EXPERIMENT 7 UNIVERSAL PROCESS CONTROL TRAINER
Aim: To study the working principle of current to pressure converter.
Theory:
A “current to pressure” transducer (I/P) converts an analog signal (4 to 20 mA) to a proportional
linear pneumatic output (3 to 15 psig). Its purpose is to translate the analog output from a
control system into a precise, repeatable pressure value to control pneumatic
actuators/operators, pneumatic valves, dampers, vanes, etc. The I/P converter provides a
reliable, repeatable, accurate means of converting an electrical signal into pneumatic pressure
in many control systems. Models of this device are usually available in direct and reverse action
and are field selectable with full or split range inputs or output as the case maybe. The most
common application of an I/P transducer is to receive an electrical signal from a controller and
produce a proportional pneumatic output for operating a control valve or positioner. The device
can be mounted on the wall or a pipe stand or directly on the valve actuator. Where the device
can withstand vibrations, they are directly mounted on the valve actuator. In many instances,
the device is remotely mounted on instrument pipe stands to reduce vibrations. The Operating
Principle of I/P converter is as follows: The I/P converter uses an electromagnetic force balance
principle to change electrical signals into pneumatic signals. Typically, a 4 – 20mA input is
converted into a 3 – 15pisg output. The operating principle of the I/P transducer is shown
below:
As shown above, a coil produces a magnetic field. Within the coil is a deflector motor with a
flapper valve attached that operates against a precision nozzle to create a backpressure on the
servo diaphragm of a booster relay. The input current flows in the coil and produces a force
between the coil and the flapper valve, which controls the servo pressure and the output
pressure. The electronic part module receives standard DC current input signal (4-20 mA) from
DCS or PLC. This current will operate coils then increasing or decreasing the magnetic force
following the input signal. Magnetic force will drive the linkage to adjust the distance between
flapper and nozzle or in other words to control bleed air through an integral flapper-nozzle
arrangement. The nozzle pressure provides the input signal to operate the relay. Then relay
output pressure is applied directly to the final control element (control valve or actuator auto
choke valve). When the flapper moves away from the nozzle, the output pressure will be
low/falls, and inversely when the flapper come closer to the nozzle the output pressure will
increase/high.
Zero adjustment of this device is made by turning a screw that regulates the distance between
the flapper valve and the air nozzle. Span adjustment is made by varying a potentiometer, which
shunts input current past the coil. The output signal of an I/P transducer easily falls to bleeds
pressure upon failure of the electrical signal. This makes it easy to detect electrical failure
signal in the device.
Experimental Procedure
1) Initialization:
Execute All Programs | Wonderware | InTouch and open UPCT Part I by double clicking
on it in In-touch‐application manager window
In Windows to open , select Home and click OK
In Intouch –Window maker screen click “Runtime “
In Intouch ‐ Window viewer select experiment Study of I/P
2) Patch Board Configuration:
Connect Controller Analog Output no.1 to I/P1
3) Valve Configuration:
Air: Close valve: V13
4) Experimentation:
Partially open compressed air line valve.
Click Next to run the experiment in Intouch software.
Increase Source mA in steps of 4 mA up to 20 mA and observe output pressure on PG2.
Note observed output pressure and corresponding source mA.
Plot the graph of Output pressure Vs Source mA.
Export data to excel.
Troubleshooting and Calibration Tips:
Most I/P converters are supplied instrument air of about 20psig above the required output of
the device. An inoperative or poorly performing I/P transducer may just be having a problem
with its air supply. So to effectively troubleshoot this device, slightly open the air set drain and
check that the supply air is dry and oil free. Checks can also be made on external bleed opening
to verify that it is clear and free from obstruction and that it is venting properly.
Observation
Fig 1: Sample graph of I/P transducer
Result:
We see that expected output pressure and measured output pressure are equal and they
increase linearly with time
Experiment B: Feedforward Control Loop (Temperature)
Aim: To study the feedforward control loop for temperature.
