Chapter one

INTRODUCTION
1.1. Background
Automatic control systems have been evolving over the past 150 years. These systems began
as simple mechanical feedback devices and have evolved into complex electronic and
computer controlled systems.

The management of water is very important to avoid its wastage. The Automatic Water Level
Control is introduced to help the human being to manage the water in their life.

This project consists of completing an apparatus that demonstrates the automatic control of
water level in a tank. Random filling of the tank represents a real life unpredictable
disturbance to the system. Automatic control is accomplished by sensing the water level and
then controlling the position of a valve that inlets water to the tank. This physical model will
be used as a teaching aid so that the students can interact with and visually see a dynamic
control system operating in real time.

The automatic water level control in a tank allows a convenient and cost effective by
preventing over heating of pump and managing of water resources. It can automatically
control the domestic water pump (valve) set depending on the tank water level. The main
advantage of this water level control is to control the water level of a tank automatically
without any human interaction.

1.2. MOTIVATION (Statement of the problem)

We are motivated to do this project “automatic tank level control” after observing the
following problems in our university:

 Over flow of water.

 Overheating of a pump.
 Absence of water in a tank.
 Incurring cost for labor force.

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 1.3) Research questions

To achieve the objective of this project, the following basic questions are stated.

1, what type of level sensor can we use?

2, reason for choosing that level sensor?

3, what type of valve can we select?

4, reason for selecting that valve?

4, what type of controller can we use?

5, reason for selecting that controller?

6, what type of flow sensor can we use?

7, reason for choosing that flow sensor?

1.4) OBJECTIVE

1.4.1) the general objective of this project is:

 To protect overflow of water from the tank.

 To create the most cost-effective and reliable water level controller.
 To regulate or to maintain the amount of water at the desired level of the tank
regardless of external influences.

1.4.2) the specific objective of this project is:

 To design PID controller.

 To study about level control of water in a tank automatically.
 To study about CASCADED PID controller mode and observe its characteristics.
 To build hard ware of water level system.
 To design the CASCADED PID controller circuit.
 To study about level sensors with their characteristics.
 To study about valves with its characteristics.
 To fabricate an automatic model water level control using the PID controller.
 To implement the existing PID controller into a control process.

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  To study about Dc motor.
 To study speed control technique of Dc motor.

1.5) Significance of the study

This project helps against overflow of water, empty tank, pump overheating and in general
economically crises in DBU.
The following are the expected importance of this project:
 It will encourage the economic development of the DBU by reducing the cost by 35%
for labor, the amount of over flow and increasing the life expectance of the pump.
 Specifically, the finding may give hint about automatic level control using cascaded
PID for companies that require automatic liquid level controller.
 Finally, the project result will may serve as bedrock for other researchers who are
interested in the area.

1.6) Delimitation of the study

The project will focuses on automatic water level control in a tank in DBU. This is because
our project helps to DBU to save their money and their resources. This project will also
delimit only to the DBU.

1.7) Operational Definitions of terms

Automatic water level control refers to the controlling of the water in a tank automatically
without any human interaction in order to save different resources.

By M D B Page 3
 Chapter two
LITERATURE REVIEW
2.1 Water Level Control System

The Level Master of water level control system had been designed by Milwaukee, WIin
January 2006 for fire tube boiler and water tube boiler which is constructed with enhanced
safety diagnostic capabilities.

Figure 2.1.level master water level control system

The Level Master water level control system as shown in figure 2.1 was designed to be a low
water cutoff controller with enhanced safety features. The Level Master’s capabilities ensure
the boiler’s water level remains at safe operating level. While monitoring the boiler's water
level, the self-checking features verify the control is operating as designed. The system can
also verify the operation of the auxiliary low water cutoff control. The Cleaver-Brooks Level
Master was built with security as a major objective. The operating parameters are password
protected to eliminate the chances of tampering with preset levels. The Level Master offers
easy accessibility to its time stamped alarm and blow down history. As a final touch to
promote peace of mind, the Level Master includes multiple alarms and a visual water level
indicator.

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 Figure 2.2. monitoring system of water level

The water column chambers have been engineered to easily replace limited, single purpose
controls with state-of-the-art electronic level sensing and monitoring. Figure 2.2 shows the
monitoring system which is display the percentages for output value of water level and
display user configurable for on-off or modulating water level control. The design also makes
the system adaptable to both new and existing boilers. The specially engineered design of the
Level Master was built to accommodate your boiler room specifications. Depending on your
boiler application, the control’s sensitivity may be selected in the field.

Figure 2.3.type of sensor

In figure 2.3, this type of sensor employs the magneto strictive principle, a non-contact, non-
wearing, long-life technology. Designed specifically for boiler applications, it will withstand
working temperatures to 400°F at 250 PSIG. It includes a 2” diameter titanium float with a
captive magnet. The sensor electronics enclosure meets NEMA 4 standards with a working
environment of 130°F.

2.2 Liquid Level Monitoring and Automatic Control Systems.

Active Control Systems have become very popular with consultants, designing Water Supply
and Disposal Schemes in Industry. The main reason is that unlike normal conductivity types,

By M D B Page 5
these are unaffected by water corrosion. This has helped to reduce the constant manual
checking, and bring about extremely high functional reliability. Most of the clients are from
professional maintenance/ project engineers and consultants. For the example, Oberoi Group
of Hotels is consistently using the systems, both in Projects and Maintenance. So is the case
with Le Meridien, Delhi, Mother Dairy, CDIL etc. This company is specializing in Liquid
Level Monitoring and Automatic Control Systems which are based on Magnetic Level
sensing.

The level sensing is done by means of a probe unit as shown in figure 2.4. It is made of
stainless Steel. A number of sensors suitably spaced, depending of functional requirements
are enclosed inside the Probe Unit. An Actuating Float, made from Stainless Steel used to
actuate these sensors. This float has a ring magnet of specific polarity for correct operation of
the control system. The control unit will receives signal from sensors as liquid reaches their
level. This signal then operates the controller or indicator system. The control Systems are
designed as ‘standalone’ units and are specific to the capacity and system of operation of
pumps. Otherwise, type of pumps or valves which can be used is any type or capacity. For
example single phase mono-block pumps, jet pumps, single or three phase submersible
pumps, or other heavy capacity pumps or pumps related to chemical or process or dozing etc.

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 Figure 2.5.DBU water tank

Figure 2.5 shows the DBU water tank system. This is a standard arrangement where water is
drawn from a tube well (submersible pump) and pumped directly to the overhead tank. A
variation to this is a sump tank where water is received from a tube well or municipal water
supply and then pumped to the overhead tank.

 Types of Level Measurement Sensors

Various systems in sensors developments have been introduced to assist in crucial

measurements of level. These sensors are most likely incorporates business obligation though
there are certain sensors provided for non-business or profitable usage and for the usage in
education purposes. There are many physical and application variables that affect the
selection of the optimal level monitoring solution for industrial and/or commercial processes.
Selection is categorized to contact and non-contact sensor. The selection criteria include the
physical: state (liquid, solid or slurry),temperature, pressure or vacuum, chemistry, dielectric
constant of medium, density or specific gravity of medium, agitation, acoustical or electrical
noise, vibration, mechanical shock, tank or bin size and shape; and the application
constraints: price, accuracy, appearance, response rate, ease of calibration or programming,
physical size and mounting of the instrument, monitoring or control of continuous or discrete
(point)levels. Different types of level sensors are listed below:

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1, Capacitance level sensor (also called RF)

Possible when the tank wall is metal, to use a single bare or insulted rod as one capacitor
plate and the tank walls as the other. An interesting application of this type of capacitance
probe is in aircraft fuel quantity indicators. Capacitance switches can be utilized to provide
non-contact point measurements of liquid level.

2. Ultrasound

Ultrasound echo ranging transducers can be used in either wetted (contact) or non-wetted
(non-contact) configurations for continuous measurements of liquid level. An interesting
application of wetted transducers is as depth finders and fish finders for ships and boats. Non
wetted transducers can also be used with bulk materials such as grains and powders.

3. Radar

Microwave sensors are ideal for use in moist, vaporous, and dusty environments as well as in
applications in which temperatures vary. Microwaves (also frequently described as RADAR),
will penetrate temperature and vapor layers that may cause problems for other techniques,
such as ultrasonic. Microwaves are electromagnetic energy and therefore do not require air
molecules to transmit the energy making them useful in vacuums. Microwaves, as
electromagnetic energy, are reflected by objects with high dielectric properties, like metal and
conductive water. Alternately, they are absorbed in various degrees by low dielectrics or
insulating mediums such as plastics, glass, paper, many powders and food stuffs and other
solids. Microwave-based sensors are not affected by fouling neither of the microwave-
transparent glass or plastic window through which the beam is passed nor by high
temperature, pressure, or vibration. These sensors do not require physical contact with the
process material, so the transmitter and receiver can be mounted a safe distance from the
process, yet still respond to the presence or absence of an object. Microwave transmitters
offer the key advantages of ultrasonic: the presence of a microprocessor to process the signal
provides numerous monitoring, controls, communications, setup and diagnostic capabilities.
Additionally, they solve some of the application limitations of ultrasonic: operation in high
pressure and vacuum, high temperatures, dust, temperature and vapor layers. One major
disadvantage of microwave or radar techniques for level monitoring is the relatively high
price of such sensors.

