P6

TEMPERATURE CONTROL

TEMPERATUR CONTROL

Description of the experimental set-up:

Temperature control trainer is designed for understanding the basic temperature control
principles. The process setup consists of heating tank fitted with SSR controlled heater
for on-line heating of the water. The flow of water can be manipulated and measured by
rotameter. Temperature sensor (RTD) is used for temperature sensing. The process
parameter (Temperature) is controlled by microprocessor based digital indicating
controller which manipulates heat input to the process. These units along with necessary
piping and fitting are mounted on support frame designed for tabletop mounting. The
controller can be connected to computer through USB port for monitoring the process in
SCADA mode.
Solid State Relay

Electric Supply
Rotameter Set Point
Temperature
Controller

Temperature
Sensor

Water
supply

Drain
Heater
Heating Tank
Theory:
In automatic controlled process the parameter to be controlled is measured and compared
with the set point by process controller. The difference between the measured signal and
the set point is error. The controller performs on-line calculations based on error and
other setting parameters and generates an output signal. The output signal drives the final
control elements like control valve or a damper to control the process to the set point.
On-Off Controller
A special case of proportional control is On-Off control. If the proportional band of the
controller is made very low (=0) the controller out put will move from one extreme
position to other for slight deviation of process value from the set point. This very
sensitive action is called On-Off control because final control element is either open (On)
or close (Off) i.e. operates like a switch. These are the simplest controllers. These
controllers incorporate a dead band to keep the output from cycling rapidly between on
and off. The controller will not turn on or off until the error signal moves Process
controllers out of the dead band. The process variable controlled by an on/off controller
always cycles back and forth about the set point as shown in the fig. Dark line and dotted
line shows process parameter and reference values respectively. Hysteresis is a value set
in the vicinity of on-off operating point. Upper hysteresis is value or band in which
process value is allowed to operate above the set point and lower hysteresis is value or
band in which process value is allowed to operate below the set point.
Proportional (P) controllers
In proportional controller the control algorithm generates a linear control output
proportional to deviation. In proportional action the amount of change in the measured
value (or deviation) is expressed in percent of span that is required to cause the control
output to change from 0 to 100 % is called the proportional band.
The controller output is given by:
100
OP  b  e
PB
Where, OP is the output, PB is proportional band in %, b is the bias value, and e is the
error signal. If there is no biasing, output OP will become zero when error is zero. Hence
bias value decides the value of output when error is zero. The proportional controllers

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usually show some difference between the set point and process variable called offset.
The offset can be reduced by decreasing proportional band or by readjusting the bias.
With decrease in proportional band the process becomes oscillatory. There are two types
of controller actions:
1) Increase-increase in which output increases as measurement increases. (error e =
measurement – set point)
2) Increase-decrease in which output decreases as measurement increases. (error e = set
point –measurement)
Proportional- Integral (PI) controllers
The offset in proportional controller can be overcome by adding integral action. The
control algorithm that applies changes in output as long as deviation exits, so as to bring
the deviation to zero, is called integral action. Output of proportional-Integral controllers
is given by:
100 1
OP  b 
PB
(e 
Ti  edt )
Where OP is the output, b is the bias, PB is the proportional band in %, e is the error
signal, Ti is integral time; this is the time required to repeat proportional action.

Proportional-Derivative (PD) controller

This mode of control is described by the relationship
100 de
OP  b  (e  Td )
PB dt
Where OP is the output, b is the bias, PB is the proportional band in %, e is the error
signal, Td is derivative time. Larger the derivative time larger is the action. Smaller is the
proportional band the larger is the derivative action. In order to achieve faster response
and more stable operation in slow processes derivative action is added to apply an output
component proportional to the rate of change of input (error). Derivative action is used
with P action or PI action.

Proportional–Integral–Derivative (PID) controllers

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PID controllers are used for controlling almost all process variables like temperature,
flow, level, pressure etc. in a continuous or batch process. The output of a PID controller
is given by:
100 1 de
OP  b 
PB
(e 
Ti  edt  T
d
dt
)

Where OP is the output, b is the bias, PB is the proportional band in %, e is the error
signal, Ti is the integral time and Td is derivative time. Selection of proportional band,
integral time and derivative time to achieve desired process response to load changes is
called tuning of controller.

