KULLIYYAH OF ENGINEERING

DEPARTMENT OF MECHATRONICS
ENGINEERING

SEMESTER II 2007/2008

Laboratory Manual

MCT 3229
Mechatronics Engineering Lab III
Control Systems

EXPERIMENT 3

Liquid Level: Measurement and Control

Part 1: Liquid Level Measurement
1. Objectives

The objective of this experiment is to measure a liquid level in a simple

tank by using the bubbling-through method, we will be investigating the
sensitivity of the differential pressure transducer, the total sensitivity of
the measurement arrangement and errors in linearity.

2. Introduction

Consider the following control system and let’s try to describe the elements
in the feedback one by one (transfer function of the tank, level measurement
element and controller).

2.1. Transfer function of the tank

From the low of mass conservation, rate change of volume of water in the tank
equal to the difference between inlet flow rate and outlet flow rate (assume water
is incompressible liquid).

dv
Thus, = F1 − F 2 …….(1)
dt

Where, v: volume of liquid

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 F1: inlet flow rate

F2: outlet flow rate

Thus, integrating the equation:

v = (h − hm) A

dv dh
Yielding: =A ……..(2)
dt dt
hm: allowable minimum level of the water
h: tevel of the water
A: base area of the tank.
F2 can be written as:

F2 = k h ……..(3)

where:

k = pump flow characteristic

Therefore,
dh
A = F1 − k h ………(4)
dt

With Taylor series, linearization at reference point is possible. By letting

f (h) = h , at reference point ho, we can find:

(h − ho)
f (h) = ho + …….(5)
2 ho

ho: steady state measurement of water level.

It can be expresses as:

f (h) = a + bh

1
a= ho
2
Where:
1
b=
2 ho

Then we define new variables:

h*: departure of h from ho

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F*: departure of F1 from Fo

Fo: steady state flowrate of F1

h = ho + h *

F1 = Fo + F *

Using Laplace Transformation and some substitutions yielding the transfer

function of the tank:

1
H * ( s) k .b
= G ( s) = ……(6)
F * ( s) A
1+ s
k .b

τ = A k .b (time constant)

2.2. Liquid level measurement

Description of the measurement procedure is as follows. Using this method

the entire hydrostatic pressure in a tank is measured. Here a pipe is inserted
into the tank with the end nearly reaching bottom of the tank. The pipe is then
filled with a gas so that gas bubbles are barely able to form and exit out of the
pipe. This gas forces the tank's fluid out of the pipe. The gas pressure here, it
must be the static pressure because the flow rate is very low, now arising in the
pipe corresponds to the hydrostatic pressure of the fluid column in the tank.
This pressure can be measured with a differential pressure transducer. Sketch
of the measurement arrangement is as figure below.

The application of the bubbling-through method is well suited for continuous

liquid level measurement. This measurement method is only suitable for fluids.
The method can also be used for pressurized fluids. The maximum excess
pressure permissible in a container may amount to 100 bar. Liquid level up to
25 m can be determined. The margin of error for this measurement method
amounts to 1% at the uppermost limit of the scale. The classical area of
application of this method is in the areas of hydraulics and waste water.

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The equation with which the liquid level can be calculated is given by:

P P
h= + ho where: = hx
ς .g ς .g

3. Experiment Procedure

• Assemble the experiment in accordance with measurement set-up.

• The left and right side of the tank are both locked with a closed plastic slide.
It is recommended that water filling procedure be performed by lifting up
the left slide by approx 5mm. While the tank is being filled, the slide on the
right remains closed. To empty the tank the right slide is simply lifted
somewhat.

a) Set the sensitivity of the differential pressure transducer to 0.66V/mbar.

b) Open the inlet slide by approx 5mm.
c) Close the outlet slide.
d) Set the desired level of water using the pump.
e) Slowly fill the tank to the first division mark.
f) Switch on the bubbling pump.
g) Set the tree-way valve of the bubbling through pump to the center
position.