Theory:
The deficiency of the feedback control system is that it reacts only after it has detected a
deviation in the value of the output from the set point value or unless an error signal is
generated. In feedback control no control action will be taken until the effect of disturbance or
change in the load variable is detected. The deviation in the measured value of the controlled
variable and set point or desired value generates the error and the feedback controller
minimizes the value of error signal which in turn produces the command signal which acts on
the control valve which in turn regulate the control variable. The feedforward control can be
used very successfully to improve a control loop’s response to disturbances. Feedforward
control reacts the moment when disturbances occur, without having to wait for a deviation in
a process variable. This enables a feedforward controller to quickly and directly cancel out the
effect of disturbance. To do this, a feedforward controller produces its control action based on
measurement of the disturbance. The application of feedforward control requires the relatively
accurate process dynamics or requires accurate values of the transfer functions of the process
and the disturbance for efficient feedforward compensation. It is necessary to be able to
measure all possible disturbances entering the process. The change in the parameter of a
process cannot be compensated by a feedforward controller because such change many times
cannot be detected immediately.
When used, feedforward control is almost always implemented as an add-on to feedback
control. The feedforward controller takes care of the major disturbance, and the feedback
controller takes care of everything else that might cause the process variable to deviated from
its set point.
Experimental Procedure:
1. Patch board configuration:
• Connect TT1 to Controller Analog Input No. 4
• Connect TT2 to Controller Analog Input No. 5
• Connect Controller Analog Output no.1 to I/P1
• Connect Controller Analog Output no.3 to SSR
• Connect Controller Analog Output no.4 to Pump2
• Connect FL1 to controller digital input No.1
• Connect FL2 to controller digital input No.2
• Connect controller digital output no. 3 to SV2
2. Valve configuration
• Water: Open valves : V17, V18, V14,
Close valves: V12, V16, V2, V6, V3, V11, V15
• Air: Open valve: V13
Ensure fresh water supply is available at supply tank inlet valve (V11)
3. Experimentation
• Turn rotary switch “COMPRESSOR” on WSP module to ON position.
• Turn rotary switch “PLUNGER PUMP” on WSP module to ON position.
• Click Next to run the experiment
• Turn rotary switch “HEATER” on WSP module to ON position.
• Note default values for FF control SP=35, OP(Pump2) = 50%, FF=1.05
• After experimentation turn rotary switch “HEATER” on WSP module to OFF position.
• After experimentation turn rotary switch “PLUNGER PUMP” on WSP module to OFF
position.
Result
Experiment C : Level Control Loop (Plunger Pump)
Aim: Study of Level Control loop
Theory: Level loops are very common in industry. They are heavily used in the process
industry like refining, petrochemical, power, paper & pulp, steel, etc. In fact around 20% of
control loops in processes industry are level loops. A level-controlled process is also called an
integrating process. This means that if there is an imbalance between what goes in and what
comes out, the level will continue to rise or fall. Many level-type processes have a very slow
rate of response after a change in controller output. You might change the output by 10% and
then you have to wait 15 minutes to see the level move by a few percent. To compensate for
this slow rate of response, a high controller gain should be used. If you lower the controller
gain in a level loop, you must at the same time lengthen the integral time proportionally to
maintain the ratio between integral and proportional, and hence maintain loop stability. This is
not necessary on self-regulating loops like flow and temperature, but it is required on level
control loops. The speed of changes in a level control loop largely depends on the size and
shape of the process vessel (e.g. larger vessels take longer to fill than smaller ones) and flow
rate of the input and outflow pipe. The final control element in level control loop is usually a
valve on the input and/or outflow connections to the tank. Because it is often critical to avoid
tank overflow, redundant level control systems are sometimes employed.
Experimental Setup and Procedure:
The water is pumped from the feed tank with the help of a plunger pump which has a Variable
Frequency Drive (VFD). The VFD is used to vary the frequency of the motor which in turn
changes the flowrate. From water plunged by the plunger pump is sent to an overhead tank.
Here the water is returned to the feed tank. From the overhead tank, the two streams - high
pressure and low-pressure streams are sent to the Differential Pressure Transducer which
converts the pressure signal into current signal. This is required since the input to the
comparator is the current signal. The comparator in this experiment is the patch board. From
the comparator, the current signal is sent to the controller (computer) and from the controller,
it is sent back to the VFD.
Experimental Procedure:
Patch Board Configuration:
• Connect DPT1 to Controller Analog Input No. 1
• Connect Controller Analog Output no.4 to Pump2
Valve Configuration:
• Water: Open valves V2, V1, V7, V8; Close valves: V17, V3, V5, V6, V20, V21,
V14
• Air: Close valve: V4
Setup Configuration:
• Ensure DPT1 is connected to PTK1
• Remove air, if any, from DPT1 (after filling water in PTK1). It is recommended
to keep open the low side air vent of DPT1.
