Level Process Station: Instrumentation and Process Control

Instrumentation and
Process Control
Level Process Station
Printed in Canada
Student Manual
75943-20

INSTRUMENTATION AND
PROCESS CONTROL
LEVEL PROCESS STATION
by
the Staff
of
Lab-Volt (Quebec) Ltd
Copyright © 2000 Lab-Volt Ltd
All rights reserved. No part of this publication may be

reproduced, in any form or by any means, without the prior
written permission of Lab-Volt Quebec Ltd.
Legal Deposit – Third Trimester 2000
ISBN 2-89289-485-9
ISBN-289289-255-4 (1st Edition)
SECOND EDITION, JULY 2000
Printed in Canada
June 2002
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Exercise 1 Level Transmitter Time Response Characteristic . . . . . . . . 1-1
Exercise 2 Level Process Characteristics . . . . . . . . . . . . . . . . . . . . . . . 2-1
Exercise 3 Calibration of a Level Transmitter . . . . . . . . . . . . . . . . . . . . 3-1
Exercise 4 Level Measurement using a Bubbler . . . . . . . . . . . . . . . . . . 4-1
Exercise 5 Level Measurement of an Open Tank . . . . . . . . . . . . . . . . . 5-1
Exercise 6 Level Measurement with Zero Suppression . . . . . . . . . . . . 6-1
Exercise 7 Level Measurement with a Wet Reference Leg . . . . . . . . . . 7-1
Exercise 8 Level Process Proportional Control . . . . . . . . . . . . . . . . . . 8-1
Exercise 9 Level Process Proportional Plus Integral Control . . . . . . . 9-1
Exercise 10 Level Process Proportional Plus Integral Plus

Derivative Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Exercise 11 Notch Tuning of a Level Process . . . . . . . . . . . . . . . . . . . . 11-1
Exercise 12 Ultimate Period Tuning of a Level Process . . . . . . . . . . . . 12-1
Exercise 13 Open Loop Tuning of a Level Process . . . . . . . . . . . . . . . 13-1
Exercise 14 Operation of a Level Measurement Channel . . . . . . . . . . . 14-1
Exercise 15 Troubleshooting a Level Measurement Channel . . . . . . . 15-1
Exercise 16 Operation of a Level Control Process . . . . . . . . . . . . . . . . 16-1
Exercise 17 Troubleshooting a Level Control Process . . . . . . . . . . . . 17-1
Exercise 18 Operation of a Flow Measurement Channel . . . . . . . . . . . 18-1
Exercise 19 Operation of a Flow Control Process . . . . . . . . . . . . . . . . 19-1
Exercise 20 Operation of a Two Element Control Process . . . . . . . . . . 20-1
Exercise 21 Operation of a Three Element Control Process . . . . . . . . 21-1
Bibliography
We Value Your Opinion!
III
IV
Introduction
The rapid advances of instrumentation technology have greatly expanded the

variety of tasks performed by instrument technicians at industrial plants. Technician
are tasked with calibrating, troubleshooting and repairing instruments ranging from
pneumatic booster relays to microprocessor based automatic controllers. To
successfully perform these tasks without adversely affecting plant availability or
maintenance costs, effective training is essential.
The Lab-Volt Mobile Process Control Trainers are designed for hands-on training
in the measurement, control and troubleshooting of processes. The stations can
operate independently, or in certain combination configurations to simulate complex
processes. All instruments in the Lab-Volt Mobile Instrumentation and Process
Control System are patch connected to permit alternate control schemes and
adaptation of new technology in the future. The Flow, Level, Heat Exchanger and
Analytic stations utilize water as the process media, while Pressure and
Temperature stations are based on air.
The student's manual introduces the instrumentation students to the basic

characteristics of the main process variables. As the program progresses, students
will proceed to study process fundamentals, calibration of sensing devices and
transmitters, operation of microprocessor-based controller. Closed loop control and
troubleshooting complete the program.
V
VI
Exercise 1
Level Transmitter Time Response

Characteristic
OBJECTIVES
At the completion of this exercise, you will be able to set up a test arrangement for
observing the time response characteristic of a level transmitter.
DISCUSSION
In many applications, level transmitters must have the ability to quickly and
accurately respond to dynamic changes in fluid level. It is important to know how
quickly a level transmitter responds to level change.
This exercise will compare the time response of the process plus transmitter to the
time response of the transmitter alone. The transmitter response must be faster
than the entire process response to changes. If the transmitter response is slower,
the transmitter will always lag behind the process, resulting in an inaccurate output
and an unstable condition.
24"
INPUT STEP
CHANGE 10"
TIME
to
t o = INITIAL TIME
t d = DEAD TIME
PROCESS T = TIME CONSTANT
RESPONSE 63.2%
TIME
to td T
TRANSMITTER
63.2%
RESPONSE
TIME
to td T
Figure 1-1.
Three important terms are used to characterize the process reaction to a

disturbance. They are process gain, time constant, and dead time. The effect that
1-1
each of these terms has on the process can be observed on the strip chart obtained
from the recorder.
Procedural Notes
1. The procedure involves a step change to the level transmitter from 10" to
24" WC.
2. The process and transmitter will take some time to respond to the step change.
The process change includes the pump, water travelling through tubing, and
transmitter. This reaction will take longer than the transmitter's reaction alone.
Figure 1-1 shows typical response curves.
EQUIPMENT LIST
Level Process Station 3503, including:

1. Differential Pressure Transmitter (LT)
2. Current to Pressure Converter (I/P)
3. Strip Chart Recorder (LR)
4. Electronic Calibrator (from 3550-M0 Cal Bench)
INSTRUMENT DATA
DEVICE MODEL SERIAL NO. CALIBRATED
LT 0-30" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
PROCEDURE
CAUTION!
Do not run pump for prolonged periods with a shut off head!
Part 1
* 1. Calibrate the level transmitter 0-30" WC or 0-75 cm water.
* 2. Set up and connect equipment as per the loop diagram.
* 3. Part one measures response of both process and transmitter:
a. close valves V4 and V5 and fill the tank to 10" (25 cm) water. Stop the
pump and close valve V1 (this will prevent the water from siphoning
1-2
back out of the tank). Vent the HP side of the transmitter. Start the
recorder, restart the pump and open valve V1. Fill the tank to 24" and
switch off the pump and recorder. (Calibrator is set to 20 mA to open
CV-1.)
Part 2
* 4. Part two measures the response of the level transmitter only:
a. drain the tank to 10" WC (25 cm), close V5, and close V6. Refill the
tank to 24" WC. Start the recorder and simultaneously open V6. Stop
the recorder when the chart record is stable at the new level.
NOTES/CALCULATIONS
Note: The transmitter response is faster than the response of the

transmitter and process combined.
Note: “t” can be measured from the recorder chart, it does not have to be
physically timed.
Part 1
Combined Response L2 L1 = L = 14"
Recorder Speed 10"/min
Time Start ts Time Finish tf
t = tf ts =
14"
Response

/min
t
Part 2
Transmitter Response L = 14"
Time Start ts Time Finish tf
t = tf ts =
14"
Response

/sec
t
1-3
QUESTIONS
1. How much faster is the transmitter response than the combined process and
transmitter response?
2. Are all of the following responsible for the overall process response time: tank
volume, pipe size, valve speed, valve size, current to pressure converter speed,
pump size, pump speed? Explain.
1-4
1-5
LOOP DIAGRAM
COMMUNICATIONS ALARM INDICATORS
A 24
24 V − DC
B 25 LR
COM. 22
RS−485 ALM−1 ALM−2
ANALOG INPUTS OUTPUTS

4-20 mA COM. CONTROL OUT
2
1 + −
26 4-20 mA 27
4
1-5 V − DC 250 æ
AUXILIARY OUT
4-20 mA
5 + − SPAN
2 8
1-5 V − DC
3
7
1-5 V − DC 250 æ DRY CONTACT CONTACT OUT
4-20 mA INPUTS RATED 24 V − 1 A − DC
21 RELAY 1 ISOLATED
3 + 29 28 + CO 1 CO 2 1-5 V − DC
23
LEVEL INPUT
1-5 V − DC 250 æ
COLUMN
4-20 mA −
18 (32) (31) V−3
U−8 U−9 250 æ
4
30
1-5 V − DC 250 æ 20
+5.0 V OPEN CIRCUIT
PRR−1 V−9
SUPPLY
100 psi PROCESS
CALIBRATOR
700 kPa 0-3 psi 4-20 mA
0-20 kPa
V−4
TO
FI
+24 V − DC
V−13
SUPPLY
H 20 psi I/P
OVERFLOW V−6 V−7 140 kPa
V−14 U−5
D/P
V−8 TE U−7
RL 4-20 mA L U−6 V−2
HA−2 SV-1
V−5
U−3
3-15 psi
20-102 kPa 3-15 psi
20-102 kPa
U−4
V−11
PUMP V−1
V−10
U−2
CV−1 HA−1
V−12
U−1
SUPPLY HOLDING TANK SUPPLY
24 V − DC 20 GALLONS
75 LITRES
SOLENOID SUPPLY PUMP MAINS INTERLOCK

− VALVE SV-1
MAINTAINED MAINTAINED
DRY CONTACT DRY CONTACT
REMOTE REMOTE
24 V − DC OPEN CIRCUIT 20 psi / 140 kPa 24 V − DC OPEN CIRCUIT PUMP-HEATER 120 V − AC
100 mA 100 mA
Figure 1-2.
1-6
Exercise 2
Level Process Characteristics
OBJECTIVES
At the completion of this project, you will be able to use standard process
instrumentation to determine the characteristics of a level process.
DISCUSSION
Understanding how a process responds to changes is important for the individual

who must calibrate the instruments used for controlling the process. It is also
important to know how quickly the output of the measuring instrument responds to
changing conditions.
An easy method for observing the characteristics of a process is by intentionally

disturbing the process, and then monitoring the reaction on a chart recorder.
Procedural Notes
1. The procedure involves a step change to the calibrator (see Figure 2-1),
performed by quickly increasing the output from 8 to 12 mA.
12 mA STEP CHANGE
8 mA
Figure 2-1.
2. The process will take some time to react to the “instantaneous” step change.
This is due to several factors, including the time it takes for the water to travel
through the system and the water level to increase.
The actual step change will be considered instantaneous to simplify calculations.

The step change and resulting process reaction are shown in Figure 2-2.
2-1
12 mA
4 mA
T = 63.2%
TIME
to td
Figure 2-2.
EQUIPMENT LIST

3. Current To Pressure Converter (I/P)
4. Electronic Calibrator (From 3550 Cal Bench)
INSTRUMENT DATA
LT 0-30" WC/4-20 mA
LR 1-5 V dc/4-20 mA
I/P 4-20 mA/3-15 psi
PROCEDURE
CAUTION!
* 2. Fill the tank to approximately 10 in./25 cm water and vent the HP side of
the transmitter.
* 3. Set the calibrator output to 8 mA (6 psi to valve).
* 4. Allow the process to stabilize.
2-2
* 5. Start the recorder at 10 in./min. (fast speed) and rapidly change the
calibrator from 8 to 12 mA. When the process has stabilized, stop the
recorder.
* 6. Record the change in process level as read on the tank scale.
L start L finish
* 7. Perform calculations (see Notes/Calculations).
NOTES/CALCULATIONS
Level start (Ls)
Level finish (Lf)
Level Change Lc = Lf Ls =
Process Gain
1. Convert the Level Change (Lc) to a percent of transmitter span:
Lc/30" x 100% =
2. Express the position change of the process input Flow Control Valve as a
percent.
9 psi 6 psi
× 100%
12 psi
Output change (in % of span)
3. Process Gain

Input change (in % of span)
Process Dead Time
4. Process Dead Time (td) = time difference between point when valve signal was
changed from 6 to 9 psi and when process level started to rise
Process Time Constant
5. Process Time Constant (-) = time taken to reach 63.2% of final steady state
value
2-3
QUESTIONS
1. If a larger diameter tank were used, how would the Process Time Constant be
affected? Explain.
2. If the length of pipe between the Control Valve and the Process Tank were
longer, how would the Process Dead Time be affected? Explain.
3. Why did the process level reach a steady state value rather than completely
filling the tank to the overflow line?
2-4
2-5
LOOP DIAGRAM
A 24
24 V − DC
B 25 LR
COM. 22

2
1 + −
26 4-20 mA 27
4
1-5 V − DC 250 æ
AUXILIARY OUT
4-20 mA
5 + − SPAN
2 8
1-5 V − DC
3
7
21 RELAY 1 ISOLATED
3 + 29 28 + CO 1 CO 2 1-5 V − DC
23
LEVEL INPUT
1-5 V − DC 250 æ
COLUMN
4-20 mA −
18 (32) (31) V−3
U−8 U−9 250 æ
4
30
1-5 V − DC 250 æ 20
+5.0 V OPEN CIRCUIT
PRR−1 V−9
SUPPLY
100 psi PROCESS
CALIBRATOR
700 kPa 0-3 psi 4-20 mA
0-20 kPa
V−4
TO
FI
+24 V − DC
V−13
SUPPLY
H 20 psi I/P
V−14 U−5
D/P
V−8 TE U−7
RL 4-20 mA L U−6 V−2
HA−2 SV-1
V−5
U−3
3-15 psi
20-102 kPa 3-15 psi
20-102 kPa
U−4
V−11
PUMP V−1
V−10
U−2
CV−1 HA−1
V−12
U−1
75 LITRES

