IMPLEMENTATION OF LEVEL CONTROL USING

YOKOGAWA DCS
PROJECT REPORT

Submitted by
SHAHID SIDDHIK P
Register No: 0114511002

in partial fulfillment for the award of the degree

of

MASTER OF ENGINEERING
IN
CONTROL AND INSTRUMENTATION

DEPARTMENT OF ELECTRONICS AND

INSTRUMENTATION ENGINEERING
NOORUL ISLAM CENTRE FOR HIGHER EDUCATION
NOORUL ISLAM UNIVERSITY
Kumaracoil, Thuckalay, Tamilnadu, India.
NOV-DEC 2015
 NOORUL ISLAM CENTRE FOR HIGHER EDUCATION

NOORUL ISLAM UNIVERSITY

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION

ENGINEERING

PROJECT WORK
PHASE I

This is to certify that the project entitled IMPLEMENTATION OF

LEVEL PROCESS CONTROL USING YOKOGAWA DCS is the bonafide
record of project work done by SHAHID SIDDHIK P., Register No:
0114511002 of M.E. Control and Instrumentation Engineering during the year
2015-2016.

Project Guide Head of the Department

Dr. S.S. Kumar Dr. G. Glan Devadhas
Associate Professor Associate Professor & HOD
Department of Electronics Department of Electronics
and Instrumentation Engineering and Instrumentation Engineering

Submitted for the

Submitted for Project Viva-Voce examination held on.

Internal Examiner External Examiner

 NOORUL ISLAM CENTRE FOR HIGHER EDUCATION

NOORUL ISLAM UNIVERSITY

DEPARTMENT OF ELECTRONICS AND

INSTRUMENTATION ENGINEERING

DECLARATION

I affirm that the project titled IMPLEMENTATION OF LEVEL

CONTROL USING YOKOGAWA DCS being submitted in partial fulfillment for
the award of MASTER OF ENGINEERING is the original work carried out by
me. It has not formed the part of any other project worksubmitted for award of any
degree or diploma, either in this or any other University.

Name:Shahid Siddhik P.
Register No: 0114511002

I certify that the declaration made above by the candidate is true.

Project Guide

Dr. S.S. Kumar

Associate Professor
Dept of Electronics and
Instrumentation Engineering
 iv

ABSTRACT

Process Control is an engineering that deals with mechanism for maintaining the

output of a specific process within a desired range. One of the most commonly controlled

parameter is Level. Control of level is most important in processes like distillation, boiler

control and tank farm systems.

Level control can be achieved using a feedback loop consisting of Level transmitter

and a Control valve. The transmitter will sense the level and sends the value to the controller.

The controller will do necessary calculations and send the output signal to the final control

element, the control valve. The most commonly used controller modes are PI and PID

control. The tuning is done by Ziegler-Nicholas tuning method with which we can find the

gains for any type of controlling modes.

The Distributed Control system (Yokogawa DCS) is used for developing the control

logic and controlling the pressure station. The advantages of DCS are scalability, redundancy

and an integrated HMI through which we can monitor and control the process.

.
 v

ACKNOWLEDGEMENT

I would like to express my deepest thanks to all people who influenced my

work.

First and foremost, I would like to take this opportunity to thank God almighty
for making the distant mirage of my project a reality.

I express my sincere thanks to our Chancellor Janab Dr.A.P. Majeed Khan

and our Pro-Vice Chancellor Dr. N. Chandrashekhar for having given me
permission to do my project at Noorul Islam University.

I would like to articulate my profound gratitude and indebtedness to

Dr. G. Glan Devadhas, Associate Professor and HOD, Department of Electronics
and Instrumentation who has been a constant motivation and guiding factor
throughout the thesis time in and out as well.

I wish to express my sincere gratitude to my Projector Co-ordinator

Prof. D. Jackson, Associate Professor, Department of Electronics and
Instrumentation for his help and support given to me in completing my project
successfully.

I am highly indebted to Dr. S.S. Kumar, Associate Professor, Department of

Electronics and Instrumentation for allowing me to do my project under his guidance.

I heartily acknowledge the co-operation and moral support of my family and

my friends who always supported me in the entire course of project study and thesis
work.

An undertaking of this nature could never have been attempted without

reference to and inspiration from the works of others whose details are mentioned in
references section. I acknowledge my indebtedness to all of them.
 vi

TABLE OF CONTENTS

PAGE
CHAPTER NO. TITLE NO.