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4) Prosonic M FMU40 Ultrasonic Level Sensor

Figure 2.6.prosonic m fmu40 ultrasonic level sensor

Areas of applications:

 The Prosonic M is used for continuous, non-contact level measurement of liquids,

pastes, and slurries.
 The measurement is not affected by changing media, temperature changes, gas
blankets or vapors.
 It provides an accuracy of ±3 mm.
 Used for flow measurement in open channels and measuring weirs.
 Used for continuous measurement in fluids and coarse bulk materials.

Features and benefits

 Simple

 Envelope curves on the on-site display for simple diagnosis

 Easy operation

 optional remote display and operation

 Integrated temperature sensor for time of- flight correction. Accurate measurements, even
for temperature changes
 Linearization function (up to 32 points) for measured value output in any unit of length,
volume or flow rate
 Non-contact measurement method, therefore almost independent of product properties.
 Specific Valve Types

There are different types of valves which are used for level control, some of them are listed
below and depending on the requirement we select one from them:

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 a) Gate Valves

Figure 2.7.gate valve

Positive Features:

1) Good choice for on-off service

2) Full flow-low pressure drop

3) Bidirectional

Disadvantages:

1) Not for throttling; use fully opened or fully closed

2) Metal-to-metal seating means not best choice for frequent operation. Bubble-tight seating

Should not be expected metal-to-metal design.

3) Difficult to automate.

b) Globe/Angle-Globe Valve

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 Figure 2.8. globe/angle-globe valve

Positive Features:

1) Recommended for throttling applications.

2) Positive bubble-tight shutoff when equipped with resilient seating.

3) Good for frequent operation Positive Features.

Disadvantages

1) Significant pressure drop due to flow path.

2) More costly than alternate valves.

c) Ball Valves

Figure 2.9. ball valve

Positive Features

1) Bubble-tight shut-off from resilient (TFE) seats

2) Quick 90° open/close, not torque-dependent for seating

3) Straight-through unobstructed flow, bidirectional

4) Minimal pressure drop if full-port selected

5) Can be throttled

6) Easier to automate than multi-turn valves

7) More compact than multi-turn valves

8) Offers high cycle life

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Disadvantages

1) Temperature range limited by seat material

b) Butterfly Valves - Resilient Seated

Butterfly Valves are used for regulating the flow of water, oil, gas, steam and chemicals
through section of circular tube or pipes in diverse segments. Innovatively designed as per the
latest domain standards & norms, these Butterfly Valves are capable to withstand high
pressure & tough working conditions. Further, to suit the specific requirements of varied
industry sectors, these Butterfly Valves are available in the market in different shapes, sizes
and dimensions.

Outstanding Features:

 Rugged construction.
 Durable finish standards.
 Precise dimensions.
 Light weight.
 High efficiency.
 Hassle free performance.
 Rust proof.
 Resistance against moisture, corrosion and abrasion.

Figure 2.10. butterfly valve

Positive Features

1) Bubble-tight shut-off from resilient seats.

2) Quick 90° open/close, easier to automate than multi-turn valves.

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3) Very cost-effective compared to alternate valve choices.

4) Broad range of throttling capabilities.

5) Nearly full flow, less pressure drop than globe valves.

6) Broad selection of trim materials to match different fluid conditions.

7) More compact than multi-turn valves.

8) Offers high cycle life.

Disadvantages

1) Not for use with steam.

2) Gear operators needed larger than 6” to aid in operation and protect against operating too
quickly and causing destructive line shock.

3) Grooved butterfly valves direct connect to pipe using iron pipe size couplings. Grooved
valves are easiest to install.

 The specific flow sensors types are:

1) Flow sensor for liquid media type 200

The flow sensor type 200 is available in various options with and without temperature
measurement. With no moving parts the flow sensor is not sensitive to debris, has marginal
pressure loss and high accuracy.
Its features;
 Flow range 0.5 ... 150 l/min
 Nominal diameters DN 6 / 8 / 10 / 15 / 20 / 25
 Temperature measurement -40 ... +125 ÀC
 Low cost product with high levels of accuracy
 Temperature non-sensitive measuring principle
 Excellent media resistance (measuring element not in contact with the media)
 Wide application temperature range
 Marginal loss of pressure
 Measuring element not sensitive to debris

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 Figure 2.11.flow sensor for liquid media type 200
2) Flow sensor for liquid media type 210
In comparison to the flow sensor (type 200), the type 210 is available with an increased range
of power supply and output signals all with and without temperature measurement. With no
moving parts the flow sensor is not sensitive to debris, has marginal pressure loss and high
accuracy.
Its features;
 Flow range 0.5 ... 150 l/min
 Nominal diameters DN 6 / 8 / 10 / 15 / 20 / 25
 Temperature measurement -40 ... +125 ÀC
 Flow measuring with voltage, current or frequency output
 Temperature non-sensitive measuring principle
 Excellent media resistance (measuring element not in contact with the media)
 Wide application temperature range
 Marginal loss of pressure
 Measuring element not sensitive to debris
 Direct temperature measurement in the medium

