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CCB 3072

PROCESS INSTRUMENTATION & CONTROL LAB


PROJECT REPORT
EXPERIMENT: TEMPERATURE CONTROL

GROUP
MEMBERS

:8
: Mohd Muizzuddin Bin Mohd Pauzi
Nurul Alia Bt Mohamad

15607

Nuralia Syairah Binti Osman

15669

Foo Wai Hun

15303

Guilles, Arielaine Fe Cruzat

17779

Lecturer

: Dr Timothy Ganesan A/L Andrew

Date Submission

: 5th August 2014

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Table of Content

No. Topic
Introduction
1
2
3
4
5
6
7
8
9

Methodology
Result of Experiment
Analysis of Instruments
Dynamic Model
Feedback Controller
Discussion
Conclusion
Reference

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Page
3
4
5
6
11
15
19
20
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Introduction
In Process Instrumentation and Control Lab, we conducted Temperature Control experiment
among other experiments. In this particular experiment, the objectives are to demonstrate the
characteristic of Proportional Only Control (P), Proportional Band and Integral Action (PI) and
Proportional Band, Integral Action and Derivative Action (PID) on a temperature process control loop.
It is also conducted to demonstrate the loop tuning procedure on a temperature process control loop.
The Air Temperature Control has been designed on how a temperature loop for an exchanger
can be controlled using a microprocessor based controller. The control panel is connected to a
Distributed Control System (DCS), which can remotely control the process plant using supervisory
control mode (SCADA) or direct digital control mode (DDC). A selector with located at the control
panel is used to select between SCADA or DDC mode. In SCADA mode the DCS can monitor and
control the process through the process controller and in DDC mode; the DCS can directly control the
plant through the Field Control Station.
The Air Temperature Control Module is an air process where 6 bar(g) compressed air is
charged into the air receiver tank V-102 and regulated to about 4 bar(g) by the air regulator PCV-102.
Air from V-102 flows through the process line into the air heater K-101 where it is heated up to 150
C and is then discharged to the atmosphere.

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Methodology
Methodology of the Temperature Control Experiment:

First of all, the compressor was started and we will wait for sufficient air pressure to build up in the
receiver tank. After that, the instrument main supply was swich on. Then, the controller was set to the
manual mode with set point of 100 . A step input was introduced and the experiment was started with
Proportional only control to observe the response produced, and then was repeated by replacing the P
Controller with a Proportional-Integral (PI) Control and then lastly to use a Proportional-IntegralDerivative (PID) Control.

Methodology of the Project

1) A dynamic model of the process was first drafted out.


2) Basic instruments to use for the process control system were analysed.
3) A feedback control system was designed and the standard block diagram for the feedback control
system was plotted.
4) The stability of the feedback control system was analysed using Routh Stability Criterion as well as
in MATLAB.
5) The behaviour of the process control system when using 3 different types of Feedback controllers
were analysed in MATLAB SIMULINK.
6) The most suitable type of controller was determined based on the results in SIMULINK.
7) The optimum parameters for the chosen controller were then determined by using MATLAB
SIMULINK.

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Result of Experiment

Closed Loop Response of PID


Controller
Temperature/C

200
150
temperature by using
PID

100
50

setpoint temperature

0
0

10

20

Time/min

Graph of temperature against time by using PID controller

Temperature/C

Closed Loop Response of PI


Rontroller
200
150
temperature by using
PI

100
50

setpoint temperature

0
0

10

20

time/min

Graph of temperature against time by using PI controller

Temperature/C

Closed Loop Response of P Rontroller


200
150
temperature by using
P

100
50

setpoint temperature

0
0

10

20

30

40

50

60

70

Time/min

Graph of temperature against time by using P controller

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Analysis of Instruments
The following diagram shows a feedback control loop which comprises of the process, the
measurement, the controller and the final control element. When all the various elements are
interconnected with each other and there exists a continuous passing of information around
the loop, then the loop becomes a closed loop control and simultaneously, an automatic
feedback exists.

Figure 1 Closed Loop Control


Furthermore, the actual setup of the instruments in the lab is also given in the figure below.