ABSTRACT iv
LIST OF TABLES viii
LIST OF FIGURES ix
LIST OF SYMBOLS x
LIST OF ABBREVATIONS xi
1 INTRODUCTION 1
1.1 OVERVIEW 1
1.2 OBJECTIVES OF THE PROJECT WORK 3
1.3 MOTIVATION OF THE PROJECT WORK 3
1.4 CHAPTER LAYOUT 3
1.5 CONCLUSION 4
THEORY OF OPERATION AND
2 5
LITERATURE SURVEY
2.1 PROCESS CONTROL SYSTEMS 5
2.1.1 Analog Control System 5
2.1.2 Digital Control System 6
2.1.3 Centralized Control System 7
2.1.4 Distributed Control System 7
2.2 Yokogawa DCS 9
2.3 BASIC COMPONENTS 9
2.3.1 FCS (Field Control Station) 10
2.3.2 OPS (Operator Station) 10
2.3.3 Communication Bus 10
2.4 SYSTEM CONFIGURATION 11
2.4.1 Field Control Station (FCS) 11

2.4.2 Engineering / Operator Station (ENG / HIS) 12

 vii

2.4.3 Communication Network 12

2.4.4 Other System Components 13
2.5 CENTUM VP SYSTEM CAPACITY 16
2.6 LITERATURE SURVEY 17
3 METHODOLOGY 19
3.1 INTRODUCTION 19
3.2 P&ID DIAGRAM 19
3.3 I/O ASSIGNMENTS 21
3.4 CONTROLLER DESIGN 22
3.5 Tuning Method 22
EMPIRICAL MODELLING OF LEVEL
3.6 25
CONTROLLER

3.6.1 Empirical Modelling for Level Controller: 25

3.6.2 Tuning the Level Controller and Closed Loop Results 25
3.7 HARDWARE CONFIGURATION DETAILS 27
3.7.1 Adding a new I/O card 27
3.7.2 Assigning Signals to Channels 28
3.8 SOFTWARE CONFIGURATION DETAILS 30
3.8.1 Creating Control Modules 30
3.8.2 Configuring Control Modules 31
HMI DETAILS
3.9 33
4 SIMULATION RESULTS 34
5 CONCLUSION 36
 viii

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

2.1 CENTUM VP Capacity 16

3.1 Instrument Specifications 21
3.2 I/O Assignments 21
 ix

LIST OF FIGURES

PAGE
FIGURE NO. TITLE NO.

1.1 Block Diagram 1

2.1 Analog Control System 5
2.2 Digital Control System 6
2.3 Centralized Control System 7
2.4 Distributed Control System 8
2.5 Yokogawa DCS evolution 9
2.6 Basic Components 10
2.7 FCS Models 11
2.8 Communication System 13
2.9 Other Components 15
3.1 Basic Feedback Control System 19
3.2 P&ID for Pressure process 20
3.3 Flow chart for tuning 24
3.4 PID Tuning Chart 25
3.5 Adding a new card 26
3.6 Final Card Details 27
3.7 Enabling a channel 27
3.8 Channel Assignments 28
3.9 Adding control module 29
3.10 Control modules after creation 29
3.11 Typical configuration AI block 30
3.12 Typical configuration PID Block 31
3.13 HMI for Pressure process station 32
4.1 Open Loop Response 34
4.2 PID Controller response 34
 x

LIST OF SYMBOLS

K System Gain
Kp Proportional Gain
Kd Derivative Gain
Ki Integral Gain
td Time Constant
Dead Time Parameter
 xi

LIST OF ABBREVIATIONS

CCS Centralized Control System

DCS Distributed Control System
FCU Field Control Unit
HIS Human Interface Station
RIO Remote Input Output
LIO Local Input Output
PID Proportional Integral Derivative
HMI Human Machine Interface
FOPDT First Order Plus Dead Time
AI Analog Input
AO Analog Output
DI Digital Input
DO Digital Output
PT Pressure Transmitter
LT Level transmitter
FCV Flow Control valve
 1

CHAPTER 1

INTRODUCTION

1.1 PROCESS OVERVIEW

Distributed control systems (DCSs) are dedicated systems used to control

manufacturing processes that are continuous or batch-oriented,
batch oriented, such as oil refining,
petrochemicals, central station power generation, fertilizers, pharmaceuticals, food
and beverage manufacturing. Fluid
F level is the important physical variable of the
industrial process and it is taken in account for control and monitor using Yokogawa
DCS. Controlled variablee is level of fluid inside the tank. Typically, the variable
chosen to representt the state of the system is termed as controlled variable.
Manipulated variable is inflow rate of the fluid into the tank.
tank. It is the one that can be
changed in order to maintain the controlled variable equal to the set point value. In
other words, the variable
iable chosen to control the system's state is termed as manipulated
variable. It is also called as controlling variable. Some variables cause disturbances in
the process. They are called as load disturbances. The load variable may change either
continuouslyy or sporadically with some function of time. Sometimes it is fixed and not
a function of time. The load variables are uncontrolled independent variables. When
there is a change in these variables, it will upset the control system and their effects
can only
y be corrected in a feedback manner. This means that a change in load variable
is not responded by the controller until they upset the controlled variable.

Figure 1.1 Block Diagram

 2

The speed of changes in a level control loop largely depends on the size and
shape of the process vessel (e.g., largervessels take longer to fill than smaller ones)
and the flow rate of the input and outflow pipes. Manufacturers may use one of many
differentmeasurement technologies to determine level, including radar, ultrasonic,
float gauge, and pressure measurement. The final controlelement in a level control
loop is usually a valve on the input and/oroutflow connections to the tank .Because it
isoften critical to avoid tank overflow, redundant level control systems are sometimes
employed
The measurement and control of flow can be said to be the very heart of
processindustries. Continuously operating manufacturing processes involve the
movement of raw materials, products, and waste throughout the process. Flow process
controller is used to perform the control action on Flow process. In this unit flow is
the process variable and is sensed and given to controller. A Differential Pressure
Transmitters used to measure the Flow of the fluid through orifice plate. In this unit,
pump sucks the water from reservoir tank and gives it to control valve. Every internal
transaction is in voltage. Here, PC acts as error detector and controller. According to
the error signal, computer develops a control signal. This control signal is given to I/P
Converter which operates the control valve. Control valve acts here as final control
element which controls the flow of the fluid in pipeline by varying stem position of
the control valve. Flow is the manipulated level signal here and is given to the Data
acquisition card. By pass liens provided to avoid the pump overloading. Data
Acquisition card has ADC and DAC, so that it acts an effective link between the
process and the controller.
 3

1.2 OBJECTIVES OF THE PROJECT WORK

To model and analyse the Level process station
I/O analysis and hardware configuration in DCS
Software configuration and HMI development in DCS
To simulate the system in MATLAB/SIMULINK

1.3 MOTIVATION OF THE PROJECT

DCS based control system is easy to implement without large modification to

the original system. The multimedia output provided helps the user to interact better
with the system. The signal and conditions can be effectively sensed without fails and
can be taken for processing. The whole system can be integrated for the networking
purpose where automatic controls of the substation can be carried with no manual
intervention. Hence this study is conducted.

1.4 CHAPTER LAYOUT

The thesis contains four chapters describing the design and control approach
for a Pressure Control Process using DCS. The chapter layout of the thesis is as
follows:

Chapter 1 : This chapter deals with the introduction of the project

Chapter 2 : Theory of Operation and Literature review associated with the

project work.

Chapter 3 : Deals with the various Methodologies followed in the project.

Chapter 4 : Deals with Simulation results

Chapter 5 : Conclusion
 4

1.5 CONCLUSION

This chapter describes an overview of the project work. The chapter also deals
with the objectives and motivation of the project. The chapter wise organization of the
thesis is also presented in this chapter.
 5

CHAPTER 2

THEORY OF OPERATION AND LITERATURE SURVEY

2.1 PROCESS CONTROL SYSTEMS

Process Control systems are primarily classified into

Analog Control systems

Digital Control Systems

2.1.1 Analog Control System

Analog control systems use operational amplifiers to do the control function.

Fig 2.1Analog Control System

In an analog control system, the process parameters are measured by the

transmitter. The transmitter generates 4-20 mA current signal corresponding to the 0-
100% process parameter measured. This signal is converted to 0-5V DC and is given
to the operational amplifier. The operational amplifier calculates the output based on
the input and the set point. The 4-20 mA current signal is given toan I/P converter and
then to the final control element.
 6

2.1.2 Digital Control System

Digital control system uses microprocessors to do the control function. In a

digital control system, the process parameters are measured by the transmitter. The
transmitter generates 4 to 20 mA current signal corresponding to 0 to 100% of the
process parameter measured. This signal is converted by signal converter into a
voltage signal. Analog to Digital Converters are used to convert this analog signal to
digital signal. This digital signal is given to the microprocessor for processing. Digital
Control system uses microprocessors to do the control function.
Digital control systems are preferred over analog control systems since it is easy to
interface with computers for data analysis.

