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Lab manuel level control

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10 views5 pages

Lab manuel level control

Uploaded by

melisasanac123
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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7.

6 Level Control System

Ankara University, Faculty of Engineering, Department of Chemical Engineering 180


CEN454 Chemical Engineering Laboratory III Level Control System

General
Liquid levels can be controlled by automatic systems which operate pneumatically and
electronically.

Objective
Main objectives of the experiment are:
1. Observing steady state conditions at different percent opening of the control valve.
2. Observing the dynamic state of the liquid level by giving a step input to the input
variable (flow rate of the fluid).
3. Deriving transfer function of the process using dynamic data by process reaction
curve method.
4. Calculating PID controller parameters by using Cohen-Coon method.
5. Performing PID control theoretically and experimentally.

Experimental System and Procedure


Figure 7.6.1 shows a schematic representation of the devices used in the liquid level
control experiment. A device that converts a signal to another signal is called a
transducer. For instance, the device that converts the pneumatic signal into electric
current is a transducer and is shown as (P/V). In Figure 7.6.1, the liquid level
measurement system is shown with a buoy. The buoy moves with liquid level
fluctuating and this movement is converted into electric current with the help of a
resistance. This transducer is indicated as (R/I). Besides, the resistance is hung with a
weight to prevent irregularities in the movements of the buoy floating at the liquid level.
The output electrical signals from the transducer (R/I) go to PID electronic control
system or to computer according to the user’s choice. According to the selection, this
signal is also transmitted to the computer. The output as electric current from PID
controller is converted into pneumatic signal by another transducer (I/P). The
corresponding pneumatic signal also proceeds to the control valve and adjusts the fluid
flow rate to the tank. As shown in the Figure, in addition to PID control system,
different measurements are also carried out. The first measurement is with the
temperature sensor called Pt 100. The output electrical signal from the Pt 100
temperature sensor goes directly to the indicator and is visually observed. Second, the
liquid level of the tank is observed with the help of the pressure gauge at the bottom of
the tank. This measuring element sends a ∆P pressure signal according to the liquid
level height and is converted into pneumatic signal with the help of a transducer (∆P/P).
This signal also gives the pressure difference in an indicator. Besides, the pH
measurement is read directly on the pH indicator with the help of the pH meter
connected to the tank outlet. The pressure difference created using the orifice meter
connected to the tank inlet to measure the flow rate of the liquid is sent to the display as
a pneumatic signal with the help of a transducer (P/∆P). The indicator receives the
pneumatic signal and gives the flow rate in L/min.

Ankara University, Faculty of Engineering, Department of Chemical Engineering 181


CEN454 Chemical Engineering Laboratory III Level Control System

Also, the pressure of the pump is shown as bar in an indicator. The (˃˃) symbol means
amplifying the signals. When a signal passes this unit, it gets a higher value. For
example, a signal that enters 1 volt can be 10 volts after passing through this unit.
As mentioned above, depending on the user selection, the PID can be performed with
the help of an electronic controller or computer. In the computer-based control, the data
are graphed versus time instantly and saved to the computer memory. Liquid levels are
obtained by using a computer graphic program for the desired period.
As shown in Figure 7.6.2, PLC (Programmable Logical Controller) control system,
widely utilized in industry, is used for the PID control system by means of the
computer. PLC control system can control many processes simultaneously, takes
measurements and plots instantaneous values. Information exchange is done with the
help of computers connected to the system online. Liquid level control system is
considered as a good application for such a process. On the computer connected PLC
system, open loop (manual) and closed loop (automatic) choices are to be made. Steady
state, dynamic state and control studies are carried out independently with the liquid
level control system.
While the system is operating in open loop (PLC in hand/manual position), the
percentage valve opening is adjusted to a certain value via computer. By activating the
pump, the liquid level is expected to come to a steady state and the inlet liquid flow rate
is measured. After the system has reached to a steady state, dynamic analysis is made by
giving a step effect to the percentage valve opening. During the dynamic analysis, the
liquid levels read from the computer screen are recorded every 20 seconds. This
operation continues until the system reaches the second steady state, and after steady
state is achieved, the inlet flow rate is measured again. The process reaction curve is
obtained by plotting the liquid level readings versus time. The reaction curve method
has the transfer function of a first order plus dead time process.

Fig 7.6.1. Transducer and indicator units used in liquid level control system.

Ankara University, Faculty of Engineering, Department of Chemical Engineering 182


CEN454 Chemical Engineering Laboratory III Level Control System

Fig 7.6.2. Liquid level control experimental setup.

The corresponding equation is given below.

(1)

Using the obtained process transfer function parameters, the PID controller parameters
are calculated by the Cohen-Coon method [1] using the equations in Table 7.6.1.
Controller performance is observed while operating the system in a closed loop at
different set points and different disturbances by using defined model parameters.

Ankara University, Faculty of Engineering, Department of Chemical Engineering 183


CEN454 Chemical Engineering Laboratory III Level Control System

Table 7.6.1. PID controller parameters calculated with Cohen-Coon method.

Kc τI τD

PID

Experimental Design Problem

Find the PID controller parameters that best control the liquid level system at different
set points from the determined transfer function by using Matlab Simulink program
[2,3].

Supplementary Questions

1. How many types of load effects (disturbances) can be given to the system?
2. How do we obtain the system model and open loop response curve for the liquid level
control system?
3. What are the input and output variables of the liquid level system?
4. What is the Taylor series expansion? Show the linearization of the liquid level system
according to the Taylor series expansion.
5. What is process control and its objective?
6. Describe the feedback PID control systems.
7. Describe the liquid level control systems.
8. How are the transfer function parameters of the process calculated from the system's
response curve?

References
[1] Stephanopoulos, G. Chemical Process Control, Prentice Hall, New Jersey, (1984),
p.310-315.
[2] Coughanowr, D., LeBlanc,S., Process Systems Analysis and Control, 3rd Edition,
McGraw Hill,(2008), p.165-185
[3] Bequette, B.W., Process Control Modeling: Design and Simulation, 1st Edition,
Pentice Hall,(2008), p.181.

Ankara University, Faculty of Engineering, Department of Chemical Engineering 184

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