Part 1: Open Loop Analysis

Controller Output in % Process Value in %

0 30.4
10 31.0
20 32.8
30 36.7
40 41.5
50 47.4
60 52.9
70 55.9
80 57
90 57.4
100 57.8

 The open loop controller works without the feedback control.

Therefore, we are able to directly control the controller output and
we can observe how temperature control works.
Part 2: ON/OFF Controller

Part 3: P Controller
 Optimal Bias = 42
 Optimal PB = 30

 Temperature, P mode, PB = 30

 Here the controller value varies proportionally to the Process

Variable (PV). If the PV varies fast then the response also tries to
match the PV.
Part 4: PI Controller
 Optimal IT = 35

 Temperature, PI Mode, IT = 50

 Temperature, PI Mode, IT = 35

 Here the initial response is not that accurate, but as time increases,
the response becomes much more accurate and tries to become
stable
Part 5: PD Mode
 Optimal DT = 2

 Temperature, PD Mode, DT = 1

 Temperature, PD Mode, DT = 2

 Here for the given system with PD controller having fixed

proportional band, change in derivative time (Td) in trial range (1-4
sec) did not introduce significant change in system. The proportional
band dominated the controller output in PD control.
Part 6: PID Mode

Result:
 The characteristics of open loop, on/off, P, PI, PD, PID controller for
the temperature controlled trainer is analysed and fine-tuned the
variables by trial and error approach.
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1. Linear Control Valve
Lift(mm) Flow(LPH) P(mmH20) Cv
14 0 1490 0.00
12 65 1374 0.21
10 125 1331 0.4
8 225 1260 0.74
6 285 1198 0.96
4 360 1100 1.27
2 480 1040 1.74
0 720 966 2.71

2. Equal % Control Valve

Lift(mm) Flow(LPH) P(mmH20) Cv
0 350 1128 1.22
2 250 1244 0.83
4 180 1302 0.52
6 100 1362 0.32
8 71.1 1374 0.22
12 41.3 1380 0.13
14 22.5 1382 0.07

3. Quick Opening Control Valve

Lift(mm) Flow(LPH) P(mmH20) Cv
14 0 1490 0.00
12 250 1244 0.83
10 630 760 2.68
8 720 464 3.92
6 760 442 4.23
4 780 400 4.57
2 790 386 4.71
0 800 380 4.85
Flow vs Lift

Cv vs Lift
Result:
Valve characteristics of linear, equal % and quick opening control valve
were plotted by calculating Cv values and flow values.
Tuning of Cascade Controllers
Secondary Loop

PB = 150

IT = 20

DT = 0.5

Primary Loop

PB = 95

IT = 15

DT = 3

PB = 95

IT = 30

DT = 2
Result:
In the cascade configuration, the input of secondary loop depends on the
output of primary loop, so initially the secondary loop is fine tunes and
then the primary loop is tuned.
Open Loop Response

Closed Loop Response

Result
PID values were calculated using the graphs plotted from the closed and
open loop response.
 A. Feedforward Control

Step Input, 50 60 %

Load Disturbance, FF = 1

Load Disturbance, FF = 0
 B. Ratio Control

RS = 0.5

RS = 1

RS = 1.5

RS = 2
RS = 2, Flow = 30LPH

Result
Feedforward is a preventive method, whereas feedback is a corrective
method. Feedforward is used in addition to feedback method as the SP
cannot be traced using the Feedforward method. Ratio control is a special
type of Feedforward method.
Result
Mathematical model of the given process was calculated by calculating
the required parameters by plotting a graph and comparing it with the
ideal graph.