Control Lab Manual PDF

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Faculty of Engineering
Chemical Engineering Department
Control Lab Manual

EAX_5_235.1
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Table of Contents
Experiment C1: Level Control....................................................................... 1
Experiment C2: Flow Control ..................................................................... 10
Experiment C3: Pressure Control ................................................................. 21
Experiment C4: Temperature Control .......................................................... 29
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Level Control Experiment
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Experiment C1:
Level Control
Objectives:
1. To study the main components of a level control system.
2. To study the influence of controller design on control action
and disturbance response.
3. To study the stability of a control loop.
4. To study the controller optimization.
II
Introduction:
The RT 010 liquid level control model represents a typical loop control
system, as is standard and widespread in engineering.
The actual loop is a cylindrical liquid level tank made of transparent plastic.
A water supply tank positioned below it contains an electrically operated
immersion pump. This acts as the actuator and is used to deliver water into
the liquid level tank. The liquid level in the tank is measured by a pressure
sensor using the height of the water column and is transmitted as an electric
voltage signal. The liquid level can also be read on a scale on the tank itself.
To represent the removal of water from the tank, an electric proportional valve
acts as an adjustable discharge. This means that additional disturbances are
possible in the system. The water pours back into the supply tank, resulting in
a closed circuit that does not require an additional water supply.
The model must be supplemented by a separate external controller to create a
complete control loop. It communicates with the peripheral equipment (e.g. a
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PC) via a USB interface. The most suitable control and regulation program is
the associated software RT 010- RT 060.
III Description:
1) Equipment layout:
Figure 1: RT 010 Overall view
1.
2.
3.
4.
5.
6.
Liquid level tank

Pump
Pump Overflow
Supply tank
Bleeder valve, electric, proportional
Pump signal lamp
7.
8.
Pump switch
Button for complete opening of bleeder
valve (Z = 100 %)
9. Bleeder valve signal lamp
10. Master switch
11. Pressure hose for liquid level
measurement
USB plug-in connection (rear of unit).

Mains connection (rear of unit).
2) Process diagram:
Figure 2: RT 010 Process diagram
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3) Function:
The RT 010 liquid level control model is used as a simple loop for a controller.
It does not include a controller itself; all control processes must be run
externally. The model communicates with external devices via a USB
interface, for which it has a plug-in connection on the rear.
The actuator is an electric immersion pump (2), which delivers water from a
supply (4) in to the liquid level tank (1). The pump must be actuated by an
external input signal, e.g. from a controller. The liquid level is recorded using
the pressure of the water column in the tank. The level tank contains an
ascending pipe for this purpose. An air hose (11) conveys the pressure from
its upper end to a pressure sensor inside the unit. The liquid level is then
provided as an electric voltage signal. The electrically operated bleeder valve
(5) can be used to set the discharge from the tank by assigning the influencing
variable Z. the valve operates proportionally and can be variably adjusted. Its
position can only be influenced by external control (e.g. via a PC). The
exception is a disturbance in the system. The bleeder valve can be
spontaneously switched to Z = 100% using the button (8).
The overflow (3) prevents water from escaping if the discharge through the
valve (5) is not sufficient. The pump signal lamp (6) and the bleeder valve
signal lamp (9) indicate whether the respective elements are actuated.
NOTE: to deliver water into the filling tank, the pump must overcome the
pressure of the water column up to the tank cover (~ 30cm = 30mbar). This
means that water only reaches the tank with an input signal above ~ y 40%.
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4) Commissioning:
Using the hole in the cover, fill the supply tank (4) with water until the
pump is completely submerged and all hoses and pipe ends are below
the water level (~3.5ltr)
Connect the model to the mains using the connecting socket on the rear.
Using the USB port on the rear of the model, connect it to an external
controller (e.g. PC).
Switch on the model at the master switch (10).
Press the button (8) to check the functioning of the bleeder valve.
The model is now ready for use.
NOTE: Differing values for the liquid level maybe displayed on the PC. This
is because the water level in the ascending pipe does not exactly correspond
to that in the tank (e.g. due to residual water, air bubbles etc.).
REMEDY:
Switch off the pump and completely drain the liquid level tank by
pressing the button (8).
Carefully remove the air hose (11) on the top of the filling tank.
Using the fitting, blow air into the ascending pipe to expel any residual
water or air bubbles located in the pipe.
Shutting down:
To shut down, switch off the model at the master switch. If the model will not
be used for a long period of time, disconnect it from the mains and drain the
water.
To do this, allow the water to drain out through the bleeder on the rear of the
supply tank with a suitable hose.
The unit is maintenance free and does not require any additional servicing.
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IV Experimental Procedure:
1) Control loop:
a) Determination of loop type:
The loop behavior is determined by a step in the reference variable and
observation of the resulting transient response
Select Manual operating mode.
Set disturbance Z= 10 %
Set manual regulation ratio Y= 40 %, wait for steady state, and TAKE
CARE OF OVERFLOW.
Perform step in manual regulation ratio,
Y= 40 %
100 %, wait for overflow of liquid level tank.
Observe the response.
Y= 100 %
0 %, allow liquid level to drain.
Y= 0 %
50 %, wait for overflow of liquid level tank.
2) Continuous control:
a) P control:
In the following section, the influence of pure P components of different levels
on the control of the reference variable is initially observed.
Select Continuous control operating mode.
Set parameters:
Kp = 10
Tn = 0
Tv = 0
Z = 50 %
W1 = 10 cm
Wait for steady state.
Set Kp = 25, wait for steady state
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Comment on the results.
b) PID control of a disturbance variable:
So far, the control has only been observed in respect of changes to the
reference variable or the control parameters.
The following section observes compensation for a disturbance variable.
Select Continuous control operating mode
Set parameters:
Kp = 28
Tn = 9 s
Tv = 0.5 s
W1 = 12 cm
Z = 10 %
Connect disturbance, Z = 100 % and observe the progression of the
control variable and the manipulated variable.
Disconnect disturbance, Z = 10 % and observe the progression of the
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Appendix
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VI Pre-Lab questions:
1. What are the inputs and outputs of the PID controller?
2. Sketch the circuit diagram of the liquid level control system.
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VII Final questions:

1. What is the effect of increasing the proportional gain K?
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2. What is the effect of the integral time constant Tn when using a PI
controller?
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Flow Control Experiment
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Experiment C2:
Flow Control
Objectives:
1. To study the main components of a flow control system.
2. To study the influence of controller design on control action and
disturbance response.
II
Introduction:
The RT 020 flow control model represents a typical loop control system, as
is standard and widespread in engineering.
The actual loop is a piping system, through which water is constantly
pumped in a circuit from a tank. The flow in this system can be influenced
by an electric regulator valve.
To do this, it is actuated by an external controller. As a disturbance, the
speed of the pump can be changed. In the system, the flow is recorded using
an electric flow sensor on the turbine principle. The circuit also contains a
flow meter with float.
The model must be supplemented by a separate external controller to create
a complete control loop. It communicates with the peripheral equipment
(e.g. a PC) via a USB interface. The most suitable control and regulation
program is the associated software RT 010- RT 060.
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III Description:
1.
2.
3.
4.
5.
Flow meter, with float

Regulator valve
Pump signal lamp
Pump
Water tank
6.
7.
8.
9.
Flow meter, turbine

Master switch
Valve signal lamp
Pump switch

2) Process Diagram
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3) Function:
The RT 020 flow control model is used as a simple loop for a controller. It
does not include a controller itself; all control processes must be run
A water tank (5) contains an immersion pump (4), which is responsible for
constantly delivering water through a piping system in a circuit. An
electrically operated proportional valve (2) acts as the actuator for this
circuit. This valve must be actuated by an external input signal, e.g. from a
controller. The flow is determined using a sensor, which works on the
turbine principle. It emits a pulse signal, the frequency of which is
proportional to the flow. This signal can be transmitted externally to a meter
output via the USB connection and then analyzed. In addition, the piping
system includes a float flow meter for verification and comparison purposes.
In normal operation, the pump always runs at Y=100 %. As a disturbance, it
can be throttled with the signal Z= 099 %. As this disturbance is
subtracted directly from the input signal, Z= 100 % means that the pump
comes to a stop as there is no input signal remaining. The pump signal lamp
(3) and the valve signal lamp (8) indicate whether the respective elements
are actuated.
4) Commissioning:
Using the hole in the cover, fill the water tank (5) with water until the
pump is completely submerged and all hoses and pipe ends are below
the water level (~3.5 ltr)
Connect the model to the mains using the connecting socket on the rear.
Switch on the pump (4).
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Shutting down:
To shut down, switch off the model at the master switch. If the model will not
be used for a long period of time, disconnect it from the mains and drain the
water.
To do this, allow the water to drain out through the bleeder on the rear of the
water tank with a suitable hose.
1) Control loop:
a) Control action of flow loop:
The actuator on the RT 020 is an electrically operated pump. Observe which
flow values X occur when varying the actuation signal Y in undisturbed
operation.
Y= 0100 %
Z= 0 %
b) Disturbance response of flow loop:
Another important feature of a loop is its response to disturbances. Observe
the response of this loop to disturbance by actuating the actuator (pump)
with Y= 100 % and the disturbance variable Z is varied.
Y= 100 %
Z= 0100%
c) Determination of loop type:
Select Manual operating mode.
Set disturbance Z= 0 %
Set manual regulation ratio Y= 20 %, wait until a steady state is
reached.
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Y= 20 %