− VALVE SV-1
REMOTE REMOTE
100 mA 100 mA
Figure 2-3.
2-6
Exercise 3
Calibration of a Level Transmitter
OBJECTIVES
When you have completed this laboratory exercise, you will be able to calibrate a
Differential Pressure Transmitter that may be used for the measurement of liquid
level.
DISCUSSION
A Differential Pressure Transmitter measures the difference in pressure applied

across its measuring element. The low pressure side of the transmitter is connected
to the low pressure source. The high pressure side of the transmitter is connected
to the high pressure source. The pressure of a column of liquid is defined by:
Pressure = Density of the Fluid x Height of the Fluid
The height of the fluid is normally expressed in inches/centimetres of water. If the

density of the fluid remains constant, which is normally the case, then the pressure
is directly related to the height of the fluid. A column of fluid thus provides a useful
standard for calibrating differential pressure transmitters. The Laboratory Exercise
3 in the Calibration Bench Student's Manual (#76015-20) covers the calibration of
a D/P transmitter at the calibration bench. For this exercise we will calibrate the
transmitter at the Level Station.
As is true of most transmitters, a Differential Pressure Transmitter has two

adjustments that relate the output signal to the sensed differential pressure. These
adjustments are zero, and span or range. The zero adjustment is used to set the
transmitter to its lower range output value with the applied differential pressure at
its minimum or lower range value.
The span or range adjustment is used to set the transmitter to its upper range
output value with the applied differential pressure at its maximum or upper range
value. Calibration of a Differential Pressure Transmitter is the process of matching
the zero and full scale outputs of the transmitter to the minimum and maximum
differential pressures applied. The actual differential pressures that are to be applied
to the transmitter are derived from the specific system application.
Procedural Notes
A Differential Pressure Transmitter should be located so that the pressure sensing

element is level with the minimum level of the column of fluid. You will find on the
3503-M0 Trainer that it is not possible to mount the transmitter so that the sensing
element is level with the bottom of the level process tank. We must therefore
3-1
become familiar with “zero suppression” and “zero elevation” when calibrating a D/P
Transmitter. This will be discussed further in Exercise 6. For this exercise we will
mount the D/P Transmitter above the centre shelf of the Process Station. You will
find that this places the pressure sensing element at approximately the 6" level of
the process column. We will therefore calibrate the transmitter for a 20" H20 span.
This may also be written as 20" WC (water column). It is important to use the
correct transmitter for each application. The standard D/P Transmitter on the 3503-
M0 station has an adjustable range of 5-30" H20 and is therefore well suited to this
process.
EQUIPMENT LIST

3. Microprocessor Based Controller (LIC)
4. Digital Multimeter (From 3550-M0 Bench)
INSTRUMENT DATA
I/P 4-20 mA/3-15 psi
LT 6-26" WC/4-20 mA
CONTROLLER CONFIGURATION
1. Auto/Manual = Manual
PROCEDURE
CAUTION!
* 2. Close valves V4 and V5. Open valves V1, V2, V3, V8, V6 and V10.
* 3. Place the controller in manual. Turn the pump switch on. Raise the output
of the controller to open the control valve and fill the process tank to
approximately 15" WC. Close Valve V1.
3-2
* 4. The low pressure side of the transmitter is left open and will therefore
measure atmospheric pressure. The high pressure side is connected to
valve V6 and measures the pressure of the column of water plus
atmospheric pressure. The difference between the two is the pressure, and
therefore the height, of the column of water. Because we are calibrating this
transmitter using water, it is necessary to purge the air from the high
pressure side. Hold a cup under the HP vent and loosen the vent plug until
a constant stream of water is flowing through. Tighten the vent plug.
* 5. Open valve V5 until the water column level drops to 6". Set the zero adjust
on the transmitter so that the DMM reads 4 mA.
* 6. Open valve V1 to fill the level column to 26". Set the span adjust screw on
the transmitter so that the DMM reads 20 mA. If this is not possible, check
the location of the coarse span adjustment jumper. Refer to the transmitter
section in your station manual
* 7. Recheck the DMM readings at 6" WC and 26" WC as either the zero or
span adjustment will affect both values.
* 8. Complete the table 3-1 in Notes/Calculations. If the actual values do not

agree with desired values, repeat the calibration procedure.
NOTES/CALCULATIONS
Application Data
Instrument No.
Function:
Location:
Input Range:
Required Accuracy:
3-3
Instrument Nameplate Data
Manufacturer’s Name:
Model No.
Serial No.
Output Range:
Date of Calibration:
DESIRED ACTUAL
INPUT % SPAN REMARKS
OUTPUT OUTPUT
25
50
75
100
75
50
25
Table 3-1.
3-4
3-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2
4-20 mA COM CONTROL OUT

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3 NOTE:
7 SPAN
1-5 V 250 æ DRY CONTACT WHEN USING 4-20 mA INPUT
CONTACT OUT
INPUTS RATED 24 Vdc 1A SWITCH TOGGLE SHOULD BE
4-20 mA RELAY 1 ISOLATED OPPOSITE TO THAT SHOWN
21
+ 29 28 + CO 1 CO 2 INPUT
3 1-5 Vdc
23
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
1-5 250 æ +5.0 V VOLTS OPEN CIRCUIT
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
MULTIMETER
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1
MAINTAINED DRY CONTACT MAINTAINED DRY CONTACT

REMOTE REMOTE PUMP-HEATER

24 Vdc OPEN CIRCUIT 20 psi/140 kPa 24 Vdc CIRCUIT OUVERT
100 mA 100 mA
Figure 3-1.
3-6
QUESTIONS
1. What would be the effect upon the accuracy of the calibration, if air was trapped
in the Differential Pressure Transmitter when water was used for the calibrating
medium?
2. A Differential Pressure Transmitter is calibrated with a fluid of one density and

it is used to sense a fluid of less density. What effect, if any, would be seen in
the resulting indication?
3-7
3-8
Exercise 4
Level Measurement Using a Bubbler
OBJECTIVES
At the completion of this project, you will be able to use a bubbler system to
measure the liquid level in an open tank.
DISCUSSION
The measurement of level in an open tank can be achieved by a simple device

called a bubbler. The bubbler operates on the principle of hydrostatic pressure. This
method of level measurement uses a pipeline called the bubbler tube that is
installed vertically in the tank with its open end at the zero level. The other end of
the bubbler tube is connected to a pressure gauge and a regulated air supply. The
tank and attached pipe form a U-tube manometer.
With both the pipe and tank open to atmospheric pressure, the liquid seeks its own
level.
The level measurement is made by adjusting the air supply regulator so that the
pressure in the bubbler tube is slightly greater than the hydrostatic pressure exerted
on the open end of the tube by the liquid in the tank. This pressure is reached by
adjusting the air pressure regulator until bubbles can be seen slowly leaving the end
of the tube. The pressure gauge then measures the bubbler tube pressure required
to overcome the pressure of the liquid head above the open end of the tube. The
gauge can be calibrated in units of feet, inches, or gallons to provide a more
convenient means of monitoring level (see Figure 4-1).
PRESSURE
GAUGE
AIR
SUPPLY
REGULATOR
VALVE BUBBLES
BUBBLER TUBE TANK
Figure 4-1.
A bubbler requires a minimum airflow to obtain the condition previously described.

Since it is usually inconvenient to observe the air bubbles in the tank, an oil-filled air
flow sight glass or an airflow meter is often used to determine when the bubbling in
4-1
the tank begins. Air flow controllers can also be used to automatically control the
bubbling rate.
EQUIPMENT LIST

1. Bubbler Assembly
INSTRUMENT DATA
LT 0-30" WC/4-20 mA
PROCEDURE
CAUTION!
Note: If you have a 0-30" WC gauge you may use it instead of the D/P
transmitter in this exercise. However, if you do not have this gauge
available, calibrate the Differential Pressure Transmitter for 0-30" WC
and use the output of the transmitter as an indication of level.
* 2. Set PRR-1 at approximately 3 psi. Turn the pump on, and slowly open V1.
Raise the tank level to 28 in./70 cm, then turn the pump off. Close valve V5
and close V1 to prevent a syphoning effect.
* 3. Set the bubble rate to approximately 6 bubbles per minute. Record the
transmitter reading in Table 4-1 under Notes/Calculations.
* 4. Use V5 to reduce the tank level to 18 in./45 cm, then close V5. Record the
transmitter reading in Table 4-1.
* 5. Reduce the level to 8 in./20 cm, close V5, and record the transmitter
reading in Table 4-1.
* 6. Changing position of bubbler tube: raise the bubbler tube to 6 in./15 cm

above the bottom of the tank. Record the transmitter reading: mA,
" WC.
4-2
* 7. Effect of increased bubble rate: position the bubbler tube at 1 in./2 cm from
the bottom of the tank. Turn the pump on. Open V1. When the level
reaches 28 in./70 cm, turn the pump off. Set the bubble rate to a constant
stream of bubbles. Record the transmitter reading in Table 4-2.
* 8. Repeat step 7, using V5 to reduce the level to 18 in./45 cm. Repeat with
8 in./45 cm. Record the transmitter readings in Table 4-2.
* 9. Perform the calculations In Notes/Calculations.
NOTES/CALCULATIONS
TANK LEVEL LT. INDICATED

in. H20 cm H20 OUTPUT LEVEL
28 70
18 45
8 20
Table 4-1.
TANK LEVEL LT. INDICATED

in. H20 cm H20 OUTPUT LEVEL
28 70
18 45
8 20
1 psi = 27.707 in. H20

1 kPa = 10.07 cm H20
Table 4-2.
4-3
4-4
LOOP DIAGRAM
A 24
24 V − DC
B 25 LR
COM. 22

2
1 + −
26 4-20 mA 27
4
1-5 V − DC 250 æ
AUXILIARY OUT
4-20 mA
5 + − SPAN
2 8
1-5 V − DC
3
7
21 RELAY 1 ISOLATED
3 + 29 28 + CO 1 CO 2 1-5 V − DC
23
LEVEL INPUT
1-5 V − DC 250 æ
COLUMN
4-20 mA −
18 (32) (31) V−3
U−8 U−9 250 æ
4
30
1-5 V − DC 250 æ 20
+5.0 V OPEN CIRCUIT
PRR−1 V−9
SUPPLY
100 psi PROCESS
CALIBRATOR
700 kPa 0-3 psi 4-20 mA
0-20 kPa
V−4
TO
FI
+24 V − DC
V−13
SUPPLY
H 20 psi I/P
V−14 U−5
D/P
V−8 TE U−7
RL 4-20 mA L U−6 V−2
HA−2 SV-1
V−5
U−3
3-15 psi
20-102 kPa 3-15 psi
20-102 kPa
U−4
V−11
PUMP V−1
V−10
U−2
CV−1 HA−1
V−12
U−1
75 LITRES

− VALVE SV-1
REMOTE REMOTE
100 mA 100 mA
Figure 4-2.
4-5
QUESTIONS
1. For step 3, does the D/P reading equal 28 in./70 cm of water (tank level)? If not,
explain why not.
2. Compare the pressures recorded in Table 4-2 to the pressures recorded in

Table 4-1. Explain any differences.
3. What factors determine the pressure exerted by a column of liquid?
4. What would be the effect upon the accuracy of the level measurement if the
temperature of the liquid within the tank was raised above the temperature at
which the bubbler system was calibrated?
4-6
Exercise 5
Level Measurement of an Open Tank
OBJECTIVES
At the completion of this project, you will be able to perform a calibration check on
a Differential Pressure Transmitter and measure the level of a fluid in a tank.
DISCUSSION
A Differential Pressure Transmitter measures the difference in pressure sensed

across its measuring element. The low pressure side of the Differential Pressure
Transmitter is connected to the low pressure source. The high pressure side of the
transmitter is connected to the high pressure source.
When using a D/P Transmitter to measure the level of a liquid in a tank, the
differential pressure detected by the transmitter is related to the level of the fluid by
the following expression:
Pressure = Density of the Fluid x Height of the Fluid.
The height of the fluid is normally expressed in in./cm of water. If the density of the
fluid remains constant, which is normally the case, then the pressure is directly
related to the height of the fluid.
For the measurement of the liquid level in an open tank, the high pressure side of
the D/P Transmitter is connected at the bottom or reference level of the tank. The
low pressure side of the D/P is open to atmospheric pressure. Connected in this
manner, the atmospheric pressure on top of the water column is compensated for
by an equal pressure at the LP side of the transmitter.
Procedural Notes
1. A D/P Transmitter may be calibrated using either water or air pressure. To

ensure accuracy, the transmitter must be filled completely with one medium,
either air or water. A mixture of the two produces calibration errors.
If air is used, any water trapped in the transmitter body or sensing lines causes error
due to its weight. Likewise, if water is used, any air in the D/P causes an error due
to its compressibility. Since we are using air for calibration, all water must be
removed from the transmitter.
2. For step 8, the D/P Transmitter will be used to measure the liquid level in the
tank. It must be completely filled with water to ensure the accuracy of the
measurement, so all air must be purged from the body and sensing lines.
5-1
EQUIPMENT LIST

