CEM3PRA-Process Control Trainer

Tutorial letter 501/0/2022

Chemical Engineering Technology III

(Practical Guide)

CEMPRA3
(PROCESS CONTROL)

Year Module

Department of Civil and Chemical Engineering

IMPORTANT INFORMATION:

This tutorial letter contains important information about your module.

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 CEM3PRA-Process Control Trainer
Introduction.................................................................................................................................................. 3

A. Process Control Trainer (Flow control-GUNT-RT 624) .................................................................... 4

1. Safety ................................................................................................................................................... 4

2. Device description .............................................................................................................................. 4

3.1 Equipment layout ........................................................................................................................ 5

3.2 Process scheme.......................................................................................................................... 6

3.3 Start-up ........................................................................................................................................ 7

3. Experimental Tests .......................................................................................................................... 7

Experiment1: Response of the control system ................................................................................. 7
Experiment 2: Flow control with a Slow PI-controller ....................................................................... 8

Experiment 3: Fast PI-controller .........................................................................................................10

Experiment 4: PI-controller with improved parameters ........................................................ ..........11

B. Process Control Trainer (Level Control-GUNT-RT 614) .................................................................12

1. Safety
................................................................................................................................
.................12

2. Device description
.............................................................................................................................1
2

2.1 Device layout ............ ................................................................................................................13

2.2 Process scheme.........................................................................................................................14

2.3 Start-up .......................................................................................................................................15

3. Experimental Tests
...........................................................................................................................15

Experiment 1: Step response of the system

...................................................................................15

Experiment 2: P-controller ....................................................................................................................16

Experiment 3: PI-controller ...................................................................................................................17

Experiment 4: PID-controller ................................................................................................................18

C. Process Control Trainer (Temperature control: GUNT-RT 644) ............................................19

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 CEM3PRA-Process Control Trainer
1. Safety ...................................................................................................................................................19

2. Equipment description .......................................................................................................................19

3.1 Equipment layout ................................................................................................................................20

3.2 Process scheme..................................................................................................................................22

4. Experimental Tests ............................................................................................................................26

Experiment 1: Step response of the system ......................................................................................26

Experiment 2: PI-controller ...................................................................................................................27

Experiment 3: PID-controller ................................................................................................................28

Introduction

Process control technology is now an integral part of nearly all areas of chemical
engineering. Accordingly, a description of its basic principles is a standard feature of
technical training programs. This demonstration unit makes it possible to ascertain
relationships between control parameters in practical experiments and demonstrate
these relationships so that they are clear and easily understood.

An extensive use of modern industrial components makes the model as realistic as

possible. Students do not only obtain knowledge of basic control principles but also an
overview of the control elements’ design, functionality and application. A software
package is also available as an accessory to this model and makes it possible to
visualize and control processes as well as to measure and evaluate data through a
computer. Communication between the demonstration model and the PC on which the
software program has been installed takes place via a USB box.

The flow control demonstration models are available with a software program allowing
data measurement and device control. This program receives the signals output by the
flow sensor and calculates corresponding input signals which are applied directly to the
demonstration model’s control valve. The program also permits recording, display and
storage of measured data.

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 CEM3PRA-Process Control Trainer
The experiments and associated parameters described in this manual are a subset of the
available possibilities. The additional variants of each demonstration model also easily
allow a realization and evaluation of control systems with different settings and control
parameters.

A. Process Control Trainer (Flow control-GUNT-RT 624)

1. Safety

• After completing experiments, always turn the pump off before turning off the
main switch.
• Exercise caution when handling electrical system components due to the danger
of electric shocks associated with such systems. Any electrical connections or
disconnections should be done by qualified personnel.
• Do not fill the water tank with more than 15 litres of water because the excess
water might overflow into the device and damage it.
• Never operate the pump without water because dry running the pump can
damage it.
• Do not change the sensor’s basic setting because altered signals can result in a
loss of process control.
• Drain the water tank prior to shutdown periods of more than 3 weeks.
• Implement the following measures prior to extended shutdown periods (longer
than ~ 3 weeks):

o Drain water out of the tank. For this purpose, connect a hose to the water
tank’s drain cock and let the water flow into a suitable container or directly
into a drainage channel (note that up to 15 litres of water need to be
drained!)
o Pull out the mains plug to disconnect the model entirely from the electrical
network.

