Experiment no 12

FLOW PROCES MODULE

PID CONTROLLER

Evaluation Table:

Organization Analysis
Component Conclusi Tot
and Content of on al
s/
(3) Results (3) (10
Weightag
(4) )
e

Obtained marks

Apparatus:

Objective:
-To verify the operation of a proportional valve for the control of flow.

List of Equipment:

● Digital Multimeter
● Set of Leads

1
 ● Flow Process Rig

Working Principle:

A proportional controller adjusts the output in direct proportion to the error, while a
proportional-integral (PI) controller also considers the accumulated error over time to
eliminate steady-state error. A proportional-derivative (PD) controller, on the other
hand, responds to the rate of change of the error to minimize overshoot and oscillations.
By varying the gain of each type of controller, the system's response to changes in the
input signal can be monitored

Theoretical Background:

What is Flow?

In the context of fluid dynamics and engineering, "flow" refers to the movement of a
fluid, which can be a gas or a liquid, through a conduit, pipe, or any other channel.

Importance of Flow Measurement

Accurate measurement and control of flow are essential in many industries to ensure
the proper functioning of systems and processes.

What are Flow Controllers?

Flow controllers are devices or mechanisms used in various engineering and industrial applications
to manage, regulate, or control the flow of liquids, gases, or other substances through a system. The
primary purpose of flow control is to ensure that the flow rate of a substance is consistent and
within desired parameters. This is crucial for a variety of reasons, depending on the specific
application.

Importance of Flow Control:

Flow control is essential in many processes and systems for several reasons, including safety,
efficiency, and performance optimization. Here are the key aspects of flow controllers and their
importance:

• Regulation of Flow Rate: Flow controllers are designed to control the rate of
flow of a fluid, which can be critical in many applications. This control can
involve maintaining a constant flow rate, varying the flow rate as needed, or

2
 shutting off the flow completely when necessary.
• Precise Control: Flow controllers are often used when precise control of flow
rate is required. For example, in chemical manufacturing, pharmaceutical
production, or semiconductor fabrication, even small variations in flow rate can
lead to product defects or safety issues.
• Safety: In various industrial processes, controlling the flow of potentially
hazardous materials is vital for safety. Flow controllers can prevent overflows,
pressure surges, or excessive flow that may result in accidents or damage to
equipment.
• Efficiency: Efficient use of resources is a key consideration in many
applications. By controlling flow rates, flow controllers help minimize waste
and energy consumption. For example, in heating, ventilation, and air
conditioning (HVAC) systems, flow controllers can optimize the use of energy
by adjusting the flow of air or water to meet the current requirements.
• Consistency: Flow control ensures that a consistent and desired flow rate is
maintained, which is crucial in applications like chemical dosing, water
treatment, and food and beverage production.
• Process Optimization: Many industrial processes depend on precise flow
control to optimize production efficiency and quality. For instance, in food
processing, the flow rate of ingredients and temperature control are essential to
maintain product quality and consistency.
• Fluid Distribution: In distribution systems, such as irrigation or plumbing,
flow controllers help distribute liquids or gases evenly to different parts of a
system, ensuring that each area receives the appropriate amount of the fluid.
• Pressure Control: Flow controllers often work in conjunction with pressure
control devices to maintain desired pressure levels in a system, which is
essential for preventing equipment damage and ensuring proper operation.
What is a Control System?

A control system is an integrated set of components or devices that work together to

maintain or modify the behaviour of a system or process. Control systems are designed
to achieve specific objectives by continuously adjusting the system's inputs or outputs
based on feedback information. These systems are indispensable in industries ranging
from manufacturing and transportation to healthcare and aerospace.

3
 Importance of Control

Control systems serve several critical purposes:

● Stability: Control systems help maintain system stability, ensuring that

processes operate within acceptable bounds, preventing instability or
catastrophic failures.
● Precision: They enable precise regulation of processes, leading to higher
product quality and consistency.
● Efficiency: Control systems optimize resource usage, leading to energy
savings and cost reduction.
● Safety: They enhance safety by monitoring and responding to unsafe
conditions, reducing risks to personnel and equipment.

Types of Control Systems

Control systems can be categorized into several types based on their characteristics and control
strategies:

Open-Loop Control Systems

Open-loop control systems, also known as non-feedback or feedforward control systems, are a
fundamental type of control system. Open-loop control systems provide a constant input to the
system without considering the actual system output. These systems are simple but lack the
ability to respond to changes or disturbances in the system.. In open-loop control, the control
action is determined solely by the input command or setpoint, without considering the actual
system output or the system's response to the control action. This control strategy relies on the
assumption that the relationship between the input and the desired output is well-defined and
predictable.