Fig 2.2 Digital Control System

Digital control systems are classified into

Centralized Control Systems (CCS)

Distributed Control Systems (DCS)
 7

2.1.3 Centralized Control System

CCS is a centralized control, centralized monitoring system. All the inputs

from the field are given to a single CPU. The relevant set points are also given to the
same CPU. The outputs are also taken from the same CPU.

Fig 2.3 Centralized Control System

In a Centralized Control System, all the field inputs PV1 to PVn are fed to a
single CPU, the relevant set points SV1 to SVn are also given to the same CPU and all
the outputs MV1 to MVn are also taken from the same CPU. Hence if the CPU fails,
the whole plant gets affected.

Drawbacks of Centralized Control System

If the CPU fails, entire plant gets affected

No redundancy concept

2.1.4 Distributed Control System

DCS is distributed control and centralized monitoring system. In a Distributed

Control System, the control function is distributed, but the monitoring is still
centralized. All the n field inputs are not fed to a single CPU. Instead they are
 8

distributed among multiple CPUs. In DCS terminology, CPUs are referred as Field
Control Stations (FCS).

Let us consider that there are n parameters from the field to be monitored and
controlled in a plant. The signal distribution is done as shown in the figure.

Fig 2.4 Distributed Control System

Advantages of Distributed Control System

Control function is distributed among multiple CPUs (Field Control Stations).

Hence failure of one FCS does not affect the entire plant.
Redundancy is available at various levels.
Generation and modifications of the interlocks are very flexible and simple.
Information regarding the process is presented to the user in various formats.
Maintenance and troubleshooting becomes very easy.
Cost effective in the long run.
 9

2.2 YOKOGAWA DCS

Yokogawa were the pioneers in introducing the first Distributed Control

System to the world. Centum was the first Distributed Control System introduced by
Yokogawa in the year 1975. Yokogawa continued its research in the DCS field and
introduced many systems in line with the technological development.

Fig 2.5 Yokogawa DCS evolution

2.3 BASIC COMPONENTS

In a Distributed Control System, the control function is distributed, but the

monitoring is still centralized. The basic components of a DCS are:

Field Control Station.

Operator Station.
Communication Bus.
 10

Fig 2.6 Basic Components

2.3.1 FCS (Field Control Station)

The Field Control Station is used to control the process. All the instruments and
interlocks created by software reside in the memory of the FCS. All the field
instruments like transmitters and control valves are wired to the FCS.

2.3.2 OPS (Operator Station)

The operator station is used to monitor the process and to operate various
instruments.

2.3.3 Communication Bus

Communication bus is used to communicate between the Field Control Station

and the Operator Station.
 11

2.4 SYSTEM CONFIGURATION

For a Distributed Control System to function three major components are

necessary.

Field Control station

Engineering / Operator Station (ENG / HIS)
Communication Network

2.4.1 Field Control Station (FCS)

This is the interface between the field instruments and the control room. This is
the component where all the control functions are executed and hence is a very
important and critical component in the overall system. Based on the I/O modules
used, there are two models of the FCS, namely the FCS for RIO and FCS for FIO.
RIO means Remote Input/Output and FIO means Field network Input/Output.

Fig 2.7 FCS Models

Under RIO Type, two types of FCS are available:

PFCS - This FCS uses Remote I/O modules and is a compact FCS. This FCS is
usually installed near the equipment or process it controls and is ideal for
communicating with subsystems. It is normally used for small plants. A single
configuration is specified as PFCS-S and a duplexed configuration is PFCD-S.
LFCS - This FCS also uses Remote I/O modules and is used for large plants. A
single configuration is specified as AFS10S and a duplexed configuration is
AFS10D.
 12

Under FIO Type, three types of FCS are available:

KFCS - This FCS uses the Field Network I/O modules, which are compact in
size and supports different types of field connections. It is normally used for
large plants. A single configuration is specified as AFS30S and a duplexed
configuration is AFS30D.
FFCS - This FCS also uses the Field Network I/O modules and is a compact
FCS. The I/O modules are integrated in to the Field Control Unit. Preferred for
small plants. A single configuration is specified as AFF50S and a duplexed
configuration is AFF50D.
FFCS-L - This is the latest FCS from Yokogawa. Also called as the V net/IP
system. This FCS has been introduced with changes in communication
protocol.The I/O modules are integrated in to the Field Control Unit and the
FCS can be used both for small as well as large applications. A single
configuration is specified as AFV10S and a duplexed configuration is
AFV10D.

