DESCRIPTION
The Temperature control trainer is designed for teaching the basic temperature control principles
study in chemical and instrumentation engineering. For ease of understanding, the product is
described with its major components.
INTRODUCTION
Temperature control loops are usually moderately slow because of the sensor lags and the
process heat transfer lags. PID controllers are often used. Proportional band setting are fairly
low, depending on temperature transmitter spans and control valve sizes. The reset time is of the
same order as the process time constant; i.e., the faster the process, smaller I can be set.
Derivative time is set something like one-fourth the process time constant, depending on noise in
the transmitter signal.
TT Temperature Transmitter
THY Thyrister Drive fie Heater
F Rotameter
SP Set Point
TIC Temperature Indicator Controller
TEMPERATURE CONTROL TRAINER
BLOCK DIAGRAM
For computational purposes, it is convenient to represent the control system shown in Figure 1
by means of the block diagram shown in Figure 2. Such a diagram makes it much easier to
visualize the relationships among the various signals.
Set Point : The set point is synonym for the desired value of the controlled variable.
Load : The load refers to a change in any variable that may cause the controlled variable
of the process to change.
In the example, the inlet flow of water is a load variable.
The control system shown in Figure 2 is called a closed loop system or a feed back system
because the measured value of the controlled variable is returned to of “fed back” to a device
called the comparator. In the comparator, the controlled variable is compared with the desired
value or set point. If there is any difference between the measured variable and the set point, an
error is generated; this error enters a controller, which in turn adjusts the final control element in
order to return the controlled variable to the set point.
PID Controller
Load
Water Inlet Flow Controlled
Comparator Variable, T
Measuring Element
(Temperature Sensor
& Transmitter)
Measured
Variable, Tm
Figure 1 shows that a temperature sensor is used to measure the temperature of water
Inlet to the Heat Exchanger, According to temperature give the output signal to the Heater
temperature controller, which produces an output in the range of 4-20 mA, which is a linear
function of the input. The output of the transducer enters the Heater temperature controller where
it is compared to the set point to produce an error signal. The controller converts the error to an
output in the range of 4 -20 mA according to the control law (P, PI, PD, PID or On-Off) stored in
the memory of the controller. The output of the controller enters the Thyrister drive, which
produces an output, which is a linear function of the input. Finally, the output of the Thyrister
drive is sent to the heater, which adjusts the flow of heat to the water. The external power of 3
Phase is required for Heater and Controller.
Figure 1 & 2 shows that another temperature sensor is used to measure the temperature of
water outlet of the Heat Exchanger, According to temperature give the output signal to the
temperature controller, which produces an output in the range of 4-20 mA, which is a linear
function of the input. The output of the transducer enters the temperature controller where it is
compared to the set point to produce an error signal. The controller converts the error to an
output in the range of 4 -20 mA according to the control law (P, PI, PD, PID or On-Off) stored in
the memory of the controller. The output of the controller enters the I-P Converter, which
produces an output, which is a linear function of the input. Finally, the output of the I-P
Converter is sent to the Control Valve, which adjusts the flow of cold water.
To see how the components interact with each other, consider the process to be operating
at steady state with the outlet temperature of water from the tank is equal to the set point. If the
inlet flow rate from the tank increases, the following events occur. Immediately the temperature
sensor & temperature transmitter detects a decrease in the temperature of the water in the tank
and produces a change in the signal to the controller. As soon as the controller detects decrease in
the temperature, relative to the set point, the controller output increases according to the control
action chosen. The increase in signal to the converter causes the output from the converter to
increase and increase the flow of heat to the water. The increased flow of heat will eventually
increase the temperature of the water move it towards the set point. From this quantitative
description, we see that the flow of signals from one component to the next is such that the
temperature of water should return to the set point. In a well-tuned control system, the response
of the temperature will oscillate around the set point before coming to steady state.
STARTUP PROCEDURE:
Connect the air compressor line to the experimental control trainer. Shut off the air
supply valve to the trainer.
Start the air compressor by providing 1 – phase electric supply to the compressor.
Close the air discharge valve while the compressor is started. Fill the air inside the
compressor cylinder.
Fill the water supply tank at the bottom of the trainer full with the fresh clean water.
Make sure that drain valve is closed.
After pressure of air inside compressor has build up sufficient (around 6-7 kg/cm 2)
open the discharge valve of compressor and supply valve to the trainer.
Apply 20-30 psi (or 1.4 kg/cm 2) to the E/P Converter by regulating pressure from air
filter cum regulator. Lock the regulator by pressing ring of it.
Give supply of 1 Phase to the trainer by the plugs provided. Switch ON Power
supply switch.
As water starts coming out from the tank by passing through the heater tanks, shell
side of exchanger to the drain, adjust the set point of the hot water by heater
controller. Initially feed set point of it to nearly 50 0C by Heater Controller. (Remove
any air from the system by opening the gate valve of the heat exchanger shell side)
Switch on the pump by the push button provided with indicating lamp. Make sure that
bypass valve is fully open.
