LABORATORY MODULE

Control Systems (ENT 364/4) Semester 1 (2008/2009)

Experiment: Level Control

School of Mechatronic Engineering Universiti Malaysia Perlis (UniMAP)

EXPERIMENT LEVEL CONTROL 1. OBJECTIVES OF THE EXPERIMENT 1.1. Calibration of a differential pressure transmitter for open-tank level measurement 1.2. Determination of the resistance and capacitance of a level process. 1.3. Identify the different closed loop responses of the Level Control System with different PID control actions. 1.4. Recognize Ultimate Gain Methods for optimal tune the controller in the system. 2. INTRODUCTION:THEORY OF LEVEL MEASUREMENT Different types of level transmitter are used for different types of applications. Some of the more important types of level transmitters are the following: i. Measurement based on hydrostatic head. Pressure and differential pressure measurement. ii. Conductance and capacitance type probes. iii. Sonar devices iv. Gamma Ray devices. In the current experiment, measurement based on pressure and differential pressure is used. The liquid in a vessel exerts hydrostatic pressure which is proportional to the liquid density and the head of the liquid. For constant density the measurement of the hydrostatic pressure or pressure at the bottom of the vessel is directly related to the level of liquid in the vessel. This principle is widely used for level measurement because of its simplicity and low cost. Absolute pressure, gauge pressure, differential pressure and vacuum Pressure is the force exerted by a gas or liquid on a surface. The SI unit of pressure measurement is the Pascal (Pa). Other common units are N/m2, Torr, psi and bar. It is critical to specify the reference point of the pressure. When we measure a pressure in a system with perfect vacuum or absolute zero as the basis then we call the value of the pressure as the absolute pressure. When the pressure is measured with reference to the atmospheric pressure as the basis then the measurement is called the gauge pressure. The relationship between absolute pressure and gauge pressure is expressed as, Pa= Pg+ 101.3 where, Pa and Pg= Absolute and gauge pressures respectively, kPa The 101.3 in the equation is the standard atmospheric pressure at the earths surface in kPa.

Vacuum gauges are used when the pressure being measured has a value less atmospheric pressure. Vacuum pressure may be expressed as absolute pressure or vacuum units. For example, 10 kPa vacuum signifies a pressure of 10 kPa below atmosphere pressure, that is, an absolute pressure of 91.3 kPa (101.3 kPa 10 kPa). Measurement above atmospheric pressure

Pg

Pa

Atmospheric pressure= 101.3 kPA

Vacuum measurements

Pvacuum

Pa
Absolute vacuum=0 Pa

Fig. 1 Relationship between absolute, gauge and vacuum measurements

Differential pressure signifies the difference in pressure between two points. Differential pressure measurement is useful for measuring flow or level. In the case of flow, a device like orifice or venturi tube is introduced into the flow path. This creates a pressure drop between the upstream and down stream points of the orifice that is related to the flow rate. Hence by measuring the pressure difference between the upstream and down stream points of the orifice we can measure the pressure drop and hence calculate the flow rate. For measuring level in tank the differential pressure between the bottom of the tank and the top of the tank is measured which is directly related to the hydrostatic head created by the liquid level which can be converted to the level using the density of the liquid.

Pressure Transmitters The deflection of the mechanical transducers due to the action of pressure is converted to an electrical signal by a variety of methods. Linear Variable Differential Transducers (LVDT), Potentiometric Transducers, Capacitance Transducers, Piezoresistive and Silicon Resonant Bridges are some of the more important methods used for this purpose. Of these methods the Silicon Resonant Sensor Method is extremely accurate and stable. The Yokogawa transmitters are based on the Silicon Resonant Sensor technique (Fig. 2a) that measures a strain-induced frequency created by the silicon resonators. The entire sensor is made from a homogeneous silicon crystal. On the silicon sensors two H shaped resonators are provided. These resonators are patterned on the silicon crystal itself. One resonator is at the center of the crystal while the other is at the outer edge of the diaphragm. When no pressure is acting on the diaphragm both the bridges oscillate at a frequency of 90 kHz. When a pressure is applied to the diaphragm the center bridge goes into tension and the outer bridge into compression. As a result the frequencies of one resonator increase and the other decreases. This difference in frequencies is measured and converted to a frequency output. The measurement can be directly converted to digital output by pulse counters (Fig. 2b). The advantages of this technique are the high accuracy, long-term stability and the facility to directly get digital signals without having to use A/D conversion.

Magnetic Field

Magnetic Field

Cavity Resonator

Diaphragm

Pressure

Exciting Current

Electro Motive Force

Output Frequency

(a)

(b)

Fig. 2 Silicon Resonant Pressure Transmitter

Differential Pressure used in Level Measurement Differential Pressure method is a hydrostatic means of level measurement. They rely on the pressure of the measured liquid head to provide indication. The differential pressure transmitter is used commonly in continuous level measurement. When the height of liquid level measured is at a pressure greater or less than the atmospheric pressure, it must be compensated on the low side of the differential pressure transmitter by zero suppression or elevation. Zero Elevation is applied to compensate the effect of the head caused by the sealed fluid in the reference leg of the transmitter in level measurement in a closed or pressurized tank. Zero Suppression is applied to compensate the effect of the liquid head in the pipe connecting the transmitter to a tank when the transmitter is mounted below the tank connection, The level (h) to be measured is related to the pressure exerted on it by: P= hg where P is the Pressure h is the height of the level is the density of the fluid g is the acceleration due to gravity. Unit and Conversion in Pressure Measurement The table below is a conversion table between the various pressure units that are available in industry Pa Bar kgf/cm2 Atmosphere mmH2O mmHg -6 1 1x 10 1.01972x10- 9.86923x10 1.01972x10- 7.50062x10-2
5 -6 1

(1)

1x105 9.80665x10
4

1 9.80665x10
1 -

1.01972 1 1.03323 1.0000x10-1 1.35951x10

3 -

9.86923x10
-1

1.01972x104 1.0000x104 1.03323x104 1 1.35951x10

7.50062x102 7.35559x102 7.60000x102 7.35559x10-2 1

9.67841x10
-1

1.01325x10
4

1.01325 9.80665x105

1 9.67841x10
-5

9.80665 1.33322x10
2

1.33322x10
3

1.31579x10
-4

Table 1: Pressure Unit Conversion Table.

3. UNCERTAINTY IN MEASUREMENT AND CALIBRATION Uncertainty of Measurement A measurement result is not complete unless it includes a statement regarding the uncertainty involved. Consider the measurement of a voltage by a voltmeter. Let the voltmeter be Class 0.5 and let the Upper Range Value be 1V. Therefore the tolerance is 0.5% of 1Volt = 0.005V = 5mV. Let the reading obtained for the input be 1.0004V for the input of 1 Volt. Since the reading is lying within 0.995 V to 1.005 V, the meter tolerance is satisfied. However, this reading of 1.0004 is the result of random errors in the measurement. Hence we need to determine the confidence limits on this measurement. In other words we should be able to say that the measurement has a value of Xy to a confidence value of say 95%. Or we are guaranteeing that when the measured value is X, that to 95% confidence the measured value is not greater than X+y or less than X-y. This value of 1 spanned by the measurement X is called the confidence interval. We express it as a percentage, say 95%. What this means is that there is a 95% chance that the measured value is lying between Xy. Our aim is to determine the lower and upper confidence limits on the measurement. This is called measurement of the uncertainty. The EJA110A Differential Pressure Transmitter has very high accuracy as listed in table 2. It is a suitable device for level measurement

Instrument

Range

Span

Accuracy

EJA110A, -100 to +100 kPa 1 to 100 kPa 0.075 % of span. Capsule M For span below 10 Differential kPa, pressure [0.025+0.5/span] transmitter % of span Table 2: Accuracy Specifications

4. OPEN AND CLOSED TANK MEASUREMENT SYSTEM

Open Tank System: In the case of liquid level measurement in an open tank, the low pressure side of the pressure transmitter is left open to the atmosphere. The liquid in the tank exert a pressure to the high side of the differential pressure transmitter. This is shown in figure 3(a).

h H L

Fig 3(a) Open Tank Measurement PL= atmospheric pressure PH-PL= g (H+h) (Differential Pressure) Where is the liquid density of the liquid in the tank

(2)

Closed Tank System: Closed tank measurements have 2 considerations. There is dry leg measurement as shown in fig 3(b) and wet leg measurement as shown in fig 3(c).