Figure 2.12.flow sensor for liquid media type 210

3) Flow sensor for liquid media type 230
The flow sensor type 230 is based on the Kármán vortex trail. You can choose between
various versions as integrated temperature measurement. The type 230 has a rugged

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construction of red brass. With no moving parts the flow sensor is not sensitive to debris, has
marginal pressure loss and high accuracy.
Its features;
 Flow range 1.8 ... 150 l/min
 Nominal diameters DN 10 / 15 / 20 / 25
 Temperature measurement -40 ... +125 ÀC
 Flow measuring with voltage, current or frequency output
 Temperature non-sensitive measuring principle
 Excellent media resistance (measuring element not in contact with the media)
 Wide application temperature range
 Marginal loss of pressure
 Measuring element not sensitive to debris
 Zinc free red brass housing
 Drinking water approval

Figure 2.13. flow sensor for liquid media type 230

4) Flow sensor for liquid media type 235

The type 235 is based on the type 200 but incorporates brass housing. The flow sensor type
235 is based on the Kármán vortex trail. You can choose between various versions as
integrated temperature measurement. With no moving parts the flow sensor is not sensitive to
debris, has marginal pressure loss and high accuracy.
Its features;
 Flow range 1.8 ... 240 l/min
 Nominal diameters DN 10 / 32
 Temperature measurement -40 ... +125 ÀC
 Low cost product with high levels of accuracy
 Temperature non-sensitive measuring principle
 Excellent media resistance (measuring element not in contact with the media)
 Wide application temperature range

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  Marginal loss of pressure
 Measuring element not sensitive to debris
 Direct temperature measurement.

Figure 2.14. flow sensor for liquid media type 235

2.3) PID Controller

In the previous years, there are many control strategy approaches for controllers’ design of
liquid level control system such as robust PID controller [Masato Kahara et.Al, 2001], Fuzzy-
PD control, Cascade control, Multiple Model Predictive Control [Ming He et. Al, 2005] and
advance PID auto tuner [Qiang Bi et. Al, 2000]. For example, [Satean Tunyasrirut et. Al,
2007] proposed a Fuzzy Logic Controller and Cascade Controller which can control the
liquid level in horizontal tank. Another example is a Generalized Predictive Control for
control the level water in couple tank developed by Ahmad ‘Athif bin Mohd Faudzi [Ahmad
‘Athif et. Al, 2006].

PID Control (proportional-integral-derivative) is by far the widest type of automatic control

used in industry[7]. A proportional–integral–derivative controller (PID controller) is a
generic control loop feedback mechanism widely used in industrial control systems. A PID
controller will correct the error between the output and the desired input or set point by
calculating and give an output of correction that will adjust the process accordingly. A PID
controller has the general form

………………………………………(1)
Where Kp is proportional gain, Ki is the integral gain, and Kd is the derivative gain.

The PID controller calculation (algorithm) involves three separate parameters; the
Proportional, the Integral and Derivative values. The Proportional value determines the
reaction to the current error, the Integral determines the reaction based on the sum of recent
errors and the Derivative determines the reaction to the rate at which the error has been
By M D B Page 16
changing. The weighted sum of these three actions is used to adjust the process via a control
element such as the level of the water in tank, the flow rate of water that pumps to a tank.
2.4. DC MOTOR

The DC motor has been popular in the industry control area for a long time, because they
have many good characteristics, for example: high start torque characteristics, high response
performance and easier to be linear control [8]. DC motor has a good speed control
despondence, wide speed control range.
Dc motors are more usable as it designed to use with batteries and solar cells energy sources,
which provide portability where we required it and provide cost effective solution because it
is not possible to have AC power supply in every place.

The specific types of DC motor are:

1. Separately excited Dc motor:

As the name suggests, in case of separately excited dc motor the supply is given separately to
the field and armature windings. The main distinguishing fact in these types of dc motor is
that, the armature current does not flow through the field windings, as the field winding
energized from the separate external source of dc current as shown in the figure below.

Figure 2.15. separately excited dc motor

2. Self excited dc motor

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In case of self excited dc motor the field winding is connected either in series or parallel or
partly in series, partly in parallel to the armature winding. It can be classified as:-

Shunt wound DC motor

Series wound DC motor
Compound wound DC motor
3. Permanent magnet dc motor

The permanent magnet dc motor consists of an armature winding as in case of a usual motor,
but does not necessarily contain the field windings. The construction of these types of dc
motor is such that radially magnetized permanent magnets are mounted on the inner
periphery of the stator core to produce the field flux. The rotor on the other hand has a
conventional dc armature with commutator segments and brushes.

Figure 2.16. simplified diagram of a permanent magnet dc motor

Chapter three

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 METHODOLOGY
3.1Study Design
In this section, we will discuss an overall overview of automatically level control of a tank.

