2.
13 Level Control
A level control loop is a fundamental process control system
used to maintain the liquid level within a tank or vessel at a
desired set point. In this system, the liquid level inside the tank
is continuously measured by a level transmitter (LT). The
transmitter sends this signal to the level controller (LC) which
compares the actual level (process variable) with the desired
level (set point). If there is any deviation or error, the controller
produces an output signal to adjust the level control valve. This
valve regulates the outflow of liquid from the tank opening more
if the level is too high or closing if the level is too low. The
control loop operates continuously to ensure that the tank level
remains stable despite variations in inflow or process conditions.
This type of feedback control is essential for safe, efficient, and
automatic operation in industrial processes involving storage
tanks, boilers, and chemical reactors.
Figure: Diagram of Level Control loop
2.13.1 Application of level control loop
Widely used in boilers, water treatment plants, chemical tanks,
oil storage units, and process industries where constant liquid
levels are critical.
2.13.2 Advantages
Maintains process stability.
Prevents overflow or dry-run conditions.
Reduces the need for manual supervision.
Improves safety and efficiency.
2.13.3 Ammonia synthesis process
An Ammonia Synthesis Unit which is part of an industrial
process used to produce ammonia. This system allows operators
to monitor and control various parameters such as level,
temperature, pressure, and flow throughout the process. The
controller is currently operating in manual mode. The figure also
shows additional process measurements, including temperatures
and pressures at different points, and the operating status of
compressors. This system interface provides real-time
monitoring and control of critical process parameters to
maintain safe, stable, and efficient operation of the ammonia
synthesis process.
Fig :
Fig :
Fig :
2.13.4 Cascade control loop of level and flow process
Fig : Cascade control loop of level and flow
In the cascade control loop of level and flow
process ,level control is a control strategy widely used in boiler
drum systems to maintain a stable water level despite
disturbances such as steam load changes or feedwater pressure
fluctuations as shown in above figure.
In this arrangement, the level controller (LIC) acts as
the master controller while the flow controller (FIC) serves as
the slave controller. The level transmitter measures the actual
drum water level and sends a signal to the LIC. The LIC
compares this value with the desired setpoint and outputs a new
setpoint to the FIC rather than directly controlling the valve. The
FIC then receives both the setpoint from the LIC and the flow
rate signal from the flow transmitter (FT). It adjusts the
feedwater control valve to ensure the actual feedwater flow
matches the desired flow rate.
This cascade setup allows the faster inner flow loop to
correct rapid disturbances before they can affect the slower outer
level loop resulting in more stable operation, reduced overshoot
and improved overall performance of the boiler system.
2.13.5 Cascade Control Loop of Boiler Level and
Flow
In the following figures show a Distributed Control System
(DCS) or SCADA ( Supervisory Control and Data Acquisition)
screen from an industrial boiler or heat exchanger control
process. It displays live process variables (temperature, pressure,
flow, level, etc.) and control loops working together to maintain
system stability of Boiler Level and Flow.
2.13.6 Control Loops Description
PV, SV, and MV represents a PID control loop:
PV = Process Variable (actual measured value)
SV = Set Value (Set Point) (desired target)
MV = Manipulated Variable (valve opening percentage or controller output)
Fig: (a) Cascade Control Loop of Boiler Level and Flow
Fig : (b) Cascade Control Loop of Boiler Level and Flow
Fig : (c) DCS Control Drawing of Cascade Control Boiler Level
and flow
Fig :(d) Tuning Setting Cascade Control Level and Flow