Dry Leg H

h
H L

Fig 3(b) : Closed tank dry leg measurement Dry Leg (Outside) PH-PL= g (H+h) (Differential Pressure) Where is the liquid density of the liquid in the tank

(3)

Wet Leg

h1

h H L

Fig 3(b) : Closed tank wet leg measurement Wet Leg(Outside) PH-PL= g (H+h)- h1g

(Differential Pressure)

(4)

Where is the liquid density of outside filled line is the liquid density of the liquid in the tank

5. EXPERIMENTAL APPARATUS The equipment required for performing the experiments are shown in Table 3.

Unit Name

Model Number

Level transmitter calibration and YLMC 02 level dynamics unit Control Measurement Station Differential pressure transmitter Digital indicator Handheld Communicator CX1000 Yokogawa Model No. EJA110A Yokogawa Model No. UM330 BT200-00

Table 3: Equipment Required 6. CLOSED LOOP LEVEL CONTROL SYSTEM In a closed control system, the controlled variable is measured and then compared to the desired value of the controlled variable (the set point). The difference between these two (the error) is used as input to the feedback controller. This controller then calculates a signal to adjust the manipulated variable. Since the manipulated variable is normally a flow, the output of the feedback controller usually is a signal to a control valve. Disturbances that enter the process tend to drive the controlled variable. The manipulated variable is used to compensate for all disturbance changes If there are changes in set point, the manipulated variable also is changed accordingly to produce the needed change in the controlled variable.

Ultimate Gain Method The closed loop-tuning method conducted with the controller in automatic mode and the integral and derivative actions turned off. The controller gain is varied until even the slightest error causes a sustained oscillation in the process variable. The smallest controller gain that can cause such an oscillation is called the ultimate gain PBu. The period of those oscillations is called the ultimate period PU. The appropriate tuning parameters can be computed from these two values according to the following rules. Refer to table 8

Table 4: Approximate PID values using Ultimate Gain Method Controller Mode P PI PID Proportional Band PB (%) 2*PBU 2.2*PBU 1.7*PBU Integral Time TI (sec) Max. 0.83PU 0.5*PU Derivative Time TD ( sec) Min . Min . 0.125*PU

Experiment 1: Calibration of a differential transmitter for level measurement in an open tank. Procedures: 1. Open valve V7 to and turn on the pump P1(Adjust MV(OUT) to 100%) to allow water into Tank T01. Close valve V6 to begin filling. When the tank T01 is being filled adjust the V6 valve to 20 % to allow a flow back to tank T02 2. Adjust control valve MV(OUT) output from the CX1000 control station to noticeably increase the water level and fill the tank. Adjust the values using from the tuning panel screen. This operation will facilitate a continuous flow of water to the tank. 3. Manipulate the MV(OUT) output of the CX1000 to increase the values upscale and decrease the values downscale. Manual valve V6 is adjusted to allow the outflow of water to enable the decreasing level measurement in the tank from 100% to 0% according to the graduated scale of the sight glass. 4. Check the zero level and adjust using the BT200 terminal to memorize the position. Ensure that the Control Valve inlet gauge reads 4 bar and lock it .Do not exceed 4 bar. 5. The measurement of water level with increasing and decreasing level in the tank is recorded for analysis in Table 5 (a) and (b) 6. Graphs of output from the differential pressure transmitter with the visual level of the water from the sight glass are plotted to analyze the sensitivity, linearity and hysterisis in Figure 4(a) and 4(b)

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Experiment 2: ULTIMATE GAIN METHOD