Now adjust the set point of the PID Controller to the 45 0C and also make necessary
P, I, D settings as per shown in the manual of PID Controller. Now close the bypass
valve slightly to supply cold water to the tube side of the exchanger through control
valve and Rotameter. Make sure that the set point of PID Controller should be 5 – 10
0
C less than the heater controller.
Make sure that needle valve of Rotameter is fully open during the whole operation.
SHUTDOWN PROCEDURE:
Close the air supply to the E/P Converter/control valve by closing the regulator
provided.
Close the gate valve located at the inlet pipe line of Heater.
Switch off the air compressor and shut off the discharge valve of it. Drain the filled
air from the cylinder of compressor by opening the drain coke at the bottom of the
compressor. Close the air supply valve to the control trainer.
Adjust the set point of the PID Controller to a lower value (around 20 0C).
Open the drain valve of Heater tank and drain the water inside the heater tank.
Stop communication from the computer and shut down it.
Switch off power supply to the trainer.
PRECAUTIONS:
For proper operation read the instruction provided and then follows it step by step.
Do not apply very high set point to the PID Controller (not above 70 0C) as it may
damage the heat exchanger / heater tank.
Do not run heater for a longer time.
Always run the heater when the flow of water is continuous through the heater tank.
Do not apply higher pressure to E/P Converter (greater than 1.4 kg/cm 2) as it may
damage it. Also the lesser pressure (less than 1.4 kg/cm 2) may not give accurate
functioning of it.
Use fresh and clean water always in the water supply tanks.
Remove all water from the tank after experiment is over.
Clean pump regularly.
Do not alter the wiring of the instrument.
TEMPERATURE CONTROL TRAINER
Do not alter or modify any component of the trainer.
Carefully read the manuals of each component fitted in the trainer and understand the
product working.
If possible put trainer in Air-conditioned room. The computer should not be farther
than the 5 meter from the trainer.
Do not put instrument idle for a longer time. Run it once in a week.
Give routine maintenance to it.
Remove dust periodically from the trainer.
Any problem encountered during the use of the setup, first refer instruction manual. If
the problem persists, contact us immediately. We provide support for your specific
questions or any up gradation.
ROUTINE MAINTENANCE:
Replace water in case suspended particles are observed. (It is advised to use clean
distilled water to improve the reliability of the product. Any suspended particles in water
may clog the pump strainer causing no discharge through the pump.)
Check the working of control panel for process parameter display.
Disconnect the electric supply to the control panel when not in use.
Clean pump strainer in sequence as mentioned below:
Remove the pump by lifting the support of the pump from the tank.
Gently remove the strainer at the suction of the pump by rotating it anti
clockwise.
Remove the mesh from the strainer. Clean and wash the mesh thoroughly.
Fix the mesh back to its location properly.
Replace the pump in tank.
Refer the pump manual for detail of troubleshooting.
Remove any excess of water from the heater tank.
Drain out excess water from the shell and tube heat exchanger.
Do not start heater without supply of water to the tank.
SR.
PART NAME PROBLEM CORRECTIVE MEASURES
NO.
No discharge through Ensure sufficient water in
1 Supply tank
pump. tank.
If Indication deviates above
+ / - 3 % from actual flow,
calibrate the Controller as
Wrong display of the mentioned in controller
2 PID Controller
Control value. manual.
PID Indicates open, when the
RTD Sensor is not properly
connected.
Check sufficient water in
supply tank.
No discharge through
3 Pump Clean pump strainer as
Pump.
mentioned In routine
maintenance.
No flow through Ensure Rotameter float is not
4 Rotameter
Rotameter clogged.
Ensure pneumatic pressure
from I / P Converter.
Control valve not Check the leakage from the
5 Control valve
operating. valve Diaphragm.
Check the transmitter
connection to PID controller.
PID CONTROLLER:
Procedure for entering the values of P,I and D : To enter the values of P, I and D into the
PID controller press Menu button for some time, then after some time SET 1
will open, now scroll down to SET 4 . Now press up/down key to see the parameter P1,I
and D.
If you want to change the valve position by manually, then change md parameter to man
from run.
Proportional
All three components of the PID algorithm are driven by the difference
between the process value (i.e. the current speed) and the reference point
(i.e. the target speed.) We will call this difference (of error) for one particular time step . For
that same time step, we call the process value and the reference point .
The output value (i.e. the accelerator position) is called . The proportional component simply
calculates based on the size of the error term by simply multiplying it by a constant, .
For simple situations, this all by itself can be a very effect control algorithm. Typically this works
For
going to be bank angle, the reference point is going to be zero (zero bank
angle means the wings are level.) Assume a well trimmed aircraft with
bank. A proportional only control would set the aileron deflection inversely
proportional to the bank angle. As the bank angle gets closer to zero, the
stable controller.