Receiver
tank
V-301

Control tank
PSV-301
PT-302

PT

PIC-302

PC

V-302

PSV-302

Figure 2 Experimental Setup of Equipments

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1. PID Controller (PIC-302)


For this experiment, PID controller is perhaps the most important tool that can determine

the success of meeting the objectives. P, I, and D stand for Proportional, which depends
on present error, Integral, which is the accumulation of past errors and Derivative, which
is the prediction of future errors, terms respectively. A simple block diagram of PID
controller is shown below.
Figure 3 PID controller block diagram
PID controller is useful in processes such as those that have rapid and large disturbances.
It must be used only when necessary because the design and tuning process of a PID
controller can initially appear to be conceptually intuitive but prove to be hard in practice.
Nevertheless, this type of control proves itself useful for various processes.
For the experiment, three different types of controller are being used in order to determine
the most suitable controller namely P controller, PI controller and PID controller. When
the P controller is used alone, it results with an offset from the set point of the process
variable. The magnitude of the offset varies depending on the value of the controller gain.
As the value of the controller gain increases, the amount of offset decreases. When used
with I controller, the offset error becomes eliminated and the movement of the process
towards the set point accelerates. However, it is important to note that since the integral
term responds to accumulated errors from the past, it can cause the present value to
overshoot the set point value. This is where the D controller plays its role by predicting
the system behaviour and improving settling time and stability as a result.

2. Recorder (PR-302)
This instrument has a pair of pen chart recorder which
continuously records the response of the process
instrument of the input and output by the means of a
graph.
This instrument is crucial for this experiment because it
enables one to study and investigate the system
responses in various tuning methods.

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3. Pressure transmitter (PT-301)


Pressure is the ratio of force to the area over which the force is distributed. It is
important to maintain the pressure at a specified level in order to prevent explosion or
implosion of tanks due to expanding or shrinking of gases or liquids present inside.
Pressure transmitter is important for the safety of the experiment as it acts as a
transducer which generates a signal as a function of the pressure.
4. Control Valve (PCV-302)
Control valves, also known as final control elements, are
valves used to control different conditions (i.e. pressure,
temperature) and which fully or partially opens or closes
depending on the signals received from controllers which
compare the set point to the process variable. The opening
and closing of the valves can either be done with the help of
electrical, hydraulic or pneumatic actuators. If different types
of valves with various sizes are subjected to the same
volumetric flow rate and differential pressure was kept contant, then all the valves will
have an equal orifice pass area.

5. Vortex flow meter (FT-301)


Flow meters are used to measure the
flow of fluids such as liquids or
gases in the system. Vortex flow
meter works by placing a bluff body
(called a shedder bar) in the path of
the fluid and as the fluid passes this
bar, it creates disturbances which
then results to vortices. The vortices
trail behind the cylinder or from
each side of the bluff body. The flow rate of the liquid is then measured using the concept
that the frequency at which the vortices alternate sides is proportional to the flow rate of
the fluid.

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6. Pressure indicator (PI-301, PI-302, PI-303, PI304)


Pressure measurements are oftentimes made relative to
some specified reference point. Some of these reference
points are absolute, gauge and differential pressure.
Absolute pressure is zero-referenced against a perfect
vacuum which makes it equal to gauge plus atmospheric
pressure. Gauge pressure, on the other hand, is zeroreferenced against ambient air pressure which makes it equal to absolute pressure minus
atmospheric pressure. Lastly, differential pressure is the measure of the differences in
pressures at two different points.
For this indicator, the pressure is equal to absolute pressure minus atmospheric pressure
which makes it equal to a gauge pressure where the negative sign is omitted.

7. Process Tanks (V-301, V-302)


In this experiment, the process tank is used to study the change in pressure by inserting air
into the tank and it is crucial for safety that the pressure be kept at a high value in order to
avoid damage to the tank.

8. Alarm annunciator (PAL-302, PAH-302)


An alarm annunciator was used in the experiment to ensure that if the pressure reaches
critical levels, the users will be made aware and can take precautionary measures.
Generally, this instrument alerts the operators of the conditions in the plant to ensure
everyones safety.

9. Pressure Relief Valve (PSC-301,PSC-302)


Pressure Relief Valve, also known as PRV, is a type of relief valve which controls the
pressure in the system by releasing excess pressure build up caused by a process upset or
instrument failure. This device is mechanically activated and works due to a spring which
is loaded to normally close the valve. If the pressure inside the system is higher than the
spring tension, it pushes the spring up and causes the PRV to open in order to purge air to
atmosphere to avoid overpressure in the tank.

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10. Solenoid Valves (HV-301, HV-302, HV-303)


Solenoid valves are electromechanically operated in which they are controlled by electric
current through a solenoid. This type of valve offers fast and safe switching, has high
reliability, long life cycle, low control power and compact design.

11. Air Regulator (PCV-301)


As the name implies, the air regulator in the experiment regulates the air supply to the
process receiver tank in order to ensure that the pressure limits are not exceeded.

12. D/P transmitter (PDT-301)


A differential pressure transmitter or sensor connects two different points and measures its
pressure difference. In the experiment, the D/P transmitter functions mainly for the
process line and it is able to measure values between 0-60 psig.