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 CEM3PRA-Process Control Trainer
2. Device description

The RT 624 demonstration model is a desktop device designed to control flow rates.
Water is used as the operating medium. Flow rates are controlled by an electronic
industrial unit which can be configured as a P, PI or PID controller. Experiments with the
demonstration model involve modifications and adaptations to system control parameters.

3.1 Equipment layout

The RT 624 flow control demonstration model has the following layout:

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 CEM3PRA-Process Control Trainer
10 11
1 Water tank
9 2 Pump
8 3 Rotameter
4 4 Control valve
5 (electric, proportional)
7
5 Flow sensor
6 Adjustment cock with scale
7 Pump switch
6
8 Jacks for the y input signal
9 Switch for internal / external
3 changeover of the y input signal
10 Controller
11 Jacks for the x signal from the
flow sensor
2 1

• Water from a water tank (1) is conveyed by a pump (2) through a cycle comprising
a small system of pipes. The pump has a fixed speed and is operated by means
of a switch (7).

• The water first flows through a rotameter (3) and then through the circuit’s
control valve (4). This valve is proportional and driven by an electric servo motor.
• A vane-wheel flow sensor (5) is used to generate electric signals for
measurement by the control system.
• The adjustment cock (6) is used to adjust the flow through the system, i.e.
introduce a disturbance variable z. To improve readability, this cock is furnished
with a pointer and scale.
• The circuit is regulated by means of an industrial controller (10). The sensor signal
x and controller signal y can be measured via jacks (8,11) and documented with
a line recorder, for example. If required, the model can also be operated via an
external control signal y. For this purpose, the changeover switch (9) is set to
the “external” mode. The external signal is applied to the jack pair (8). This is the
case, for example, when the accessory software package is used.

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 CEM3PRA-Process Control Trainer
• The electrical connection for the demonstration model is established via a mains
cable. The model is turned on by means of the main switch on the left-hand side
of the device.

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 CEM3PRA-Process Control Trainer

3.2 Process scheme

10

5
4

3
6

2
1

1. Water tank
2. Pump
3. Rotameter
4. Control valve
5. Flow sensor
6. Adjustment cock
10. Controller

Controller

The digital universal controller is equipped with a

microprocessor which digitally processes input signals and
converts them back into analog variables prior to output.

3.3 Start-up

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 CEM3PRA-Process Control Trainer

• Fill the tank via its filler opening (O) with tap water (capacity: ~15 litres). The water
level can be checked via the gauge glass (S) and should lie in the visible range.
• Connect the mains power supply.
• Turn on the demonstration model by means of its main switch (H).
• Switch the controller to the manual mode and fully open the electric control valve.
• Input signal y: 100%
• Half open the adjustment cock (6) to a setting between ~ 40°and 50°
• Turn on the pump switch (7) and perform a test run.

3. Experimental Tests

Experiment 1: Response of the control system

This experiment is intended to ascertain the properties and response of the control system
underlying the model. For this purpose, steps in control value are applied successively to
the system in the non-regulated mode and the system’s response is observed.

Experimental procedure:

• Turn on the demonstration model via its main switch.

• Fully open the adjustment cock (6). Setting: 0°

• Set the controller to manual operation and the manipulated variable y to 10% (= 2.5

ltr/min).

Note! The controller displays ltr/min while the rotameter displays Itr/h

• Turn on the pump. After a certain time, the flow rate assumes a constant value.
Read and note this value.

• Increment the manipulated variable successively by 10%, waiting briefly each time
until the flow rate has attained a constant value. Read and note these values too.

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 CEM3PRA-Process Control Trainer

Results and discussions:

From your experimental observations, comment on the rate of response of the system to
changes in the valve setting. Also comment on the state of the final value of the system.

Experiment 2: Flow control with a Slow PI-controller

In this experiment, a controller with proportional and integral components is used for flow
control, accompanied by variations in parameters. The controller’s differential component
remains inactive. The control circuit’s response to changes in the reference variable ‘w’
is observed.