Figure 2 Open Loop Control System

4
Closed-Loop (Feedback) Control Systems

Closed-loop control systems, also known as feedback control systems, incorporate a feedback
loop that continuously compares the system's output to a reference value (setpoint). Based on
this comparison, a controller adjusts the system's inputs to maintain the output close to the
desired setpoint. Closed-loop systems are widely used for their ability to handle disturbances
and maintain system stability.

Figure 3 Closed Loop Control System

Proportional-Integral-Derivative (PID) Control

PID control is a common control strategy used in closed-loop systems. It combines

proportional, integral, and derivative control actions to achieve precise and stable control. The
proportional term corrects the current error, the integral term eliminates past errors, and the
derivative term anticipates future errors, resulting in a well-balanced control response. In PID
control, the three control actions work together to provide precise and stable control in a wide
range of applications.

Proportional Control (P-Controller)

Introduction

Proportional Control, often abbreviated as P-Controller, is a fundamental building block of

control systems engineering. It forms the basis for more complex control strategies and is
essential in the regulation of various processes.

Operating Principle

5
The P-Controller operates on the principle of adjusting the control input in direct proportion to
the current error, which is the deviation between the desired setpoint and the actual process
variable. The control action (u) at any given time 't' is calculated using the proportional gain
(Kp):

u(t)=Kp∗e(t)

Where:

u(t) is the control action at time 't'.

Kp is the proportional gain, a constant that governs the controller's sensitivity to the error.

e(t) is the error at time 't'.

Advantages

• Simplicity: P-Controllers are straightforward to understand and implement. They serve

as a foundation for control system design.
• Quick Response: P-Controllers are highly responsive to changes in the error, making
them suitable for systems requiring rapid adjustments.

Limitations

• Steady-State Error: P-Controllers cannot entirely eliminate steady-state errors,

resulting in a residual error even after system stabilization.
• Potential for Oscillations: High proportional gain (Kp) values can lead to oscillations
and instability, necessitating careful tuning.

Proportional Integral Control (PI-Controller)

Introduction

The Proportional Integral Controller, or PI-Controller, builds upon the P-Controller's

framework by incorporating an integral action. The goal is to eliminate the steady-state errors
that persist in P-Controllers.

Operating Principle

6
In a PI-Controller, the control action (u) at any time 't' is a combination of proportional and
integral actions:

u(t)=Kp∗e(t)+Ki∗∫e(τ)dτ

Where:

u(t) is the control action at time 't'.

Kp is the proportional gain.

Ki is the integral gain, a constant controlling the controller's sensitivity to the cumulative error.

e(t) is the error at time 't'.

∫e(τ) dτ signifies the integral of the error over time, indicating the accumulation of past errors.

Advantages

• Steady-State Error Elimination: The integral action ensures that steady-state errors
are driven to zero, enhancing system accuracy.
• Improved Stability: PI-Controllers offer superior stability when compared to P-I
Controllers.

Limitations

• Slower Response: The integral action may slow the response time in certain systems,
which can be undesirable in applications requiring rapid adjustments.
• Potential for Oscillations: High integral gain (Ki) values can lead to oscillatory
behavior, necessitating precise tuning.

Proportional Derivative Control (PD-Controller)

Introduction

The Proportional Derivative Controller, or PD-Controller, enhances control by introducing a

derivative action, which considers the rate of change of the error. This action can improve the
transient response of a system.

Operating Principle

7
In a PD-Controller, the control action (u) at any time 't' combines both proportional and
derivative actions:

u(t)=Kp∗e(t)+Kd∗ dt de(t)

Where:

u(t) is the control action at time 't'.

Kp is the proportional gain.

Kd is the derivative gain, a constant that controls the sensitivity to the rate of change of the
error.

e(t) is the error at time 't'.

{de(t)}{dt} represents the rate of change of the error with respect to time.

Advantages

• Improved Transient Response: The derivative action helps reduce overshoot and
enhance the system's transient response, making it valuable in applications where
overshoot minimization is critical.
• Damping Oscillations: PD-Controllers can be used to dampen oscillations in a system,
improving overall stability.

Limitations

• Amplification of Noise: PD-Controllers may amplify high-frequency noise, requiring

additional filtering in some cases.
• Ineffectiveness for Steady-State Error: PD-Controllers alone cannot eliminate
steadystate errors, and they are often used in combination with PI-Controllers or PID-
Controllers for this purpose.