2. Electronic Calibrator (From 3550-M0 Cal Bench)
3. Pneumatic Calibrator (From 3550-M0 Cal Bench)
INSTRUMENT DATA
LT 0-30" WC/4-20 mA
PROCEDURE
CAUTION!
Part 1
* 2. Purge the High and Low sides of the transmitter with air.
* 3. Verify that with the pneumatic calibrator set to 0" WC, the transmitter output
reads 4 mA.
* 4. Calculate and record the calibration input pressures in in./cm for the LT that
correspond to the % span values in Table 5-1 (see Tables/Calculations).
* 5. Raise the output of the pneumatic calibrator to the values listed in Table
5-1. Record the corresponding pressure indicated by the transmitter in
Table 5-1. Lower the output to the values listed and record the pressure.
Part 2
* 6. Disconnect the tubing and the pneumatic calibrator. Connect the D/P
transmitter to the Level Process Station.
* 7. To raise the tank level:
a. close V4 and V5
5-2
b. turn the pump On
c. slowly open V1, raise the tank level to 10 in./25 cm, turn the pump off,
close V1.
* 8. Purge the HP side of the transmitter. Open V5 and drain the tank. Record
the value indicated for 0 in./cm in Table 5-2. Close V5.
* 9. Turn the pump on, slowly open V1 and raise the tank level to the values
listed in Table 5-2. Record the corresponding pressures indicated by the
LT. Turn the pump off. Open V5.
* 10. Answer the questions at the end of the exercise.
NOTES/CALCULATIONS
CALIBRATION DIFFERENTIAL
% SPAN INPUT PRESSURE
(in./cm) TRANSMITTER READINGS
0 0 4.0 mA
20
40
60
80
100 30"/75 cm 20 mA
80
60
40
20
Table 5-1.
5-3
TANK LEVEL DIFFERENTIAL

PRESSURE
TRANSMITTER READINGS
in. H20 cm H20
0 0
7 17
14 34
21 51
28 68
Table 5-2.
5-4
5-5
LOOP DIAGRAM
PART 1
+24 V-DC
H
D/P
L
DIGITAL
MULTIMETER
SET TO CALIBRATOR
READ DC mA 0-160" WC
COMMON
OF 24 V DC SUPPLY
LEVEL
COLUMN
PART 2 V−3
U−8 U−9
PRR−1 V−9
SUPPLY
100 psi PROCESS
CALIBRATOR
700 kPa 0-3 psi 4-20 mA
0-20 kPa
V−4
TO
FI
+24 V − DC
V−13
SUPPLY
H 20 psi I/P
V−14 U−5
D/P
V−8 TE U−7
RL 4-20 mA L U−6 V−2
HA−2 SV-1
V−5
U−3
3-15 psi
20-102 kPa 3-15 psi
20-102 kPa
U−4
V−11
MULTIMETER
PUMP V−1
V−10
U−2
CV−1 HA−1
V−12
U−1
75 LITRES

− VALVE SV-1
REMOTE REMOTE
100 mA 100 mA
Figure 5-1.
5-6
QUESTIONS
1. What is the effect on the D/P Transmitter readings if the centre of the sensing
element is not level with the bottom of the tank? What must be done to correct
the results in Table 5-2?
2. If the liquid in the tank was heated at about 100 degrees C, would the D/P read
higher or lower than the actual tank level? Explain.
3. What would be the effect upon the accuracy of the Differential Pressure
Transmitter if water was trapped within the body when air was used for the
calibrating medium?
5-7
5-8
Exercise 6
Level Measurement with Zero Suppression
OBJECTIVES
At the completion of this laboratory exercise you will understand the term “zero
suppression” and be able to calibrate a Differential Pressure Transmitter that is
mounted below the minimum level value that is to be measured.
DISCUSSION
In Exercise 3 we calibrated a Differential Pressure Transmitter (used for level

measurement) where the pressure sensing element was at exactly the same height
as the minimum liquid level value to be measured. With some system applications,
it is not possible to mount the transmitter in this optimum position. You will
remember that in Exercise 3 we used 6" WC as our minimum value because it was
not possible to mount the transmitter level with the bottom of the process tank. In
many industrial configurations you will find the transmitter mounted below the
minimum level to be measured.
Consider an application on the 3503-M0 Station where we wish to control the level
in the process tank from 0"-28" WC. If the D/P transmitter is mounted 12" below the
base of the level column, you will see that when the level column is empty, the
transmitter will still be measuring 12" WC and therefore giving an output of
approximately 10.9 mA. To properly calibrate the transmitter, this value must be
reduced to 4 mA. This is accomplished by changing the zero adjustment of the
transmitter, and is referred to a “zero suppression”. The opposite of this situation,
where the transmitter is mounted above the lowest level value, would require “zero
elevation”.
Most D/P Transmitters are designed to operate with a suppressed zero range. The
manufacturer's specifications will indicate the amount the zero can be suppressed.
For the standard 3503-M0 level transmitter (Foxboro 823DP) you will find in your
station manual that the zero can be suppressed up to 150% of the calibrated span.
Therefore our example of a 28" WC span would allow the zero to be suppressed up
to 42" below the base of the level column.
For this exercise we can set up one of the following configurations:
a) Physically mount the D/P Transmitter below the centre shelf of the trainer-in
which case any chosen span would require zero suppression.
b) Leave the transmitter mounted above the centre shelf and calibrate it for a span
where the minimum desired level is above the sensing element of the transmitter.
This is the configuration that is applied to the procedure in this exercise.
6-1
EQUIPMENT LIST

4. Digital Multimeter (From 3550-M0 Calibration Bench)
INSTRUMENT DATA
I/P 4-20 mA/3-15 psi
LT 10-20" WC/4-20 mA
PROCEDURE
CAUTION!
* 2. Close valves V4 and V8. Open valves V1, V2, V3, V5, V6 and V10.
* 3. Set the controller in manual. Turn the pump switch on. Raise the output of
the controller to open the control valve and fill the process tank to
approximately 15" WC. Close valve V1.
* 4. Purge any air trapped in the high pressure side of the level transmitter.
Hold a cup under the vent and loosen the vent plug until a constant stream
of water is flowing through. Tighten the vent plug.
* 5. Check that the level transmitter is mounted so that the sensing element is
at approximately 5 1/2" on the level column.
* 6. Open valve V8 and drain the water down to 10" WC. Set the zero
adjustment on the transmitter so that the output reads 4 mA on the DMM.
6-2
* 7. Raise the tank level to 20" WC and set the span adjust so that the
transmitter output reads 20 mA on the DMM.
* 8. Recheck both settings several times as either the zero or span adjust will
affect both settings.
* 9. Complete the Table 6-1 in Notes/Calculations. If the actual values do not

agree with the desired values, repeat the calibration.
NOTES/CALCULATIONS
Application Data
Instrument No.
Function:
Location:
Input Range:
Required Accuracy:
Model No.
Serial No.
Output Range:
6-3
DESIRED ACTUAL
OUTPUT OUTPUT
25
50
75
100
75
50
25
Table 6-1.
6-4
6-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
1-5 V 250 æ DRY CONTACT NOTE:
CONTACT OUT
INPUTS RATED 24 Vdc 1A WHEN USING 4-20 mA INPUT
4-20 mA RELAY 1 ISOLATED
21 SWITCH TOGGLE SHOULD BE
+ 29 28 + CO 1 CO 2 OPPOSITE TO THAT SHOWN INPUT
3 1-5 Vdc
23
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
MULTIMETER
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 6-1.
6-6
QUESTIONS
1. What determines the minimum tank level detectable by the Differential Pressure
Transmitter?
2. Briefly define a transmitter with suppressed-zero range capability.
6-7
6-8
Exercise 7
Level Measurement with a Wet Reference Leg
OBJECTIVES
At the completion of this laboratory exercise, you will be able to calibrate a

differential pressure transmitter with a wet reference leg.
DISCUSSION
In all of the previous exercises, we have concentrated on methods of measuring

level in an open tank. If the tank is closed we can no longer use atmospheric
pressure as our reference for the LP side of the D/P Transmitter. The pressure of
the vapour above the fluid in the closed tank will vary according to rate of inflow
versus outflow, heating of the liquid, etc. To compensate for this pressure variation,
the LP side of the transmitter can be connected to the quick-connect fitting on the
top of the 3503-M0 level column. This is known as a Dry Reference Leg.
However, in some pressurized system applications the contents of the tank is a

condensible fluid such as steam or water. To prevent condensation from introducing
an error, a filled, or Wet Reference Leg is used. This applies a constant hydrostatic
head pressure to the LP side of the transmitter, as long as the reference leg is
maintained full. With a constant pressure on the LP side, any differential pressure
applied to the transmitter is due to a change in pressure at the HP side. As in the
dry reference leg, any gas or vapour pressure is cancelled out because it is equally
applied to both sides of the differential pressure sensing element.
The reference leg is filled to the maximum detectable level in the tank. When the
liquid level is at the minimum detectable level point, the sensing element is exposed
to a maximum differential pressure. Note, however, that the pressure is greater on
the LP side of the transmitter. This means the transmitter output would be minus 20
mA at minimum level, and 4 mA (or zero differential pressure) at maximum liquid
level. A transmitter range that exists with an LP side pressure greater than the HP
side pressure is referred to as an elevated zero range.
One method employed to overcome this problem is to compensate for the pressure
applied to the LP side of the transmitter. Recall that zero suppression was used to
compensate for undesired pressure applied to the HP side of the transmitter.
Reversal of this concept, known as Zero Elevation, can be used to compensate for
undesired pressure applied to the LP side.
7-1
Procedural Notes
In this experiment we will demonstrate level measurement with a wet reference leg
using an open tank. Similar to the previous experiments, atmospheric pressure will
be cancelled by being applied to both sides of the transmitter.
EQUIPMENT LIST

4. Digital Multimeter (From the 3550-M0 Calibration Bench)
INSTRUMENT DATA
I/P 4-20 mA/3-15 psi
LT 6-26" WC/4-20 mA
PROCEDURE
CAUTION!
* 1. Set up and connect equipment as per the loop diagram. Install the stand
pipe after valve V14 on union U-7. Keep the flexible tubing connections
between the transmitter and the level tank as short and straight possible as
movement in these lines will cause fluctuations in your readings.
* 2. Close valves V4, V8, and V12. Open valves V1, V2, V3, V5, V6, V10, V13,
and V14.
* 3. Set the controller in manual. Turn the pump switch on. Raise the output of
the controller to open the control valve and fill the column up to 26 inches
by regulating valve V2.
7-2
* 4. Hold a cup under the transmitter vents and purge any air from both sides
of the transmitter and close valve V14.
* 5. Lower the water level in the process tank to 6" WC.
* 6. Set the zero adjustment on the transmitter so that the output reads 4 mA
on the DMM.
* 7. Raise the level in the tank to 26" and set the span adjustment so that the
transmitter output reads 20 mA on the DMM.
* 8. Recheck the upper and lower values several times as either the zero or
span adjust will affect both settings.
* 9. Complete the Table 7-1 in Notes/Calculations. If the actual values do not

agree with the desired values, repeat the calibration.
NOTES/CALCULATIONS
Application Data
Instrument No.
Function:
Location:
Input Range:
Required Accuracy:
Model No.
Serial No.
Output Range:
7-3
DESIRED ACTUAL
OUTPUT OUTPUT
25
50
75
100
75
50
25
Table 7-1.
7-4
7-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
1-5 V 250 æ NOTE:
DRY CONTACT CONTACT OUT
INPUTS RATED 24 Vdc 1A WHEN USING 4-20 mA INPUT
+ 29 28 + CO 1 CO 2 OPPOSITE TO THAT SHOWN INPUT
3 1-5 Vdc
23
1-5 V 250 æ
- LEVEL
4-20 mA
21 (32) (31) COLUMN
V-3
4 30 250 æ
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
FI
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7
D/P U-5
20 psi
V-8 V-14 140 kPa
LP
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 7-1.
7-6
QUESTIONS
1. If the transmitter were mounted below the bottom of the level tank in this
experiment, would zero suppression be used?
2. What would be the effect on indicated level, if the reference leg were to leak
down by 3"/7.5 cm?
7-7
7-8
Exercise 8
Level Process Proportional Control
OBJECTIVES
instrumentation to observe and analyze proportional control.
DISCUSSION
Understanding how a controlled process responds to supply or demand

disturbances is important for the individual who must calibrate the instruments used
for controlling the process. An easy method for observing how the controller
adjustments affect the characteristics of a process is by intentionally disturbing the
process and then monitoring the reaction on a multi-speed recorder.
A setpoint is chosen, representing the desired value of the controlled variable. The
controller inputs the result of a measurement of a controlled variable and determines
an appropriate output for the final control element according to the magnitude of
deviation from setpoint, and how the operator has set, or tuned, the instrument. The
results of different settings can be observed from the strip chart obtained from the
recorder.
PROCESS
VARIABLE
OFFSET
ERROR
SETPOINT
TIME
PROPORTIONAL CONTROL
Figure 8-1.
A proportional controller functions to maintain the process within a specified band

of control. It gives an output to input relationship which is linear.
% Change in input
Proportional Band
× 100%
% Change in output
8-1
Gain, the ratio of output to input of any section of a controlled system, is inversely
related to proportional band.
Output Change
Gain
Input Change
With a lower gain, a larger change in the input signal is required to cause the output
to change from 0-100%. Within the proportional band, the controller output is
proportional to the input signal, and the gain factor determines the proportional
relationship. The magnitude of the offset error is directly related to the proportional
band. Higher gain settings result in reduced offset error, but increased instability.
EQUIPMENT LIST