Experimentation:
• Turn rotary switch “PLUNGER PUMP” on WSP module to ON position.
• Click Next to run the experiment.
• Click on Auto and select Man mode.
• Increase output OP (Pump2) to 100%.
• Adjust PTK1 outlet valve V7 such that the level in PTK1 is @95‐100%
• Remove air from air vents of DPT1.
• Click on Man and select Auto mode.
• Proceed to Sub Experiments Part‐IV section (Note default values for PID mode
SP=70, PB=50%, IT=30 sec, DT=0 sec)
• Turn rotary switch “PLUNGER PUMP” on WSP module to OFF position after
experimentation.
Results and Observation:
Experiment D: FLOW CONTROL LOOP (TANK OUTLET)
Aim:
To study the flow control loop
Theory:
In automatic controlled process the parameter to be controlled is measured and compared with
the set point by process controller. The difference between the measured signal and the set
point is error. The controller performs on-line calculations based on error and other setting
parameters and generates an output signal. The output signal drives the final control elements
like control valve or a damper to control the process to the set point.
1) Patch Board Configuration:
• Connect DPT2 to Controller Analog Input No. 2
• Connect Controller Analog Output no.1 to I/P1
• Ensure PUMP1 is short.
2) Valve Configuration:
• Water: Open valves V10, V12, V16, V1, V8, V6, V15,
Close valves: V17, V18, V3, V5, V20, V21, V7, V22, V14
• Air: Open valves: V13
Close valves: V4
3) Experimentation:
• Partially open air compressor line valve.
• Switch on Pump1 from control panel
• Adjust bypass valve V10 to set rotameter flow at its maximum range.
• Remove air from air vents of DPT2.
• Click Next to run the experiment
• Note default values for PID mode SP=60, PB=120%, IT=25 sec, DT=0 sec
Results :
Discussion
In this experiment, we studied about I/P Transducer, flow control, level control, and
temperature control. To do so we used a Universal Process Control Trainer which is used to
control variables such as flow, temperature, level, etc. The apparatus uses a PID controller.
I/P Transducer
An I/P transducer is a device that converts an analog signal (current) to a proportional linear
pneumatic output (pressure). In the first experiment, we send a current input which induces a
magnetic field. The magnetic field in turn causes the deflector motor to start rotating. The
deflector motor is connected to a flapper nozzle. If the flapper is away from the nozzle, the
pressure is reduced and when it is closer to the nozzle, the pressure is increased which causes
the booster relay to output a pressure signal. In this way, a current signal is converted into a
pressure signal.
Flow Control Loop
In flow control loop, we use a feedback control system. Here, we set a desired value as set
value and compare the two values to get an error value. This error value is sent to the control
unit and process which will give us the controlled variable. The controlled variable is sent back
to a sensor which measures the value of the variable which in turn would be compared against
the desired value. In this way, the loop is complete. In the experiment, we use a rotameter to
pump water from a feed tank which is sent to air to open valve. Through the valve, it is sent to
orifice meter where the water is returned back to the feed tank. The two streams of high and
low pressure from the orifice meter and sent to the DPT which will convert the pressure signal
to a current signal so that it can be sent to the comparator (patch board). The current signal is
sent from comparator to the controller and front the controller to a I/P transducer which would
convert the current signal to a pressure signal and send it to the open valve. This I/P transducer
is necessary since the air to open valve can take only pressure signals and not current signals.
Level Control Loop
Level Control Loop is again a feedback control system. Here, water is pumped from the feed
tank with the help of a plunger pump which has a Variable Frequency Drive (VFD). The VFD
is used to vary the frequency of the motor which in turn changes the flowrate. From water
plunged by the plunger pump is sent to an overhead tank. Here the water is returned back to
the feed tank. From the overhead tank, the two streams - high pressure and low pressure streams
are sent to the Differential Pressure Transducer which converts the pressure signal into current
signal. This is required since the input to the comparator is the current signal. The comparator
in this experiment is the patch board. From the comparator, the current signal is sent to the
controller (computer) and from the controller, it is sent back to the VFD.
Feed Forward Control Loop
A feedforward control loop is used to improve the response of a control loop to disturbances.
They react the moment when the disturbance occurs without having to wait for a deviation in
a process variable. In this experiment we pumped water from a sump tank using a plunger
pump. The water is sent to a heater and the water from the heater is drained to regulate
temperature. The electrical signal is converted into heat using Solid State Relay (SSR)