ABSTRACT

The project “CASCADE CONTROL OF OPEN TANK LEVEL AND MONITORING OF

INDUCTION MOTOR PARAMETERS” deals with the study of the pilot plant, which is modeled
after a real time plant and to implement level control of open tank using cascade loop. It also aims at
monitoring of induction motor parameters such as voltage, current, temperature, frequency.

The cascade control uses two PID controllers for a better performance of the level control. The
primary controller is the level controller(LC) which utilizes the level set point and contributes to set
point of the secondary controller ie; flow control(FC) which in turns drive the input flow valve (CV).

This project also aims at monitoring various parameters of the machines and prevents damage to the
machine.

ABB PM581 PLC and LabView DSC are used for controlling and monitoring the overall process.
 1. INTRODUCTION
1.1 System Analysis

This project uses the process automation training plant situated at NIELIT,Calicut.This is
designed and developed at this centre for studying and advanced control stratagies required for the
basic processes in various industries.The plant has fundamental control loops such as
level,temperature,pressure,flow and interactive control loops of temperature,level and pressure.

1.2 Description of Pilot Plant

The main objective of NIELIT is to conduct training courses for engineers, supervisors and
maintenance personals from industries. In recent years, the performance requirement of process
plant has become increasingly difficult to satisfy. Stronger competition, tougher environment and
safety regulations and globalizations of economy have been key factors for tightening product
quality specification.

It has got a pilot plant similar to that of process plants in industries and is configured with real
size equipments comprising of an open tank, pressure tank, heat exchanger, level transmitter,
control valves, orifice plates, centrifugal pumps, solenoid valves, flow meter, indicators, led
display, stirrer, heater, industrial PC and oil free compressor. And hence the pilot plant is easily
tailored for teaching and experimentation of the various advanced control strategies required for
process automation.

For studying, analyzing, troubleshooting and experimenting with various control strategies, a
training plant using real size equipment is essential. The effectiveness of the modern process
control algorithms, like adaptive control and predictive control aspects can be better studied in a
plant using real sized equipment rather than lab instrument. The urge has lead to design and
development of process control training plant.

The plant consists of an open tank, which is acting as a water storage tank. The drain from the
tank is connected to the tank through manual control valve. The recirculation tank acts as a buffer
tank for smoothing out supply.

Solenoid valve and hand valve are used for applying step disturbance in out flow. The out flow
disturbance can be generated by switching on and off the solenoid valve for the preset values. The
hot and cold water supply to the tank can be controlled using continuous control valves. The
training plant also has a shell and tube type exchanger, which is very commonly used in
industries. The water from the tank is pumped with centrifugal pump to a pressurized vessel that
is designed to withstand pressure upto 14bars.The water flow into the tank is regulated using
control valves.
 5. PROCESS DESCRIPTION
The pilot plant has different control loops that can be automated. The aim of the project is to maintain
water level in the open tank by manipulating the inlet flow. The water to open tank is supplied from a
storage tank. There is a constant output flow for the open tank which in turn can be adjusted by a
manual drain valve. The water from the tank is drained out. The control is achieved by implementing
a cascade loop based control.

The process plant has four tanks (cold water over head, hot water overhead, open tank and close
tank).The controlled variables in the open tank are the constituents of the fluid (mixture of hot water
and cold water) flowing into the tank. The process fluid in open tank is a mixture of cold water and
hot water in a particular ratio set by the operator. The level is maintained in open tank by adjusting
cold water flow control valve LV006.

The open tank has three drain valves (HVN3, HV4 and HV5) which are operated manually by the
operator. If any of these valves are not closed properly, then the process won’t be started. This
operation is monitored using limit switch fixed near the ball valve.

The pump2 is used for pumping hot water from the heater tank to the hot water overhead tank. With
the start of the process, pump2 is switched on, so that continuous flow of water is obtained across the
two tanks. If the maximum level of the overhead tank is reached, then there is a safety vent through
which excess water flows to the heater tank again. The heater in the tank can be operated in two
modes (manual/automatic mode).In manual mode, the heater is being kept on for 20s or 30s as
required by the process and then it is turned off. In automatic control, a simple on/off control strategy
is used. If the specified temperature of the heating tank is reached, the heater is turned off
automatically. Cold water flows to open tank through YV11 and LV006 which is opened and YV09 is
closed.YV11 and LV006 are normally closed valves and YV09 is normally open.