80 %
a) P control:
In the following section, the influence of pure P components of different
levels on the control of the reference variable is initially observed.
Set parameters:
Kp = 0.1
Tn = 0
Tv = 0
Z=0%
W1 = 120 l/h
calculate the maximum percentage overshoot, the rise time, the
settling time (0.02 criteria) and the peak time.
Set Kp = 0.2, wait for steady state
What are the effects of increasing Kp?
Comment on P control.
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b) PI control:
As the pure P component obviously does not result in satisfactory control of
the flow loop, the following section is designed to illustrate how an additional
I component influences the control of the reference variable.
Set parameters:
Kp = 0
Tn = 1.0 s
Tv = 0
W1 = 120 l/h
Z=0%
Perform step in reference variable by selecting W2 = 160 l/h, wait for
steady state.
Set parameters:
Kp = 0.1
Tn = 0.5 s
W1 = 120 l/h
steady state.
Set parameters:
Kp = 0.2
Tn = 0.5 s
W1 = 120 l/h
steady state.
Set parameters:
Kp = 0.2
Tn = 0.6 s
W1 = 120 l/h
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steady state.
Comment on PI control.
c) PI control of a disturbance variable:
So far, the control has only been observed in respect of changes to the
reference variable or the control parameters.
The following section is designed to show whether the parameters found for
favorable control of the reference variable are also suitable to compensate for
a disturbance variable.
Set parameters:
Kp = 0.2
Tn = 0.6 s
Tv = 0 s
W1 = 120 l/h
Z=0%
Set parameters:
Kp = 0.4
Tn = 0.3 s
Tv = 0 s
W1 = 120 l/h
Z=0%
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Comment on the PI control of a disturbance variable
d) Two point control:
So far, only continuous control has been observed. For a qualitative
comparison, it is interesting to compare this to two-point control.
Two- point control can normally be achieved using simpler methods than
continuous control. Therefore, this often leads to the economic question of
how high the required control quality actually has to be and what cost it
justifies.
Select Step control operating mode.
Set values: Y limit:
Min= 20 %
Max = 80 %
Xsd = 50 l/h
Z = 0 % (off)
W= 120 l/h
Observe signals.
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Appendix
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1. Describe the dynamic system of the flow control.
2. Sketch the process model of the flow control.
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1. What are the input and the output of the PID control?
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2. What is the main function of the electric actuator valve?
..
3. What are the optimal gains of the PI controller for

W= 120 l/h
Z=0
Y = 0100%
At these values calculate the maximum percentage overshoot, the rise
time, the settling time (0.02 criteria) and the peak time.
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Pressure Control Experiment
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Experiment C3:
Pressure Control
Objectives:
1. To study the main components of a pressure control system.
II
Introduction:
The RT 030 pressure control model represents a typical loop control system,
as is standard and widespread in engineering. The actual loop is a cylindrical
metal pressure vessel. An externally actuated, electrically operated
compressor performs the function of the actuator and is used to increase the
air pressure in the vessel. The value of the relative excess pressure in the
vessel is recorded by piezo-electric pressure sensor and provided as an electric
voltage signal. Two valves are used to bleed the air from the vessel. One of
them is a manual valve, which can be used to simulate continuous pressure
tapping. An additional electric valve can also be connected as a sudden
disturbance.
complete control loop. It communicates with the peripheral equipment 9e.g. a
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III Description:
1.
2.
3.
4.
5.
Compressor
Compressor switch
Bleeder valve
Disturbance valve, electrically operated
Pressure sensor
6.
7.
8.
9.
10.
Manometer
Pressure vessel
Compressor signal lamp
Disturbance valve signal lamp
Master switch