All the FCS can be used in either a single configuration or duplexed configuration.
Single configuration uses a single processor card while a duplexed configuration uses
a redundant processor card configuration. A duplexed configuration is normally
preferred.

2.4.2 Engineering / Operator Station (ENG / HIS)

The operator controls the plant from this station. The same component can be
used to do the configuration changes. The operator station or the Man Machine
Interface (MMI) is called the Human Interface Station (HIS) in CENTUM VP system.
The component used for configuration is called the Engineering station (ENG). Both
these components can reside in one hardware.

2.4.3 Communication Network

The FCS and HIS are connected via a real time control network. This communicates
all theparameters to and from the Field Control Station to the Human Interface
 13

Station. The communication cable for the control network can be an Ethernet cable or
V net / VL net cable.

Fig 2.8 Communication System

The type of communication cable used is decided by the FCS used in the CENTUM
VP system. If the communication network is Ethernet based, the system is called a V
net / IP system and if it is V net or VL net based it is called as a V net system.

2.4.4 Other System Components

Various other components also form part of the CENTUM VP system. Each of the
components on the real-time network is called as a station and has a unique station
address.

Safety Control Station (SCS)

Safety Control Station is the component that performs the processing and
logical computation of Emergency Shutdown inputs and outputs. Yokogawas
Emergency shutdown system is called ProSafe System.
 14

ProSafe COM

ProSafe COM is a component of the ProSafe System, which connects the DCS
System to the ProSafe System.

Communication Gateway Unit (CGW)

The Communication Gateway Unit is a gateway that connects the supervisory

computer with the VL net or V net, which are the control communication networks
for the CENTUM VP system.

EXAOPC Server (EXAOPC)

Exaopc is an OPC (OLE for Process Control, OPC is a standard interface

developed by the OPC Foundation) server, which can be connected to a variety of
DCS (Distributed Control Systems). With the package, the OPC client can acquire
and define process data from various DCS and receive alarm events.

Plant Resource Manager (PRM)

Field devices have become more intelligent. These intelligent field devices
communicate digitally to the Field Control Station. Plant Resource Manager
handles field device management and maintenance work. Plant Resource Manager
maintains a historical record of device parameters and maintenance records.

EXAQUANTUM Server

A Distributed Control System typically produces large amounts of data that

must be converted into information to facilitate management decisions and
optimize the operation of the plant. Exaquantum is a Plant Information
Management System (PIMS), which processes these data and delivers information
to all decision makers throughout the organization.
 15

Fig 2.9 Other Components

 16

2.5 CENTUM VP SYSTEM CAPACITY

The number of Field Control Stations to control a process plant is decided

based on the Input/Output count, Input/Output segregation based on the different
sections of the plant, Field Control station CPU load and the Field Control Station
hardware capabilities.

The number of Human Interface Stations is decided based on the number of

operators required to control the process plant considering number of screens required
during startup and shutdown situation.

The table below shows the capacity of a CENTUM VP system.

Maximum number of stations per domain 64 stations

Maximum number of HIS per domain 16 stations
Station number for HIS 1 to 64 in descending order
Station number for FCS 1 to 64 in ascending order
Maximum number of domains 16 per system
Numbering of domains 1 to 64
Maximum number of stations per system 256 per system

Table 2.1 CENTUM VP Capacity

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2.6 LITERATURE SURVEY

Modeling, Simulation and Control of Temperature and Level in a Multivariable

Water Tank Process
VassiliosTzouana, Sanjo Peter, Matthew Stevenson, Truong Doan
This paper is concerned with the design of a water tank process and
experimental evaluation of feedback control structures to achieve water level and
temperature control at desired set point values. The manipulated variables are the
pump power, on the water outflow line, and heat supply to the tank. Detailed, first
principles-based, dynamic models as well as empirical models for this interactive and
multivariable process have been developed and used for controller design.
Furthermore, this experimental study entails and discusses the design of the water tank
process and associated instrumentation, real time data acquisition and control using
the DeltaV distributed control system (DCS), process modeling, controller design, and
evaluation of the performance of tuning methodologies in a closed loop manner.