13. Rotameter (FI-301, FI-302)


A rotameter is another flow rate measuring device which measures liquid or gas flow rates
enclosed in a tube. It is one type of variable area meters which measures flow rate by
varying the cross sectional area where the fluid flows. In this experiment, it acts as a flow
rate measuring device for the process line.

14. Hand Valve (HV-304, HV-309)


A hand valve is a type of isolation valve which stops the
flow of process media at a given location when
necessary. Oftentimes, during maintenance or for safety
purposes, the flow has to be completely stopped. In this
experiment, the hand valves are isolation valves for the
input and output air and determines the direction as well
as the load changes of the air flow.

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15. Fault Simulation Switches (HS-30, HS-302, HS-303)


These switches act as a cut-off switch for emergency purposes. In this experiment, it
comes in handy whenever there is a leakage at the pressure control tank. It can also be
used to shut off the outlet to the pressure control tank if the instrument air supply has been
cut off for any reason.

16. Control Panel


The control panel in this experiment acts as a motherboard of pressure control. It mounts
the controller, alarm annunciator, recorder, push button power supply switch and
changeover switch between the distributed control system (DCS) and local control.

Dynamic Model

Mass balance

Since density and volume is constant

Energy balance

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Let

and

At steady-state

Laplace Transform:

Thus, the dynamic model for the heat exchanger is

Parameter values:
Air temperature
Based on density tables,

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From previous equation,

While

Hence,

Characteristic Equation

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Lowest limit

Using Routh Array,

Therefore

The range of

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is

Feedback Controller
For P Controller

Block Diagram of the process with P Controller to control the output of temperature.

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For PI-Controller
Block Diagram

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For PID Controller


Block Diagram

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Discussion
As the figures shown previously, the output of 3 types of controller, namely, P controller, PI controller
and PID controller were compared and the results can be observed from simulink done.
No
1
2
3

Type of Controller
P-controller
PI-controller
PID-controller

Overshoot (%)

Settling Time (s)

Steady State error

24.9
6.26
8.58

72.3
108
73.6

Yes
No
No

From the above observations, it is clear that PI controller gives the best result compared to other type
of controller. The use of P-only controller which not only give more overshoot and longer settling
time, but also steady-state error for the system, hence is not selected. We decided to choose PI
controller to control for our process over PID control because of the less overshoot percentage and
also easier to be tuned compared to PID controller.
Begin with PID controller, the outcome of simulink has given us a hint that the time taken to reach the
new set point is shorter as compared to the actual experiment result.
As for PI controller, the simulated result gives a better outcome as comparison to the result obtained
from the experiment conducted, offset is eliminated. However, for this controller, it takes lengthier
duration to reach the desired value as the order of the system increase that produce sluggish outcome.

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Finally, for P controller, in the conducted experiment, the graph obtained has shown an offset while
reaching the set point value. By comparison to the graphs as simulated, an expected of sluggish
response is common as it takes a long period of time to respond. Both graphs have indicated that the
desired set point value will not be achieved by using P controller alone as it is very sluggish.
Transfer function and gain values included Simulink software may contribute to the errors or deviation
from the actual experiment results. This may cause the delay in the system. Besides, the inaccurate
transfer functions and the assumptions of ideal system might cause the results vary from the actual
results. The order of the transfer function plays an important role in producing accurate outcome. The
transfer function used is first order. This may not be true as the system in the actual experiment is
more complex and may have transfer function other than first order.

Conclusion
Based on the temperature control experiment done for the Process, Instrumentation & Control Lab, a
dynamic model for the physical appendage scheme was developed using the data obtained from the
experiment. An analysis on the basic instrumentation used for the summons arrangement was also
done. Finally, a feedback controller arrangement was designed to fit the process system referring to the
possible parameters that needed to be controlled using different tuning method. Based on the results
obtained and figuring, the best controller system for this process is the PI-controller because of the less
overshoot percentage and also it is easier to be tuned.

Reference
P.Sivakumar, D.Prabhakaran & T.Kannadasan. (2012). Temperature control of shell and tube
heat exchanger by using intelligent controllers. International journal of computational engineering
research, 2(8).
Seborg D.E., T.F. Edgar and D.A. Melliechamp, Process Dynamics and Control, John Wiley
and Sons, New York, 1989, pp 116-118.
The Controller. (n.d.). Retrieved 7 1, 2014, from Control Actions:
http://www.see.ed.ac.uk/~jwp/control06/controlcourse/restricted/course/second/course/lecture5.html
What is an Integral Control System? . (n.d.). Retrieved 7 1, 2014, from Integral Control
Systems: http://www.facstaff.bucknell.edu/mastascu/econtrolhtml/intro/intro3.html

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