1. Microprocessor PID Controller (LIC)
4. Chart Recorder (LR)
INSTRUMENT DATA
LT 0-30" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
2. Setpoint = 50%
3. Gain = 1 (Prop. Band = 100%)
4. Reset minimum rep/min. (Maximum integral time)
5. Action = Reverse (inc./dec.)
6. Remote/Local = Local
7. Derivative = Off or Minimum
PROCEDURE
CAUTION!
* 1. Set up and connect the equipment as per the loop diagram.
8-2
* 2. Calibrate the transmitter for 0-30" (0-75 cm) WC.
* 3. Set the controller as per the Instrument data. Start the recorder and place
the controller in Automatic. manually adjust the controller output until the
measured variable equals the setpoint.
* 4. Effect of original gain in response to setpoint changes:
a. Rapidly increase the setpoint to 75%,
b. Stop the recorder when the process stabilizes,
c. adjust the setpoint to 50% and allow the process to stabilize.
* 5. Decreasing gain in response to setpoint change:
a. Adjust the gain to ( % PB)
b. Start the recorder.
c. Rapidly increase the setpoint to 75% (d) stop the recorder when the
process stabilizes.
d. Adjust the setpoint to 50% and allow the process to stabilize.
* 6. Increasing gain in response to setpoint change:
a. Increase the gain to ( %PB)
b. Repeat step 5 (b), (c) and (d).
* 7. If you have time, repeat steps 4-6 using a load change instead of a setpoint
change. To make a small load change restrict valve V2. To cause a large
change, completely close valve V3 and hold it closed for several seconds
before reopening it. If your station has solenoid valve SV-1 and valve V11,
use them to configure an alternate flow path from the process column to
effect a load change.
* 8. Answer the questions.
8-3
8-4
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
1-5 V 250 æ DRY CONTACT CONTACT OUT
INPUTS RATED 24 Vdc 1A NOTE:
21 WHEN USING 4-20 mA INPUT
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
23 OPPOSITE TO THAT SHOWN
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 8-2.
8-5
QUESTIONS
1. For the setpoint change to the process (step 4), describe the waveform on the
recorder in terms of offset error and stability.
2. For step 5, describe the waveform on the recorder and compare with step 4.
3. For step 6, describe the waveform on the recorder in terms of offset error and
stability.
4. What effects on offset error and stability are caused by using a high gain setting
on the controller?
5. In terms of stability and offset, how would the response to a setpoint change be
affected by changing the LT calibrated range from 0-30 in. to 0-20 in.? Assume
the controller gain adjustment is not changed.
8-6
6. After a setpoint change is made to a process, how could the offset error be
removed?
8-7
8-8
Exercise 9
Level Process Proportional Plus Integral Control
OBJECTIVES
instrumentation to observe and analyze the effects of demand and setpoint changes
on a proportional plus integral controller used in a level process.
DISCUSSION

disturbances is important for the individual who must calibrate the instrument used
The addition of integral action, also called RESET action, to a proportional controller
results in the elimination of offset error.
The main advantage of the integral control mode is that the controller output
continues to reposition the final control element until the error is reduced to zero,
within system design limitations.
PROCESS
VARIABLE
SETPOINT
TIME
P + I CONTROL
Figure 9-1.
The main disadvantage of the integral control mode is that the controller output does
not immediately direct the final control element to a new position in response to an
error signal.
9-1
The controller output changes at a defined rate of change, and time is needed for
the final control element to be gradually repositioned.
The addition of integral action to proportional control automatically performs the gain
resetting that was manually accomplished. For this reason, proportional plus integral
controllers are sometimes referred to as proportional plus automatic reset, or simply
proportional plus reset controllers.
Higher gain settings result in increased instability. An increase in RESET (Repeats

per Minute) will cause the process to return to the setpoint value faster, but also
produces instability if adjusted too high.
EQUIPMENT LIST

INSTRUMENT DATA
LT 0-30" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
2. Setpoint = 50%
3. Gain = 1 (Prop. Band = 100%)
4. Reset = 0.1 rep/min (Integral Time = 10 minutes)
5. Action = Reverse (Inc/Dec)
6. Derivative - Off or Minimum
PROCEDURE
CAUTION!
9-2
* 2. Manually adjust the controller output to approximately 50%. Turn the pump
on, open V1, fill tank to 15 in. (38 cm), and vent the HP side of the
transmitter.
* 3. Calibrate the level transmitter.
* 4. Set the controller as per the Controller Configuration. Start the recorder and
place the controller in Automatic.
* 5. Load change disturbance to process: close valve V3 for 2 to 3 seconds,

then fully open valve V3 and allow the process to stabilize.(Or open valve
V11 and then open SV-1 for approximately 3 seconds). Stop the recorder
when the process stabilizes.
* 6. Increasing gain in response to load change:
a. increase the gain to ( % P.B.),
b. start the recorder,
c. repeat step 5.
* 7. Increasing integral action in response to load change:
a. increase the reset to rep/min ( min/rep),
b. start the recorder, (c) repeat step 5.
* 8. Effect of original settings in response to setpoint change:
a. Set gain to 1 (100% P.B.),
b. start the recorder and rapidly decrease the setpoint to 20%,
c. stop the recorder when the process stabilizes, adjust the setpoint to
50%.
a. adjust the gain to ( % P.B.),
b. repeat step 8 (b)-(c).
9-3
* 10. Increasing integral action in response to setpoint change:
a. adjust the reset to repeats/min ( min/rep),
* 11. Answer the questions at the end of the exercise.
9-4
9-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 9-2.
9-6
QUESTIONS
stability.
2. For step 6, describe waveform on the recorder in terms of offset error &
stability.
3. For step 7, describe the waveform on the recorder in terms of offset error &
stability.
stability.
stability.
stability.
9-7
7. What advantage is obtained by adding integral action to a proportional

controller?
8. Could a change in the process occur resulting in such a large offset error that
even high amounts of integral action could not eliminate it? Explain.
9. How would the control channel respond if the controller was configured to Direct
Action (inc/inc)?
9-8
Exercise 10
Level Process Proportional Plus Integral

Plus Derivative Control
OBJECTIVES
instrumentation to observe and analyze the effects of demand and setpoint changes
on a proportional plus integral plus derivative controller used in a level process.
DISCUSSION

disturbances is important for the individual who must calibrate the instrument used
For processes that cannot tolerate continuous cycling, a proportional controller is

used. For processes that cannot tolerate continuous cycling or offset error, a
proportional plus integral controller is used.
For processes that need improved stability and can tolerate offset error, a
proportional plus derivative controller is used.
10-1
PROCESS
VARIABLE
SETPOINT
TIME
PID CONTROL
Figure 10-1.
Derivative control is rarely used with Proportional Control only. PD control is

desirable in processes where there are several different lag times.
Some processes cannot tolerate offset error, yet need good stability. In this case
a control mode that combines the advantages of proportional, integral, and
derivative (PID) control is used.
Derivative action causes the proportional output to be advanced which provides an

output signal to the final control element sooner. As the error signal rate of change
increases, the initial controller output is larger. This helps the controller anticipate
large error amplitudes that are a result of rapidly changing error signals.
Derivative action is not usually used with fast responding processes such as flow
control, or with noisy processes, because the derivative action responds to any rate
of change in the error signal, including noise.
Derivative control is used in process control systems where the lag time (the time
it takes a change to be measured) is large. Derivative control is considered difficult
to implement and adjust; therefore, it is only used when the amount of lag time is
extensive. It is typically used as PID control for temperature control and other slow
applications.
EQUIPMENT LIST

10-2
INSTRUMENT DATA
LT 0-30" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
2. Setpoint = 50%
3. Gain = 1 (Prop. Band = 100%)
4. Reset = 0.1 rep./min (Integral Time = 10 minutes)
5. Action = Reverse (Inc/Dec)
6. Derivative = 0.05 min.
PROCEDURE
CAUTION!
* 2. Manually adjust the controller output to approximately 50%. Turn the pump
on, open V1, fill tank to 15 in. (38 cm), and vent the HP side of the
transmitter.
* 4. Set the controller as per the Controller Configuration. Start the recorder and
place the controller in Automatic.
* 5. Load change disturbance to process: close valve V3 for 2 to 3 seconds,

then fully open valve V3 and allow the process to stabilize.(Or open valve
V11 and then open SV-1 for approximately 3 seconds). Stop the recorder
when the process stabilizes.
10-3
* 6. Increasing gain in response to load change:
a. increase the gain to ( %P.B.),
b. start the recorder, (c) repeat step 5.
* 7. Increasing integral action in response to load change:
a. increase the reset to rep/min ( min/rep),
c. repeat step 5.
* 8. Increasing derivative action in response to load change:
a. set the derivative to minutes,
c. repeat step 5.
* 9. Effect of original settings in response to setpoint change:
a. Set P and I to the original settings
b. start the recorder and rapidly decrease the setpoint to 20%,
c. stop the recorder when the process stabilizes, adjust the setpoint to
50%.
a. adjust the gain to ( % P.B.),
* 11. Increasing integral action in response to setpoint change:
a. adjust the reset to repeats/min ( min/rep),
10-4
* 12. Increasing derivative action in response to setpoint change:
a. adjust the derivative to minutes,
b. repeat step 9 (b)-(c), and turn off pump.
* 13. Answer the questions.
10-5
10-6
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
1-5 V 250 æ DRY CONTACT CONTACT OUT NOTE:
INPUTS RATED 24 Vdc 1A
4-20 mA RELAY 1 ISOLATED WHEN USING 4-20 mA INPUT
21
+ 29 28 + CO 1 CO 2 SWITCH TOGGLE SHOULD BE INPUT
3 OPPOSITE TO THAT SHOWN 1-5 Vdc
23
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 10-2.
10-7
QUESTIONS
stability.
2. For step 6, describe the waveform and compare with step 5.
5. For step 9, describe the waveform in terms of offset error and stability.
10-8
9. In the level process, what would be the result of high derivative settings?
10. With the same settings of integral and derivative control, what is the change in
the integral and derivative action, caused by increasing the gain of the
controller?
11. Is the integral action of the PID controller affected by adjusting the derivative
action?
10-9
10-10
Exercise 11
Notch Tuning of a Level Process
OBJECTIVES
At the completion of this project, you will be able to use the Notch Method of
Controller Tuning to determine the correct PID settings for a level controller.
DISCUSSION
The Notch Method of Controller Tuning is a systematic means of determining the

correct settings of Proportional Action (Gain), Integral Action (Reset) and Derivative
Action (Rate). It consists of making small setting changes, disturbing the process,
then evaluating the response to determine what setting values cause a unity
process gain. These values are then used to calculate the proper settings to achieve
a Quarter-Amplitude dampened process reaction.
CONTROLLER
GAIN
NOTCH
RESET RATE
PROPORTIONAL
FREQUENCY
Figure 11-1.
EQUIPMENT LIST

11-1
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
1. Setpoint = 50%
2. Gain = 1 (Prop. Band = 100%)
3. Reset = minimum rep/min. (max. Integral Time)
4. Derivative = minimum minutes
5. Auto/Manual = Auto
PROCEDURE
CAUTION!
* 3. Place the controller in automatic, setpoint at 50%.
* 4. Set: Proportional Band to 100% (Gain=1)

Integral Time to Maximum (Min.Repeats/Min.)
Derivative To Minimum Minutes
* 5. Disturb the process by making 5% setpoint changes.
* 6. Alternately continue to make small increases in proportional action and 5%

setpoint changes until the chart recorder indicates the process is reacting
with constant amplitude oscillations.
* 7. Use this value in equation 1 to calculate the proper proportional action

setting. Adjust the controller to this setting.
11-2
* 8. Repeat step 5 making small increases in integral setting and 5% setpoint

changes. Use the integral value that causes constant amplitude oscillations
in equation 2. Adjust the controller to this setting.
* 9. Repeat step 5 using derivative setting adjustments. Use equation 3 to

determine the correct derivative setting.
* 10. Using the three calculated settings, evaluate the controller response to
setpoint and demand disturbances. Fine tuning may be necessary.
NOTES/CALCULATIONS
Gain
1. Gain Setting