Experimental procedure:

• Turn on the demonstration model via its main switch.

• Set the controller and demonstration model as shown in the following table:

Controller type PI-controller

Controller mode Automatic

P-component >> Pb.1 250

I-component >> rt 4s

D-component >> dt 0.0 s

Controller Start value: settings 6 ltr/min (30%)

Step value:
12 ltr/min (60%)
Adjustment cock half open, 45°

• Observe the flow rate using the readings indicated by the controller and rotameter.
After a certain time, the flow rate assumes a constant value of 6ltr/min.

• Increment the reference variable ‘w’ by setting the controller to 12 ltr/min. The flow rate

increases and assumes a constant value of 12 ltr/min after a certain time.

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 CEM3PRA-Process Control Trainer

Results and discussions:

From your experimental observations, describe how the controller responds to changes
in the reference variable, paying particular attention to the integration time.
Compare and contrast the actions of the controller’s P-component with that of the I -
component with regards to integration time and oscillations.

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 CEM3PRA-Process Control Trainer

Experiment 3: Fast PI-controller

In this experiment, a controller with proportional and integral components is used for flow
control. The controller’s differential component remains inactive. The integration time -
i.e. the controller’s I-component is set to a notably low value. The control circuit’s response
to changes in the reference variable ‘w’ is observed.

Experimental procedure:

• Turn on the demonstration model via its main switch.

• Set the controller and demonstration model as shown in the following table:

Controller type PI-controller

Controller mode Automatic

>> Pb.1 250

P-component
>> rt 1.0 s
I-component
>> dt 0.0 seconds
D-component
Controller settings Start value: 6 ltr/min (30%)
Step value: 12 ltr/min (60%)

Adjustment cock half open, 45°

• Observe the flow rate using the readings indicated by the controller and rotameter. After
a certain time, the flow rate assumes a constant value of 6 ltr/min.

• Increment the reference variable w by setting the controller to 12 ltr/min. The flow rate
increases and assumes a constant value of 12 ltr/min after a certain time.

Result:

From your experimental observations, comment on the rate at which the controller
generates values. Also comment on the controller’s response to changes on the reference
value.
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 CEM3PRA-Process Control Trainer

Experiment 4: PI-controller with improved parameters

In this experiment a controller with proportional and integral components is used for flow
control. The controller’s differential component remains inactive. The results obtained The
control circuit’s response to changes in the reference variable ‘w’ is observed.

Experimental procedure:

• Turn on the demonstration model via its main switch.

• Set the controller and demonstration model as shown in the following table:

Controller type PI-controller

Controller mode Automatic

>> Pb.1 250

P-component
>> rt 2.0 s
I-component
>> dt 0.0 seconds
D-component
Controller settings Start value: 6 ltr/min (30%)
Step value: 12 ltr/min (60%)

Adjustment cock half open, 45°

• Observe the flow rate using the readings indicated by the controller and rotameter.
• Increment the reference variable ‘w’ by setting the controller to 12 ltr/min.

Results and discussions:

From your experimental observations, comment on the response of the flow rate after a
certain time, what is the final value? Describe the behaviour of the control variable with
reference to the set point.

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 CEM3PRA-Process Control Trainer

B. Process Control Trainer (Level Control-GUNT-RT 614)

1. Safety
• Electrical connections are exposed when the switch cabinet is open. This poses a
dangerous work environment in there being a possibility of an electrical shock.
Therefore, before opening the switch cabinet (if need be) disconnect from the
mains supply. Work on this unit should only be performed under the guidance of
qualified UNISA demonstrators.

• Do not fill the water tank with more than 15 litres of water; this is because the
overflowing water might enter the device resulting in damage to the equipment
• Never operate the pump without water; this is because dry running can damage
the pump.
• Do not change the sensor’s basic setting, because altered signals can result in a
loss of process control.
• After completing experiments, always turn off the pump and then the demonstration
model via its main switch.
• Implement the following measures prior to extended shutdown periods (longer than
~ 3 weeks):
o Drain water out of the tank. For this pur- pose, connect a hose to the water
tank’s ball valve and let the water flow into a suitable container or directly into
a drainage channel (note that up to 15 litres of water need to be drained!)
o Pull out the mains plug to disconnect the model entirely from the electrical

network.

