Level Control Experiment
Setup
The process, shown in Figure 1, consists of two tanks, the process tank and the sump tank. Water is
pumped from the sump tank to the process tank, and the flow is measured using a flow meter (F-1). As
water is pumped to the process tank, level is measured using the flow sensor. The sensor used in the
experiment is a floater sensor.
The sensing mechanism consists of a custom, weighted float and counterweight which are attached by
a cord. The cord runs over a notched pulley to give a positive drive. As the water level rises or drops,
the float goes up or down, thus turning the pulley. The pulley shaft is coupled to a potentiometer. The
potentiometer converts voltage to digital form for connection to a data logger.
Water flows out of the process tank through a manual valve (V-4) which is opened and closed manually
or through one of two solenoid valves (SOL2 & SOL3). A solenoid is an electromechanical device
which allows an electrical device to control the flow of a gas or liquid.
The valve changes state, either opening or closing to allow a liquid to either flow through or be blocked
by the solenoid valve.
Response to signals received from controllers that compare a "set point" to a "process variable" whose
value is provided by sensors that monitor changes in level inside the process tank. The opening or
closing of control valves is done by means of electrical signal. Positioners are used to control the
opening or closing of the actuator based on Electric Signals to manipulate the input flow rate to the
process tank.
Figure 1. Schematic of the experimental setup.
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Figure [Link] monitoring and control application.
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Part 1: Sensor Calibration
Objectives
To calibrate the level sensor
Procedures
Calibration: the aim of this experiment is to calibrate the level sensor to give the following
characteristics:
• Minimum Level: 30mm=0%.
• Maximum Level: 130mm=100%.
1. Press calibration icon on graphical interface for level experiment to open calibration window
2. Operate Pump by clicking on its icon to give green color.
3. Wait until the level in the process tank reaches 30 mm then stop pump.
4. Click on set as 0% button.
5. Operate the pump again and wait until the level reaches 130 mm then stop the pump.
6. Click on set as 100% button
7. Click Ok button, wait till the calibration takes place
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Part 2: Linearity & Hysteresis
Objectives
To investigate the linearity and hysteresis of the sensor.
Procedures
Increasing Decreasing
Linearity and hysteresis: having calibrated the
sensor it is interesting to determine the linearity PV(mm) PV (%) PV(mm) PV (%)
of the output over the conditioner operating range
from minimum to maximum level. 30 130
1. Adjust the level of water in the process tank 40 120
in steps of 10 mm from the maximum level
(130 mm) to the minimum level (30 mm). 50 110
2. Record the level reading in tank as(mm)and
level reading as (%) from icon (2.6). 60 100
3. Repeat the procedure by increasing the level
from minimum value to maximum one, to do 70 90
that
80 80
4. Press on start button, choose manual control.
5. Press on pump icon to get green color. 90 70
6. From the control valve opening (2.3) set
Power output to 50%. 100 60
7. Open drain valve(V-4) in a suitable opening
(to get uniform increment in water level". 110 50
8. Record the level reading in tank as (mm) and
level reading as (%) from icon (2.6) as 120 40
follows:
130 30
Discussion
1. Plot the level mm versus the output. Comment on linearity and hysteresis and find the relation
between both.
2. Calculate the transmitter gain (KT)?
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Part 3: Control Valves Characteristics
Objectives
• Demonstrate manual operation of the motorized control valve and determine its characteristics.
• Determine solenoid valves (SOL2 & SOL3) actions and coefficients (Cv). Objectives
Procedures: Motorized Valve
Increasing Decreasing
1. Press on start button and choose Flow Flow
manual control. Pr % Pr %
rate rate
2. Set Pr to 100% and make sure that 0 100
flow rate (F-1) = 3000 cm3/min.
3. Set Pr to 0%. 10 90
4. Change Pr in steps of 10 from 0%- 20 80
100% increasing and decreasing 30 70
and record the corresponding flow 40 60
rate.
