model is assembled using Simulink

library
 Then the calibration curve Fin vs h is drawn by applying various
step inputs.
 From the calibration curve, the operating point is fixed.
  Then the time constant ( ) and sensitivity are found by giving a
positive step input and a negative step input from the fixed
operating point.
 Time constant is the time taken to reach 63.2% of the fixed value.
Sensitivity (K) is the ratio of change in output to change in input.
From this we get the Transfer function .
 Compare the response of the real time model and the Transfer
function by providing the same step change.

DESCRIPTION:

POSITIVE STEP INPUT:

Step input value of operating point is increased to 10% and the

value is given as input and the corresponding value of height is noted.

NEGATIVE STEP INPUT:

Step input value of operating point is decreased to 10% and the

value is given as input and the corresponding value of height is noted.

FINDING TIME CONSTANT:

With positive step as input, the corresponding height is noted and

the time constant for the positive step is calculated as

τ1 = initial value + [steady state value – initial value]

Time constant for the negative step is found in same way and the time
constant for the entire process is given by

= ( 1 + 2)/2
FINDING GAIN:
Gain is calculated as ratio of change in output to change in input.
For positive step input the gain is calculated by

Gain for negative step is found in the same way and the gain for the
entire process is given by

FINDING TRANSFER FUNCTION :

The Transfer function of the system is given by

T.F =
FEED FORWARD CONTROLLER
TABULATION: FEED-FORWARD CONTROL
SIMULATION RESPONSE WITH RESPONSE WITHOUT
TIME FFC FFC
CASCADE CONTROLLER
TABULATION: CASCADE CONTROL
SIMULATION RESPONSE WITH RESPONSE WITHOUT
TIME CASCADE CASCADE
 DESIGN OF FEED FORWARD AND CASCADE
CONTROLLER

AIM:
To design and simulate a cascade controller at regulatory level
and also design a feedback and feedforward controller for the given
transfer function. Compare the output of the FFC with the FBC.

SIMULATION NEEDS:

 Software-MATLAB
 Tool - simulink.

PROCEDURE:

Cascade control design:

 Use Simulink tool in MATLAB to place appropriate blocks in

model.
 Use ZN open loop method and calculate the transfer function for
secondary loop.
 Reduce the secondary loop and cascade it.
 Calculate KP and KI using ZN closed loop method and determine
the parameters of primary controller to obtain the
characteristics.
Feed forward controller design:

 Place the blocks model of MATLAB using Simulink and give step
input to the system.
 Design the PID controller for a given transfer function.
 Give a step input without feedforward controller.
 Now include the feed forward controller and obtain the step
response.
 Compare the characteristics of transfer function based on
external disturbances.
 PROPORTIONAL KICK

PROPORTIONAL KICK ELIMINATION

 DERIVATIVE KICK

DERIVATIVE KICK ELIMINATION

INTEGRAL WIND UP

ANTI-RESET WIND UP
P KICK ELIMINATION :
SIMULATION WITHOUT WITH ELIMINATION
TIME ELIMINATION

D KICK ELIMINATION:
SIMULATION WITH D KICK WITH ELIMINATION
TIME
 INTEGRAL WIND UP :

SIMULATION SIGNAL INTEGRAL SATURATION ANTI RESET

TIME ACTION
 PID IMPLEMENTATION ISSUES
AIM:

To design a circuit in MATLAB to reduce proportional kick,

derivative kick and integral windup.

APPARATUS REQUIRED:

 Software- MATLAB
 Tool- Simulink
PROPORTIONAL KICK:

Proportional kick may be reduced by using p-action based on

process variable. Compute both graph in scope, it is found that P-kick is
reduced when P-action back is based on process variable.

DERIVATIVE KICK:

Derivative kick may be reduced by making action based on

process variable, that error comparing both waveforms we find the
derivative kick is reduced when D-action is base.

INTEGRAL WINDUP:

Integral windup can be reduced by using anti-reset windup as per

the windup diagram and that integral windup can be eliminated.
SETUP OF SPEED CONTROL SYSTEM
TABULATION :
REFERENCE TACHO GENERATOR ATTENUATION ERROR SPEED(RPM)
VOLTAGE(V) VOLTAGE(V) POSITION VOLTAGE(V)
 SPEED CONTROL OF DC SERVO MOTOR

AIM:
To perform speed control operation(servo) on the dc servomotor
and to investigate the relationship between speed and error voltage.

EQUIPMENT REQUIRED:

 OP-AMP unit
 Attenuator unit
 Servo amplifier
 Power supply
 Tacho unit
 Dc motor

PROCEDURE:

1) The connections are made as shown in the circuit diagram given.