• The RT 614 demonstration model does not require any further maintenance
measures.

2. Device description
The RT 614 (Fig. 1) demonstration unit is a desktop device designed to control filling
levels. Water is used as the operating medium. Filling levels are controlled by an
electronic industrial unit which can be configured as a P, PI or PID controller.
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 CEM3PRA-Process Control Trainer

Experiments with the demonstration model involve modifications and adaptations to

system control parameters.

Figure 1: The RT 614 Level control unit

2.1 Device layout
The RT 614 demonstration model for filling-level control has the following layout:

9 2 Level sensor
1
3 Ball Valve with scale
8
4 Water tank

5 Pump
7
6 Electric proportional valve

6 7 Pump switch

2 8 Jacks for the y control signal

9 Switch for internal / external

3 changeover of the y control signal
5
4 10 Controller

11 Jacks for the x signal from the level sensor

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 CEM3PRA-Process Control Trainer

• The filling-level cylinder (1) consists of a transparent plastic container with a glued
scale. This cylinder has an inlet connected to the pump, an outlet leading to the
water tank via a ball valve, and an overflow safety channel which leads directly to
the storage tank.

• A transmitter which measures the hydrostatic pressure of the water column in the
cylinder serves as the level sensor (2).

• A ball valve (3) makes it possible to adjust the water flow from the filling-level
cylinder. Used to apply a disturbance variable z, this ball valve is equipped with a
pointer and scale allowing readability.

• The water flowing out of the filling-level cylinder travels to a water tank (4) which is
furnished with a gauge glass and serves as a storage tank.

• A pump (5) conveys the water through the demonstration model’s pipe system. The
pump has a fixed speed and can be started via the switch (7).

• The control circuit’s actuator consists of an electric proportional valve (6).

• An industrial controller (10) is used to control the circuit. The sensor signal x and
controller signal y can be measured via jacks (8, 11) and documented with a line
recorder, for example. If required, the model can also be operated via an external
control signal y. For this purpose, the changeover switch (9) is used to set the
“external mode”. The external signal is applied to the jack pair (8).

2.2 Process scheme

10
1. Filling-level cylinder
2. Level sensor
3. Ball valve
1 4. Water tank
6 5. Pump
6. Control valve
10. Controller
5 3

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 CEM3PRA-Process Control Trainer

2.3 Start-up

• Fill the tank via its filler opening (O) with tap water (capacity: ~15 litres.) The water
level can be checked via the gauge glass (S) and should lie in the visible range.
• Connect the mains power supply.
• Turn on the demonstration model by means of its main switch (H).
• Switch the controller to the manual mode and fully open the electric control valve.
Control signal y: 100%
• Half open the ball valve (3) to a setting between ~40° to 50°
• Turn on the pump switch (7) and perform a test run.
• After finishing test runs and experiments, always turn off the pump before turning
off the main switch.

3. Experimental Tests

Experiment 1: Step response of the system

This experiment is intended to ascertain the properties and response of the control
system underlying the model. For this purpose, a step-in control value is applied to the
system in the non-regulated mode and the system’s response observed.

Experiment procedure:
• Turn on the demonstration model via its main switch.

• Switch the controller to the manual mode and set control variable y to 30%.
• Set the ball valve to ~50°.

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 CEM3PRA-Process Control Trainer

• Turn on the pump and observe the filling level in the cylinder. After a certain period,
the filling level will remain constant.
• Increment the control variable by setting the controller to a value of 60%. After a
certain period, the filling level will again become constant.
• Set the ball valve to a different value (for example ~60° to 65°) and repeat the
procedure just described.

Results and discussions: comment on your observations, and also on the factors that
affect the final value of the filling level

Experiment 2: P-controller

A simple proportional controller is used in this experiment. The controller’s integral and
differential components remain inactive here.

The control circuit’s response to changes in the reference variable is to be displayed.

Experimental procedure:

• Turn on the demonstration model via its main switch.