Figure 3.1. over view of the project

3.2. System Block Diagram
The following figure shows block diagram of the system

Figure 3.2. a typical liquid level control system

3.3. System Description

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 A) Level Sensor

Level measurement is an integral part of process control, and may be used in a wide variety
of industries. Level measurement may be divided into two categories, point level
measurement and continuous level measurement. Point level sensors are used to mark a
single discrete liquid height, a preset level condition. Generally, this type of sensor is used as
a high alarm, to signal the existence of an overfill condition, or as a marker for a low alarm
condition. The more sophisticated continuous level sensors can provide complete level
monitoring of a system. A continuous level sensor, as the name implies, measures the fluid
level within a measurement range, rather than at a specific, single point. The continuous level
sensor provides an analog output that directly correlates to the level within the containing
vessel. This analog signal from the sensor may be directly linked to a visual indicator a level
management system.

B) PID CONTROLLER

A Proportional-Integral-Derivative (PID) controller is a general feedback control loop

mechanism widely used in industrial process control systems. A PID controller corrects the
error between a measured process variable and the desired set point by calculating the value
of error. The corrective action can adjust the process rapidly to keep the error minimal.

The PID controller separately calculate the three parameters i.e. the proportional, the integral
and the derivative values. The proportional value determines the reaction to the current error.
The integral value determines the reaction based on the sum of recent errors as past error. The
derivative value determines the reaction based on the rate at which the error has been
changing as a future error. Some applications may require only one or two parameters of the
PID controller to provide the appropriate control on system. A PID controller will be called a
PI, PD, P or I controller in the absence of the respective control actions. This is achieved by
setting the gain of undesired control outputs to zero. PI controllers are very common, since
derivative action is very sensitive to measurement noise and the absence of an integral value
may prevent the system from reaching its target value due to control action.

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 Figure 3.3. block diagram of PID controller in a feedback loop

In this project we use two cascaded PID controller to control the level of the tank and amount
of flow water through the valve. That is the output of the PID level controller is input for PID
flow controller.

table 3.1 effect of p, i and d.

C) Cascaded PID controller

Cascaded PID controller is a controller having of two PID controllers which are cascaded to
each other. The output of the first PID controller is an input to the next PID controller. When
the level controller changes its set point it leads to vary the input of the first PID controller, if
there is a change in the input of PID1 the output also changes, due to this the input of the

By M D B Page 21
PID2 controller becomes change. A change in the input of the second PID controller have an
effect to sense the change by the flow sensor, finally the flow sensor gives a message to the
flow controller and the flow controller sends a signal to the Dc motor to adjust the position of
the valve in order to control the amount of flow.

Figure 3.4. block diagram of cascaded pid controller

D) Flow sensor

A flow sensor is a device for sensing the rate of fluid flow. Typically a flow sensor is the
sensing element used in a flow meter, or flow logger, to record the flow of fluids. As is true
for all sensors, absolute accuracy of a measurement requires functionality for calibration.

The main function of the flow sensor is to sense the amount of flow through the pump.

E) Pump (Valve)

A valve is a device that regulates the flow of materials (gases, fluidized solids, slurries, or
liquids) by opening, closing, or partially changing its position. Valves are technically pipe
fittings.

F) DC MOTOR

Dc-motor is a device which is used to drive the valve. Since dc motor is variable speed it
causes to vary the position of the valve by controlling its speed using PID controller [8].

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DC drives, because of their simplicity, ease of application, reliability and favorable cost have
long been a backbone of industrial applications.

Since, DC motor is considered a SISO (single input and single output) system having
torque/speed characteristics compatible with most mechanical loads; it can design to drive the
valve to the desired position.

3.4) Selection of equipment

a) Selection of Level Measurement

Measurement is the estimation of the magnitude of some attribute of an object, such as its
length or weight, relative to a unit of measurement. Measurement usually involves using a
measuring instrument, such as a ruler or scale, which is calibrated to compare the object to
some standard, such as a meter or a kilogram. Measurements are crucial in purposes such as
in science and in engineering. Measurements always have errors and therefore uncertainties.
In fact, the reduction and the elimination of uncertainty is the central concept of
measurement. Measurement errors are often assumed to be normally distributed about the
true value of the measured quantity. Since accurate measurement is essential in many fields,
and since all measurements are necessarily approximations, a great deal of effort must be
taken to make measurements as accurate as possible. These errors even though seemed
neglect able are crucial in determining the accumulating costs, the perfections of each product
produced and the quality of any creations.

Selection of Level Sensor in This Project

The level sensor we have selected is shown below:

Float Sensors allows to be used reliably in aggressive liquids such as saline ground water.

The main advantages of float sensors:

 Corrosion free.
 Proves to be very accurate.

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  High durability.
 Long life (More than 5 Years)

 Reason for selecting this type of level sensor is due to the following main points :
 It is highly cost effective.
 It is easily available in the market.
 It is accurate.
b) Selection of Valve

A valve is a device that regulates the flow of materials (gases, fluidized solids, slurries, or
liquids) by opening, closing, or partially obstructing various passage ways. Valves are
technically pipe fittings.