2) On the op amp unit, set the feedback selector switch to the 100kΩ
resistor.
3) Vary the reference voltage and note down the voltage for which
the motor starts rotating.
4) Now vary the voltage and note down the tachogenerator voltage,
error voltage and speed in the table voltage.
BLOCK DIAGRAM OF CASCADE CONTROL
CASCADE LEVEL CONTROL LOOP
TABULATION :

TIME(S) LEVEL(mm Of wc) LEVEL(%)

 CASCADE LEVEL CONTROLLER FOR PLINT
SETUP USING DCS
AIM:
To study the level control loop and control the level of the tank
C2, using cascade level control in PLINT setup.

APPARATUS REQUIRED:

 PLINT setup
 Yokogawa DCS(centum cs 3000)

PROCEDURE:

In a cascade configuration, we have one and more than one

measurement. The cascade control uses two control loops.
1. The loop that measures controlled variables to the primary or
master control loop and uses a set point supplied by operator.
2. The loop that uses output of the primary controller as the set point
and is called secondary or slave loop.

Disturbances arising within the secondary loop are connected by

secondary controller before they can affect the value of the input,
primary controller output. The dynamics of the secondary loop is much
faster than the primary loop.

SAFETY PRECAUTIONS:

1. Check whether the controllers are in manual mode before

switching on the pump.
2. Check whether the control valves are in automatic mode.
STEPS TO BE FOLLOWED:
1. Switch ON the plint setup and HIS64 of the DCS unit.
2. Open the plint setup in DCS graphics inbox.
3. Select the cascade control loop and cascade control graphics
page.
4. Set the set point of the level controller only between 20% and
70%. Switch on the pump.
5. Tune the primary controller and secondary (flow) controller with
the following settings.
Primary: P=100 I=20 Seconds
Secondary: P=100 I=5 Seconds
6. Change the level controllers to auto mode and flow controller in
cascade mode.
7. Note down the level variations in tank C2, in terms of mm of W.C
and percentage for every 10 sec.
GAIN SCHEDULING-SCHEMATIC DIAGRAM
OPEN LOOP : FRONT PANEL AND BLOCK DIAGRAM
CLOSED LOOP : FRONT PANEL AND BLOCK DIAGRAM
TABULATION :

FIN(V) h (cm) h (V) KP TP KC TI

 IMPLEMENTATION OF GAIN SCHEDULED PID
CONTROLLER
FOR LEVEL IN CONICAL TANK SYSTEM
AIM:

To design and implement a gain schedule PID controller for level

control in a conical tank process and obtain the servo response for a
step input operating in different operating region .

THEORY:
Gain Scheduling:

 Gain scheduling is an approach to control of non-linear systems

that has a family of linear controllers.
 It is a strategy to control the process whose dynamics varies with
time or operating condition.
 The main advantage of gain scheduling is its potential to
incorporate LINEAR ROBUST CONTROL methods into non-linear
control design.

PROCESS DESCRIPTION:
The conical tank system shown in the figure consists of an inverted
conical tank with an inlet flow (Fin) at the top and an outlet flow (Fout)
at the bottom. A pump that delivers liquid flow and a valve with valve
coefficient (Cv) to manipulate inlet flow. The mathematical model of
the process is given by
 where,
h – Level of liquid in the tank (m)
Fin – input flow to the tank (
Cv – valve coefficient
g – Acceleration due to gravity (m/ )
R – Maximum radius of the tank
H – Maximum height of the tank

PROCEDURE:

Open loop response:

 Open a blank VI in labVIEW

 Save the VI filename as open loop
 Build the block diagram and front panel for the open loop conical
tank process
 Fin (voltage=0 to 5v) is generated from PC through DAQ USB6008.
Assign an analog output channel
 Connect the analog output channel to V-I converter with a current
signal in the range (4-20 mA) and then give to I/P converter
 Output of the level transmitter is given to I/V converter and
converted into appropriate voltage (1-5v). The acquired signal is
fed to DAQ USB6008 through an analog input channel
 Run VI
 Adjust conical tank outflow Fout and obtain the steady state
values for Fin = 2v and Fin = 3v
 Fin = 2v corresponds to the region 1 for the level ranging from
0cm to 30cm
  Fin = 3v corresponds to the region 2 for the level ranging from
30cm to 60cm
 Calculate the individual static gains Kp and p for operating
regions considered here
 Obtain the Open Loop Transfer function
 Save VI

Closed loop response:

 Open a blank VI in labVIEW
 Save the VI filename as gain schedule
 Build the block diagram and front panel for the closed loop conical
tank process
 Obtain the controller settings using direct synthesis method
 Add PID gain schedule block and give the calculated values for
controller settings (Kc = 1/Kp) and Tf = p (in minutes) for region 1
and region 2
 Fin (0 to 5v) is generated from PC using DAQ USB6008. Assign an
analog output channel.
 Connect the channel to a V/I converter with a current signal range
4-20mA and then give to I/P converter
 Output of the level transmitter is converter (1-5v) and the
acquired signal is fed to the DAQ through input channel.
 Run VI
 Plot output response for the step set point Fin = 25cm and Fin =
40cm
 Save VI