50 50
60 40
Procedures: Solenoid Valve
70 30
1. Press on start button, choose manual control,
set Pr to 100%. 80 20
2. Note the action of the 3 solenoid valves (1, 2 90 10
and 3"based on its color"). 100 0
3. Press on each solenoid valve individually
and observe what changes.
4. Keep solenoid 1 open, closed solenoid 2, make sure that (V-4) is closed, and solenoid3 open.
5. Adjust Pr value (flow rate value) until the level in the process tank = 50%.
6. Record the corresponding flow rate on (F-1) and level in the tank (mm).
7. Repeat the above procedure (step 4-6) but for SOL2 open and close SOL3
Discussion
1. Determine valve and controller action, (explain).
2. Plot the resulting data and determine the valve characteristic: (write characteristic equation
and determine its parameters).
3. Calculate the Cv for SOL2 and SOL3.
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Part 4: Controller Tuning
Objectives
Use one of the widely used field methods for optimizing the P-only, PI and PID settings on the controller
to suit the characteristics of the process: Ultimate Period/ Ziegler-Nicholas (closed loop).
Procedures:
1. Set the controller manual then press start button.
2. Set Kc=10, Ti=0, & Td=0.
3. Remove initial offset by:
a. Open Solenoid 2 and close (V-4) and solenoid 3.
b. Change Pr manually until PV=SP…. (Set Sp = 50).
4. Change the controller to automatic controller with P-only setting (ie Kc= 10).
5. Apply a step change to the process by opening or closing SOL2 or SOL3 as appropriate.
6. If the process variable (PV) remains steady: calculate offset
7. Increase Kc in suitable range and re-apply a step change until reach the ultimate region for the
process variable. (PV oscillates around SP with constant amplitude).
Discussion
1. At Kc = Kcu, calculate three-term controller type settings using Ziegler-Nicholas equations.
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Part 4: Optimization of PID Controller
Objective
• Demonstrate the characteristics of: P-only, PI and PID process controller and the response to a
change in set point (SP) or to disturbance to the Process
• Determine experimentally the optimum value(s) of Kc for P-only, Kc & Ʈi for PI controller and
Kc, Ʈi & Ʈd for PID controller type.
Procedures: P-only controller
1. Set the controller to automatic controller.
2. Set the value of Kc that calculated in the previous part.
3. Press on start button, pump button and open solenoid 2, set the Sp=50%.
4. Observe the response behavior (stability, speed and error value), if the system is stable (has no
oscillation and minimum error value), make a disturbance on SP (increasing/decreasing) and
observe the resulted response.
5. Increase/decrease Kc value based on response behavior and stability
6. Make another disturbance on outlet flow rate and observe the resulting response.
7. Observe the response of the process and discuss what happens and why.
Procedures: PI controller
1. Set the controller to automatic controller.
2. Set the value of Kc & Ti that calculated in Part 4
3. Repeat the same procedure as P-only controller step (3-8) for different Ti and or Kc values
4. Observe the response of the process and discuss what happens and why.
Procedures: PID controller
1. Set the controller to automatic controller.
2. Set the value of Kc, Ti and Td that calculated in Part 4
3. Repeat the same procedure as P-only controller step (3-8) for different Td and or Kc values
4. Observe the response of the process and discuss what happens and why.
Procedures: Further experiment:
Do any experiment with any values if you need to prove or try anything (PD, open both solenoid valves
for any controller type, do multi disturbances on system).
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Part 5: On/Off Controller
Objectives
1. Define one of the controller types: (On/Off), and define the main variables controlled it.
2. Determine the effect of Hysteresis (deadband) on-off controller output.
Procedures and Discussion:
1. Select ON/OFF controller.
2. Set the SP = 50%.
3. Set the value of (hysteresis) Upper and Lower ………% of SP.
4. Wait for the response to plot 2 or 3 cycles.
5. Repeat for different values of hysteresis such as 10%…. or change SP value.
6. Discuss the response of the controller