College of Applied Sciences Sohar

Course Name: process dynamic and control

Course Code: CHEN4352

Experiment name and Number

2-THE EFFECT OF PI AND PID CONTROLLERS
ON FLOW CONTROL SYSTEM

Abstract:-1

1
his experiment was performed to study the effect of PI and PID controllers on flow
control system. A( PCT-100 ) device was used in this experiment.

In any automation process, controllers are required, to control some of the parameter
such as temperature, pressure, flow rate, level etc. The difference between the
reference signal and the feedback signal is error signal. The error signal drives a
control valve or a damper to control, the process variables like tank level, fluid flow,
pressure or temperature to the set point.

P-I controller is mainly used to eliminate the steady state error resulting from P
controller. However, in terms of the speed of the response and overall stability of the
system, it has a negative impact. This controller is mostly used in areas where speed
of the system is not an issue. Since P-I controller has no ability to predict the future
errors of the system it cannot decrease the rise time and eliminate the oscillations. If
applied, any amount of I guarantees set point overshoot.

P-I-D controller has the optimum control dynamics including zero steady state error,
fast response, no oscillations and higher stability. The necessity of using a derivative
gain component in addition to the PI controller is to eliminate the overshoot and the
oscillations occurring in the output response of the system. One of the main
advantages of the P-I-D controller is that it can be used with higher order processes
including more than single energy storage.

2- Table of content:

2
Table of content: page

Table of content 3

Objective 4
Introduction 4
Equipment 5
Method and experiment procedure 6

Results 7
Discussion 15

Conclusion 15

References 16

List of tables:

Table 7.1 PI controller

Table 7.2 PID controller

List of figures:

Figure 5.1 The Device PCT-100 includes the following elements

Figure 7.1 Graph of flow rate vs time

Figure 7.2 Graph of flow rate vs time

Figure 7.3 Graph of flow rate vs time

Figure 7.4 Graph of flow rate vs time
Figure 7.5 Graph of flow rate vs time
Figure 7.6 Graph of flow rate vs time
Figure 7.7 Graph of flow rate vs time
Figure 7.8 Graph of flow rate vs time
Figure 7.9 Graph of flow rate vs time
Figure 7.10 Graph of flow rate vs time
Figure 7.11 Graph of flow rate vs time
Figure 7.12 Graph of flow rate vs time
Figure 7.13 Graph of flow rate vs time

3-Objectives:

3
To study the effect of PI and PID controllers on flow control system.

4-Introduction:

The controller (an analogue/digital circuit, and software), is trying to keep the
controlled variable such as temperature, liquid level, motor velocity, robot joint angle,
at a certain value called the set point (SP). A feedback control system does this by
looking at the error (E) signal, which is the difference between where the controlled
variable called the process variable (PV) is, and where it should be. Based upon the
error signal, the controller decides the magnitude and the direction of the signal to the
actuator.

The proportional (P), the integral (I), and the derivative (D), are all basic controllers.
Types of controllers: P, I, D, PI, PD, and PID controllers PI-controller: it includes two
control actions (1) proportional and (2) integral, this integral action eliminates the
offset, order increases, if the order increases, then the overall response will be
sluggish, To speed up the process, either kc (PG) value has to be increased or integral

(i) value has to be decreased, but if the kc value is sufficiently large or (i) value is
sufficiently small then instability problem will arise. On the other hand PID-
controller: it includes three control actions, proportional, integral and derivative. It
eliminates the offset because of integral action, the addition of derivative action
improves the stability of the process, and if the error is constant then no derivative
action is required. For a noisy response with almost zero error, the derivative term
leads to large control action although that is not required.

The performance of the control systems is determined by the nature of the process, the
characteristics of the controller, the location and magnitude of the disturbance.
Sometimes the
performance of feedback control system will be unsatisfactory because of large
uncontrolled load
changes, hence other control schemes can be considered. The best way of using an
additional controller to decrease upsets is to use the scheme called cascade control.

4
 5-Equipment:

A PCT-100, Process Control Technology model is a bench-top system which

implements several continuous fluid processes. The main elements of the PCT-100
are the process rig and control module. The rig includes the following elements:
sump, pump, turbine flow meter, process tank, sensor for level, vent pipe, needle
drain valve, proportional drain valve, pressure transducer, float switch, check valve,
forced air cooler and proportional valve.

1. Process tank 2. Sump tank 3. Cooler Unit

4. Sump tank Temperature sensor (PRT) 5. Variable speed pump with filter and pressure 6. 3/2 Diverter valve
switch
7. 2/2 Proportional control valve 8. Flow rate sensor 9. One way check valve

10. 2/2 Proportional drain valve 11. Needle valve 12. Pressure relief valve

13. Heater 14. Level sensor 15. Pressure transducer

16. Float switch 17. Overflow/Vent valve 18. Digital LCD displays

19. Indicator lights

Figure 5.1: The Device PCT-100 includes the following elements

5
6-Method and experiment procedure:

PI Controller

1. Ensuring that the vent valve at the top of the process tank was opened.

2. The menu flow controller was clicked.

3. Set Point (SP) was kept as constant value of (2).

4. steady state input signal was set.