Importance of Three-Elements Boiler Drum Level Control and its Installation in

Power Plant
Sanjoy Kumar Chakraborty ,Nilotpal Manna and SurodhDey
Conversion of water into steam is the primary function of a utility boiler. The
steam pressure is used to turn a steam turbine thus, generating electricity. Within the
boiler drum there exists a steam/water interface. Boiler steam drum water level is one
of the important parameters of power plant that must be measured and controlled. For
safe and efficient boiler operation, a constant level of water in the boiler drum is
required to be maintained. Too low water level may cause damage boiler tube by
overheating. Turbine may also be damaged by moisture or water treatment chemicals
carryover. The amount of water entering the boiler drum must be balanced with the
amounts of steam leaving to accomplish the constant water level in the drum.
Therefore it is extremely important to have the knowledge of the operating principles,
installation requirements, strength and weaknesses of drum water level control system.
 18

Ignoring these considerations can result in misapplication, frequent maintenance,

unsafe operation and poor instrument as well as system performance

A Modelling and Analysis of Level ProcessUsing Different Control Techniques

Pradibaa.S, Srimathi.R, Suganya.S, Sivaranjani.T, Aravind.P
The work focuses on the development of model and analysis of different
control techniques for level process. The objective of this paper is to maintain the
liquid level in a cylindrical tank at desired set value. The process is identified by step
test. Based on the obtained model Ziegler-Nichols and Internal Mode control
techniques are employed. The results are compared and the best among the two is
validated. This comparative study is carried out and the best one will be highlighted
with the help of time domain analysis.
 19

CHAPTER 3

METHODOLOGY

3.1 INTRODUCTION

Every system that runs autonomously will need a very reliable controller to
control and regulate all the inputs and outputs related the environment of the system.
Usually a controller is considered reliable when the controller itself can detect the
inaccuracy in its reading and adjust accordingly to the inputs and output so that the
desired results can be achieved. Closed loop controlling system is the terms given to
this controller with ability and capability to detect and adjust its input or output
condition based on the error detected in its reading. This is called feedback and the
feedback is important in closed loop controlling system to ensure the controller is
reliable.

Figure 3.1: Basic Feedback Control System

3.2 P&ID DIAGRAM

P&ID stands for Piping and Instrumentation Diagram. P&ID shows the outline
of the process units and the piping that connects them as well as a symbolic
representation of the instrumentation and control system.P&IDs typically use symbols
to represent various types of instrumentation devices. These symbols, normally called
ISA symbols, are defined by ISA-5.1-1984

ISA symbols indicate by graphical means where a device is located or accessed

(on the control panel, in the field, etc.) as well as the type of signal (pneumatic,
electric, etc.) that interconnects devices or functions. They also provide for a device
 20

tag that consists of amnemonic designation for the overall function of a device plus
additional letters or numbers that provide for unique loop identification

Figure 3.2 P&ID for Levelprocess

The measurement and control of flow can be said to be the very heart of
processindustries. Continuously operating manufacturing processes involve the
movement of raw materials, products, and waste throughout the process. Flow process
controller is used to perform the control action on Flow process. In this unit flow is
the process variable and is sensed and given to controller.. In this unit, pump sucks the
water from reservoir tank and gives it to control valve. Every internal transaction is in
voltage. Here, PC acts as error detector and controller. According to the error signal,
computer develops a control signal. This control signal is given to I/P Converter
which operates the control valve. Control valve acts here as final control element
which controls the flow of the fluid in pipeline by varying stem position of the control
valve. Flow is the manipulated level signal here and is given to the Data acquisition
card. By pass liens provided to avoid the pump overloading. Data Acquisition card has
ADC and DAC, so that it acts an effective link between the process and the controller.
 21

The hand valves HV1 is for regulating the out flow whereas the valve HV2 is fro
quick drain.

HV3 is for reducing any back pressure to the reservoir pump and the valve HV4 is
to manually adjust the input flow rate of the fluid from the tank

Sl No Device Type Range

1 Level Transmitter capacitive 0-700
2 Pressure regulator 0-25
3 Pneumatic Control Valve 0-15
4 Rotameter CD200 0-1000
5 Electro Pneumatic 760 0-15
converter

Table 3.1 Instrument Specifications

3.3 I/O ASSIGNMENTS

Before starting the project, the I/O assignment is done. This process is done
right after the P&ID verification to check if the I/Os are in accordance with the
system and if the I/Os can be accommodated in the system.