• Set the controller and ball valve as shown in the following table:

Controller type P-controller

Controller mode Automatic

P-component >> Pb.1 100

I-component >> rt 0.0 sec

D-component >> dt 0.0 sec

Controller settings Start: x Step: 15 cm

x 30 cm
Ball valve settings (Disturbance
variable z) 50°

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 CEM3PRA-Process Control Trainer

• Turn on the pump and observe the filling level in the cylinder. After a certain period, the
filling level will remain constant.

• Increment the reference variable by setting the controller to 30. After a certain period,
the filling level will again become constant.

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Results and discussion:

From your experimental observations comment on the time it takes for the control system
to attain a final value when only the controller’s P-component is active. Compare the set
point to the final value and comment on this observation.

Experiment 3: PI-controller

A controller with proportional and integral components is used in this experiment. The
differential component remains inactive. The control circuit’s response to changes in
the reference variable is to be displayed.

Experiment procedure:

• Turn on the demonstration model via its main switch.

• Set the controller and ball valve as shown in the following table:

Controller type PI-controller

Controller mode Automatic

P-component >> Pb.1 80

I-component >> rt 5 sec

D-component >> dt 0.0 sec

Controller settings Start: x 15 cm

Step: x 30 cm

Ball valve settings

(Disturbance variable z) 50°

• Turn on the pump and observe the filling level in the cylinder. After a certain period, the
filling level will remain constant.

• Increment the reference variable by setting the controller to 30. After a certain period,
the filling level will again become constant.

Results and discussions:

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From your observations comment on the controller’s response time. Also comment if there
is any overshoot or oscillations about the set point.
“A controller with active P and I components is just as responsive as a controller with only
an active P-component” comment on whether this statement is true or false?

Experiment 4: PID-controller
A controller with all components (proportional, integral and differential) is used in this
experiment. The aim is to ascertain whether the controller’s response can be accelerated
further by means of the differential component. The control circuit’s response to changes
in the reference variable is to be displayed.

Experiment procedure:

• Turn on the demonstration model via its main switch.

• Set the controller and ball valve as shown in the following table:

Controller type PID-controller

Controller mode Automatic

P-component >> Pb.1 75

I-component >> rt 10 sec

D-component >> dt 5 sec

Controller settings Start: x 15 cm

Step: x 30 cm
Ball valve settings
(Disturbance variable z) 50°

• Turn on the pump and observe the filling level in the cylinder. After a certain period, the
filling level will remain constant.

• Increment the reference variable by setting the controller to 30. After a certain period,
the filling level will again become constant.

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Results and discussions: Comment on the circuit’s response in comparison with the
responses of the previous circuits.

C. Process Control Trainer (Temperature control: GUNT-RT 644)

1. Safety

• Exercise caution when handling electrical system components due to the danger
associated with electric shocks.
• Do not touch the heater housing, because it becomes hot during operation. Do not
operate at temperatures beyond 70 °C because of the danger of burning.
• After completing experiments, always turn off the pump and heater before turning
off the demonstration unit via its main switch.
• Do not fill the water tank with more than 15 liters of water. Excess water might
overflow into the device and damage it.
• Never operate the pump without water because dry running can damage the pump.
• Never operate the heater in its dry state because this might damage the heater
despite its safety cutoff circuit.
• Do not change the sensor’s basic setting because altered signals can result in a
loss of process control.
• Drain the water tank prior to shutdown periods of more than 3 weeks
• Implement the following measures prior to extended shutdown periods (longer than
~ 3 weeks):
o Drain water out of the tank. For this purpose, connect a hose to the water
tank’s drain cock and let the water flow into a suitable container or directly into
a drainage channel (note that up to 15 Liters of water need to be drained). o
Pull out the mains plug to disconnect the unit from the electrical network.

2. Equipment description

The demonstration unit is a desktop device designed to investigate the area of temperature
control. The unit incorporates two cycles. The primary cycle contains hot water serves as
a thermal source. The secondary cycle receives cold water which is to be heated in a
controlled manner. Both cycles are coupled thermally by means of a heat exchanger. The
22
controller regulates the flow of hot water from the primary cycle through the heat
exchanger, i.e. the amount of heat transferred to the cold water. This process not only
finds widespread application in the industry, but is also used to supply house- holds via
district heating networks. The experiments with this demonstration unit involve changes
and adaptations to system control parameters.