Hand valve is used to create step disturbance in the process manually. Level is measured by level
transmitter LT008 and LT071 which transmits the level signal to the analog module of PLC. Based
upon the set point of level controller output signal from the output module of PLC goes to I/P
converter TY007,FY027 and LY))&.The I/P converter converts 4-20mA current signal to -5psi and
transfer it to the pneumatic control valve.

By setting the level of the tank as constant, output flow rate and tank level are cascaded such that the
output flow can be maintained in a constant set point. The level in the open tank is checked if water in
the open tank is more or less than the specified level, then the flow is altered to meet the set point
level. If the water in the open tank goes below the desired set point the process valve of level is
measured and set to the primary controller. It computes the manipulated value which is fed to another
secondary controller as the set point. This is done to increase the response time of the process. The
manipulated value is given to the final control element which controls the outlet flow which
determines the level of the closed tank.
 2. NOMENCLATURE OF THE EQUIPMENT
UNDER CONSIDERATION
ELEMENT PNEUMONIC

Atmospheric tank ATNK

Centrifugal pump PUMP

Alarm for high deviation of level LDA

Alarm for high rate of change of level dL/dT

Alarm for high deviation for the temp measured TDA

Alarm for high rate of change of temperature dT/dt

Alarm for high deviation for the flow measured FDA

Alarm for high rate of change of flow dF/dT

Alarm for high deviation of pressure measured PDA

Alarm for high rate of change of pressure dP/dT

Alarm for high value of control signal XAH

Alarm for low value of control signal XAL

I to P converter for level control valve LY

I to P converter for flow control valve FY

I to P converter for temperature control valve TY

I to P converter for pressure control valve PY

Controlling valve for flow FV

Controlling valve for level LV

Controlling valve for temperature PV

Flow measuring element FE

Flow indicator FI

Flow transmitter FT

Flow indicating controller FIC

Heat exchanger XCHG

Heating element HE

Differential pressure type, cold water transmitter FT092

Cold water orifice plate FE091

Cold water flow control valve (NC) LV006

Heat exchanger service fluid solenoid valve (NO) YV09

Heat exchanger bypass fluid solenoid valve (NC) YV11

Open tank water level limiting ON/OFF valve HV2

Level gauge ON/OFF valve for LGI of open tank HV1&HV3

Open tank drain ON/OFF valve HV4

Main pump return flow ON/OFF valve HV5

Open tank outflow disturbance similar solenoid valve HV6

Open tank outflow disturbance similar needle valve HVN1&HVN2

Worn pump effect simulator needle valve HVN3

Worn pump effect simulator solenoid valve YV2

Differential pressure type, water level sensor and transmitter LT008

Level calibration ON/OFF HV12&HV15

Main pump’s return flow control valve FV026

Control valves (FV026 and FV027) I/P converter FV027

Pump leakage simulator solenoid valve (NO) YV3

Pump leakage simulator needle valve HVN4

Flow blockage hand valve HV8

Pressure tanks inlet water flow transmitter FT028

Main pump’s outflow magnetic flow meter FE027

Main pump’s outflow indicator FI029

Main pump’s forward flow control valve FV030

Differential pressure type water level sensor and transmitter LT071

Level transmitter calibration ON/OFF HV16&HV17

 6. BLOCK DIAGRAM

The primary controller is the level controller(LC) which utilizes the level set
point and contributes to set point of the secondary controller i.e. flow
control(FC) which in turns drive the input flow valve (CV).
 7. CASCADE CONTROL
Cascade control has multi-loop structure, where the output of the controller in
the outer loop (primary) is the set point of a controller in the inner loop
(secondary).The secondary measurement is an intermediate process variable that
can be used to achieve more effective control of the primary process variable. In
the cascade configuration, the process is divided into two parts and therefore
two controllers are used, but only one process variable is manipulated.