2) Process diagram:
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3) Function:
The RT 030 pressure control model is used as a simple loop for a controller.
It does not include a controller itself; all control processes must be run
A compressor (1), which is powered by a DC motor, is used as an actuator.
The compressor pumps air into a pressure vessel (7). This pressure is directly
indicated on a manometer (6) and is also measured using a piezo-electric
sensor, which outputs a corresponding voltage signal for possible control. The
bleeder valve (3) is used to set variable continuous pressure tapping. As a
disturbance in the system, a second electrically operated valve can be
connected. The disturbance valve can also be variably adjusted. Its switching
behavior is not proportional; it has binary switching (open or closed). The
disturbance valve can only be influenced by external control (e.g. via PC).
Note: The compressor has a response threshold. This means that it only
starts to move when the control signal y is at least 30% of its full final
value (~ 3.5 V).
The compressor cannot start up against pressure.
1) Control loop:
a) Preparing the loop:
Switch on the master switch (10) and compressor switch (2) on the RT
030 unit and start the RT 010 060 Principles of Control Engineering
software.
Select Manual operating mode and set the manual regulation ratio to
y = 100 %.
The compressor starts.
Open the bleeder valve (3) and adjust it to give a constant pressure of ~
1 bar.
Then use the Z button to open the disturbance valve (4) and adjust it
to give a pressure of ~ 0.8 bar.
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b) Determination of loop type:

Select Manual operating mode, set the manual regulation ratio to y =
40 % and wait until the pressure reaches a steady state.
Carry out a step in the manual regulation ratio of :
y = 40 %
y = 60 %
a) P control:
In the following section, the influence of pure P components of different levels
on the control of the reference variable is initially observed.
Set values:
Kp = 200
Tn = 0 s
Tv = 0 s
W1 = 0.7 bar
Ylimit : 0 to 100 %
Wait until the pressure has reached a steady state.
Perform step in reference variable by selecting W2 = 0.8 bar, wait for
steady state.
steady state.
Calculate the steady state error (es.s.) in each case.
Where es.s.
Cout C ref
C ref
*100
Comment on P control.
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b) PI control with disturbance variable:

So far, the control has been considered in respect of changes to the reference
variable. The following section is designed to show the extent to which the
parameters found for favorable control of the reference are also suitable to
compensate for a disturbance variable.
Set parameters:
Kp = 750
Tn = 5 s
Tv = 0 s
W1 = 0 bar
Wait until the pressure has reached a steady state.
steady state.
Connect disturbance and observe the progression of the control
variable and the manipulated variable.
steady state.
Comment on the result
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Appendix
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1. Draw the circuit diagram of the pressure control and explain its
components.
2. How can we evacuate the air from the vessel?
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1. Explain in details the effect of Kp on the pressure response.
2. What is the effect of PI controller under the disturbance conditions?
..
3. For P control, at Kp = 250 and W = 0.7 bar, calculate the steady state
error.
..
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Temperature Control Experiment
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Experiment C4:
Temperature Control
Objectives:
1. To study the main components of a temperature control system.
II
Introduction:
The RT 040 temperature control model represents a typical loop control

system, as is standard and widespread in engineering.
The actual loop is a metal bar inserted into a heat-insulating cladding tube.
The end of the bar is heated by an electric heater. Along the axis of the bar,
i.e. in the direction of dispersion of the heat, are three equally spaced
temperature sensors, which can be used as signal transmitters for a controller.
As a disturbance, a small electric fan can be connected, which dissipates part
of the heat output and withdraws it from the bar.
complete control loop. It communicates with the peripheral equipment (e.g. a
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III Description:
1.
2.
3.
4.
5.
Fan
Heater and cooler
Bar in cladding tube
Control thermometer
Temperature measuring points T1, T2,
and T3
6.
7.
8.
9.
10.
Heater switch
Master switch
Heating signal lamp
Cooling signal lamp
Fan signal lamp