Integral
Unfortunately life is often more complicated than we'd like, and even in the
case of a simple wing leveler, you encounter situations where the aircraft
isn't perfectly trim and zero aileron deflection does not always equal zero
deflection needed to keep the wing level can vary with speed. In these
cases, a proportional only controller will stabilize out quickly, but will
stabilize to the wrong value. We need a way to drive the error in the
PID algorithm. Remember back to your calculus days, integral refers to the
area under a curve. If you have a function, the integral of that function
produces a second function which tells you the area under curve of the first
function. Fortunately we usually don't have a formula for the first function
car.) That means we can't integrate this function directly and we are
approach to approximate the error under the process value curve. At each
time step we know which is the difference between the process value
TEMPERATURE CONTROL TRAINER
and the reference point. If we multiply this distance times (the time step)
we get an area which approximates the error under the curve just for his
time step. If we add these areas up over time, we get a very reasonable
approximation of the area under the curve. Essentially what this does is
that the longer time passes with us not at our target value, the larger the
sum of the (error dt)'s becomes over time. If we use this sum to push our
output value (i.e. our accelerator position) then the longer we don't quite hit
our target speed, the further the system pushes the accelerator pedal.
Over time, the integral component compensates for the error in the
speed.
Derivative
Hopefully someone else can chip in and add more explanation to this
implies the rate of change of the function output. If you know the function,
you can take the derivative of that function to produce a second function.
For any point in time, the derivative function will tell you the rate of change
(or slope) of the first function. Conceptually, this makes sense in the
context of a controller. How quickly we are closing on our target value (i.e.
the rate of change from each time step to the next) is an important piece of
information that can help us build a more stable system that more quickly
achieves the target value. For a car cruise control, we are measuring
out to 82km/hr.) If we build an integral only controller it will quickly hit the
target value, but will overshoot, then overcompensate, and will oscillate
ildly around the target value. It is very unstable. The trick then is to
is equal to what the P component says the output should be plus what the I
component says the output should be plus what the D component says the
output should be. You can assign a weighting value to each component to
increase or decrease it's relative power to influence the final output value.
As you can see, the actual math involved in a PID controller (while rooted
in some deep theory) is actually quite simple to implement. The real trick
for creating a well behaved PID controller and a well behaved autopilot is
PROCEDURE:
OBSERVATIONS:
TEMPERATURE CONTROL TRAINER
Controller
Sr. Temperature
Output
No. Deg. C
(%)
1 10
2 20
3 30
4 40
5 50
6 60
7 70
8 80
9 90
10 100
CALCULATIONS:
From the above data calculate the output required for maintaining the Temperature in the tank at
the desired value with fixed disturbance.
AIM : To Study the Closed Loop (Auto Mode) Control (On/ Off Control).
PROCEDURE:
OBSERVATIONS:
Observe that if the process variable (temperature) value exceeds the set point beyond the
difference value controller totally shutoff the control valve and if process variable (temperature)
value decreases than the control valve is opened fully i.e. process is operating as an On-Off
switch.
AIM : To Study the Closed Loop (Auto Mode) Control (Proportional Control).
PROCEDURE:
OBSERVATIONS:
Observe that the offset decreases with decrease in the proportional band value.
Observe the effect of load & set point change on the behavior of the system.
AIM : To Study the Closed Loop (Auto Mode) Control (Proportional + Integral Control).
PROCEDURE:
Observe that at any value of proportional band & reset time the value of offset is zero, however
the time required for the same varies as the value changes.
Observe the effect of load & set point change on the behavior of the system.
AIM : To Study the Closed Loop (Auto Mode) Control (Proportional + Derivative
Control).
PROCEDURE:
The value of load change / set point change should be approximately 20% of the range to
obtain proper response otherwise the controller may track to its set point without any
overshoot/ undershoot.
Observe that at any value of proportional & rate time the process variable is not able to reach the
set point value.
Observe the effect of load & set point change on the behavior of the system.
AIM : To Study the Closed Loop (Auto Mode) Control (Proportional + Integral +
Derivative Control).
PROCEDURE:
Observe that at any value of proportional, reset time & rate time the process variable reaches the
set point value.
Observe the effect of load & set point change on the behavior of the system.
As shown above this is the home screen for temperature control trainer. There are two
temperature controllers, p&id, switches for pump1-2, heater in the home screen.
There is a provision for process value, set point,output(%), Alarm high and low. One can also set
proportional constant, integrating time, derivative time manually to check performance of the
different control mechanism i.e. proportional, derivative and integral, p-i, p-d, pid control.
In manual mode, one can directly set manual o/p in terms of percentage. Above things are
applicable for temperature controller 2.
There is a provision for switches for simulation of pumps and heater.
P&ID screen shows the schematic as per mechanical scheme. As shown in the above figure shell
contain cold water and tube contain hot water in the heat exchanger. Heater and rotameter with
bar graph is shown in the p&id as per the percentage output of the thyristor and control valve
respectively.
This is panel screen. There are two controllers TIC1 and TIC2. This shows process value in
green colour, set point in red colour and output in 4-20 mA meter. There is provision to simulate
pump1,pump2 and heater.
This report screen shows all the parameter for two temperature controllers.
This is tabular screen where bar graph for pv,sp and mv1(op) is shown above.
Trend screen shows there are double trend display. In above portion first group of parameter for
temperature controller 1 and in below portion second set of variables are displayed. Their colours
are shown in the left side. Range is to be set from the right side.