3.1 Equipment layout

The RT 644 temperature control demonstration unit has the following layout:

18 19

17
1
6

2
15
14
3
13
4
12

11
5

10 9 8 7

1 Temperature sensor at the cold water outlet

2 Adjustment cock with scale

3 Heat exchanger
4 Cold water regulating valve
5 Cold water flow meter
6 Cold water connection
7 Electric heater
8 Water tank
9 Electrical proportional valve
10 Pump
11 Hot water flow meter
12 Hot water thermometer after heat exchanger

23
 13 Hot water thermometer before heat exchanger
14 Heater switch
15 Pump switch
16 Jacks for the input signal y
17 Internal / external (red) change- over switch for the input signal y 18 Controller
19 Jacks for the x signal from the temperature sensor

• The water tank (8) is equipped with an electric heater (7) which heats the water in the
tank. An adjustable thermostat is located on the front of the heater. This thermostat’s
rotary knob can be used to set the required hot water temperature. The water tank
serves as a heat source for the control experiments.
• The hot water travels from a pump (10) through the primary cycle of a heat exchanger
(3). This pump has a fixed speed and is operated via the switch (15).
• A flow meter (11) indicates the volume of hot water being conveyed.
• A thermometer (13) indicates the temperature of the hot water on its entry into the
heat exchanger.
• The heat exchanger’s secondary cycle conveys cold water which comes in through a
cold water connection (6) and travels via an additional flow meter (5).
• The adjustment cock (2) and regulating valve (4) can be used to control the flow of
cold water.
• The thermometer (12) indicates the temperature of the hot water on its emergence
from the heat exchanger.
• The temperature sensor (1) measures the temperature of the process water on its
emergence from the heat exchanger. The x signal is fed as an input variable to the
controller.
• The control circuit’s actuator consists of an electric proportional valve (9). This valve
influences the flow of hot water in the primary cycle.
• Actual control is performed by an industrial controller (18). The sensor signal x and
controller signal y can be measured via jacks (16,19) and documented with a line
recorder, for example.
• If required, the unit can also be operated via an external control signal y. For this
purpose, the changeover switch (17) is used to set the “external” (red) mode. The
external signal is applied to the jack pair (16). The electrical connection for the

24
 demonstration unit is established via a mains cable. The unit is turned on by means of
the main switch on the left-hand side of the device.

3.2 Process scheme

1 Temperature sensor

18 2 Adjustment cock

1 3 Heat exchanger
2
9 4 Regulating valve
5 Cold water rotameter
11 3
4 6 Heater
7 Control valve
5
8 Water tank
8 7 10 Pump
10
11 Hot water rotameter
18 Controller

Controller

The digital universal controller is equipped with a

microprocessor which digitally processes input signals and
converts them back into analog variables prior to output.

In manual mode, the controller output can be altered by hand

To switch to manual mode, hold the EXIT key for two seconds. In controller mode manual
mode, the icon is displayed. To switch back to the automaticmode also hold the EXIT
key for two seconds.

The following describes an example of how the parameters of a PID - controller can be
entered.

Controller type PID - controller

Controller mode automatic

P - component >> Pb.1 45

I- component >> rt 30 sec

D- component >> dt 15 sec

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Input Display Comment

OPr Operator level

PArA Parameter level

PAr1 Parameter set 1

Pb1 Proportional band

Pb1 flashing - entry mode

45.0 Push this keys until this value is reached

Stops flashing - value is stored (This can be car-
Pb1 ried out only after a change in the value)

dt Derivative time

dt flashing - entry mode

15 Push this keys until this value is reached

Input Display Comment

Stops flashing - value is stored (This can be car-
dt ried out only after a change in the value)

rt Reset time

rt flashing - entry mode

30 Push this key until this value is reached

Stops flashing - value is stored (This can be car-
rt ried out only after a change in the value)
PAr1
PArA Push this key until the value of the reference vari-
OPr able of the temperature is shown again