P.B. Setting
2(P.B.)
2
Repeats/Minute
2. Integral Setting

or: 3 (MINUTES/REPEAT) =
Derivative Time
3. Derivative Setting

11-3
11-4
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 11-2.
11-5
QUESTIONS
1. Why does increasing the controller proportional action cause the process to
become unstable?
2. Why does each of the three controller modes have the ability to cause the
process to become unstable?
3. What characteristics of the process determines the need for adding derivative
action in the controller to achieve good process control?
4. Is the notch method an open-loop method of controller tuning? Explain.
11-6
Exercise 12
Ultimate Period Tuning of a Level Process
OBJECTIVES
At the completion of this laboratory exercise you will be able to use standard
process instrumentation to observe and analyze the effects of setpoint and gain
changes on a controller and, using the observed information, determine the
optimum settings required to tune the controller.
DISCUSSION
Understanding how a controlled process responds to changes is important for the

individual who must calibrate the instruments used for controlling this process.
An easy method for observing how the Controller adjustments affect the
characteristics of a process is by intentionally disturbing the process and then
monitoring the reaction on a Chart Recorder.
The Ultimate Period Method requires placing the process in continuous amplitude
oscillation and then using the Controller setting and measurements from the Strip
Chart to determine the optimum settings of Gain, Integral Action and Derivative
Action for the Controller and the process.
MEASURED
VARIABLE
Pu
TIME
Figure 12-1.
EQUIPMENT LIST

12-1
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
1. Setpoint = 50%
2. Gain = 1 (Prop. Band = 100%)
3. Reset = minimum rep/min. (max. Integral Time)
4. Derivative = minimum minutes
5. Auto/Manual = Auto
PROCEDURE
CAUTION!
* 3. Set the Controller as per the Controller Configuration.
* 4. Manually adjust the controller output until the measured variable equals the
setpoint. Start the recorder and place the controller in Automatic.
* 5. Rapidly increase the setpoint to 60%. If the chart recorder displays the
process as being in continuous amplitude oscillations proceed with step 9.
Otherwise proceed with step 6.
* 6. Place the controller in manual. Decrease the setpoint to 50%. Adjust the
output until the measured variable equals the setpoint.
* 7. On the controller increase the Gain (decrease the Proportional Band) to

give more proportional action.
12-2
* 8. Repeat steps 5 to 7 until the process responds with constant amplitude

oscillations.
* 9. Use the proportional setting and the period of oscillation in the Zeigler-
Nichols equations to determine the optimum controller settings.
* 10. Using the three calculated settings, evaluate the controller response to
supply and demand disturbances. Fine tuning may be necessary.
NOTES/CALCULATIONS
Kp = Calculated controller gain setting
PB = Calculated Proportional Band setting
Ti = Integral Time (min/repeat)
RPM = Reset (repeats/min)
Td = Derivative Time (min)
Ku = Controller gain setting which resulted in constant amplitude oscillations
Pu = Period of oscillation (minutes)
Proportional
Kp = 0.5 Ku = PB = 2 PBu =
Proportional and Reset
Kp = 0.45 Ku = PB = 2.2 PBu =
Ti = Pu/1.2 = RPM = 1.2/Pu =
Proportional and Reset and Rate
Kp = 0.6 Ku = PB = 1.66 PBu =
Ti = Pu/2 = RPM = 2/Pu =
Td = Pu/8 =
12-3
12-4
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
4-20 mA
RELAY 1 ISOLATED
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 12-2.
12-5
QUESTIONS
1. Is the Ultimate Period Method an open-loop or closed-loop method of Controller

Tuning? Explain.
2. For the Ultimate Period Method, why is the calculated gain value different for
PI control and straight Proportional control?
3. What information must be obtained to tune a controller using the Ultimate

Period Method and what is it used to determine?
12-6
Exercise 13
Open Loop Tuning of a Level Process
OBJECTIVES
At the completion of this laboratory exercise you will be able to use standard
process instrumentation to observe and analyze the effects of demand and setpoint
changes on a process and determine the optimum tuning settings for a controller.
DISCUSSION
This procedure provides two methods for open loop controller tuning. The controller
is first placed in Manual so that the measurement values can be established without
the controller affecting the process. The chart recorder then indicates and records
the process measurement values. the resulting PROCESS REACTION CURVE
provides the data necessary to determine the optimum controller settings.
The TIME CONSTANT METHOD uses the time constant, process gain, and dead
time values from the process reaction curve.
The REACTION RATE METHOD uses the reaction rate and dead time values from
the process reaction curve.
After the optimum controller settings have been established using the equations
provided, the controller is tuned to the calculated values and placed in Automatic.
Setpoint disturbances are introduced to the process, and two tuning methods can
be evaluated and compared. The desired response is Quarter Amplitude
Dampening.
PROCESS
VARIABLE
a a/4
SETPOINT
a/16
TIME
1/4 WAVE DAMPING
Figure 13-1.
13-1
EQUIPMENT LIST

4. Strip Chart Recorder (FR)
5. Digital Multimeter (From 3550 Calibration Bench)
6. Electronic Calibrator (From 3550 Calibration Bench)
7. Pneumatic Calibrator (Optional-from 3550 Calibration Bench)
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
1. Modes = PID
2. Action = Inc/Dec
3. Measurement: Format = Linear (LIN)
4. Output: Format = Linear (LIN)
PROCEDURE
CAUTION!
* 1. Calibrate the level transmitter. If you use the pneumatic calibrator, be sure
to purge any water from the transmitter and sensing lines.
* 2. Calibrate the I/P converter and recorder.
* 3. Calibrate the controller inputs and outputs. Configure controller as per the
Instrument Data.
13-2
* 5. Purge any air from the transmitter and sensing lines.
Note: Both methods of Open Loop Tuning require the same

procedure to obtain a graph from the chart recorder of the
process response. The methods differ only in the mathematical
formulas applied the measurements and values derived from the
recorder printout. Therefore it is necessary to disturb the
process only once.
* 6. Place the controller in Manual. Raise the output to 10%.
Note: It is necessary to know the chart speed. If this is not

available form the manufacturer's data, you will have to manually
time the chart speed in a test run before continuing with this
exercise.
* 7. Simultaneously mark the chart paper and increase the controller output by
25%. When the process stabilizes, stop the recorder.
* 8. Perform the calculations (see Notes/Calculations).
* 9. Adjust the controller to the settings derived from the Time Constant
Method. Place the controller in Auto. Start the recorder.
* 10. Evaluate the process response to setpoint and demand disturbances.
* 11. Repeat steps 9 and 10 with the controller settings derived from the reaction
method.
NOTES/CALCULATIONS
Time Constant Method
Change in measured variable in % of span

K
Process Gain
Change in Controller output in % of span
- = Process Time Constant =
td = Process Dead Time =
13-3
Proportional Action
Gain (Kp) = 0.9-/(td K) = PB = 100%/Kp =
Integral Action
Integral Time (Ti) = 3.33 td = RPM = 1/(3.33 td) =
Reaction Rate Method
Rr = Process Reaction Rate

Rr

Changein time × Change in Controller output in % of span
Proportional Action
Gain (Kp) = 0.9/(Rr td) = PB = 100%/Kp =
Integral Action
Integral Time (Ti) = 3.33 td = RPM = 1/ (3.33 td) =
13-4
13-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 SWITCH TOGGLE SHOULD BE INPUT
3 1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 13-2.
13-6
MEASURED
VARIABLE
SUPPLY
DISTURBANCE
63.2%
DEAD TIME TIME

TIME CONSTANT
Figure 13-3. Time Constant Method for a single capacity process with measured variable dead time
approximation.
MEASURED
VARIABLE
SUPPLY
DISTURBANCE
MEASURED
VARIABLE
DEAD TIME TIME

TIME
Figure 13-4. Reaction Rate Method for a single capacity process with dead time approximation.
13-7
QUESTIONS
1. Why is Quarter-Amplitude Dampening normally the desired process reaction

when tuning a controller?
2. If the process is very sluggish and slow to recover from a disturbance what
should be done to the controller Proportional Band Adjustment?
3. If the controller is responsive to a disturbance, but then takes a long time to

eliminate the offset error, should the controller integral action be adjusted for
higher or lower Repeats per Minute? Explain.
4. If the process is unstable, should derivative action be increased or decreased?

Explain.
13-8
Exercise 14
Operation of a Level Measurement Channel
OBJECTIVES
At the completion of this laboratory exercise you will be able to assemble level
measurement channel and measure liquid level in the process tank.
DISCUSSION
A Differential Pressure Transmitter measures the difference in pressure applied

across its measuring element. The differential pressure detected by the Differential
Pressure Transmitter used for measuring liquid level is created by a column of fluid.
The applied differential pressure is related to the level of the fluid by the following
equation:
Pressure = Density of the Fluid x Height of the Fluid.
Assuming the density of the fluid remains constant, then the pressure is directly
proportional to the height of the fluid above the level measuring point.
When measuring the level in an open tank, the high pressure side of the Differential
Pressure Transmitter is connected to the bottom, or reference level of the tank, and
the low pressure side of the transmitter is vented to atmosphere. When measuring
the liquid level in a tank that is pressurized from the vapour pressure of the liquid,
both the high pressure and low pressure sides of the Differential Pressure
Transmitter must be connected to the tank. The low pressure side of the transmitter
is connected to the top of the tank so that it is exposed to the gas or vapour
pressure within the tank. The high pressure side is connected to the bottom of the
tank so that it is exposed to the hydrostatic head pressure of the liquid plus the gas
or vapour pressure that is exerted on the liquid surface. Therefore the gas or vapour
pressure is exerted on both sides of the measuring element and its effect is
cancelled out, so only the liquid level pressure is sensed by the transmitter.
EQUIPMENT LIST

6. Pneumatic Calibrator (Optional-From 3550 Calibration Bench)
14-1
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
PROCEDURE
CAUTION!
* 1. Calibrate the Differential Pressure Transmitter. If you perform an air

calibration, purge all water from the transmitter and sensing lines.
* 2. Calibrate the I/P converter. Check your supply air is 20 psi.
* 3. Calibrate the recorder.
* 5. Use the Electronic Calibrator input to the I/P Converter to operate the
control valve.
* 6. Fill the tank to approximately 50%. Purge any air from the Level
Transmitter and sensing lines.
* 7. Use valves V1 and V8 to control the level in the process tank.
Note: If you only close valve V8 to maintain the water level, you
may find the water in the process tank will syphon back out the
inflow piping. In this case close valve V1.
14-2
* 8. Set the level in the process tank at 6" WC. Increase the level in increments
of 2" and complete the table 14-1 in Notes/Calculations. Graph your results.
* 9. If your actual results do not match your expected results, perform a

calibration check on the instruments in the measurement channel.
NOTES/CALCULATIONS
Level VRS Recorder Values
Note: Actual and desired values refers to recorder indication.
DESIRED ACTUAL
H20 % SPAN REMARKS
VALUE VALUE
10
12
14
16
18
20
22
24
26
Table 14-1.
14-3
14-4
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA NOTE:
5 + -
WHEN USING 4-20 mA INPUT
2 8
1-5 Vdc
7 SPAN
250 æ OPPOSITE TO THAT SHOWN
1-5 V DRY CONTACT CONTACT OUT
INPUTS RATED 24 Vdc 1A
21
+ 29 28 + CO 1 CO 2 INPUT
3 1-5 Vdc
23
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 14-1.
14-5
QUESTIONS
1. Why are some tanks not open to the atmosphere?
2. Why do both sides of a Differential Pressure Transmitter have to be exposed

to the pressure of a closed tank?
3. Could a wet reference leg be used with a pressurized tank application?
4. Is there a limit to the amount of pressure on a closed tank that a Differential

Pressure Transmitter can stand?
14-6
Exercise 15
Troubleshooting a Level Measurement Channel
OBJECTIVES
At the completion of this laboratory exercise you will be able to troubleshoot a level
measurement channel using the sequential troubleshooting method.
DISCUSSION
Troubleshooting is a term that is applied to a variety of techniques used for isolating

the cause of failure of a complex control channel to a single component in the
system. Logical troubleshooting, however, implies that some preconceived method
has been established for isolating the control channel failure to a faulty component.
This method must be general enough such that, if repeated, it could be used to
locate any faulty component in the system. The Sequential Troubleshooting Method
is this type of logical troubleshooting procedure.
The Sequential Troubleshooting Method is based on the sue of a Troubleshooting

Flow Chart. Each test or observation that a technician makes helps him to more
clearly define the nature of the fault. The Troubleshooting Flow Chart aids the
technician in performing the appropriate tests and in drawing logical conclusions
about the results of each test or observation. In addition, because the flow chart can
be used for any system problem, the technician has a logical, repeatable
troubleshooting method.
EQUIPMENT LIST

