Manipal University

Department of Chemical Engineering

CE 1833- Process Dynamic Control LAB

IV YEAR, 8TH SEMESTER, 2019

EXPERIMENT # 6
Cascade control for liquid level in non-interacting tanks
INSTRUCTOR:
Dr. Anees Y. Khan
Dr. Abhishek Sharma

SUBMITTED BY: Mustafa Barwaniwala

Experiment carried on: 5/03/19
Report submitted on: 12/03/19

PRELAB (10) ______

EXECUTIVE SUMMARY (10) ______

INTRODUCTION/OBJECTIVES/SCOPE/PROCEDURE (30) ______

RESULTS & DISCUSSION (30) ______

CONCLUSIONS (5) ______

REFERENCES (5) ______

APPENDIX
a) Original data, sample calculations, other information (5) ______

GENERAL COMPLETENESS
a) Conciseness and neatness (5) ______
TOTAL (100) ______
Contents
Executive Summary ................................................................................................................... 3
Introduction ................................................................................................................................ 4
Objective .................................................................................................................................... 5
Experimental Set Up .................................................................................................................. 6
Procedure ................................................................................................................................... 6
Results & Discussion ................................................................................................................. 7
Conclusion ................................................................................................................................. 7
References .................................................................................................................................. 7
Appendix .................................................................................................................................... 8
Executive Summary
An experiment was carried out to study the response of cascade control in non-interacting
tank. The experiment was carried out at set point of 50mm and a step up was given at the set
point of magnitude of 50mm. The response time as 9 minute for the first set point an 18
minutes for the second set point an offset of zero was observed according to the data obtained
shown in appendix. The experiment was carried out successfully and it was found that
cascade control is efficient for controlling tank level in non-interacting tanks.
Introduction
Cascade control
It is an approach that can significantly improve the dynamic response to disturbance by
employing a secondary measurement and a secondary feedback controller. The secondary
measurement point is located so that it recognize the upset condition sooner that controlled
variable but the disturbance is not necessarily measured [2]

Figure 1cascade block flow diagram for two non-interacting system

The controls of liquid level in multiple tanks and flow between the tanks are basic problems
in the process industries. The process industries require liquid to be pumped and stored in the
tanks and then pump it to another tank. [1]

In non-interacting tank system, we assume that the tanks have uniform cross sectional area and
the flow of resistance is linear. A mass balance equation gives the transfer function around the
tanks and that relates H2 to Q. [2]

Figure 2Two Tank- non interacting process [2]

Where
h1 = Height of liquid in tank 1, (cm)
h2 = Height of liquid in tank 2, (cm)
q(t) = Rate of flow of liquid into the tank 1, (cm3/min)
q1 = Rate of flow of liquid out of the tank 1, (cm3/min)
q2 = Rate of flow of liquid out of the tank 2, (cm3/min)
A1= Cross sectional area of tank 1, (cm2)
A2= Cross sectional area of tank 2, (cm2)
R1= Resistance for liquid out in tank 1,
R2 = Resistance for liquid out in tank 2,
Ʈ1 = Time constant of tank1,
Ʈ2 = Time constant of tank2,

The two tank non-interacting liquid level system is shown in Fig. 1. It consists of two tanks,
namely tank 1 and tank 2. Various parameters are mentioned above. The outlet flow from the
tank 1 discharges directly into tank 2. Moreover, liquid flow through valve R1 depends only
on h1. The variation in h2 in tank 2 does not affect the transient response occurring in tank 1.
Hence, this type of a system is known as a non-interacting system. By simple mathematical
calculation one can get transfer function of system. Let us apply mass balance equation to
tank 1 as[2]

𝑞 − 𝑞1 = 𝐴1( 𝑑ℎ1/ 𝑑𝑡) (1)

Similarly, applying mass balance to tank 2 gives

𝑞1 − 𝑞2 = 𝐴2( 𝑑ℎ2/ 𝑑𝑡) (2)

Combining (1)-(4), transfer functions for tank 1 and tank 2 are obtained as
𝑞1(𝑠) 1
𝑞 (𝑠)
= (𝜏1𝑠+1) (5)
𝑞2(𝑠) 1
𝑞1(𝑠)
= (𝜏2𝑠+1) (6)