Typical format includes Tag no, Description of the service, Signal direction,
Signal type and the assigned Card and Channel no. Here we have one analog input
LT-201 and an analog output FCV-201 Both are 4-20 mA signals with LT-201 being
an input to the system and FCV-201 being an output signal from the system. The LT-
201 signal is connected to AI-01 Ch-02 and FCV-201 is connected to AO-01 Ch-02.

Sl Signal Assigned Channel

Tag No Description Direction
No type card No
Outlet Level
1 LT-201 Input 4-20 mA AI-1 Ch 2
Transmitter
FCV-
2 Control Valve Output 4-20 mA AO-1 Ch 2
201
Table 3.2 I/O Assignments
 22

3.4 CONTROLLER DESIGN

A controller in proportional mode (P mode) outputs a signal (m(t)

manipulated variable) which is proportional to the difference between the target value
(SP: set point) and the actual value of the variable (c(t) controlled variable). This
simple scheme works well but typically causes an offset. The only parameter to tune is
the controller gain Kc (or the proportional band (%PB=100%/Kc) if your controller
uses this parameter instead).

A controller in proportional/integral mode (PI mode) works in a fashion similar

to a controller in P mode, but also integrates the error over time to reduce the residual
error to zero. The integral action tends to respond slowly to a change in error for large
values of the integral time Ti and increases the risks of overshoot and instability for
small values of Ti. Thus, the two parameters which require tuning for this control
method are Kc (or PB%) and Ti (or the integral gain, defined as Gi= 1/Ti)

3.5 TUNING METHOD

The steps for tuning are as follows

1. Set the controller in the mode you want to use: P, PI, PD, or PID. Follow
the instructions to adjust every parameter relevant to the mode you are
using. Note that you can use the PID mode to perform any of the modes
by simply setting the parameters to appropriate values (e.g. Td = 0 for PI mode)

Adjusting the P action

2. With the controller in manual mode, turn off the integral and derivative actions
of the controller by setting Ti and Td respectively to the largest possible value
and 0
3. Set the controller gain Kc to an arbitrary but small value, such as 1
4. Place the controller in the automatic (closed-loop) mode.
5. Make a step change in the set point and observe the response of the controlled
variable. The set point change should be typical of the expected use of the
 23

system. Since the controller gain is low, the controlled variable will take a
relatively long time to stabilize (i.e. the response is likely to be overdamped).
6. Increase Kc by a factor of 2 and make another step change in the set point to
see the effect on the response of the controlled variable.
The objective is to find the value of Kc at which the response becomes
underdamped and oscillatory. This is the ultimate controller gain. Keep
increasing Kc by factors of 2, performing a set point change after each new
attempt, until you observe the oscillatory response.
Once the ultimate controller gain is reached, revert back to the previous value
of Kc by decreasing the controller gain by a factor of 2. The P action is now set
well enough to add another control action if required.
Adjusting the I action
7. Start bringing in integral action by setting the integral time Ti at an arbitrarily
high value. Decrease Ti by factors of 2, making a set point change after each
setting.
Do so until you reach a value of Ti at which the response of the controlled
variable becomes underdamped and oscillatory. At this point, revert back to the
previous value of Ti by increasing Ti to twice its value.
The I action is now set and you can now proceed to the adjustment of the D
action if required.
Adjusting the D action
8. Start bringing in derivative action by setting the derivative time at an arbitrarily
low value. Increase Td by factors of 2, making a set point change after each
setting.
Do so until you reach the value of Td that gives the fastest response without
amplifying the overshooting or creating oscillation.
The D action is now set.
Fine-tuning of the parameters
9. Fine-tune the controller until the requirements regarding the response
time and overshooting of the controlled variable are satisfied.
 24

Fig 3.3 Flow chart for tuning

 25

3.6 EMPIRICAL MODELLING OF LEVEL CONTROLLER

Empirical models between controlled and manipulated variables are being

developed by collecting and analyzing process data gathered under controlled, open
loop conditions by stepping the manipulated variables. Using such models and certain
tuning methods, initial tuning parameters for the water level and temperature PI
controllers are calculated. Finally, the closed loop performance of the PI controllers is
tested for set point changes and the interaction of the two control loops is being
accessed.

