Addis Ababa Science and Technology University

College of Biological and Chemical Engineering

Department of Chemical Engineering

Process control lab

Automatic Level and Flow-Rate Control (mod. REGA-L/EV)

Objective of the Experiment

The main aim of this experiment is to see the effect of Proportional (P) and PI controller on flow
and level control and to observe the effect of the increment of the gain value on offset value and
the stability of the process.

2
 CHAPTER ONE
LEVEL AND FLOW-RATE CONTROL
1.1Brief Description of the cycle
The process control system mod. REGA-L/EV mainly consists of a 100-l tank, a column, two
centrifugal pumps (G1 and G2), two differential pressure transmitters and two pneumatic control
valves (FV1 and LV1), see its operation diagram herewith attached.

The centrifugal pump G1 sucks the water from the bottom of the tank D1 and sends it to the
column D2 whose level has to be controlled. Then, using centrifugal pump G2, the water returns
to the tank D1.

The constant head tank D3 allows to feed the column D2 with a fixed flow rate.

Figure 1.1: Automatic Level and Flow-rate contro

3
1.2Equipment and Instruments of the Cycle
• Stainless steel AISI 304 framework with castors
• 100-l feed tank, stainless steel AISI 304L execution, code D1
• Borosilicate glass column, DN 200, H = 1000 mm, code D2
• 50-l constant level tank, stainless steel AISI 304 execution, code D3
• Stainless steel AISI 316 pneumatic flow rate control valve, DN15, Cv = 2.5, code FV1
• Stainless steel AISI 316 pneumatic level control valve, DN15, Cv = 2.5, code LV1
• 2 electropneumatic converters; 4÷20 mA / 3÷15 psi (0.2÷1 bar), accuracy ±1%
• 2 centrifugal pumps, with flow rate of 5 m3/h and head of 30 m of water column,
stainlessn steel AISI 304 execution, code G1 and G2
• Electronic differential pressure transmitter, range 0÷1200 mm H2O; 4÷20 mA output
signal, code FT1
• Electronic differential pressure transmitter, range 0÷800 mm H2O; 4÷20 mA output
signal, code LT1
• Multi-loops electronic PID controller
• Calibrated orifice, stainless steel AISI 316 execution, orifice diameter 15.1 mm, range
0÷2000 l/h
• Calibrated orifice inserted into the discharge line of tank D3 toward column D2, d = 12
mm, code FE
• Piping and valves in stainless steel AISI 304 – 316
• IP55 electrical switchboard with plant synoptic and E.L.C.

Display indications

• 1st line: text line reporting the menus and the submenus indications
• 2nd line: process variable
• 3rd line: display of the set-point value (SP), error; out, selectable with the key Ind
• 4th line: current loop indication

Front panel indication

4
 • Key Loop: it enables to select the wished loop
• Key Ind: it enables to change the parameter displayed on the third line of the display or
to set the parameters as explained after
• Key Esc/Menu: it enables to enter the menu or to exit the menu and the submenus
without saving the made changes
• Key Enter: it enables to enter the menus, the submenus and to confirm the made changes
• Key M/A/C: it enables to switch from automatic to manual mode
• Keys : they enable to increase or drop the set-point value of the parameter selected
in the programming or to scroll the menus and submenus
• Key SP-w: it enables to display the set-point value on the third line

Parameters setting

The setting of the parameters is carried out from the submenu Parameter which is accessed
according to the following procedure:
• Enter the main menu pressing the key Esc/Menu; set on the parameter submenu scrolling
the list of submenus with the keys □ ; enter the sub menu pressing the key Enter
• Select the parameter to be changed scrolling the list with the keys □ □and press the
key Enter to select it
• To change the value of the parameter press the key Enter and then the keys □ ; with
the key Ind it is possible to move on the digits of the number to be changed; pressing the
key Ind for 3 sec you shift the decimal point
• To exit without confirming press the key Esc/Menu
• To confirm the change press the key Enter

Example: changing the values of GAIN (proportional band), integrative and derivative action
•  Press the key Esc/Menu
• Scroll the list of submenus with the keys □ □up to Parameter
• Press the key Enter
□ Set on the concerned loop with the keys □ □

5
 • Press the key Enter, GAIN appears on the 1st line (or select RESET TIME Tn or RATE
TIME TV, with the keys □ , if you want to change the integrative or the derivative
action respectively.
• Press the key Enter
• Set on the digit to be changed pressing the key Ind
□ Increase or drop the value with the keys □ □
• Confirm the change pressing the key Enter
• To change the integrative action (RESET TIME Tn) act as for GAIN
• To change the derivative action (RATE TIME Tv) act as for GAIN

Changing the P, I and D action

• Press the key Esc/Menu
• Scroll the list of submenus with the keys □ □up to Confi(free)
• Press the key Enter
□ Set on the required loop with the keys □ □
• Press the key Enter and with the keys □ □select CONTR. PARAM.
• Press the key Enter  Press again the key Enter
• With the keys □ □select 1 for P action, 2 for PI action, 3 for PD action, 4 for PID
action
• To confirm press Enter and then with the key Esc/Menu return to the starting
window The configuration of the controller is the following:
LOOP 1 (FIC1): Control of the flow rate FI1, range 0-100%, output 0-100% proportional to the
opening of valve FV1
LOOP 2 (LIC1): Control of the level LI1, range 0-100%, proportional to 0-800 mm, output 0-
100% proportional to the opening of valve LV1

1.3Step for using software

1.3.1General notions
The process supervision software enables to control the system from P.C.
It has the typical structure of the systems used in the industry.
In fact, it is possible to:

6
• display on the monitor the synoptic of the systems which operation is to be controlled and
supervised;
• display the process parameters into numerical shape or as real- or historical-time trends;
• change the operating conditions acting on the set-point, PID control parameters, ON-OFF
elements, etc.