Where, Ʈ1= R1 A1 and Ʈ2 = R2 A2. Therefore the overall transfer function is determined as
ℎ2(𝑠) 1 𝑅2
𝑞(𝑠)
= (𝜏1𝑠+1) (𝜏2𝑠+1)
(7)

For step change q(s) = A/S, putting this in equation.7

𝑅2 𝐴
ℎ2(𝑠) = 𝑆 (𝜏1𝑠+1)(𝜏2𝑠+1)

Objective
To study the cascade control of liquid level in tank in non-interacting tank system
Experimental Set Up

Figure 3 Experimental Set Up

The setup consist of a liquid level sensing element i.e. metal probe, which is inserted vertically
into the medium from the top of the tank into the liquid .the probe is used as ground reference
the level transmitter is used to measure the level of water in the tank. A fluid level of water is
to be maintained in the tank with the help of the controller and the software. The controller
sends signals to the dosing pump to perform the specified i.e. pumping the fluid from the drain
tank to single tank. The level transmitter gives DC output to the water level in the controller
process and the process variable input with respect to the set point and gives the connective
signal to the doing pump so as to control the desired value of heater in tank. In this system for
tank 2 the disturbance is the outlet flowrate of tank1 and for tank 2 the disturbance is inlet
flowrate of tank1 so to maintain the level of tank2 first maintain the flowrate so that the level
of tank 1 is maintained.

Procedure
1. Switch on the power supply to the setup
2. Switch on the computer and all the switches on the control panel also switch on the
pump.
3. Open the software in the P.C. through which we send the signals to the controller.
4. A setup valve of 15 cm that could be used in different setting of PID controller and the
time taken at each case can be measured and compared.(time taken to reach set point)
5. The level transmitter sensor sends the signals which corresponds to the level in tank in
terms of current signals.
6. The controller sends corrected output signals to the pump.
7. The pump maintained the flow of water in second tank in order to maintain or achieved
the corrected level.
8. For each new setting the level has to be recorded at an interval of 30 sec.
Results & Discussion
Level V/s Time
120
100
80
Level (mm)

60
40
20
0
0 5 10 15 20 25 30 35 40 45
-20
time (min)

Tank 2(mm) Tank 1(mm)

Figure 4 Response v/s time

Data was obtained for cascade control at set point = 50 mm in tank 2 (lower tank) with P=1
I=0.01 for master control and P=1 I=0 for slave control. The response time was around 9
minutes. A step up was given on set point of 50 i.e. set point = 100. The response time after
step up was 18 minutes hence almost twice as much for the initial set point. Offset in both the
cases was 0. The level in tank 1 reaches 0 for the set point of 100 because the resistance in tank
1 is too low maintain the tank level in Tank 2 as compared to resistance in Tank2.

Conclusion
The experiment was carried out successfully and it can be concluded that cascade system is
efficient as the offset is zero and steady tank level was obtained as well.

References
[1] W. Boltan, Electronic control system in mechanical and electrical engineering, Singapore:
Longman, 1999.
[2] D. R. Coughanowr and S. E. LeBlanc, "Controllers and Final Control Element," in Process
System Analysis and Control, New York, McGray Hills, 2009, pp. 194-195.
Appendix
Observation data obtained for the experiment is shown in Table 1.

Table 1 Observation data

Time (min) Tank Tank

2(mm) 1(mm)
0 0 61
1 1 62
2 15 64
3 18 64
4 28 64
5 30 65
6 33 65
7 45 65
8 48 68
9 50 50
10 50 50
11 50 50
12 50 50
13 50 50
14 56 25
15 60 29
16 64 30
17 65 34
18 69 40
19 69 40
20 71 45
21 74 45
22 76 48
23 80 49
24 86 50
25 87 50
26 89 54
27 90 55
28 92 57
29 95 57
30 96 43
31 98 38
32 100 29
33 100 14
34 100 0
35 100 0
36 100 0
37 100 0
38 100 0
39 100 0