CHE3002 PROCESS INSTRUMENTATION AND CONTROL

Experiment No : Name:
Date : Register No:

Aim:

To control temperature in a mixing-heating tank process using On-Off Controller, PID

controller.

Description:

A temperature control system for a water tank with continuous inflow and outflow is
simulated. The water is heated by a heating element which is controlled by the controller. The
temperature is measured by a temperature sensor which in practice may be a Pt100 element
or a thermocouple.

The process model on which the simulator is based is a first order model based on energy
balance under the assumption of homogenous conditions in the liquid and in the tank. The
process model also contains a time delay. In addition the simulator contains a first order
transfer function representing a time constant in the heating element.

The parameter values are shown on the front panel of the GUI. The process model used in the
simulator is based on energy balance:

(1) d(c  V T1)/dt = Ke u + c w (Tin - T1) + U (Tenv - T1)

where Keu = P is the power delivered by the heating element. T1 is the temperature in the tank
assuming homogenous conditions. In practice there is a time delay between an excitation in
the heating element and the response in the temperature sensor. P is the manipulated variable.

(2) The measured value of temperature is T(t) = T1(t-)

We assume that this time delay is inversely proportional to the mass flow w:

(3)  = Kt/w

By taking the Laplace transform of the model above, one can get the following transfer
function from the control signal to the temperature T:

(4) Gp(s) = T(s)/u(s) = [Kp e-s /(s+1)]

The corresponding expressions for the model parameters are:

Gain Kp = Ke / (c w + U)

Time constant  = V / (w + U/c)

CHE3002 PROCESS INSTRUMENTATION AND CONTROL

Time delay  = Kt / w

In addition, the heating element also has dynamics and is represented with a first order
transfer function model with unity gain and time constant.

The nominal operating conditions in the process are:

• The tank temperature T is 50 degrees C.

• The inlet temperature Tin is 20 degrees C.

The default process parameter values are shown on the GUI.

Procedure:

Unless otherwise stated, all the default values of the parameters are given in the GUI.
1. On/Off Control: Set the controller in On/Off mode. Observe the oscillations and the
magnitudes. Draw the corresponding graphs.

2. PID Control: Set the controller in PID mode. Use the default PID controller values
given and for a specific set-point of tank temperature, observe the closed loop
performance. (a) Change the set point as a step, say from 40 to 50 degrees C. (b)
Change the disturbance Tin from 20 to 15 degrees C, and analyze the disturbance
rejection ability of the controller. Are you able to obtain zero steady-state control
error? Draw the graphs.

Additional Understanding: Reset the settings of the simulator to its default values
(menu: Operate / Reinitialize All to Default). Check what happens with the stability
of the control system at the below parameter changes. In each of the
subtasks/experiments you can excite the control system using a small step in the set
point. The experiments shall be performed independent of each other, that is, the
parameters should be reset to the default values for each study.
a. Change the Controller gain Kp .
b. Change the Integral time Ti
c. Change the Derivative time Td
d. Decrease the Mass flow ‘w’
e. Change the Measurement element gain Km. (If you change the measurement
range, you must also change the set point range accordingly, otherwise there
will be a steady-state error.)

Observations:
CHE3002 PROCESS INSTRUMENTATION AND CONTROL

Graphs:

Draw relavant graphs

Inference and Conclusions: