Open Ended Lab Report

Process Instrumentation and Control Lab

Open Ended Lab Report - Temperature Sensor

Submitted By
Ms. Alisha Atta 2019-CH-44
Ms. Atsah 2019-CH-62
Ms. Amina Sheihk 2019-CH-66
Ms. Arooj Awan 2019-CH-68
Submitted to
Dr. Sidra Jabeen

Group no.2 (B2 Lab)

Session: 2019
Department of Chemical Engineering
University of Engineering and Technology Lahore

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Open Ended Lab Report

Proportional, Integral and Derivative (PID) regulator
Objective
1. To find out the effects of Proportional, Integral and Derivative (PID) regulator
actions on closed loop step response on the process trainer
2. To gauge the process transfer function from an open loop step of the process trainer
3. Utilizing MATLAB simulations and carry out model-based tuning of PI controller
4. Utilize the tuned PI controller in the process trainer

Equipment Required
 Digital multimeter
 Set of leads

Theory
Partial Integral Derivative (PID) is a control is a control loop system. It is commonly utilized in
manufacturing and other uses needing the use for control. PIDs regulate processes, gauging
sensors, control processes and final regulatory features. All these features get joint to what’s
known as a control loop. Various regulatory processes and assemblies like feed forward and
feedback could be combined with regulatory systems. Alternative, methods in tuning could be
engaged, Cohen-Coon, Rule of Thumb and Ziegler Nichols methods.

Figure (1): PID Controller

A numerical PID regulator that is present in the Process Trainer (PT) computer, it regulates the
procedure. The PT regulator comprises of a white operator interface or white system unit
(keyboard and monitor). The keys O and C are utilized to alternate closed loop or open loop
process of the PT, the key K is utilized to alternate the PID regulator gains and the key P is
utilized to print procedure time responses that are shown on the monitor. Within a closed loop
system there’s a procedure within the plant to be regulated G(s), sensors identify the PV (process
value) for example a thermocouple, a controller which gives regulator of which procedure,
indicated to the above as a PID term, an outcome to a device or actuator to regulate the input
incentive to the procedure like heat.

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Figure (2): Block Diagram of PID Controller

When loop tuning there are various methods which may be utilized, the usual
methods utilized are:
 Ziegler Nicholls
 Cohen & Coon
 Rule of Thumb
The Ziegler Nicholls method comprises placing a loop into oscillation and gauging the
oscillation phase T. Oscillation is created by putting Integral and Derivative relations to off,
decreasing the Proportional section till the loop just oscillates. The P terms stabilization at the
beginning of oscillation is utilized to gauge the required Proportional section (Px).

Figure (3): Damping System Types

The Cohen & Coon method applies power from a low process rate, a note is constructed for time
prior to any response is monitored (dead-time) in addition the greatest rate of change of the
process outcome. By uniting this info with the final stabilization of the process outcome
following on from the power applied, the Partial, Integral and Derivative outcomes are worked
out.

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Figure (4): Time Constant and Response Curve

The Rule of Thumb method is generally an easier method in gauging the Partial, Integral and
Derivatives outcomes by setting the I and D terms to off in addition making the Proportional
range to minimum. Subsequent oscillation width X(osc) in addition to oscillation phase t(osc)
may be utilized to gauge the Partial Integral Derivative options below:
 P=2.0 x X(osc)
 I=1.5 x t(osc)
I
 D=
5

I
5
Within proportion regulator procedure, the regulator value is relative to the error signal, that is
the change between the allocated point (v) and the output y(t). It may be mathematically state as:

Kp represents the proportional gain

Figure (5): Proportional Controller Block Diagram

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when Kp is alternated there are various effects which take place when Kp is increased, this
results in:
 alternations in transient and steady-state responses
 reduction in steady state error
 Reduction in stability

Figure (6): Proportional Controller Graphical Representation

Integral regulation (also known as reset), the regulator output is proportional to the
integral of error, this can be displayed as:

when Ki is the the integral gain, this is a tuning band. The integral regulator is barely utilized on
its own. Its generally utilized with proportional control. When K i is increased without alternating
kp then the effects are:
 No alteration in the steady state error
 Minor increase in settling time
 Reduction in stability (rise in maximum overshoot and oscillations)

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Figure (7): Integral Controller Graphical Representation

The regulator in derivative control the output will be proportional to the initial derivative (also
known as the slope) of error corresponding to time. The regulatory procedure can be stated as:

When Kd is in a system with Partial and Derivative regulators the increasing K d without any
alteration to Kp then this equates to:
 no alteration in steady state error
 decreased settling time and rise time
 increased stability (maximum overshoot and reduction in oscillations)

Figure (6): Derivative Controller Graphical Representation

Applications
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Temperature sensors are all around us, monitoring temperature is a vital process in many fields
and needs to be measured in a highly accurate and efficient way.
Some temperature sensor applications are;
1. Motorsport and other vehicles – within motorsports there are many temperature sensor
applications. These include; ensuring motors do not overheat, surface plate temperature,
exhaust gas temperature, oil temperature etc
2. Industrial equipment – most machinery used within industrial equipment and
manufacturing will contain a temperature sensor for safety reasons. Temperature sensors
used within this environment are required to be highly robust and resistant to dirt and
moisture.
3. Medical Applications – Temperature sensors are used for patient monitoring as well as
within machines and devices for a range of medical procedures. To be used in this
industry temperature sensors will require various safety standards and approvals.
4. Food and Beverage Industry – temperature sensors are used within this environment as
part of food safety standards, ensuring food is kept at the correct temperature. They are
also used on various manufacturing equipment used within this sector.
5. Home appliances and white goods – many appliances within the home will contain a
temperature sensor; oven, toaster, kettles, washing machines, coffee machines,
dishwashers, electric radiators, boilers etc.
6. Computers and devices– temperature sensors are used within computers and other
devices to ensure they do not overheat and become dangerous.
7. More temperature sensor applications and areas:
Calibration and Instrumentation
Transit – refrigerated vans and lorries
HVAC – Heating Ventilation and Air Conditioning
Power and Utilities
Renewable energy
Heat Exchangers
Drilling
Laboratory and testing applications

Procedure
In total there where 4 task which were completed in this lab, the way in which each task
for the lab was carried is stated below:
Task 1:
Acquire copies of closed loop step response on the process trainer to the following outcomes:
 Proportional control (KI=Kd=0) with KP=0.5, 1, 2
 Proportional plus Integral control (Kp=1.0, Kd=0), with KI= 0.25, 0.5, 1.0
 Proportional plus derivative control (Kp= 0.5, KI=0), with Kd= 0.1, 0.2,0.5
Task 2:
In this task a different hand-out is given that consists of:
 a sample open-loop step response of the process trainer
 a detailed step by step process for guessing the open loop band K, Tp and Td
of the process

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on the process trainer, acquire a printed copy of the open loop step response of the procedure.
Utilizing the printed reaction in addition the process in the hand-out, guess K, Tp and Td.
Task 3:
For this task simulations of process regulation will be carried out utilising Matlab software
that’s installed on the simulation computer (black monitor, system unit and keyboard).
 Start Matlab
 Download L5_PT_Matlab_Sim.m file from the Control lab folder on
blackboard and save it on the F drive.
 Open the L5_PT_Matlab_Sim.m on Matlab, in order to do the step response
simulation of a closed loop system under Partial Integral Derivative regulation,
the lines 22-24 will need to be altered of the Matlab simulation to allocate the
suitable outcomes for the regulator gains Kp, KI and Kd.
 On the simulation utilize the step response simulations of closed loop
system under PI regulation in order to tune the PI regulator, allocate
KI=Kd=0
 Increase Kp until output is a constant oscillation ( at that point Kp=Kp,cr)
 After step E is achieved, set Kp=0.5Kp,cr for a quarter amplitude decay, label the
closed loop outcome plot generated with values of Mp, tss and yss, copy the
outcome and paste it into a word document.
 Increase KI (with Kp=0.5Kp,cr) until rapid settling time is achieved and adequate
maximum overshot is achieved, this requires trailing various values of K p,
graphically showing the resulting Mp and tss outcomes, in addition picking the
best outcome of KI.
 For every outcome of KI attempted, label the final closed loop step outcome
plot generated with outcomes of Mp, tss and yss.
 Mirror the labeled plot and paste it onto the word document created for the
lab results.

Task 4:
In task 4 the Process Trainer computer will be switched on, utilising the keyboard the tuned PI
regulator from task 3 will be entered in to the regulator gains and acquire a printed copy of the
closed loop step outcome plot. Beginning with Kp=KI=1, Kd=0, try manual fine tuning of the PI
regulator to acquire a close loop step outcome with better settling time and maximum overshoot.

Precautions
Wear Lan coat and take safety measures.
In case of any Emergence immediately Contact Lab Supervisor

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Results
MATLAB Graphical Results

Graph 1
Kp = 2.440, Ki= 0.000, Kd=0.000

Graph 2
Kp = 1.220, Ki= 0.000, Kd=0.000

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Graph 3
Kp = 1.220, Ki= 0.577, Kd=0.000

Graph 4
Kp = 1.220, Ki= 0.673, Kd=0.000

Graph 5
Kp = 1.220, Ki= 0.769, Kd=0.000

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Graph 6
Kp = 1.220, Ki= 0.885, Kd=0.000

Graph 7
Kp = 1.220, Ki= 0.962, Kd=0.000

Graph 8
Kp = 1.220, Ki= 1.154, Kd=0.000

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Graph 9
Kp = 1.220, Ki= 1.250, Kd=0.000