8
All this is summarized below

Control Action Description

Proportional control, often referred to as P-control, adjusts the system's input in direct
proportion to the current error, which is the difference between the desired setpoint and
the actual system output. The control output is calculated as Pout=Kp ⋅e(t), where Kp is
Proportional Control
the proportional gain, and e(t) is the error at time t. This control action corrects the
current error but does not consider past or future errors, potentially leading to
oscillations and steady-state errors.

Integral control, also known as I-control, addresses steady-state errors by accumulating

the past errors over time. It continuously adjusts the system input based on the integral
(sum) of all previous errors. The control output is given by Iout =Ki ⋅∫e(t)dt, where Ki is
Integral Control
the integral gain and ∫e(t)dt represents the integral of the error with respect to time.
Integral control eliminates steady-state errors and provides improved system stability.
However, it can lead to control windup if not implemented properly.

Derivative control, or D-control, anticipates future errors by considering the rate of

change (derivative) of the error. It adjusts the system input based on the rate of change
of the error with respect to time. The control output is determined as Dout =Kd ⋅dtde(t) ,
Derivative Control
where Kd is the derivative gain, and dtde(t) represents the time derivative of the error.
Derivative control helps dampen oscillations and improve system response. However,
it can amplify noise if the error signal is noisy.

Gain in Control Systems

Gain, in the context of control systems, refers to a numerical value that multiplies the error
signal to determine the control action. It plays a pivotal role in influencing the dynamic
response and performance of the controlled system.

Types of Gain

Proportional Gain (Kp)

Proportional gain, often denoted as Kp, determines the strength of the proportional control
action in a system. It represents the proportionality between the error and the control action.
Higher Kp values result in a stronger response to errors, leading to faster system adjustments.

9
Integral Gain (Ki)

Integral gain, represented as Ki, contributes to eliminating steady-state errors in a control

system. It accumulates the past error values and produces a control action based on the integral
of error over time. A higher Ki value increases the system's ability to drive the error to zero
over time, enhancing steady-state accuracy.

Derivative Gain (Kd)

Derivative gain, known as Kd, introduces a damping effect to the control system. It takes into
account the rate of change of the error, mitigating overshoot and oscillations. Higher Kd values
lead to stronger damping and can result in a quicker response with reduced oscillations.

Influence of Gain on Dynamic Response

Proportional Gain (Kp)

Higher proportional gain amplifies the control action's response to errors. This leads to a faster
reaction to disturbances and rapid adjustments to reach the setpoint. Lower Kp values result in
a weaker response, potentially causing sluggish or inadequate control, especially in the
presence of disturbances.

Integral Gain (Ki)

A higher integral gain enhances the system's ability to eliminate steadystate errors by gradually
accumulating error over time. However, it can also slow down the system's transient
response.Lower Ki values may result in improved transient response but may not completely
eliminate steady-state errors.

Derivative Gain (Kd)

Increasing the derivative gain introduces stronger damping, reducing overshoot and
oscillations. This results in a faster response with improved stability. Lower Kd values lead to
weaker damping, potentially allowing for more oscillations and overshoot, especially in
systems with high inertia.

Balance and Tuning

10
The choice of gain values, or gain tuning, is a critical aspect of control system design.
Achieving the desired dynamic response requires a balance between proportional, integral, and
derivative gains. An effective control system often involves trial-and-error tuning to optimize
the system's performance while meeting specific control objectives.

The dynamic response of a system is significantly influenced by the choice of gains. Proper
gain tuning is essential to ensure that the control system responds appropriately to disturbances,
settles quickly, and maintains steady-state accuracy. Balancing these factors is a complex and
iterative process, and it requires an understanding of the system's characteristics and control
objectives.

Procedure:

1. Connect through leads bush no 9 of the WATER PUMP DRIVER its adjacent bush and
bush no 10 to the bush adjacent to it.
2. Connect the bush of the SETPOINT 1 to bush no. 8 of the PUMP DRIVER.
3. Press the main switch ON.
4. Connect bush No. 1 of the FLOW SENSOR to its adjacent bush of the relevant interface
and bush no 2 to it’s adjacent bush.
5. Connect, the Bush of SETPOINT 2 to Bush no 4 of the PID controller and Bush no 3
of the flow sensor to the Bush no 3 of the PID controller.
6. Insert one terminal of the digital voltmeter set in DC in the Bush of SETPOINT 2 and
the other one in the earth Bush.
7. Regulate the Proportional control knob at 25%.
8. Connect pin number 11 of the MOTORIZED VALVE DRIVER to its adjacent bush
and pin number 12 to the bush adjacent to it.
9. Connect pin no 5 of the controller to pin no 5 and pin no 8 of PID controller to pin no
8 of the MOTORIZED VALVE DRIVER
10. Starts the pump regulating the voltage on point 1 at 6V.
11. Regulate the voltage on setpoint 2 at 3 V and the motorized valve will start to close to
regulate the flow of the setpoint value before stopping there would be some oscillations.
12. Regulates the voltage on setpoint at 4.5 Volt. The motorized valve will open increasing
the flow.