The valve we have selected for our project is shown below:

Figure 3.5.flow serve 3200iq valve

Features of the LOGIX 3200IQ control valve:

i) Utilizes the HART protocol.

ii) Fully powered by 4-20mA current.

iii) Position of actuator defined in either analog or digital signal. In analog source, the 4-
20mA signal is converted to percentage. During loop calibration, the signals corresponding to
0% and 100% are defined and setting of 0% = 4mA / 100% = 20mA is selected.

By M D B Page 24
iv) It is set to ATO (Air-to-open) setting which means giving pressured air to open the valve
were used to achieve aim of the project.

 Reason for selecting this type of valve is due to the following main points :
 It is highly cost effective in relative with the others.
 It is easily available in the market.
 It is accurate.
C) SELECTION OF FLOW SENSOR

The type of flow sensor selected for our project is Flow sensor for liquid media type 230
 Reason for selecting this type of flow sensor is due to the following main points :
 It is highly cost effective in relative with the others.
 It is easily available in the market.
 It is accurate.
D) SELECTION OF DC MOTOR

The type of DC motor selected for our project is brushless permanent magnet dc motor.
 Reason for selecting this type of DC motor is due to the following main points:
 High efficiency electrical design
 Low loss steal laminations
 Easily reversible
 Excellent heat dissipation
 Lighter and compact
 Reliable and consistent performance
 No need of field excitation arrangement
 No field coil hence space for field coil is saved which reduces the overall
size of the motor

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 Figure 3. 6. permanent magnet dc motor

3.5) System Flowchart

Chart 3.1. flow chart of the overall system

3.6) Study Area

The project will be conducted in Debre Berhan University at around the Health science LAB. Debre
Behan University is one of the universities in Amhara region. It locates in north shoa zone and it was
established in 1999 e.c.
This project will benefit the DBU by solving the following limitations of the DBU water supply
system:
By reducing labour cost
By minimizing overflow of water
By keeping the pump from overheating

By M D B Page 26
 Chapter Four

DESIGN AND MODEL OF THE SYSTEM

This chapter contains the electrical design and the mathematical modeling of the system. The
electrical design composed of design of water flow, dc-motor speed control design and design
of water level as well as design of cascaded system.

4.1. DESIGN OF CASCADE SYSTEM

Below is a classic level-to-flow cascade architecture as shown, an inner secondary sensor

measures the feed flow rate. An inner secondary controller receives this flow measurement
and adjusts the feed flow valve.

With this cascade structure, if liquid level is too high, the primary level controller now calls
for a decreased liquid feed flow rate rather than simply a decrease in valve opening. The flow
controller then decides whether this means opening or closing the valve and by how much
with the help of dc motor.

Note in the diagram that, true to a cascade, the level controller output signal (CO1) becomes
the set point for the flow controller (SP2).

Figure 4.1. design of cascaded system

By M D B Page 27
As shown in the block diagram above; there are:

 ▪ Two controllers - the outer primary level controller (LC) and inner secondary feed flow
controller (FC).
 ▪ Two measured process variable sensors - the outer primary liquid level (PV1) and inner
secondary feed flow rate (PV2).
 ▪ One final control element (FCE) - the valve in the liquid feed stream.
4.2. MATHEMATICAL MODELLING

Basic idea

 The basic principle behind water level control of a tank is to make the level of the
tank at a set point by controlling the inlet flow of the valve keeping the outlet flow of
the water constant.
 The level of the tank is compared with the desired level and error signal is fed to level
controller. Controller output will vary whenever there is a difference in the reference
speed and the speed feedback.

The basic block diagram for water level control of a tank is shown below:

Figure 4.2. block diagram of the system

By M D B Page 28
4.2.1. Mathematical model of water tank

Figure 4.3. model of the tank system

where Q = steady-state liquid flow rate, m3/sec
H = steady-state head, m
The system model is determined by relating the inlet flow Qi in to the tank to the out flow Qo
leaving through the valve at the tank bottom. Using a balance of flows equation on the tank, it
is possible to write:

…….…………………..……………………...(2)

Where, A is the cross sectional area of the tank and H is the height of the water in the tank.

H= (Qout)2/(cda)2*(2g)…………………………………………………(3)

From this equation

[2]………………………………………………….………(4)

In this equation a is the cross sectional area of the valve,(in practice the cross sectional area
will be given by the dimension of the valve and the flow channel in which it is mounted). Cd
is the discharge coefficient of the valve. And g is the gravitational constant which is 9.8 m/s2.

By M D B Page 29
The small change in height of the water in the tank (h) is given by the following equation:

h=qo*R, differentiating this with respect time

so, A(dh)=(qi-qo)dt

RCdh/dt+h=Rqi , where RC is time constant.