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h) Set the air flow with the needle valve. Regulate the flow of air bubbles
down to a minimum, but only to the point where the indicator just
remains idle (approx. 3 air bubbles per second).
i) Read off the measured value of voltage.
j) Set the tree -way valve to the upward position. In the process bear in
mind the measurement range of the connected voltmeter. The air flow
through the bubbling pipe is now interrupted and a new liquid level can be
set without affecting the water surface through the escaping air bubbles.
k) Raise the liquid level to the next partial division.
l) Continue with g - l (while omitting h).
m) What effect does an air bubble flow have on the indicator when it is set too
low (e.g. 1 air bubble per second), and when it is set too high (try it!).
First calculate the respective hydrostatic pressure for the partial division marks
and enter the values into the table. Take the height ho of the measurement in to
account (ho=10mm). Record the measurement values of voltage for raising
kg
water level at room temperature. (Note:1 2
= 1Pa = 10 − 2 mbar )
m.s

Division Liquid level Hydrostatic Voltage U (volt)

(1Div=15mm) division h (mm) pressure (mbar) (rising water)
1 15 ≈ 0.5
2 30
3 45
4 60
5 75
6 90
7 105
8 120
9 135
10 150

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4. Measurement Evaluation

a. Plot the measured values for rising water level in a graph (actual curve).
b. Draw the desired curve into the diagram (linear curve).
c. Determine the maximum absolute linearity error
d. Calculate the maximum relative linearity error.

Again plot the measured values of voltage for rising liquid level in the
range 15-150 mm in a graph. Seal the horizontal axis also in pressure
units (mbar).
Determine the sensitivity of the measurement arrangement in the range
15-150mm in V/cm.
Determine the sensitivity of the differential pressure transducer in the
range 15-150mm in V/mbar (sensitivity=variation in output/variation in
input).

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e. How can any eventual linearity errors be explained?
f. Explain the nature of the characteristic curves.

Part 2: Liquid Level Control

5 . Objective
The purpose is to control the liquid level by two position and a P-I
controller in the feedback system. The control can be done whether by two-
position or P-I controller.

5.1. Two-position control.

Two-position control has the widest industrial and domestic use on process
having not more than two energy-storage elements. In operation, two-position

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control is very simple, but in theory the action is difficult to analyze because of
the discontinuous nature of changes in the manipulated variable. Consider the
following process plant:

The most elementary case of two-position control is illustrated in this

figure. The level control LC turns on the inflow when the level is too low,
and turns it off when the level is too high. The switching on/off in this
experiment is realized by the float-type switch. This figure shows the
design of the float type switch. At the lower end of longer tube on the left
there is an NC (normally closed) contact, designed as a Reed contact
.This reed contact is activated by a small permanent magnet located
inside the polystyrene float. By shifting the linkage, different liquid levels
can be set. The linkage can be shifted by 120mm. The lowest liquid level
amounts to approx 0.35 mm. This results in a maximum setting for the
liquid level of around 155 mm.

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Measurement assembly: The Reed contact can switch currents up to a
maximum of 50 mA. This has to be taken into consideration when
installing the float-type-switch. Thus it is recommended that the float-
type switch be installed in the measurement set-up between the
Reference-variable generator and the power amplifier (see set-up fig 2).
Choose a reference level. Run the experiment according to the assembly
panel. Record the output level with the help of the oscilloscope.
a. Measure the amplitude of oscillations
b. Measure the period of oscillations, explain and comment on the
results.

It's said that the two-position control is just suited for the control of first
order system with a large dead time. Do you agree? Why?

5.2. P-I Controller

5.2.1. Background
First order systems as water level in a simple tank can be well controlled
by a P-I controller. Consider our system (tank) characterized by a first
order transfer function.
The control objectives are to obtain a closed -loop system having a zero
steady-state error for a step input, an a periodic response without
overshoot, and a given rise time Tr.
The feedback system with P-I controller can be designed.

The transfer function of the P-I controller is more or less following:

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 1
Gc = K (1 + ) with K represents the proportional gain and
τs
τ represents the integral action of controller. The more detail explanation
about P-I controller would be obtained from the control system lecture.

5.2.2. Experiment procedure.

Assemble in accordance with the feed-back block diagram.
A) P controller
Adjust K p = 5, 10, 20, 70, and then 80.
1. Give a step input to your system.
2. Record output level, use the oscilloscope.
3. Evaluate final values, rise times, steady state error.
4. Evaluate the closed-loop transfer function.
5. What is the effect of the proportional gain in the feed-back system?
6. Explain the results.
B) P-I controller:
Adjust K p = 5 with K i = 4, 8, 40, and then 90.
Do steps 1. to 6.
Why first order systems need P-I controllers? Explain!

6. Report
For Part 1, write a report on the experiment and answer the question
given. Include the response curves in your report.
For Part 2, include the response curves in your report. Once the transfer
function of your system was determined, use SIMULINK to simulate. Give
the same values to Kp and Ki, plot step responses.
If any differences, explain why? Give analysis, deductions and comments
on the results. Give Conclusion.

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