Graph 10
Kp = 1.220, Ki= 1.058, Kd=0.000

Graph 11
Kp = 1.220, Ki= 1.346, Kd=0.000

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Graph 12
Kp = 1.220, Ki= 1.442, Kd=0.000

Graph 13
Kp = 1.220, Ki= 1.138, Kd=0.000

Ki Mp (overshoot %) ts,Settling Time

0.3/Tp 0.353 9.01
0.35/Tp 2.81 7.52
0.4/Tp 5.33 6.39
0.45/Tp 7.85 5.57
0.5/Tp 10.5 4.79
0.55/Tp 15.7 3.5
0.6/Tp 18.4 3.42
0.65/Tp 13 4.45
0.7/Tp 21.1 3.37
0.75/Tp 23.8 3.35
0.8/Tp 26.5 3.34

Calculations

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Task 2 Calculations

Discussion
The simulation part of the lab was had no disturbance as it was done on a simulation
program ensuring a more stable outcome, whereas the process trainer had other factors
which could have affected its stability as a whole. The task 1 outcomes agree with the
theoretical expectations. The theory states that when Kp is increased the stability is
reduced and steady state error is reduced also. The Graphs in the Process Trainer section
show that asthe Kp is increased the stability is reduced, the difference can be seen in
Graph 1 and Graph 3 in the Process Trainer section of the report, Graph 1 appears to be
more stable than Graph 3 as graph 3 has a higher Kp value.

Another theoretical claim is that there will be alterations in the transient and steady state
responses. The Process Trainer shows that the higher the Kp value the lower the
transient response and the lower the steady state response. As shown in graph 1 and
graph 3 of the Process Trainer. The theory states that when K1 is increased there is no

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alteration to the steady state error, there is a slight rise in the settling time and reduction
in stability and increased maximum overshoot and oscillations. The process trainer
provers that this theory is correct as shown in graph 4 and graph 6 in process trainer,
when the K1value is increased, from 0.25 to 1, the oscillations increase and the
settling time increases as well, this means there is a higher percentage of overshoot and
the oscillations mean that the stability is significantly reduced.

The theory states that when K1 is increased there is no alteration to the steady state
error, there is a slight rise in the settling time and reduction in stability and increased
maximum overshoot and oscillations. The process trainer provers that this theory is
correct as shown in graph 4 and graph 6 in process trainer, when the K1value is
increased, from 0.25 to 1, the oscillations increase and the settling time increases as
well, this means there is a higher percentage of overshoot and the oscillations mean that
the stability is significantly reduced.

The theory explains also when Ki is increased there is no alternation in steady state
error, there is a reduction in rise time and settling time and increased stability meaning a
reduction in maximum overshoot and oscillations. The process trainer agrees with some
of the theory as Graph 7 and Graph 9 (from 0.1to 0.5) that graph 7 has a higher
overshoot and settling time as well as more oscillations compared to graph 9, this means
its more stable. However, an increase in the derivative in the Process Trainer means
sound will increase as the derivative value is increased making it less stable and more
distorted. The derivative action amplifies noise and an increase in derivative action
means an increase in noise.

When calculating K, Tp and Td for task 2 reading needed to be taken from an open step
loop graph, depending on the person taking the measurements from the graph, it
required skills like drawing a straight line and measuring using a ruler. To ensure
accuracy and reliability the work was compared to others to see that the values were
similar, this stated that the work was accurate and reliable.

The Process Trainer and the Matlab simulation were gave similar results with the
graphs. As K,was increased, the overshoot was increased for graph 14 on the Matlab
simulation and graph 6 in the process trainer, in the Matlab simulation as the K, value
was increased the overshoot percentage increased except for one anomaly at Kfi Tp at
0.65 where the overshoot percentage equated to i3. A difference however is that in the
process trainer an increase in K1 meant an increase in settling time but for the
simulation the increase in K, meant the settling time got less as the percentage of
overshoot increased. As long as there is integral action then there is no steady state
error.

When the values of the tuned Pi controller where put in the Process trainer off line it
was more stable and had less distortion, this was because the system wasn't running and
it was using the simulations values, this meant there was little to no interference from
noise.

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Conclusion:
Overall, this lab allows engineers to regulate manufacturing process, with control
various aspects can be regulated with PID controller. It also gives the understanding of
closed and open loop systems and how it reacts to the three parameters Kp, K1 and Ki.
It also states the step responses and indicates settling time, overshoot and rise time.
However, it is imperative to understand how to tune and use the Partial
Integral and Derivative control. If this lab was t be conducted again it would be advised
that because of the analogue electrical components noise disruption creates instability in
the process trainer, to invest in more modern electrical components and without the
analogue noise the derivative action won't be able to amplify noise causing instability.

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