Take the Laplace transforms of both sides of the equation by assuming the zero initial
condition.
Therefore, (RCS + 1)H(s)=RQi(s)

Where, H(s) =£[h] and Qi(s) = £[qi]

If qi is considered the input and h the output, the transfer function of the system is

……………………………………………………………..(5)

Where:

R is the resistive factor and

C is the capacitive factor of the tank

By M D B Page 30
4.2.2. Mathematical model of dc motor

Figure 4.4. model of the permanent magnet dc motor

The armature equation is shown below:

Va =Eg+ IaRa+ La (dIa/dt) ………………………………………………………………(6)

The description for the notations used is given below:

 Va is the armature voltage in volts.

 Eg is the motor back emf in volts.
 Ia is the armature current in amperes.
 Ra is the armature resistance in ohms.
 La is the armature inductance in Henry.

The electromagnetic torque developed by the permanent magnet DC motor is:

Te =Ka*Ia………………………………………………………………………………(7)

Where:

 Te is electromagnetic torque in Nm.

 Ka is torque constant.

By M D B Page 31
The viscous friction torque is:

Tviscous=Bm*𝔀r

Where:

 Βm is friction coefficient of the motor.

 𝔀r is angular velocity in rad/sec.

Using newton’s second low we have

d ẇ
∑ T =J ȧ=J dt
…………………………………………………………………………(8)

The load torque is denoted by TL

d wr 1 1
= (Te – Tviscous-TL) = (KaIa - Bm𝔀r – TL)
dt J J

The dynamics of the rotor angular displacement is:

dƟ
=w r
dt

Let Ia=X1

Ɵ=X2(angular displacement)

𝔀r=X3

Va=U

And assuming load torque as zero, we have the following three deferential equations.

d w r Ka Bm
= Ia - 𝔀r
dt J J

 dX3/dt=(Ka/J)X1 -(βm /J)X3 ------------------------------------------------------------(9)

Va =Eg+ IaRa+ La (dIa/dt)

dIa
Solving for we get
dt

By M D B Page 32
dIa 1 Ra Ka
= Va− Ia− wr
dt La La La

Rearranging and substituting,

 dX1/dt= U/La –(Ra/La)X1 –(Ka/La)X3------------------------------------------------(10)

We have also that,

dƟ
=w r
dt

 dX2/dt=X3-------------------------------------------------------------------------------(11)

From the above three equations, we have the following complete state space model for a
permanent magnet DC motor.

−Ra Ka

[ ][ ] [ ]
' 0– 1
X1 La La X 1

[ ]
X 2' =
X 3' K
J
001
0–
B
J
X 2 + La ∗U
X3
0
0

We assume our output is angular velocity (𝔀r)

X1
[ ]
Y=𝔀r=[ 0 0 1 ] X 2
X3

For our modeling the following assumptions are considered [4].

 Ra=0.05Ω
 La=0.1H
 J=50 kg m^2
 Β=0.5
 Ka=5v*sec/rad

So the above state model will be,

X 1' −0.5 0−50 X 1 10

[ ]['
X2 = 001
X 3' 0.1 0−0.01 X 3
][ ] [ ]
X 2 + 0 ∗U
0

By M D B Page 33
 X1
[ ]
Y =[ 0 0 1 ] X 2
X3

From these we can find transfer function using MATLAB as follows,

>> A=[ −0.5 0−50; 0 01 ; 0.1 0−0.01 ] ;

>> B=[ 10 ; 0 ; 0 ] ;

>> C=[ 0 0 1 ];

>> D=0;

>>TF=tf(ss( A,B,C,D))

Running the above program we get the overall transfer function of the motor part. i.e. the
plant or process.

1
Gp(s) = 2 ……………………………….. (12)
s + 0.51 s+5.005

4.3. ELECTRIC
AL DESIGN
The electrical design of the Automatic water level control System involves the electrical
components used, and the specification of the electrical components on the system. under this
there are different types of electrical design.

4.3.1. Design of water level control

This design is the design of the level control of the water in a tank. The level sensor senses
the condition of the water in the tank and this is compared with the set point then after if there
is error the PID1 controller takes an action.

By M D B Page 34
 Figure 4.5. design of level control system

4.3.2. Design of water flow control

The electrical design of the water flow is based on the flow sensor that senses the flow
amount of water through the valve. In addition to this in the design there is a PID2 controller
to control the amount of water flow by comparing the desired flow (SP2) which is the output
of PID1 and the amount of flow that receives from the flow sensor signal. Its electrical design
is shown below:

By M D B Page 35
 Figure 4.6. design of flow control system

4.3.3. Design of Dc motor speed control

DC motors provide excellent control of speed for acceleration and deceleration. The power
supply of a DC motor connects directly to the field of the motor which allows for precise
voltage control, and is necessary for speed and torque control applications.