2) Process diagram:
Figure 8: RT 040 Process Diagram
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3) Function:
The RT 040 temperature control model is used as a simple loop for a
controller. It does not include a controller itself; all control processes must be
run externally. The model communicates with external devices via a USB
The active actuator on this model is an electrically operated Peltier element
(2), which can be used for either heating or cooling. These two options open
up the possibility of three-point control. The element is fitted between a
dissipater (1) and a heat conducting bar (3). For heating, it is supplied with an
electrical voltage of appropriate polarity, such that the side facing the bar is
cooled.
As an additional disturbance, an electrically powered fan (1) is fitted before
the dissipater on the side facing away from the bar, which can optionally be
connected. To allow dosing of the disturbance, actuation is cyclic, with a
changing pulse/pause ratio.
Equally spaced PTC resistors (5) are inserted into the heat conducting bar to
record the temperature.
T1 - Start of bar (close to heater)
T2 - Centre of bar
T3 - End of bar
Depending on the sensor position, the resulting loop behavior is different, e.g.:
T1 - PT1 behavior
T2 - Noticeable idle time behavior
To create uniform thermal conditions, the heat conducting bar is embedded in
an insulated cladding tube (3).
As the temperature is measured by sensors, the control thermometer (4) is
only intended to provide a guide to the temperature in the centre of the bar
(plausibility).
Note: The fan should always be operated at maximum speed for use with no
active disturbance (Z = 0%).
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4) Commissioning:
Connect the model to the mains using the connecting socket on the
rear.
Switch on the heater (4).
Shutting down:
To shut down, the model only needs to be switched off at the master switch.
The model should be disconnected from the mains if it will not be used for a
long period of time.
1) Control loop:
a) Determination of loop type:
The loop type is determined by way of a step in the reference variable and
observation of the resulting transient response.
Select Manual operating mode and set the manual regulation ratio to
y = + 100 % (heating).
Now wait until the temperatures have reached a steady state.
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a) P control:
In the following section, the influence of a pure P component on the control
of the reference variable is initially observed.
In System diagram, select measuring point T3
Set parameters:
Kp = 10
Tn = 0 s
Tv = 0 s
W1 = 25C
Perform step in reference variable by selecting W2 = 35 C, wait for
steady state.
b) PID control of reference variable:
The following section is designed to demonstrate how an additional I and D
component affects the control of the reference variable.
In System diagram, select measuring point T3
Set parameters:
Kp = 1.1
Tn = 750 s
Tv = 75 s
W1 = 20C
Perform step in reference variable by selecting W2 = 35C, wait for
steady state.
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Appendix:
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35
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1. What are the inputs and the outputs of the PID controller?
2. Enumerate the steps of the control process using a proportional

controller.
36
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1. Study the performance of the system when provided with proportional
controller of gain Kp =8 and W1 = 25C.
..
2. Calculate the steady state error of the temperature T1 when the system
is provided with PID controller of parameters
Kp = 1.2, Tn = 750, Tv = 75 and W1 = 25C.
37
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Level Control Experiment

Level Control Experiment

Figure 1: RT 010 Overall view

Liquid level tank

USB plug-in connection (rear of unit).

Figure 2: RT 010 Process diagram

Level Control Experiment

Level Control Experiment

Level Control Experiment

Level Control Experiment

Set Kp = 50, wait for steady state

Level Control Experiment

Level Control Experiment

2. Sketch the circuit diagram of the liquid level control system.

Level Control Experiment

VII Final questions:

Flow Control Experiment

Flow Control Experiment

Figure 3: RT 020 Overall view

Flow meter, with float

Flow meter, turbine

USB plug-in connection (rear of unit).

Figure 4: RT 020 Process diagram

Flow Control Experiment

Flow Control Experiment

Flow Control Experiment

Perform step in manual regulation ratio,

Flow Control Experiment

Flow Control Experiment

Perform step in reference variable by selecting W2 = 160 l/h, wait for

Flow Control Experiment

Disconnect disturbance, Z = 0 % and observe the progression of the

Flow Control Experiment

Flow Control Experiment

2. Sketch the process model of the flow control.

Flow Control Experiment

VII Final questions:

3. What are the optimal gains of the PI controller for

Pressure Control Experiment

Pressure Control Experiment

Figure 5: RT 030 Overall view

USB plug-in connection (rear of unit).

Figure 6: RT 030 Process diagram

Pressure Control Experiment

Pressure Control Experiment

b) Determination of loop type:

Pressure Control Experiment

b) PI control with disturbance variable:

Pressure Control Experiment

Pressure Control Experiment

2. How can we evacuate the air from the vessel?

Pressure Control Experiment

VII Final questions:

2. What is the effect of PI controller under the disturbance conditions?

Temperature Control Experiment

The RT 040 temperature control model represents a typical loop control

Temperature Control Experiment

Figure 7: RT 040 Overall view

USB plug-in connection (rear of unit).

Figure 8: RT 040 Process Diagram