3.6.1 Empirical Modelling for Level Controller:

The water tank level is held constant by equalizing the water flow out and the
flow in. Then, the flow out is changed in a step wise manner and the level response is
being observed. A series of step changes is introduced while the water level is
maintained within range. As expected, the level behaves like an integrating (or ramp)
process. Using step test data, an average time delay (in min) and gain ( in % of
level/min per % of power) were calculated. These values are as follows:

Level Process Gain:

Kpl= 0.073 %Level/min

Level Time delay:

l= 8.5 sec =0.14 min

3.6.2 Tuning the Level Controller and Closed Loop Results:

Using the IMC tuning method, and for various values of the closed loop time
constant, c, the tuning parameters are shown in the table with the integral time in
seconds.

By comparing the different system responses, it seems that when Kc=34.5 and
ti=76.5 sec, the level responds very well to set point changes
 26

c (CL time Kc i (Integral

Sl No constant) (Gain) Time)

1 8.5 73.32 25.2

2 17 54.35 42
3 25.5 42.8 58.8
4 34 34.5 76.5
5 42.5 29.89 92.4
6 51 25.95 109.2

Table 3.3 Level Controller tuning using IMC methods

 27

3.7 HARDWARE CONFIGURATION DETAILS

3.7.1 Adding a new I/O card

Go to the I/O section in the Controller, right click and select New Card

Fig 3.4 Adding a new card

Here we can enter the Description, change the Card class, Type and Slot position. In
this particular project, C01 is the Analog Input card and C02 is analog output card.
Both cards have 8 Channels for receiving I/O.
 28

Fig 3.5 Final Card Details

3.7.2 Assigning Signals to Channels

Dig into the card and right click the channel properties.

Fig 3.6 Enabling a channel

 29

Here we can enable the channel and add details like Description and Device Tag
(Signal name)

Fig 3.7 Channel Assignments

 30

3.8 SOFTWARE CONFIGURATION DETAILS

3.8.1 Creating Control Modules

Right click inside the control strategy and add new control module. Here we can add
details like module name, and algorithm type (FBD, ST etc.)

Fig 3.8 Adding control module

Fig 3.9 Control modules after creation

 31

3.8.2 Configuring Control Modules

For blocks configured as AIs the range of the transmitter has to be entered as
AI$OUT_SCALE. Also we can configure the alarm limits also.

Fig 3.10 Typical configuration AI block

For Configuring PID block, both Input and output has to be linked and parameters like
Kp(Gain), Ki(Reset) and Kd(Rate) has to be entered.
 32

Fig 3.11 Typical configuration PID Block

 33

3.9 HMI DETAILS

Given below is the HMI developed for the level process

Fig 3.12 HMI for Level control station

 34

CHAPTER 4

SIMULATION RESULTS

Dynamics of many industrial processes can be in practice sufficiently modelled

by the stable first-order plus dead time (FOPDT) transfer function:

( )=

Where

K is the system gain

td > 0 is the time constant and
> 0 is the dead time parameter.

The model allows simple experimental identification from the step response,
which can be in most cases easily measured.

For PID controller

From empirical tuning data,

Kp=34.5
Ti=76.5
 35

Figure 4.1 Output with PID Controller

 36

CHAPTER 5

CONCLUSION

Fluid level is the important physical variable of the industrial process and it is
taken in account for control and monitor using Yokogawa DCS.

Distributed control systems (DCSs) are dedicated systems used to control

manufacturing processes that are continuous or batch-oriented, such as oil refining,
petrochemicals, central station power generation, fertilizers, pharmaceuticals, food
and beverage manufacturing. The application of DCS in Level Control applications
like Tank farm management, Boiler drum level control etc has been proved to increase
the efficiency. Also the initial investment can be reasoned with the profits achieved
during long run.

DCS based control system is easy to implement without large modification to

the original system. The multimedia output provided helps the user to interact better
with the system. The signal and conditions can be effectively sensed without fails and
can be taken for processing. The whole system can be integrated for the networking
purpose where automatic controls of the substation can be carried with no manual
intervention.
 37

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Modeling, Simulation and Control of Temperature and
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3. Brendan Galloway, Gerhard Hancke,P. (2008) Introduction to Industrial

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 38

8. Athi Thilagalakshmi R, Vijay Anand L D (2013), Simulation of Neuro-PID

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