5. The Proportion Gain (PG) value was kept constant as (1).

6. The flow loop experiment was started with addition of an element of integral (I)
action after
about ten seconds.

7. The set up was started and the necessary arrangements ware done to operate the
control system through computer system.

8. This process was repeated several times and each time increased the amount of
integral action (I).

9. The final steady state flow value was recorded (if the flow actually did settle) and
main observations as to the nature of the response also recorded.

PID Controller

10. The instructions (1-5) were followed and derivative (D) was included the effect of
derivative action was investigated by run a flow experiment with SP= 1, PG=1 and
vary the I and D values.

11. The observations were inference.

12. The response was studied, the steady state values were recorded and observations
were commented.

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7-Results:

*Calculate Experimental offset by graph the different between flow rate and
time.

SP
*Theoretical offset =
1+PG

*Error Percent difference = * 100%.

Part 1: PI Controller.

Table 7.1: PI controller

No SP PG I Steady Theorrtical Experimental Time

state offset offset constant
1 2 1 999 1.17 1 0.83 -
2 2 1 500 1.2 1 8 -
3 2 1 10 1.92 1 0.08 -
4 2 1 0.5 1.99 1 0.01 0.6
5 2 1 0.2 2.01 1 0.01 0.62
6 2 1 0.1 2 1 0 0.65

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Figure 7.1: Graph of flow rate vs time (No.1).

Figure 7.2: Graph of flow rate vs time (No.2).

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Figure 7.3: Graph of flow rate vs time (No.3).

Figure 7.4: Graph of flow rate vs time (No.4).

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Figure 7.5: Graph of flow rate vs time (No.5).

Figure 7.6: Graph of flow rate vs time (No.6).

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 Part 2: PID controller.

Table 7.2: PID controller

No SP PG I D Steady Theorrtical Experimental Rise Peak Settling Decay

state offset offset time time time ration
(tr) (tp) (ts)
1 2 1 - - 1.19 1 0.81 1.01 1.20 2.21 -
2 2 1 0.35 - 2 1 0 1.25 2.21 7.9 0.06
3 2 1 1 - 1.99 1 0.01 5.3 7.5 7.6 -
4 2 1 0.35 1 2 1 0 1.51 2.6 10.2 0.07
5 2 1 0.35 1.9 2 1 0 1.75 3.4 12.2 0.118
6 2 1 0.35 2.3 2 1 0 1.85 3.3 12.7 0.118
7 2 1 0.35 2.7 2.01 1 0.01 1.93 3.5 13.8 0.116

Steady period Time damping Theoretical Theoretical Decay

No. I D
State T constant coefficient Rise time Peak time ration

1 - - 1.19 - -

2 0.35 - 2 2.9 0.462 0.082 2.9 1.45 0.59

3 1 - 1.99

4 0.35 1 2 6.2 0.987 0 0 0 0

5 0.35 1.9 2 7.4 1.178 0 0 0 0

6 0.35 2.3 2 8 1.274 0.071 7.2 4 0.63

7 0.35 2.7 2.01 7.8 1.242 0.001 2 3.9 0.99

= 2
2
=

1
=


r= + sin1
1 2 12

2
tp=
12

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Figure 7.7: Graph of flow rate vs time (No.1).

Figure 7.8: Graph of flow rate vs time (No.2).

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Figure 7.9: Graph of flow rate vs time (No.3).

Figure 7.10: Graph of flow rate vs time (No.4).

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Figure 7.11: Graph of flow rate vs time (No.5).

Figure 7.12: Graph of flow rate vs time (No.6).

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Figure 7.13: Graph of flow rate vs time (No.7).

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8-Discussion:
There are two sections in this experiment .the PI and PID section.after obtaining the
steady state .when the integer I decrease the flow rate increase at the constant SP and
PG .in the chart that makes a wave shapes. for the PID ,at constant SP and PG .we
constant the I and D ,when we set the I and increase the D .the settling time increase
and the decay ratio decrease. The error may present due to human mistake or
apparatus performance.

9-Conclusion:
The performance of the control systems is determined by the nature of the process, the
characteristics of the controller, the location and magnitude of the disturbance.
Sometimes the performance of feedback control system will be unsatisfactory because
of large uncontrolled load changes, hence other control schemes can be considered.
The best way of using an additional controller to decrease upsets is to use the scheme
called cascade control. Output of the primary controller is used to adjust the set point
of the secondary controller, which in turn sends a signal to the control valve. The
process output is fed back to the controller, and a signal from an intermediate stage of
process is fed back to secondary controller. The main advantage of the cascade
control is that the performance is better for all types of load changes. For disturbance
that enters near the beginning of the system, the secondary controller starts corrective
action before the process output shows any deviation.

10-References:

Lap manual of process dynamic and control.

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