Experiment 9

Summary
The objective of this experiment is to get familiar with how to develop a first order plus time
delay (FOPTD) model using step test response of a chemical process and after that, to design
and tune Proportional Integral Derivative (PID) controllers using the developed model. In this
experiment a definite tank level was maintained by using automatic valves controlled by a
computer system. The model parameters were calculated from the observed data obtained
from the response graph of an open loop system. These parameters were used to design PI
and PID control systems. . In this experiment, pneumatic controlled system (compressed air)
was used to control the valve. An air-to-open valve was used as the final control element.
First the set point of this experiment was to a certain step (15.7 mA to 16.2 mA) and the
response of the process was observed by using a computerized control interface. All the
control parameters such as gain, time constant, time delay were directly measured by the
response of the process. The software has the provision for saving the course of control action
and the necessary plots. The system parameters were found to be, Kc=0.086, l= 191s for PI
controller and Kc=0.087, l= 191.5 s, d=0.498 s for PID controller.
Experimental Setup
Fig 01: Experimental setup of study of process control II
Background
The standard form of a first order plus time delay model is
() =

+ 1
The standard form of a PI controller is

1
)

= (1 +
The standard form of a PI controller is
= (1 +
1
+ )

IMC Method for Controller Design

Controller settings for PI controller
and =
Controller settings for PID controller
1 +/2
+/2
= + /2
A typical closed loop process diagram appears like-
and
2+
Open Loop Block Diagram
Figure 02: Open loop block diagram
Closed Loop Block Diagram
Figure 03: Closed loop block diagram
Observed Data
Figure 04: Graph for step response of the process
From graph,
System gain, K1 =
86.550.5
16.215.7
= 72
For 63.2% response,
Time constant, 1 = (1500-1309) s
= 191 s
Time delay, = 1 s
Calculated Data
Direct Synthesis Method
Taking c = 30 s (< c < 1 )
Controller Gain, Kc = 0.086
Time delay, = 191 s
Internal Model Control (IMC) Method

1. Proportional-Integral (PI) controller
Design value for the PI controller,
Taking c = 30 s (< c < 1 )
Controller gain, Kc = 0.086
Reset time, I = = 191 s
2. Proportional-integral-differential (PID) controller

Design value for the PID controller,
Controller gain, Kc= 0.087
Reset time, I= 191.5 s
Derivative time, D = 0.498 s
Sample Calculation
Direct Synthesis Method
Taking c = 30 s (< c < 1 )
1
Controller gain, Kc =
=
K c+
1
191
72 1+30
= 0.086
Time delay, = 191 s
Internal Model Control (IMC) Method

1. Proportional-Integral (PI) controller
Design values for the PI controller,
Taking c = 30 s (< c < 1 )
1
Controller gain, Kc =
=
K c+
1
191
72 1+30
= 0.086
Reset time, I = = 191 s
2. Proportional-integral-differential (PID) controller

Design values for the PID controller,
Controller gain, Kc=
+ 2
K c+
2
191+0.5
72 36.67+2.5
= 0.087
Reset time, I= +
= 191 +
1
2
= 191.5 s
Derivative time, D =
=
2+
1911
2191+1
= 0.498 s
Results and Discussions

In this experiment, a process of water tank system was presented by an open loop system. In
this process, height of water tank can be changed by changing the inlet water flow rate.
Response of the system (height of tank) to a step change in the input (electrical flow that
controls the valve of water) was observed from a graph of Height vs Time (figure 4). From
this figure, the design parameter of PI and PID controller was calculated.
Design values for proportional-integral (PI) controller parameters were found
Kc = 0.086, I = 191 s
Design values for proportional-integral-differential (PID) controller parameters were found
Kc = 0.087, I = 191.5 s, D =0.498 s
In figure 6 response of system with PID controller system was shown for design parameters.
To get better performance, a system can be tuned using new design parameters. But as the
system reached to a steady state with the design parameters and no oscillation was seen,
tuning with different values was not attempted.
Proportional control speeds up the process response and reduces the offset. The addition of
integral control action eliminates offset but tends to make the response more oscillatory.
Adding derivative action reduces both the degree of oscillation and the response time.
Increasing the controller gain tends to make the process response less sluggish. However, if
too large the value of Kc is used. The response may exhibit an undesirable degree of
oscillation or even become unstable.
Increasing the integral time, l usually make PI and PID control slower. Theoretically, offset
will be eliminated for all value of l. But for very large value l , the controlled variable will
return to the set point very slowly after a disturbance or set point change occurs.

Experiment 9

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Summary

Fig 01: Experimental setup of study of process control II

The standard form of a PI controller is

IMC Method for Controller Design

Controller settings for PID controller

A typical closed loop process diagram appears like-

Open Loop Block Diagram

Figure 02: Open loop block diagram

Closed Loop Block Diagram

Figure 03: Closed loop block diagram

Figure 04: Graph for step response of the process

Internal Model Control (IMC) Method

2. Proportional-integral-differential (PID) controller

Internal Model Control (IMC) Method

2. Proportional-integral-differential (PID) controller

Controller gain, Kc=

Results and Discussions

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