26
3.3 Start-up

• Fill the tank via its filler opening (O) with water (capacity: ~15ltr).
• The water level can be checked via the gauge glass (S) and should lie in the
visible range.
• Establish a supply of cold water via the corresponding connection Wz.
• Ensure a discharge of cold water via the connection ‘ Wa’ into a drain.
• Connect the mains power supply
• Turn on the demonstration unit by means of its main switch (H).
• Set the controller to the manual mode and fully open the electric control valve.
• Input signal y: 100%
• Turn on the pump by means of the switch (15) and allow the air present in the
primary cycle to escape. Observe the water tank’s filling level in this process.
• Set the heater thermostat to roughly 40°C and turn on the heater switch (14).
• Fully close the cold water regulation valve.
• Fully open the adjustment cock (2), Setting: 0°

• Slowly open the regulation valve until the cold-water flow meter (5) indicates 300
ltr/h. The cold water cycle has now attained its operating range.

27
 4. Experimental Tests

Experiment 1: Step response of the system

This experiment is intended to ascertain the properties and response of the control system
underlying the unit. For this purpose, a step in control value is applied to the system in
the non-regulated mode and the system’s response observed.

Experimental procedure:

• Turn on the demonstration unit via its main switch.

• Using the heater, raise the temperature of the water in the tank to ~55°C

• Using the adjustment cock (2), set the flow of cold water to 100 ltr/h

• Set the controller to the manual mode and the manipulated variable y to 10%.

• Observe the temperature of the cold water at the heat exchanger’s outlet.
This temperature is indicated on the controller. After a certain time, the temperature
attains a constant value.

• Increment the manipulated variable by setting the controller to a value of 45%. After
a certain time, the temperature will again become constant.

• Now, change the flow of cold water via the adjustment cock (2) to 200 ltr/h or 300
ltr/h for example, and repeat the procedure described above.

Results and Discussions: From your experimental observations, comment on the

response of the system to changes on the disturbance variable, as a function of time

Experiment 2: PI-controller

A controller with proportional and integral components is used to control cold water
temperature (20°C) in this experiment. The differential component remains inactive here.

The control circuit’s response to changes in the reference variable is to be displayed.

28
Experiment procedure:

• Turn on the demonstration unit via its main switch.

• Set the controller and demonstration unit as shown in the following table:

Controller type PI-controller

Controller mode Automatic

P-component >> Pb.1 75

I-component >> rt 70 s

D-component >> dt 0.0 s

Controller settings
Start value: 23 °C
30 °C
Step value:
Hot water temperature 60 °C

Cold water flow rate 100 ltr/h

• Observe the temperature indicated by the dial thermometer and controller. After a
certain time, the temperature assumes a constant value of 23°C.
• Increment the reference variable by setting the controller to 30°C. The temperature rises
to assume a constant value of 30°C after a certain time.

Results and discussions:

From your experimental observations, comment on the controller response to changes in

the control variable, paying particular mention on the time it takes for the system to reach
steady state. Describe the separate contributions made by the controller’s P- component
and I-component towards the overall system response.

Experiment 3: PID-controller

A controller with all components (proportional, integral and differential) is used in this
experiment. The aim is to ascertain whether the differential component can further
accelerate the controller’s response and improve control performance.
The control circuit’s response to changes in the reference variable is to be displayed.

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Experiment procedure:

• Turn on the demonstration unit via its main switch.

• Set the controller and demonstration unit as shown in the following table:

Controller type PID-controller

Controller mode Automatic

P-component >> Pb.1 75

I-component >> rt 30 s

D-component >> dt 5s

Controller setting
Start value: 30 °C
Step value: 40 °C

Hot water temperature 60 °C

Cold water flow rate 100 ltr/h

• Observe the temperature indicated by the dial thermometer and controller. After a
certain time, the temperature assumes a constant value of 23°C.
• Increment the reference variable by setting the controller to 30°C. The temperature rises
to assume a constant value of 30°C after a certain time.

Results and discussions:

From your experimental observations, ascertain whether the differential component can
further accelerate the controller’s response and improve control performance. Propose a
technique that can be applied here in order to further optimize the system response.

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