Disturbances

Secondary process Primary process

Secondary controller Primary controller

7.1 CASCADE CONTROL WITH FEEDBACK CONTROL:

 This is the method that can significantly improve dynamic response to
disturbances; it employs a secondary measurement point and secondary
controller.
 The secondary measurement point is located so that it recognizes the
upset condition sooner than control variable. This approach is called
cascade control.
 The output signal of the primary controller acts as the set point for the
secondary controller.
 CoDeSys
CoDeSys is a complete development environment for ABB PLC.CoDeSys
stands for (Controlled Development System).It puts a simple approach to the
powerful IEC language at the disposal of the PLC programmer.Use of the
editors and debugging functions is based upon the proven development program
environments of advanced programming languages such as C++.

How is a project structured?

A project is put into a file named after the project.The first POU (Program
Organization Unit) created in a new project will automatically be named
PLC_PRG.The progress begins here (in compliance with the main function in C
program), and the other POUs can be accessedfrom the same
point(programs,function blocks and functions).Once we have defined a task
configuration,it is no longer necessary to create a PLC_PRG.There are different
kinds of objects in a project POUs,data types,display elements(visualization)
and resources.The object organizer contains list of all the objects in our project.

How to setup project?

First we should configure our PLC in order to check the accuracy of the
addresses used in the project,then we create POUs needed to solve the
problem.Now we can program the POUs we need in the desired languages.Once
the programming is completed,we can compile and remove the errors if any.

How to test the project?

Once all the errors have been removed,activate the simulation,log into the
simulated PLC_PRG and “Load” our project to the PLC.Go to Online
mode.Now open the window with our PLC configuration and test our project
for correct sequence.To do this,enter input variables manually and obser ve
whether the output are as expressed.We can also observe the value sequence of
the load variables in the POUs.In the watch and receipt manager,we can
configure data records whose values we wish to examine.

Debugging

In case of a programming error we can add breakpoints,If the process stop at

such a breakpoint,we can examine the values of all project variables at that
point of time.By working through sequential steps we can check the logical
correctness of our project.

Further debugging fuctions

We can set program variables and inputs/outputs at certain values.We can use
the flow control to check which program line have been run.A lg records
operations,user actons and internal process during an online session in a
chronological order.If activated in the target setting the sampling traces allows
us to trace and display actual course of variables over an extended period of
time.Also a target specific function is the PLC browser which can serve to
request certain information from the PLC.Once the project has been setup and
tested,it can be loaded down to the hardware and tested as well.The same online
fuctions as we used with the simulation will be available.

Additional CoDeSys features

The entire project can be documented or exported to a text file at any time.For
communication purposes CoDeSys have a symbolic interface and a DDE
interface.A gateway sever plus OPC server and DDE sever are components of
the CoDeSys standard installation packet.Using the appropriate target
settings,which can be loaded with the aid of a target file (Target Support
Package),allows to load the same CoDeSys project to various system.

Network global variables and a parameter manager might be available,if

activated by the current target setting,for data exchange with in a network of
controllers.

ENI: The ‘Engineering Interface’ can be used to access any desired source code
management program via the ENI server ,which is running as an independent
process.CoDeSys,POUs and compile file can be filed in the database and are by
that accessible also by other clients of ENI server.This allows multi user
operations during the work on a CoDeSys project,it provides a common data
pool for different tools besides CoDeSys and it makes possible a version
management.

TOOLS:This functionality also is a target dependent and allows to start target

specific executable files in a CoDeSys project.Conection to external tools can
be predefined in the target file or inserted in the project resources tree.CoDeSys
visualization can be processed target specifically to be available as Web-
Visualization via internet or on a PLC monitor.
Induction Motor Controlling Using PLC
In a normal industrial environment there are lots of machines that operate on different functions.
The proper functioning of these machines is necessary to ensure good productivity and safety. But
failures become inevitable in an environment where there are lots of external parameters that
influence the functioning of the machines. Induction motor is one such machine which is used
extensively from small agricultural fields to large complex industrial houses. They are susceptible to
lots of variations because it is connected to external common power lines. This project aims at
monitoring various parameters of the machines and prevents damage to the machine.

The project aims at monitoring the important parameters of an induction motor substation. The
parameters that are to be monitored are temperature. The project also includes monitoring
parameters like voltage and current frequency. These parameters are taken and given to the PLC
after converting into required formats. The PLC transmits the parameters using suitable medium to
a PC that is attached to a level converter.