1.3.2The Supervision Software

• From Windows, install the supervision software (PROGRAM INSTALLATION) and the
specific software of the system (PLANT INSTALLATION) on the P.C. using the autoplay of the
CD ROM.

• Connect the plant to the P.C., using the proper serial cable, on port COM1 (or COM2).
• Run the supervision software Pilot for Windows.
Set the Parameters menu as follows:

7
  Select COM2 whenever the serial port COM2 is used.
 Open file REGAL to carry out the system’s supervision.
The operative formalities are the same when you operate in automatic mode.
For further information on the use of the software, see the help on line.
Some examples of possible screens are reported in the next pages.

8
9
3.3System start up, run
• Select the loop n°1 on the controller with the pushbutton Loop
• Set the loop to manual mode (pushing the key M/A/C switch the red led in the position M)
• Open at 50% the control valve FV1 (select the Out output with the key Ind and adjust the
value with the key to 50%).
• Select the loop n°2 on the controller with the pushbutton Loop
• Set the loop to manual mode (pushing the key M/A/C switch the red led in the position
M)
• Open at 50% the control valve LV1 (select the Out output with the key Ind and adjust the
value with the key to 50%).
• Start pump G1
• When the level in the column D2 is about 20%, start pump G2

10
 • Select the loop n°1 on the controller with the pushbutton Loop
• Fix the set point (press the key SP-w , and adjust the value with the keys ) e.g. to
50%
• Set the loop to automatic mode (pressing the key M/A/C switch on the green led to the
position A)
• Select the loop n°2 on the controller with the pushbutton Loop
• Fix the set point (press the key SP-w , and adjust the value with the keys ) e.g. to
50%
• Set the loop to automatic mode (pressing the key M/A/C switch on the green led to the
position A)
• Increase or reduce the level and flow values by varying the related instrument set-point
3.4System shut down
• Switches off pumps G1 and G2
• For long periods (2 or 3

CHAPTER TWO: EXERCISE

EXERCISE NO. 2. 1: Tuning of the controller with “Ultimate Gain Method”
1. Set 1st loop (FIC1) and 2nd loop (LIC1) in manual and adjust the output to 50%
2. Switch on pump G1 and when the level in the column D2 is about 20%, start pump G2
3. Set the 2nd loop (LIC1) in automatic mode with the set point at e.g. 50%
4. For 1st loop (FIC1), switch off integral and derivative action to have a proportional
controller
5. Set the Gain of 1st loop (FIC1) to e.g. 0.5
6. Start pump Gl
7. Set the set point of 1st loop (FIC1) to e.g. 50% and switch the loop in automatic
8. When the flow rate is constant, increase the gain (e.g. G = 1) and make a small change in
set point (e.g. from 50% to 55% and vice versa)
Question: Repeat step 8. until the loop oscillates with constant amplitude; record the value of the
gain that produces constant amplitude oscillation (Gu) and the relative period of oscillation (Tu).
Use Gu and Tu for calculating the tuning parameters.

11
 9. Introduce the integral action

Question: After the integral action is introduced, evaluate the flow control using PI controller of
gain value with P controller of gain value. Take also the average relative period of oscillation
(Tu) from the graph. Use the above equation to calculate the gain value (G) and integral value
(I).
10. Repeat the test with the 1st loop (FIC1) in manual with the output at 50% and the 2nd
loop (LIC1) in automatic mode.
Question: Find the ultimate gain (Gu) that produces constant amplitude oscillation for level
control using P controller and the value of the gain that produces constant amplitude oscillation
(Gu) and the average relative period of oscillation (Tu) from the graph for PI controller.

EXERCISE NO. 2.2: Flow and level control with only P controller using water as fluid
1. Using the value of gain (G) obtained in exercise 4.1, control the flow and/or the level to
e.g. 50%.
2. Observe the offset (steady-state deviation of PV from SP or steady state error)
Question: Record the offset value for both flow and level control when the controller is P
controller.
3. Try to vary the gain
Question: Observe and evaluate the value of the offset and the stability of the process at the
increment of the gain value.

EXERCISE NO. 2.3: Flow and level control with PI controller using water as fluid
1. Switch on integral action to have a PI controller
2. Using the value of gain (G) and integral time (I) obtained in exercise 4.1, control the flow
rate and the level to e.g. 50%

Question: Observe the ability of integral action with regard to the value of the off set for both
flow and level control.

12
EXERCISE NO. 2.4: Level control using tank D3
This exercise enables a constant feed flow without disturbances (noised caused by the pump).
1. Shut off the pneumatic valve FV1
2. Shut valves V1, V3, V4 and V5
3. Open partially valve V2
4. Set the 2nd loop (LIC 1) in automatic mode
5. Start pump G1 and wait the water discharge from tank D3 toward D1
6. Start pump G2
7. Once the level regulation is established, act on valve V2 so to have a constant discharge
to tank D1
8. You can see there is no noise on the level control when the calibrated orifice, inserted on
the output of tank D3, enables a constant regulation of this variable.
Question: What do you see on the noise of level control when the calibrated orifice, inserted on
the output of tank D3?

13