Figure 4.7. design of dc motor speed control

In this design system there is a tachometer to measure the speed of the Dc motor in rpm and
this rpm is converted to voltage with the help of speed to voltage converter device. Basically
the design has its own controller which is PID3 to control the speed of the Dc motor.

By M D B Page 36
 CHAPTER FIVE

SIMULINK RESULT AND ANALYSIS

5.1. CONTROL ARCHITECTURE

Figure 5.1. architectural design of the system

Where

C1=it is a level controller (PID1)

C2=it is flow controller (PID2)
C3=it is dc motor speed controller(PID3)
H1, H2 & H3=these are feedback gains of level, flow and speed sensors respectively.
r1=it is the desired input
y1=it is the output of the system

By M D B Page 37
 5.2. RESULT OF SIMULINK

The simulink diagram of the system is shown below:

Figure 5.2. simulink model of the system

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 1. First Controller (PID1)

Figure 5.3. simulink result of level controller

 Result analysis

By M D B Page 39
From this simulink result we can conclude that, when the water level sensor senses the level
of the water in the tank then at that time the controller takes an action to minimize the error
and makes our system stable. Stable means the level of the water in the tank is under control.

2. Second Controller (PID2)

Figure 5.4. simulink result of flow controller

 Result analysis

By M D B Page 40
From the above simulink result we can observe that, when the flow sensor senses the amount
of flow through pump, the flow controller takes an action or response to control the amount
of flow by adjusting the position of the valve with the help of dc motor.

3. Third Controller (PID3)

Figure 5.5. simulink result of speed controller

 Result analysis

By M D B Page 41
From the above simulink result we can observe that, when the speed of the DC motor senses
by the speed sensor then the speed controller takes an action to adjust the speed of the DC
motor accordingly.

CHAPTER SIX

CONCLUSION AND RECOMMENDATION

6.1. CONCLUSION

In this thesis two cascaded PID controllers are designed to control the level and flow of the
water in a tank. The level of the water is detected by a level sensor where as the flow of the
water is detected with the help of flow sensor. The valve position is varied with the help of dc
motor. The dc motor speed is also controlled using a PID controller.

The mathematical models of the dc motor and the tank is modeled and its simulation is
obtained by using MATLAB tools. The MATLAB simulation result which was obtained
before and after tuning are slightly the same with the expected result especially the result of
after tuning this shows the system is under control.

Therefore, we can conclude that the PID controller is the most effective controller that
eliminates the offset of the proportional mode and still provides fast response. That is why
PID controller has been chosen. It may be further stated that because of the action of
Proportional parameter, the plot result will respond to a change very quickly. Due to the
action of Integral parameter, the system is able to be returned to the set point value. The
Derivative parameter will measure the change in the error and help to adjust the plot result
accordingly.
Finally, we believe that this thesis project is appropriate and more useful for DBU.

6.2. RECOMMENDATION

In this project we can recommend some points, but the one and the most recommendation is:

By M D B Page 42
  To implement this project in to hardware implementation by the next year
graduate students in order to use it in our university.

The other some recommendations are:

 It is better to change this PID controller by using PLC controller.

 To redesign the system for coupled tanks.
 To redesign the system for both inlet and outlet valves.

References
[1] Alen.Morries, Measurement and instrumentation principle, electronic equipments,3 rd
edition.
[2] Balanger,_Modern approach control engineering, mathematical model, 2nd ed. New york
[3] Englewood Cliffs ,Integrated Electronic Systems,2nd ed. NJ: Prentice-Hall, 1970.
[4] Rubaai A., Kotaru R., Online identification and control of a DC motor using learning
adaptation of neural networks, IEEE Trans. Industry Application, Vol. 36, p. 935 – 942,2000.
[5] Subrahamanyam _Electrical drives concept and application _second edition
[6] Westinghouse Electric Corporation (Staff of Technology and Science, Aerospace Div.),
[7] Ahmed Ullah Abu Saeed(et al.) Industrial Application of Automatic controls in
Bangladesh, Feb.1989
[8] Raghavan S., Digital Control for Speed and Position of a DC Motor, MS Thesis, Texas

A&M University, Kingsville, Aug. 2005.

[9] T.Kalaiselvi1(et al.),Automatic level control System With User Defined Volume
Selection,Kingsville,Feb.2002

[10]F.kumar.(1987,September 12) Solenoid-operational-principle

www.pneumaticpart.com/solenoid-valve/Solenoid-operational-principle

[11] J. Jones. (1991, May 10). Networks (2nd ed.) [Online]. Available: http://www.atm.com

[12] K.H.Johanson(2000,may16).Quadrapletankprocess(2nded. )
http://www.levelcontrol.com/

[13]M.Jonathan.(1984,april21).Liquidsystem(2nded.)http://share.pdfonline.com/

By M D B Page 43
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