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 Experiment - A

Aim of the experiment: Study of open loop response (Manual control)

Experimental procedure
1. Start water supply to the heater by opening the valve in the supply line
2. Open the rotameter valve and circulate the water. Adjust water flow rate to 40
LPH.
3. Switch on the supply for both connection and switch on “Mains”.
4. Set the Digital indicating controller to auto mode by pressing A/M key.
5. Initialize Modbus communication on the computer i.e.Start| All programs |
Wonderware FactorySite | IO Servers | Modicon MODBUS.
6. Execute Programs | Wonderware | InTouch for Temperature control. Select All in
Windows to open and Click “Runtime”.
7. Select open loop Experiment (click on “Change Expt.” Button, click on
“Change”, Click on “Open Loop” button.)
8. Decrease the controller output to 0%. Note down steady state process value.
9. Apply the step change by 10% to controller output and wait for the temperature to
reach the steady state value. Note down the process value.
10. Repeat the above step until the controller output reaches to maximum i.e. 100%
and for each change, note steady state process value.
Observation
Table1:
Controller out put in % Process value in 0C
0
10
20
30
40
50
60
70
80
90
100

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 Experiment - B
Aim of the experiment: Study of on/off controller
Experimental procedure
1. Follow steps 1 to 6 from experiment 1
2. Select On-Off Mode Experiment (click on “Change Expt.” Button, click on
“Change”, Click on “On-Off Mode” button.).
3. Change Hystresis value to 1% (Range 0.1-10%).
4. Change the values of the set point and observe the On-Off control operation.
Observations
Observe that if process value exceeds the set point and increases than the value of (0.5x
Hysteresis), controller switches off the SSR and if process value decreases below the set
point by (0.5 x Hysteresis), SSR switches on i.e. controller operates like On/Off switch.

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 Experiment - C
Aim of the experiment: Study of Proportional (P) controller
Experimental procedure:
1. Follow steps 1 to 6 from experiment 1
2. Select P Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “P Mode” button.)
3. Keep the set point to 40%. Change output mode to Manual.
4. Adjust output value so as to match the process value with set point and apply this
output value as bias value to the controller.
5. Adjust the proportional band to 50%.
6. Switch the controller to Auto mode.
7. Apply step change to set point, step change should be of 2 to 3 % and observe the
response.
8. Switch the controller to Manual mode. Decrease proportional band to half of the
previous value & then shift controller to Auto mode. With each decrease, obtain a
new response of the step change. Ensure that the set point changes are around the
same operating point (@ 2-3% only).
9. Using trial and error approach, find a value of proportional band so that the response
to a step change has at most one overshoot and one undershoot.
10. Set the controller to the settings obtained in the above step and wait for the system to
reach at steady state.
Observation
 Observe the variation in steady state error with the variation in proportional band.
 Observe the effect of very low proportional band values.
 Observe the response of the system to load change. Load change can be given by
slightly varying the inlet flow rate.

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 Experiment - D
Aim of the experiment: Study of Proportional Integral (PI) controller

Experimental procedure
1. Follow steps 1 to 6 from experiment 1
2. Select PI Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “PI Mode” button.).
3. Adjust the process value by changing the output of controller in manual mode to a
particular temperature (set point =40%).
4. Set the proportional band estimated from Proportional control (from previous
experiment).
5. Start with derivative time=0 and integral time=6000 sec., which will cut off the
derivative action and widen the effect of integral action.
6. Set the set point to desired temperature (@40%). Allow the process to reach at
steady state. Record the steady state error.
7. Switch on the controller to manual mode. Reduce the integral time to half of the
previous value. Switch to Auto mode and apply step change to the set point by 2 to
3%. Note the response of the system.
8. Using trial and error, find out an integral time, which gives satisfactory response to
the step change in set point.
Observations
Observe the effect of reducing integral time on offset and on the response of the process.

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 Experiment - E
Aim of the experiment: Study of Proportional Derivative (PD) controller
Experimental procedure:
1. Follow steps 1 to 6 from experiement 1.
2. Select PD Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “PD Mode” button.).
3. Select PD controller. Set the proportional band estimated from Proportional control
(P only).
4. Start with integral time=0 and derivative time=6000 sec., which will cut off the
integral action and widen the effect of derivative action.
5. Set the set point to desired temperature (@ 40%). Allow the process to reach at
steady state. Note the response of the system.
6. Switch on the controller to manual mode. Increase the derivative time by 1 sec.
7. Switch to Auto mode and apply step change to the set point by 2 to 3%. Note the
response of the system.
8. Increase the derivative time gradually and observe the process response for step
change.
Observation:
Observe the effect of increasing derivative time. Also note that the process may show
offset as effect of integral action is cut off.

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 Experiment - F
Aim of the experiment: Study of Proportional Integral Derivative (PID) controller
Experimental procedure:
1. Follow steps 1 to 6 from experiment 1
2. Select PID Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “PID Mode” button.)
3. Switch the controller to manual mode.
4. Change the proportional band to the value that estimated in proportional controller.
Set integral time and derivative time based on the responses in previous experiments.
5. Change the controller to Auto mode. Apply step change by 2 to 3% to the set point
and observe the response of the process.
6. Change the proportional band, integral time, derivative time and observe the
response of the process for step change for each change in setting.
Observation
Compare the steady state response of the PID controller with P, PI and PD controller
obtained in the previous experiments.