5. Pneumatic Calibrator (From 3550 Calibration Bench)
15-1
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
PROCEDURE
CAUTION!
* 1. If you have just completed Exercise 16, the Level Measurement Channel
should already be prepared for this exercise.
* 2. If you have not just completed Exercise 16, calibrate the recorder and I/P
converter. Be sure the supply air is 20 psi.
* 3. Calibrate the transmitter 6-26" H20. If you perform an air calibration, be

sure to purge any water form the transmitter and sensing lines.
* 5. Set the calibrator signal to the I/P at 12 mA. Purge any air from the Level
Transmitter.
* 6. Verify the Level Measurement Channel is operating correctly.
* 7. Notify your instructor that you are ready to begin the first troubleshooting
exercise.
* 8. When the instructor informs you that the process is available for
troubleshooting, turn to the Troubleshooting Flow Chart and begin at the
box marked START. When the fault has been found and corrected, answer
the questions on page 6.
* 9. When the fault has been isolated and corrected, observe the operation of
the Level Measurement Channel to verify the channel is operating correctly.
* 10. Repeat steps 7, 8 and 9 for subsequent troubleshooting exercises.
15-2
15-3
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 15-1.
15-4
A B
START
VARY PROCESS DISCONNECT OUTPUT

FROM TRANSMITTER RECONNECT
USING RECORDER
MANUAL VALVES CONNECT DMM
FROM OUTPUT
TO -24 V dc.
VARY PROCESS
DOES YES DOES YES

RECORDER TRACK C RECORDER C
LEVEL DOES TRACK LEVEL
TRANSMITTER YES
OUTPUT TRACK
PROPERLY
NO NO
NO DISCONNECT
MEASURE RECORDER.
POWER SUPPLY PERFORM
AT TRANSMITTER CALIBRATION CHECK
CALIBRATE
TRANSMITTER
IS YES DID YES

POWER SUPPLY RECORDER
OK DID CALIBRATE
TRANSMITTER YES
A
CALIBRATE
TROUBLESHOOTING FLOW CHART
NO NO
RECORDER
NO IS FAULTY
MEASURE
Figure 15-2.
POWER SUPPLY
AT SOURCE CONTACT
CHECK INSTRUCTOR
TUBING
CONNECTIONS
FAULTY WIRING
RECONNECT
IS YES BETWEEN
RECORDER.
POWER SUPPLY POWER SUPPLY
TRANSMITTER CHECK WIRING
OK AND
TRANSMITTER ARE YES IS FAULTY CONNECTIONS
CONNECTORS
OK CONTACT
NO
INSTRUCTOR
POWER SUPPLY NO B
IS DEFECTIVE
REPAIR WIRING
CONTACT
REPAIR
INSTRUCTOR TUBING
CONNECTIONS
START
15-5
15-6
A
USE CALIBRATOR
TO VARY I/P
OVER FULL RANGE
CHECK
VALVE RESPONSE
VAALVE
DID IS FAULTY
VALVE CHANNEL
OPERATE YES IS CONTACT
OVER FULL OPERATING INSTRUCTOR
RANGE CORRECTLY
END
NO
CONNECT
TEST GAUGE CHECK TUBING CHECK 20 psi
TO I/P OUTPUT CONNECTIONS SUPPLY AIR
TO VALVE
VARY OUTPUT
IS IS YES
YES IS 20 psi SUPPLY
I/P OPERATING TUBING
CORRECTLY OK
OK
Figure 15-3.
NO
NO NO
SUPPLY AIR
IS
FAULTY
PERFORM
REPAIR
CALIBRATION CHECK CONTACT
TUBING
ON I/P INSTRUCTOR
I/P
C IS
YES FAULTY
DID I/P C
CALIBRATE CONTACT
INSTRUCTOR
NO
QUESTIONS
1. a) What fault was located during troubleshooting Exercise 1?
b) What effect did fault 1 have on the Level Measurement Channel?
15-7
15-8
Exercise 16
Operation of a Level Control Process
OBJECTIVES
At the completion of this exercise you will be able to assemble and tune a control
loop to maintain tank level.
DISCUSSION
The Level Control Loop you will assemble consists of a Differential Pressure
Transmitter, Microprocessor Based Controller, Current to Pressure Transducer,
Pneumatic Diaphragm Actuated Control Valve, and Strip Chart Recorder.
You will calibrate the Level Transmitter for a specified range and calibrate the
controller, recorder and I/P for standard process signals.
You will then use the Time Constant Method to tune the Controller. Equations for
both a PI and PID controller are given in this exercise. You will use both formulas
and compare the controller response to system disturbances.
You will need to disturb the process once to obtain a chart recorder graph of the
system response. The process can then operate in manual while you calculate the
correct settings for both a PI and PID Controller.
EQUIPMENT LIST

16-1
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
1. Action = Inc/Dec
4. Step 11: Modes = PI
5. Step 13: Modes = PID
PROCEDURE
CAUTION!
* 1. Calibrate the Level Transmitter. If performing an air calibration, be sure to

purge any water form the transmitter and sensing lines.
* 2. Calibrate the I/P Converter. Check that the instrument supply air is set at
20 psi.
* 3. Calibrate the Recorder.
* 4. Calibrate the inputs and outputs of the controller. Set the controller to the
configuration listed under Instrument Data.
* 6. Manually fill the tank approximately 50%. Purge any air from the
transmitter.
* 7. With the controller in manual, set the output to 25%. Allow the process to
stabilize and start the recorder.
16-2
* 8. Apply a step change by quickly raising the controller output to 50%.

Simultaneously mark the chart paper.
* 9. Allow the process to stabilize. Stop the recorder.
* 10. Measure the process change; dead time and time constant from the chart
and use these values in the equations in Notes/Calculations.
* 11. Tune the controller to the correct settings for a PI controller. Place the
controller in Auto and observe the response to setpoint changes.
* 12. Restrict valve V2 and observe the response to setpoint changes.
* 13. Change the controller to PID. Tune in the correct settings for a PID
controller and repeat steps 11 and 12.
NOTES/CALCULATIONS
Time Constant Method

K
Process Gain
Change in Controller output in % of span
- = Process Time Constant =
PI: Proportional plus Integral Controller
Proportional Action
Gain (Kp) = 0.9-/(td K) = PB = 100%/Kp =
Integral Action
Integral Time (Ti) = 3.33 td = RPM = 1/(3.33 td) =
16-3
PID: Proportional plus Integral plus Derivative Controller
Proportional Action
Gain (Kp) = 0.9/(Rr td) = PB = 100%/Kp =
Integral Action
Derivative Time (Td) = 0.5 td =
QUESTIONS
1. If the controller in this exercise were a significant distance from the I/P
Converter and valve, would there be any effect on the control characteristics?
Explain.
2. By increasing the Dead Time of a process, what would be the corresponding

change in the control adjustments for a PID Controller?
3. Did the controller respond to the restriction of valve V2 better as a PI or PID

controller? Explain.
16-4
16-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 16-1.
16-6
Exercise 17
Troubleshooting a Level Control Process
OBJECTIVES
At the completion of this laboratory exercise, you will be able to troubleshoot a

pressure measurement channel using the sequential troubleshooting method.
DISCUSSION
Troubleshooting is a term that is applied to a variety of techniques used for isolating

the cause of failure of a complex control channel to a single component in the
system. Logical troubleshooting, however, implies that some preconceived method
has been established for isolating the control channel failure to a faulty component.
This method must be general enough such that, if repeated, it could be used to
locate any faulty component in the system. The Sequential Troubleshooting Method
is this type of logical troubleshooting procedure.
The Sequential Troubleshooting Method is based on the sue of a Troubleshooting

Flow Chart. Each test or observation that a technician makes helps him to more
clearly define the nature of the fault. The Troubleshooting Flow Chart aids the
technician in performing the appropriate tests and in drawing logical conclusions
about the results of each test or observation. In addition, because the flow chart can
be used for any system problem, the technician has a logical, repeatable
troubleshooting method.
EQUIPMENT LIST

3. Current to Pressure Converter I(/P )
17-1
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
LR 1-5 V dc/4-20 mA
1. Modes = PI
2. Action = Inc/Dec
PROCEDURE
CAUTION!
* 1. If you have just completed Exercise 18, the Level Control Channel should
already be prepared for this exercise.
* 2. If you have not just completed Exercise 18, calibrate the recorder and I/P
converter. Be sure the supply air is 20 psi.
* 3. Calibrate the transmitter. If you perform an air calibration, be sure to purge

any water from the transmitter and sensing lines.
* 4. Calibrate the inputs and outputs of the controller. Set the configuration as
per the Controller Configuration. Set the tuning parameters to the settings
from Exercise 18.
* 6. With the controller in Manual, raise the level in the process tank and purge
any air from the transmitter.
* 7. Place the controller in Auto and verify the Level Control Channel is
operating correctly.
17-2
* 8. Notify your instructor that you are ready to begin the first troubleshooting
exercise.
* 9. When the instructor informs you that the process is available for
troubleshooting, turn to the Troubleshooting Flow Chart and begin at the
box marked START. When the fault has been found and corrected, answer
the questions on page 6.
* 10. When the fault has been isolated and corrected, observe the operation of
the Level Control Channel to verify the channel is operating correctly.
* 11. Repeat steps 8, 9 and 10 for subsequent troubleshooting exercises.
QUESTIONS
1. a) What fault was located during troubleshooting exercise 1?
b) What effect did fault 1 have on the Level Control Channel?
17-3
17-4
17-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
HP
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
LP V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
DMM
PUMP V-1
V-10
U-2
CV-1 HA-1
V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 17-1.
17-6
A B
START
CHECK
CONNECT CONTROLLER
VARY RECONNECT
TRANSMITTER OUTPUT OUTPUT
SETPOINT THROUGH DMM
CONTROLLER
WITH DMM
TO -24 V DC
VARY PROCESS
DOES DOES
MEASURED YES CONTROLLER YES IS YES
VARIABLE TRACK C INDICATE OUTPUT C
DOES
SETPOINT YES LEVEL OK
TRANSMITTER
OUTPUT TRACK
LEVEL
NO NO NO
NO CONTROLLER
MEASURE CALIBRATE IS DEFECTIVE
POWER SUPPLY CONTROLLER
AT TRANSMITTER CALIBRATE INPUT CONTACT
TRANSMITTER INSTRUCTOR
IS OUI DID YES

POWER SUPPLY CONTROLLER B
DID CALIBRATE
OK YES
TRANSMITTER A
CALIBRATE
NO NO
NO CONTROLLER
MEASURE IS DEFECTIVE
Figure 17-2.
POWER SUPPLY
AT SOURCE CHECK CONTACT
TUBING INSTRUCTOR
CONNECTIONS
LES
RACCORDEMENTS
IS YES ENTRE LE
POWER SUPPLY TRANSMITTER

TRANSMETTEUR ET ARE
OK YES IS FAULTY
L'ALIMENTATION CONNECTIONS
SONT DÉFECTUEUX OK
CONTACT
NO INSTRUCTOR
NO
POWER SUPPLY
IS DEFECTIVE
REPAIR
WIRING REPAIR
CONTACT
INSTRUCTOR TUBING
CONNECTIONS
START
17-7
17-8
C D E
RECONNECT I/P
PERFORM
VARY PROCESS CHECK
CALIBRATION CHECK CHECK RECORDER
ON I/P VALVE OPERATION OPERATION
IS
YES IS LEVEL CONTROL
YES VALVE YES
DID I/P ACTION RECORDER CHANNEL
END
CALIBRATE CORRECT CORRECT IS OPERATING
CORRECTLY
NO NO NO
CHECK
TUBING DISCONNECT RECONNECT
CHECK
CONNECTIONS RECORDER RECORDER
20 psi
FROM PERFORM CHECK
AIR SUPPLY
I/P TO VALVE CALIBRATION CHECK OPERATION
IS YES IS YES DID IS

YES YES
20 psi SUPPLY TUBING RECORDER RECORDER END
Figure 17-3.
OK OK CALIBRATE OK
NO NO NO NO
AIR SUPPLY
IS DEFECTIVE RECORDER WIRING
REPLACE IS FAULTY IS FAULTY
TUBING
CONTACT CONTACT CONTACT
INSTRUCTOR INSTRUCTOR INSTRUCTOR
I/P IS D LE CONVERTISSEUR
D
DEFECTIVE I/P EST
DÉFECTUEUX
CONTACT AVISEZ VOTRE
INSTRUCTOR PROFESSEUR
Exercise 18
Operation of a Flow Measurement Channel
OBJECTIVES
At the completion of this laboratory exercise, you will be able to assemble a flow
measurement channel at the level process station.
DISCUSSION
A Flow Measurement Channel consists of a primary element that develops a

differential pressure equivalent to the rate of flow of a fluid through it, the Differential
Pressure Transmitter, a square root function device (in this case incorporated into
the Microprocessor based controller) that linearizes the flow rate signal, and a
receiving device (indicator or recorder) that indicates the actual rate of flow.
The primary element used in this exercise is a Venturi Tube which is simply a
restriction placed in the line and across which a differential pressure is produced
when flow is present in the line. The differential pressure is then sensed by a
Differential Pressure Transmitter which converts the pressure into a suitable
transmission signal. The relationship between flow rate and differential pressure
developed across a venturi is non-linear. The differential pressure is proportional to
the square of the flow rate. Since standard indicating devices are linear, the
transmitter output must be linearized before being sent to the indicator or recorder.
Accordingly, a square root extractor is a necessary element of most flow
measurement channels.
This exercise is very similar to Exercise 13 in the Level Station Student's Manual
(#75942-20). However, in this case you will assemble the flow channel at the Level
Process Station and use a Pneumatic Diaphragm Actuated Valve as the final control
element. This will also help you prepare for later exercises of 2 and 3-element
control at the Level Process Station.
EQUIPMENT LIST

