Lab Report

Process Modelling and Control

BEng Chemical Engineering
Year 2
Mariam Munir

Introduction:
A control system is an arrangement of physical components connected or
related in such a manner as to regulate itself or another system. In this
experiment, we used CE117 Process trainer and CE2000 Control Software
to test such systems.
Process control is the act of controlling a final control element to change
the manipulated variable to maintain the process variable at a desired Set
Point. Controlling a process requires knowledge of four basic elements, the
process itself, the sensor that measures the process value, the final
control element that changes the manipulated variable, and the controller.
Sensors measure the value of the process output which we wish to effects.

Experiment 1 & 2
Experiment 1- Process Loop Pump Characteristic
Procedure:
First part of the lab procedure was to design a graph of flow against pump
voltage. We did this by first setting the pump voltage to 0V, valve voltage
to 10V and run the software and start recording. We then increased the
pump voltage to 6V (lab script said 10V) and allowed the flow to stabilise
before recording the voltage from the transmitter for each pump voltage.
Pump (Volt)
0
1
2
3
4
5
6

Flow transmitter (Volt)

0.020
1.415
2.630
3.455
4.045
4.485
4.855

Flow rate (litre/min)

No flow
1.415
2.630
3.455
4.045
4.485
4.855

After plotting this graph, we returned the pump voltage to 3V (6V stated in
lab script) and then increased it to 4V (7V stated in lab script). The flow
rate transient was recorded on the graph shown below.

From the graph above, T=10.93s

10.93 x 63 =

1
a

Therefore, a = 0.145s
From the data recorded for this part of the experiment, at 10.93s
flow is approximately equal to 2.650
2.650=

k
a

Therefore, k=2.650x0.145=0.384
K=gain=0.384

Experiment 2- Valve Characteristics

The procedure for this part of the experiment was that now the pump
voltage is kept constant at 10V (full flow) and the valve voltage is set to
0V. We then allow the flow to stabilise and record transmitter voltage
before increasing the voltage in steps to 7V (10V stated in lab script).
Valve voltage (Volt)
0
1
2
3
4
5
6
7

Flow transmitter (volt)

1.705
2.515
3.420
4.140
4.685
5.055
5.295
0.000

Flow rate (litre/min)

1.705
2.515
3.420
4.410
4.685
5.055
5.295
0.000

Analysis: Experiment 1 & 2

1- The pump and valve flow characteristics are non-linear
2- At 1.415V the pump starts to create a significant flow
3- At 2.515V the valve starts to allow a significant flow

Experiment 3 Level Transmitter Characteristics

The procedure for this part of the experiment was to design a graph of
level transmitter output against the actual level in the vessel.
To do this we first connected the CE117 mimic panel as shown in the lab
script and then switched pump 2 to manual. Valve voltage was set to
10V. We then used the manual control to slowly increase the level in the
vessel. The water level and transmitter voltage was recorded at every
10mm step until the required level was reached.
The graph obtained is shown below:

The first two values are a little displaced from the original readings
because the record button was pressed a little late. This graph shows that
the level transmitter is non-linear.

Experiment 4 Level Control Dynamics

The procedure for this experiment was to first connect the CE117 mimic
panel as shown in the lab script. Process loop bypass valve was closed
while the drain valve and air vent valve were open. Pump 2 was set to
external. We then ran the software and applied 10V(fully open) to the
valve. Pump 2 voltage was then set to 3.2V (4V stated in the lab script).
We then adjusted pump 2 voltage until the level stabilised. Flow rates
were recorded once we were sure the level (Level A) is stable. We then
increased the pump voltage by 0.2V and waited to record the level (Level
B) until it was stabilised.
The following table shows our recorded values for level A and B:
Flow (V)

Flow
Flow
h (mm)
3
(litres/mi (m /s)
n)
Level A
2.8
2.8
4.67x10-5
108
-5
Level B
2.9
2.9
4.83x10
127
The graph obtained for the level transmitter output is shown

h (m)

0.108
0.127
below:

From the graph above, T=227.05s

227.05 x 63 =

1
a

Therefore, a = 6.99x10-3
From the graph, at 227.05s flow is equal to 9.5V
9.5=

k
a

Therefore, gain=k=0.066
Now, to compare your values with those calculated we use the following method:
2

1- Cross sectional area of vessel =

2- Change in level =
3- gain=

h=0.1270.108=0.019m

1
1
k= =
5.650
A 0.177
5

4-

a=

d 2 ( 150 x 0.001 )
=
0.177 m 2
4
4

q ( 4.834.67 ) x 10
=
=4.757 x 104 s
A h
0.177 x 0.019

Experiment 5 - Proportional Control

The procedure for this experiment is to increase the proportional gain set
values and use the software to record the level, the pump voltage and the
setpoint for these values until the setpoint becomes stable. We then
compete the speed of response and the steady state error for each gain
valid.
We start this experiment by connecting CE117 mimic panel. Pump 2
switch is set to external. In this experiment, integral and derivative
parameters are set to 0. Proportional gain is set to 10. We then run the
software, adjust setpoint to 6V and valve voltage to 10V. We then increase
the voltage to 6.5V and record the level until it becomes stable.
We repeated the experiment with the Proportional Gain set to values of 5
and 20. The graphs obtained are as follows:
Proportional Gain of 10:

Proportional Gain 5:

Analysis:
When we compare this graph with that of Proportional Gain 10, we
can clearly see that smaller gain gives a bigger offset. The

Proportional Gain 20:

Analysis:

When we compare this graph with that of Proportional Gain 10, we

can clearly see that increase in gain gives a smaller offset. The
speed of response for bigger gain is greater than that of smaller
gain. This implies that it takes less time for response when we
increase the gain.

Experiment 6 Proportional-Integral (PI) Control

In this experiment, we have repeated experiment 5 but this time
with the parameters now of Proportional Gain set to 5 and Integral =
0.5.
This experiment cancels the offsets. It introduces overshoots to the
graph.
The graph we obtained is shown below:

Analysis:

If we compare Proportional Integral Control with Proportional

Control, we can clearly see that Proportional Integral Control system
responds slower than Proportional Control system. It takes more
time to respond and the speed is slower.