11
 13. Observe the response, while the flow will stabilize at the new value and write down the
flow value read on the flowmeter.
14. Repeat the previous operations regulating the norm proportional. Firstly at 50%, then
at 75% and eventually 100% and observe what happens. The valves can oscillate
continuously without finding a stability position.
15. For the value, also intermediate which gives the best stability and write it down.
16. Put the off main switch
17. Analyze the result.
18. Repeat the experiment for Proportional Integral and Proportional Derivative control.

Lab Precautions:

● Turn on the main switch after cables have been connected.

● Do not touch the apparatus with wet hands as it might result in electric shock.
● Connect the wires carefully.
● Perform experiment carefully and with responsibility.

Circuit Connections:

Proportional Controller:

12
 Proportional Integral Controller:

Proportional Derivative Controller

Observation and Calculation:

Proportional Controller

Proportional Controller
Flow
Gain

L/min L/min
%
6V 7V
25% 4.7 3.5
50% 4.6 4.5

13
 75% 4.3 4.6
100% 4.2 4.7

Discussion:
In general, increasing the proportional gain will either increase or decrease the flow in the
transducer, depending on the direction of the error. If the actual flow is less than the desired
flow, then increasing the proportional gain will increase the flow in the transducer. This is
because the controller allowing more flow. If the actual flow is more than the desired flow,
then increasing the proportional gain will decrease the flow in the transducer. This is because
the controller will output a smaller signal and allow less flow. However, our results differ from
those suggested by the literature. Our value decreased by increasing gain even though our value
was less than desired. Literature suggests that sometimes at higher gain the controller
overcompensates by reacting too quickly which results in overshoots and the flow settles at a
much lower value than desired.

Conclusion:
Increasing gain should have increased the value of flow however our value decreased with
increasing the value of gain.

Proportional Integral Controller

Proportional Integral
Flow
Gain

L/min L/min

6V 7V
25% 4.3 3.5

14
 50% 4.7 4.4
75% 4.9 4.6
100% 5.2 4.7

Discussion:
In general, increasing the proportional integral gain will either increase or decrease the flow in
the transducer, depending on the direction of the error. If the actual flow is less than the desired
flow, then increasing the proportional gain will increase the flow in the transducer. This is
because the controller allowing more flow. If the actual flow is more than the desired flow,
then increasing the proportional gain will decrease the flow in the transducer. This is because
the controller will output a smaller signal and allow less flow. The resuts of our experiment
were coherent with this theory.

However, one odd behaviour was observed in our system. Increasing the setpoint decreased
the value of flow. This is because the system is overcompensating. If the setpoint is too high,
the controller may react too quickly to changes in the error signal and overshoot the desired
flow. This can cause the flow to oscillate and eventually settle at a lower value.

Conclusion:
Increasing the gain increased the flow. The flow however unexpectedly decreases with
setpoint.

Proportional derivative Controller:

Proportional Derivative
Flow
Gain

% L/min L/min

15
 6V 7V
25% 3.2 3.5
50% 4 4.5
75% 4.1 4.6
100% 4.2 4.7

Discussion:
In general, increasing the proportional derivative gain may increase or decrease the flow. If the
actual flow is less than the desired flow, then increasing the proportional gain will increase the
flow in the transducer. This is because the controller allows more flow. If the actual flow is
more than the desired flow, then increasing the proportional gain will decrease the flow in the
transducer. This is because the controller will output a smaller signal and allow less flow. The
results of our experiment were coherent with this theory. Also increasing the setpoint increases
the flow as expected.

Conclusion:
Increasing the gain increased the flow. The flow increased with setpoint.

References:

• "Principles of Industrial Instrumentation" by D. Patranabis, Publisher:

Prentice-Hall, Year: 1997.
• "Instrumentation and Control Systems" by William Bolton, Publisher:
Newnes, Year: 2006.
• "Flow Measurement: Principles and Methods" by Henry V. Moyer, Publisher:
Wiley, Year: 2015.
• "Process Control: A Practical Approach" by Myke King, Publisher: Wiley, Year:
2014.

16
17