1. Differential Pressure Transmitter (FT)
(From 3502 Flow Station)
2. Microprocessor Based Controller (FIC)
4. Venturi Tube Assemble (FE)
18-1
INSTRUMENT DATA
FT 2-50" H20/4-20 mA
I/P 4-20 mA/3-15 psi
FR 1-5 V dc/4-20 mA
1. Measurement: Format = Square Root

2. Output: Format = Linear
3. Output 2 = Process Measurement
PROCEDURE
CAUTION!
* 1. Calibrate the Flow Transmitter 2-50" H20. From the Venturi Flow Curve in
your Flow Station Operator's Manual you will see this should correspond to
2-10 US gal/min. If you perform an air calibration be sure to purge any
water from the transmitter and sensing lines. If you calibrate the transmitter
at 2-10 gal/min at the Level Station, purge any air from the transmitter and
sensing lines.
* 2. Calibrate the I/P Converter. Check that the Instrument Air Supply is set at
20 psi.
* 3. Calibrate the Recorder.
* 4. Calibrate the inputs and outputs of the controller. Configure the controller
as per the Controller Configuration.
Note: The controller is being used in this exercise to utilize its

built in Square Root Extractor Function. It is not being used to
control the process automatically.
* 5. Insert the Venturi Element in Header Assembly 1 (HA-1).
18-2
* 7. If you have not already done so, purge any air from the Flow Transmitter.
* 8. With the controller in Manual, increase the output to vary the flow rate over
the entire span 2-10 gal/min.
* 9. Use the recorder values to complete the Table 18-1 in Notes/Calculations.
NOTES/CALCULATIONS
FLOW RATE DESIRED ACTUAL

% SPAN REMARKS
GAL/MIN VALUE VALUE
10
Table 18-1.
18-3
18-4
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
PUMP V-1 HA-1

V-10
U-2
CV-1 V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 18-1.
18-5
QUESTIONS
1. Why would a 3-Valve Manifold be desirable in the configuration?
2. Why was it necessary to use the Differential Pressure Transmitter from the
3502 Flow Station for this Exercise?
3. If the water in the process piping was under pressure but not flowing, what
would be the indication from the Differential Pressure Transmitter? Explain.
18-6
Exercise 19
Operation of a Flow Control Process
OBJECTIVES
At the completion of this laboratory exercise you will be able to assemble a flow
control channel using a venturi tube as the flow measuring element. You will use the
reaction rate method for tuning the flow controller.
DISCUSSION
In this laboratory exercise you will calibrate a Differential Pressure Transmitter to

produce a flow rate signal from the differential pressure developed by the Venturi
Tube. A flow control loop will be assembled which includes this calibrated flow
transmitter. By placing the Flow Controller in the manual mode for the Reaction
Rate Method of tuning the loop will be open. This simply means that the automatic
signal from the controller does not reach the final control element. The Reaction
Rate Method of tuning a controller eliminates the need to put the process into
oscillations, a requirement in closed loop controller tuning that could produce
harmful effects in an actual working industrial situation. Using this method, the
process is disturbed only one time, and the change in the magnitude of the
controlled process variable is limited by the magnitude of the change in the manual
output of the controller.
Once the formulas are used to calculate the optimum values for the PID settings,
the values are set into the controller for a One-Quarter Amplitude Dampening Wave
response when the process is disturbed. You will tune the controller using data
collected near the 50% span value of the process. You will make large setpoint
changes towards the upper and lower span limits and observe that the gain settings
for the 50% point will result in a slight instability at lower flow rates, and over-stability
at higher flow rates. For this reason it is desirable to tune the controller using data
collected at or near the normal operating point of the process.
EQUIPMENT LIST

2. Microprocessor Based Controller (FIC)
5. Venturi Tube Assembly (FE)
19-1
8. Pneumatic Calibrator (Option-From 3550 Calibration Bench)
INSTRUMENT DATA
FT 2-50" H20/4-20 mA
I/P 4-20 mA/3-15 psi
FR 1-5 V dc/4-20 mA
1. Modes = PI
2. Action = Inc/Dec
3. Measurement: Format = Square Root
4. Output: Format = Linear
5. Output 2 = Process Measurement
PROCEDURE
CAUTION!
* 1. Calibrate the Differential Pressure Transmitter 2-50" H20. If performing air

calibration, be sure to purge any water from the transmitter and sensing
lines.
* 2. Calibrate the I/P Converter. Check the 20 psi air supply.
* 3. Calibrate the recorder.
* 4. Calibrate the inputs and outputs of the controller. Set the configuration as
per the Controller Configuration.
* 5. Insert the Venturi Tube Assembly into Header Assembly 1 (HA-1).
* 7. Close valves V3 and V5. Open valves V1,V2, V4, V8 and V10.
19-2
* 8. Start the pump and manually set the controller output at 40%.
* 9. When the process stabilizes, start the recorder.
* 10. Quickly increase the controller output to 50% and simultaneously mark the
chart paper.
* 11. When the process stabilizes, stop the recorder.
* 12. Use the graph from the recorder and the formulas in Notes/Calculations to
calculate the correct PI settings for the controller.
* 13. Insert the calculated PI settings into the controller and place the controller
in Automatic.
* 14. Make setpoint changes from 40% to 50% and 50% to 60%. Observe the
response on the chart recorder.
* 15. Make a setpoint change from 50% to 20%. Observe the response on the
recorder.
* 16. Make a setpoint change from 50% to 80%. Observe the response on the
recorder.
NOTES/CALCULATIONS
Reaction Rate Method
Rr = Process Reaction Rate
Change in measure variable in % of span

Rr

Changein time × Change in Controller output in % of span

Kp = Proportional Action
PB = Proportional Band
Ti = Integral Action
RPM = Repeats per Minute
19-3
Proportional Plus Reset (PI) Controller
Proportional Action
Gain (Kp) = 0.9/(Rr td) = PB = 100%/Kp =
Integral Action
19-4
19-5
LOOP DIAGRAM
A 24
24 Vdc
B 25
COM 22 LR
RS-485 ALM-1 ALM-2

2
+ -
1
4 26 4-20 mA 27
1-5 V 250 æ
AUXILIARY OUT
4-20 mA
5 + -
2 8
1-5 Vdc
3
7 SPAN
+ 29 28 + CO 1 CO 2 INPUT
1-5 Vdc
1-5 V 250 æ
-
4-20 mA
21 (32) (31)
V-3
4 30
20
PRR-1 V-9
SUPPLY
100 psi
700 kPa
0-3 psi
0-20 kPa 4-20 mA
V-4
LEVEL
COLUMN
F1
TO
+24 Vdc
SUPPLY I/P
V-6 V-7 U-5
D/P 20 psi
V-8 140 kPa
TE
RL 4-20 mA V-2
U-6
HA-2 SV-1
V-5
U-3
3-15 psi
20-102 kPa 3-15 psi
U-11 20-102 kPa
U-4
PUMP V-1 HA-1

V-10
U-2
CV-1 V-12
HOLDING TANK U-1

SUPPLY SUPPLY
24 Vdc 20 GALLONS
75 LITRES

- VALVE SV1


100 mA 100 mA
Figure 19-1.
19-6
QUESTIONS
1. Why is the Reaction Rate Method of control loop tuning used on a critical
process instead of the Notch Tuning Method?
2. What is the major difference between open loop and closed loop tuning?
3. What are the three things that need to be known for the Reaction Rate Method
of tuning?
4. If this process must be operated at setpoints ranging from 20% to 80% under
normal conditions, at what setpoint would you tune the controller? Explain.
19-7
19-8
Exercise 20
Operation of a Two Element Control Process
OBJECTIVES
At the completion of this laboratory exercise you will be able to assemble a two
element flow/level control loop. This is called a cascade control system.
DISCUSSION
Cascade control is a natural extension of feedback control. The purpose is to

increase the accuracy of the controlled variable by adding a second control loop to
regulate a second controlled variable which could cause fluctuations in the primary
variable. They are termed the primary loop and secondary loop, sometimes also
called the master and slave.
You will be aware from previous exercises that you have achieved level control by
controlling flow into the level process tank. The two variables are interdependent.
Level is actually the result of the difference between the rate of inflow and outflow.
In this exercise you are again primarily concerned with level control. The level
control loop is therefore the primary loop. However, now you will also measure and
control flow as the secondary loop. The output signal from the level controller does
not operate the final control element. Instead this output signal becomes the
setpoint of the flow controller, therefore the term slave. If the level falls below
setpoint, the level controller output increases which increases the flow controller
setpoint. The flow controller output therefore increases and it is this signal which
operates the final control element to bring level back up to setpoint.
The increased accuracy results from the fact that the flow controller will sense any
flow disturbance before it has an effect on level and can therefore minimize the
disturbance immediately, rather than waiting for a feedback signal from the level
transmitter.
EQUIPMENT LIST

1. Flow Process Station 3502
8. 2 Flexible Hoses
20-1
Note: The I/P is only used if the Cascade Loop is configured entirely at the
Level Station.
INSTRUMENT DATA
FT 0-9 (gal/min)/4-20 mA
I/P 4-20 mA/3-15 psi
LT 6-26" WC/4-20 mA
1. LIC Modes = PI
Action = Inc/Dec
Output = Linear
Local/Remote = Local
2. FIC Modes = PI
Action = Inc/Dec
Measurement = Square Root
Output = Linear
Local/Remote = Remote (Input 4)
PROCEDURE
CAUTION!
Note: In this procedure you will connect the Flow and Level
Station process piping and use the variable speed pump as the
final control element. It is also possible to configure a cascade
loop entirely at the Level Station, using the Pneumatic Valve as
the final control element.
* 1. At the Flow Station, calibrate the variable speed drive 0-9 gal/min. Calibrate
and configure the controller as per the FIC Controller Configuration. Insert
the Venturi Tube in the header assembly and set up a standard flow control
loop (Level Station Student's Manual (#75942-20), Exercise 15). Calibrate
the flow transmitter 0-100% of flow. Tune the loop using any method you
are familiar with.
* 2. It is usual to tune the secondary control loop first. This loop may now be
treated as a final control element.
20-2
* 3. At the Level Station, calibrate the level transmitter and the I/P converter.
Configure the controller as per the LIC Controller Configuration.
* 4. In this step you will physically connect the two stations so that you will only
use the water from the flow station, thereby reducing the risk of overflow.
Connect one of the flexible hoses between U2 (Flow) and U2 (Level).
Connect the other hose between U3 (Flow) and U3 (Level). On the Flow
Station close valve V3. On the Level Station close valves V1 and V8 (and
V4)
* 5. Connect the Cascade Control Loop as per the loop diagram.
* 6. Start the process and tune the level controller as you would for a standard
single element level control loop.
20-3
20-4
FREQUENCY INPUT
+ + F1 F2 −
FLOW PROCESS STATION LEVEL PROCESS STATION
15 13 14
CAUTION:
A 24 DO NOT SET F max.
24 V − DC ABOVE 70 Hz OR COMMUNICATIONS ALARM INDICATORS
PUMP MAY BE
DAMAGED
B 25 A 24
24 V − DC
B 25 LR
COM. 22 FR
RS−485 ALM−1 ALM−2 COM. 22
ANALOG INPUTS OUTPUTS RS−485 ALM−1 ALM−2
4-20 mA COM. CONTROL OUT TO PUMP

