Process control handles the regulation of processes by utilizing the feedback principle

using various computing devices, mainly digital computation. Sensors are required for process
control for measuring variables and valves for implementing decisions. Process control systems
provide precise control of liquids and gases. These systems control liquid and gas variables such
as flow rate, pressure, temperature, liquid level, density, and pH. Basically there are two types of
process control system, open loop system (automatic) and closed loop system (manual).
In an open loop system, a process can be categorized into two categories; self-regulating
process or a non-self regulating proces. Liquid level control is generally a non self regulating
process. The process varies until it reaches its limit in an open loop test as can be seen in figure
1.

Figure 1 Non self regulating process

Liquid level in tank control using level sensor and PID controller system applies PID
controller application into designing an intelligent and automatic level control of water/ liquids/
solids. The mode of control generally used for this process is P+I control as it has a fast process
response and is noisy. The system allows users to measure and set the desired level of water with
the PID controller controlling the process of water flowing into the tank. A control valve and
level sensor is connected to the system for the control section. The system is able to show the

trend of water flowing into the tank and the responses of the measurements.

Figure 2
The schematic above illustrates a general block diagram used for liquid level control
system. The pump which fills the tank with water is operated by the controller. The input
receives the water level data through the backward signal. The controller could be changed in its
characteristics between PID, some of them and all together to change the properties of the
control-process.
For an open loop test, parameters of response rate (RR), dead time (T d) and time constant
(TC) shall be analysed. These parameters are the essence to the optimum controller setting.
In this experiment, a reformulated tangential method was used to calculate the three
parameters stated. The formula is as given:
Response Rate,
RR =

tan a

MV b

Dead time,
Td(time) = Td (length) x b
Time constant,
TC (time) = TC (length) x b
Table 1- Tuning Rules by Ziegler-Nichols:
Mode

100RRTd

PI

111.1RRTd

3.33Td

PID

83.3RRTd

2Td

0.5Td

The process parameters is then substituted into the tuning rules based on the mode of
control selected. The calculated optimum P,I and D values shall gives an optimal control of the
process towards the desired setpoint.