Further all the obtained data and the control data are displayed on the PC which runs Labview which
is an advanced measurement and automation software. Use of VI has innumerable advantages such
as easy configuration, easy control, variety of data representation, ease of modification, low cost
and a host of others. The user-friendly control panel gives the operator to operate everything in
mouse clicks whereas its robust architecture gives a reliable security and an unmatched accuracy.

The VI has everything in digital so any change can be made with ease. Further a lots of analysis such
as histogram, graphs, etc which are not possible in a conventional software can be plotted on the
screen. As it’s relatively new and more advanced the project has a good level of advanced concepts.
Software Tools
LabView
Hardware Required

• PLC
• Current Sensor
• Voltage Sensor
• Temperature Sensor
• PC Interface
• PC
• Alarm
INDUCTION MOTOR MONITORING UNIT
 IMPLEMENTATION
Our control objective is to control the level in the open tank. For implementing cascade
control, two PID blocks are used. There is a primary and secondary control. The set point
(level) is given to the primary controller. The level measured from the level transmitter is fed
to this control as PV. The output of this controller is given as the set point to the secondary
controller. The flow rate which is measured by the orifice type flow meter is fed as PV to the
secondary controller, the manipulated variable (output) of this secondary controller is given
as control signal to the pneumatic control.

Various Actions Taken For The Proposed Project

 For incoming water flow to open tank ATANK-1, valves YV11 &LV006 is opened.
YV11 and LV006 are normally closed valves.
 Initially, drain valves are opened slightly to maintain a certain amount of outflow. The
openings of these hand valves are adjusted manually according to the control
requirement.
 We are assuming the flow rate of the incoming cold water as constant. It will not
create any disturbance in the process, though there will be minor.
 Disturbance due to cold water flow rate and temperature are not considerable.
 The orifice plate (FE091) is used to measure the flow rate of water, which is our
manipulated variable, and acting as the secondary loop in cascade control for previous
control of water level in open tank. This secondary loop (controlling flow rate) is fast
acting as compared to the primary loop (controlling water level).
 Solenoid valves and the hand valves are used to create step disturbances in the process
manually.

Major Control Loop Elements

1. Open type tank
2. Solenoid valve
3. Continuous valve
4. Orifice type flow meter
5. Level transmitter
6. Ball (manual) valve
 PLC HARDWARE
An electronic Programmable Logic Control (PLC) is an industrial device which accepts inputs
(digital/analog) from field,executes the logic so programmed in its memory and gives output to the
field for protection,control and safety of factor.The output signal may be given to relays,solenoid
valves,contactors for motors/drives.push button indicators etc.
 TECHNICAL SPECIFICATIONS:

Solenoid Valve
Model No 9230D254
Pipe size 1”
Normal working pressure 0 to 4 bar
Operating voltage 110 V
Coil insulation Ambient up to 75 deg C
Insulation class F(150 deg C)
Material body BR
Material seat BN

Flow Control Valve

Make Valtek
Actuator Diaphragm Actuator
Type Mark one
Body material Carbon steel
Body size 0.75”
Flow character Linear
Trim 0.72
Packing Teflon v ring
Inlet pressure 11 bar
Inlet temperature 80 deg c
Action Air to Open, Air to Close
Input signal Air at 3-15 psi
Air supply 15 psi

I/P Converter
Input 4-20mA
Output 3-15 psi
Pressure 0.2-1 kg/sq cm
Linearity 0.50%
Sensibility 0.10%
Power Supply 110/220V,+/-10%,50Hz AC

Pump 1:

Input 4-20mA
Output 3-15psi
Pressure 0.2-1kg/sq cm
Linearity 0.50%
Sensitivity 0.10%
 Power Supply 110/220V,+/-10%,50Hz Ac

LT 071 Level Transmitter

Make Encardio
Model EDPT-12
Range 0-750mm WC to 0-3750mm
Output 4-20mA DC
Power Supply 12-45V DC
Load Limitation 600 to 1650 Ohms for 24 to 45 V DC
Temperature Limits Operation: -40 to 90 0C
Sensor: -40 to 90 0C
EMI/RFI 20 to 500MHz,upto 10 V/m
Line Pressure 10Kg/cm2
Turn On Time 5s
Temperature Effect 2% of Span/500C
Sensitivity 1% of Span/500C

Magnetic Flow Meter:

Make KROHNE MARSHEL K 300

Accuracy Between 20-100% flow +/- 1% of measured
value
0-20% +/- 0.2 of full scale
Electrical Conductivity >=20 micro sec/cm
Temperature of Liquid Max 800C
Measuring Range 0.3 to 11 m/s
Signal O/P 0-20mA,4-20mA,0-16mA
Time Constant 3.5s
Reproducibility +/- 0.02% of full scale range
Power Consumption <20VA

DI 810 Digital Module Specifications:

Feature DI 810
Digital Input Module.
Number of channels 16(2*8) current sinking
Rated Voltage 24V DC
Input Voltage Range “1” 15 to 30 V
Input Voltage Range”0” -30 to +5V
Nominal Channel Input Current 6mA,24 V DC
Input Impedance 3.5 K Ohm
Maximum Field Cable Length 600 m
Current Consumption 50mA
Power Dissipation 1.8W
Maximum Ambient Temperature 55/400C
Isolation Groupwise isolated from ground(RIV=50V)
Module Terminations Unit TU810,TU812,TU814,TU830,TU838
MTU Keying Code AA
DO820 Digita Output Module Specifications:

Feature DO820
Digital Output Module
Number of channels 8
Type of output Relay(NO)
Voltage Range 5-250 V AC/DC
Load Current Maximum 3A
Load Current Minimum 5 mA
Max. Make Current 30 A, 200 ms
Max. Break Power Ac. 720 VA @ Power Factor>0.4, DC 40W
Max. field Cable Length 600 m
Module Termination Units TU 811, TU 831, TU 836, TU 837
MTU Keying Code AD
 LABVIEW DSC
OVERVIEW LVDSC
LVDSC: LabVIEW Data and Supervisory Control

The DSC Module extends the LabVIEW graphics development environment with additional
functionality for the rapid development of distributed measurement, control and high-channel-
monitoring application.

The DSC Module also enhances the LabVIEW shared variable. Use the shared variable to access and
pass data among several Vis in a LabVIEW project or access a network. A shared variable can
represent a value or an I/O point. With DSC module, you can log data automatically; add alarming,
scaling and security to the shared variable; and configure the shared variable programmatically. The
DSC module includes the following components:

 Functions and Viz palettes: The DSC module installs the following palettes: Alarms
and Events, Engine Control, Historical, Security and Shared variables. The DSC Module
also includes the Historical Trend Express VI and the Real Time Trend Express VI.
 DSC Module Controls Palettes: The DSC Module installs the following controls palettes
to help you build use interfaces that resemble a plant or system and to view real-time data
from the plant or system: 2D Controls, 3D Controls, Alarm Controls, Trend Controls and
Vessels. The DSC Module also includes the Historical Trend Control and Real-Time Trend
Control.
 Citadel Database: The DSC module logs shared variable data to the Citadel database. The
Citadel database stores Historical data, Alarms and Events. You can access and view Citadel
data using the Historical Data Viewer and using the Historical Vis.
 Historical Data Viewer: Use the Historical Data Viewer to view data stored in the Citadel
database. Select Tools >>DSC Module View Historical Data to launch the Measurements and
Automation Explorer (MAX). Expand the Historical Data category to select a database that
appears under Citadel 5 Universe. You can use the Call HDV VI to launch the Historical Data
Viewer programmatically.
 Shared Variable Monitor: Use the Shared Variable Monitor to view the current value of a
shared variable and its status and its alarm state. Select Tools>>DSC Module>>Monitor
variable to launch the Shared Variable Monitor.

The DSC Module also provides tools for graphing historical or real-time trend, enhancing the
security of front panels, and writing custom I/O servers. You can read or write to OLE for process
control (OPC) connections, programmable logic controllers (PLC), or custom I/O servers that you
write. The DSC Module provides solutions for supervisory control of a wide variety of distributed
systems using graphical LabVIEW programming.

An I/O server is an application that communicates with and manages I/O devices such as PLC’s
remote I/O devices, remote Shared Variable Engines and Data Acquisition (DAQ) plug-in
devices. The servers read selected input items and write to them on demand. The DSC module can
be connected to any OPC-compliant server and many third-party device servers. We can also
creates custom I/O servers. The periodic I/O server will run as a service and publish NI-
Publish_subscribe Protocol (NI-PSP) data items to the network.