2 ANALOG INPUTS OUTPUTS
1 + −
26 27 2
4 4-20 mA
1-5 V − DC 250 æ 1 + −
AUXILIARY OUT 26 4-20 mA 27
4
4-20 mA
LOOP DIAGRAM
1-5 V − DC 250 æ
5 + − INPUT
AUXILIARY OUT
8 3 SIGNAL 4-20 mA
2 1-5 V − DC SPAN 5 + − SPAN
7 + − 2 8 3
1-5 V − DC 250 æ DRY CONTACT CONTACT OUT 1-5 V − DC
4-20 mA 7
INPUTS RATED 24 V − 1 A − DC 1-5 V − DC 250 æ DRY CONTACT CONTACT OUT
4-20 mA
21 RELAY 1 ISOLATED RATED 24 V − 1 A − DC
4-20 mA INPUTS
+ 29 28 + CO 1 CO 2 21 RELAY 1 ISOLATED
3 + 29 28 + CO 1 CO 2
1-5 V − DC 3 1-5 V − DC
1-5 V − DC 250 æ 23 LEVEL
INPUT 23 INPUT
1-5 V − DC 250 æ
4-20 mA − COLUMN
18 (32) (31) 4-20 mA −
18 (32) (31) V−3
250 æ U−8 U−9 250 æ
4 4
30 30
1-5 V − DC 250 æ 20 +5.0 V OPEN CIRCUIT 1-5 V − DC 250 æ 20
+5.0 V OPEN CIRCUIT
PRR−1 V−9
SUPPLY
100 psi
700 kPa 0-3 psi 4-20 mA
0-20 kPa
HA−1 V−4
TO
+24 V − DC FI
TO
+24 V − DC
V−13
FI SUPPLY
U−3
H 20 psi I/P
V−14 U−5
D/P
D/P V−8 TE U−7
RL 4-20 mA L V−2
U−6
RL 4-20 mA
HA−2 SV-1
U−3 V−5
V−4
3-15 psi
V−3 20-102 kPa 3-15 psi
Figure 20-1.
20-102 kPa
U−4
V−5 V−7 V−11
TO VSD
V−6
PUMP V−1
V−10
V−2 U−2
U−2
V−1 CV−1 HA−1
V−12
HA−2
U−1
U−1 24 V − DC 20 GALLONS
SUPPLY HOLDING TANK PUMP SUPPLY 75 LITRES
75 LITRES +
+
SUPPLY MAINS − VALVE SV-1
−
REMOTE REMOTE
100 mA 100 mA
20 psi / 140 kPa
20-5
QUESTIONS
1. Is Cascade Control normally used with “fast” or “slow” processes?
2. What is the normal MODE configuration of the secondary controller? Explain.
3. Why do we tune the secondary control loop first?
20-6
Exercise 21
Operation of a Three Element Control Process
OBJECTIVES
At the completion of this laboratory exercise you will be able to assemble and
understand a three element control loop utilizing both feedforward and feedback
control.
DISCUSSION
In this laboratory exercise you will configure a standard boiler control loop where
measurements of the feedwater into the boiler drum, drum level, and “steam” flow
out of the drum will be combined into one control loop.
In a pressurized boiler drum the water level is affected by the pressure of the steam
bubble in the drum. The interaction is such that when there is a sudden demand for
steam, the pressure in the drum will be reduced and the level will increase. The
level transmitter may then indicate that less feedwater is required when, in fact,
more feedwater is required to replace the steam that has been lost. Therefore
measuring level alone is not sufficient for this control loop.
What we do in this situation is take other measurements that will indicate a change
in level. If we compare the flow of feedwater entering the drum to the flow of steam
released from the drum, we know that any difference between the two flow rates is
a direct indication of a change in level. This configuration also improves the
response time of the control loop to any process changes. If the steam flow
transmitter indicates a sudden increase in flow, it indicates that an increase in
feedwater is required without waiting for the level to change and the level transmitter
to indicate the change. This increase in feedwater is Feedforward Control because
we are responding to a change in drum level before it has been sensed by the level
transmitter. For safety reasons we will not generate steam in this exercise. The
principal of steam flow measurement is exactly the same as any other fluid flow and
we can therefore model this process using water flow both in and out of the “boiler
drum”.
Note: Feedforward control is inherently unstable. Large process disturbances

may put the process in oscillation. Adjust your controller tuning accordingly.
21-1
EQUIPMENT LIST

2. Differential Pressure Transmitter (SFT)
(Steam Flow Transmitter)
3. Differential Pressure Transmitter (FFT) (Feedwater Flow Transmitter)
6. Microprocessor Based Controller (FY)
7. 2 Venturi Tube Assemblies (FE)
INSTRUMENT DATA
LT 6-26" WC/4-20 mA
I/P 4-20 mA/3-15 psi
FFT 0-100%/4-20 mA
SFT 0-100%/4-20 mA
1. LIC Modes = PI
Action = Inc/Dec
Measurement = Linear: A + B
Output = Linear
Proportional Band = 145%
Integral = 0.04
2. FY
Note: This is being used as a Summer and Square Root Extractor, not
as a controller.
Measurement = Linear: A + B
A = Square Root (SQR): GAIN = 1
B = Square Room (SQR): GAIN = -1
Output 2 = Process Measurement
21-2
PROCEDURE
CAUTION!
* 1. Insert the two flow elements into the header assemblies (HA-1 and H1-2).
* 2. Calibrate the level transmitter 6-26" H20. Calibrate the I/P Converter.
* 3. Set up a standard level control loop and verify it is operating correctly.
* 4. Connect the two flow transmitters to their respective flow elements. Purge
any air from the transmitters and sensing lines.
* 5. Slightly restrict valve V8. Close valve V4.
* 6. In this step you will calibrate the flow transmitters in place. Adjust the zero
on both transmitters. Manually control the output of the controller to open
the control valve. Regulate valve V2 so that the water in the tank is steady
at 26" WC. At this point the rate of inflow and outflow is exactly the same.
Adjust the span on both transmitters to output 20 mA. Simultaneously close
valves V1 and V5. Check the zero. Repeat this until the transmitters are
calibrated exactly. Any difference in indication will result in an error in the
control signal.
* 7. If you do not have a summer, configure a second microprocessor controller

as per the FY data. Connect the feedwater transmitter to input A and the
steam flow transmitter to input B.
* 8. Configure the level controller as per the LIC data. Connect the output of the
“Summer” to input B as per the loop diagram.
* 9. Manually raise the tank level to 16" WC. Place the set-point at 50% and set
the controller to automatic.
* 10. Use valves V8 and V1 to disturb the process.
* 11. Adjust your controller tuning as necessary.
21-3
21-4
LEVEL PROCESS STATION COUPLED TO A SECOND PROCESS STATION

A 24
A 24 24 V − DC
24 V − DC
B 25
B 25 LR
COM. 22
COM. 22

ANALOG INPUTS OUTPUTS 4-20 mA
2 COM. CONTROL OUT
2 1 + −
+ − 26 4-20 mA 27
1 4
26 27 1-5 V − DC 250 æ
4 4-20 mA
1-5 V − DC 250 æ AUXILIARY OUT
4-20 mA
AUXILIARY OUT 5 + −
4-20 mA
5 + − SPAN 2 8 3
1-5 V − DC
2 8 3 7
1-5 V − DC 1-5 V − DC 250 æ
7 DRY CONTACT CONTACT OUT
1-5 V − DC 250 æ DRY CONTACT CONTACT OUT INPUTS RATED 24 V − 1 A − DC
4-20 mA
RATED 24 V − 1 A − DC 21 RELAY 1 ISOLATED
4-20 mA INPUTS
21 RELAY 1 ISOLATED + 29 28 + CO 1 CO 2
3
+ 29 28 + CO 1 CO 2
LOOP DIAGRAM
3 1-5 V − DC 23
LEVEL 1-5 V − DC 250 æ
23 INPUT
1-5 V − DC 250 æ −
COLUMN 4-20 mA
− 18 (32) (31)
4-20 mA
18 (32) (31) V−3
U−8 U−9 250 æ 4
30
4 20
30 1-5 V − DC 250 æ +5.0 V OPEN CIRCUIT
1-5 V − DC 250 æ 20
+5.0 V OPEN CIRCUIT
PRR−1 V−9
SUPPLY
100 psi
700 kPa 0-3 psi
0-20 kPa 4-20 mA
V−4
TO
FI
+24 V − DC TO
V−13 +24 Vdc
SUPPLY
H 20 psi I/P
V−14 U−5
D/P
V−8 HA−2 D/P
TE U−7
RL 4-20 mA L V−2
U−6
4-20 mA
V−5 SV-1
U−3 H L
3-15 psi
20-102 kPa 3-15 psi
20-102 kPa
Figure 21-1.
U−4
V−11
PUMP V−1
V−10
U−2
CV−1 V−12 HA−1
U−1
75 LITRES
+
TO
+24 Vdc
− VALVE SV-1
D/P
4-20 mA
H L
REMOTE REMOTE

100 mA 100 mA
21-5
QUESTIONS
1. When is Feedforward Control most useful?
2. Describe exactly what happens in your three element control loop if the “steam”
flow increases and how the loop may become unstable.
21-6
Bibliography
Hughes “Measurement and Control Basics” ISA 1988.
Johnson “Process Control Instrumentation Technology” Wiley 1982.
Murrill “Fundamentals of Process Control Theory” ISA 1981.
Shinsky “Process Control Systems” McGraw-Hill 1979.
Mobile Level Station Instruction Manual 75943-D0: Foxboro Insert M1020-331.
Foxboro 760 User's Manual, 1989.
Foxboro 760 Instruction Manual.

INSTRUMENTATION AND PROCESS CONTROL
LEVEL PROCESS STATION
75943-20
Second Edition, July 2000
Printed: June 2002
We Value Your Opinion!
Please take a few minutes to complete this questionnaire. Your answers and
comments will enable us to produce better manuals. Return it to the address on the
reverse side of this page or ask your instructor to forward it.
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Instrumentation and

Level Process Station

LEVEL PROCESS STATION

Copyright © 2000 Lab-Volt Ltd

All rights reserved. No part of this publication may be

Legal Deposit – Third Trimester 2000

SECOND EDITION, JULY 2000

Exercise 1 Level Transmitter Time Response Characteristic . . . . . . . . 1-1

Exercise 2 Level Process Characteristics . . . . . . . . . . . . . . . . . . . . . . . 2-1

Exercise 3 Calibration of a Level Transmitter . . . . . . . . . . . . . . . . . . . . 3-1

Exercise 4 Level Measurement using a Bubbler . . . . . . . . . . . . . . . . . . 4-1

Exercise 5 Level Measurement of an Open Tank . . . . . . . . . . . . . . . . . 5-1

Exercise 6 Level Measurement with Zero Suppression . . . . . . . . . . . . 6-1

Exercise 7 Level Measurement with a Wet Reference Leg . . . . . . . . . . 7-1

Exercise 8 Level Process Proportional Control . . . . . . . . . . . . . . . . . . 8-1

Exercise 9 Level Process Proportional Plus Integral Control . . . . . . . 9-1

Exercise 10 Level Process Proportional Plus Integral Plus

Exercise 11 Notch Tuning of a Level Process . . . . . . . . . . . . . . . . . . . . 11-1

Exercise 12 Ultimate Period Tuning of a Level Process . . . . . . . . . . . . 12-1

Exercise 13 Open Loop Tuning of a Level Process . . . . . . . . . . . . . . . 13-1

Exercise 14 Operation of a Level Measurement Channel . . . . . . . . . . . 14-1

Exercise 15 Troubleshooting a Level Measurement Channel . . . . . . . 15-1

Exercise 16 Operation of a Level Control Process . . . . . . . . . . . . . . . . 16-1

Exercise 17 Troubleshooting a Level Control Process . . . . . . . . . . . . 17-1

Exercise 18 Operation of a Flow Measurement Channel . . . . . . . . . . . 18-1

Exercise 19 Operation of a Flow Control Process . . . . . . . . . . . . . . . . 19-1

Exercise 20 Operation of a Two Element Control Process . . . . . . . . . . 20-1

Exercise 21 Operation of a Three Element Control Process . . . . . . . . 21-1

We Value Your Opinion!

The rapid advances of instrumentation technology have greatly expanded the

The student's manual introduces the instrumentation students to the basic

Level Transmitter Time Response

Three important terms are used to characterize the process reaction to a

Level Process Station 3503, including:

DEVICE MODEL SERIAL NO. CALIBRATED

I/P 4-20 mA/3-15 psi

* 1. Calibrate the level transmitter 0-30" WC or 0-75 cm water.

* 2. Set up and connect equipment as per the loop diagram.

* 3. Part one measures response of both process and transmitter:

* 4. Part two measures the response of the level transmitter only:

Note: The transmitter response is faster than the response of the

Combined Response L2 L1 = L = 14"

Recorder Speed 10"/min

Time Start ts Time Finish tf

Transmitter Response L = 14"

Time Start ts Time Finish tf

COMMUNICATIONS ALARM INDICATORS

RS−485 ALM−1 ALM−2

ANALOG INPUTS OUTPUTS

SOLENOID SUPPLY PUMP MAINS INTERLOCK

Level Process Characteristics

Understanding how a process responds to changes is important for the individual

An easy method for observing the characteristics of a process is by intentionally

The actual step change will be considered instantaneous to simplify calculations.

Level Process Station 3503, including:

DEVICE MODEL SERIAL NO. CALIBRATED

I/P 4-20 mA/3-15 psi

* 1. Set up and connect equipment as per the loop diagram.

* 3. Set the calibrator output to 8 mA (6 psi to valve).

* 4. Allow the process to stabilize.

* 6. Record the change in process level as read on the tank scale.

* 7. Perform calculations (see Notes/Calculations).

Level start (Ls)