Procedures: 1. Check the Control Measurement Station CX1000 is at MANUAL mode, adjust the Level Controller output (MV) of CX1000 to 50%.Verify the control valve stem position of LCV01 is open at about 50%. Set P=100%, I=6000 , D= off at the CX1000 and start pump P1. 2. Open the discharge valve V6 to 20 when water increase until 50% of tank T1 and observe its discharge at tank T02. Ensure that the Control Valve inlet gauge reads 4 bar and lock it Do not exceed 4 bar. 3. Regulate manually the control valve from the controller CX1000 (MANUAL mode) so that the water level in tank T01 remains at steady state. Use the EJA110A as the reference for height value. This is an operational exercise of controlling level manually. 4. Set the control station CX1000 Process Value(PV), Manipulated Value (MV) and Set Point (SP) are displaying 50 % (ie 50 % water tank level) Set the Recorder to AUTO Mode and Press START to begin recording. 5. Introduce a 20 change in the output discharge valve V6. Wait until the level response reaches its steady state. Observe and record the process reaction from the above step change of 20 discharge opening. Reduce the P Values in CX1000 until you obtain oscillations of PV and MV. Record this in fig 5. 6. From the graph, plot and determine the respective process parameters in table 6. Refer to table 4. These parameters could be used for computation of optimal settings for controller tuning using the Ziegler Nichols Ultimate Gain Method and plot the new response in Fig 6 for P , PI and PID.(Change data for P, PI and PID on tuning screenAlways give disturbance when value of PID is change.) 7. Obtain the optimized values ( Try and error according to value from Ziegler Nichols Ultimate Gain Method) and plot in Fig 7.

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7. RESULT

Table 5: Open tank Calibration (a) Upscale Calibration Level Tank (%) 0 20% 40% 60% 80% 100% (b) Downscale Calibration Level Tank (%) 100% 80% 60% 40% 20% 0% Sight Glass (mm) EJA110A UM330 Sight Glass (mm) EJA110A UM330

(mmH2O) output (mA)

(mmH2O) output (mA)

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Fig 4a : Linearity Curve of Open Tank Calibration

Fig 4b : Hysterisis Curve of Open Tank Calibration

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Ultimate Gain, PBU,= ___%. Period, PU = Fig 5: Oscillatory Response

Table 6: Approximate Values from Ultimate gain Method Controller Mode Proportional Band Integral P (%) Time(I) TI (sec) P PI PID off Derivative Time(D) TD ( sec ) off off

a) Proportional control , P=

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b) Value for PI control , P=

%,I=

sec

c) PID control ,P=_____%,I=____Sec, D=____Sec Fig 6: Response curve for Different Controls

c) PID control ,P=_____%,I=____Sec, D=____Sec Fig 7: Optimized Response curve for Different Controls

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8. QUESTION Pressure Transmitter as a level sensor 1) What is the effect of a change in density on the level measurement by differential pressure transmitter? 2) Why is the differential pressure unit more suitable for measurement of level in closed pressurized tanks? Level Tank dynamics 1) Does the installed position of the differential pressure transmitter have an effect on measurement ? 2) Describe the meaning of open tank and closed tank measurement? How do the measurements compare? Process Tuning 1) 2) 3) 4) What is process reaction method tuning? What is ultimate gain method tuning? How does the valve behave during auto-tuning? Why is PI control only suitable for Level Measurement?

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9. CONCLUSION From my observation the Suitable PID ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ______________________________________________________

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10. REFERENCES 1. 2. Yokogawa, EJA110A, EJA120A and EJA130A Differential Pressure Transmitters Users Manual, 7th Edition, IM 01C21B01-01E Yokogawa, DAQSTATION CX1000/CX2000Functional Changes Resulting from firmware Upgrae (Version 3.02) Users Manual, 1st Edition, IM 04L31A01-05E Yokogawa, Models UM350 / UM330 Digital Indicator with Alarms Installation Users Manual, 2nd Edition, IM 05F01D02-01E Yokogawa, Models CX1000ModelCX1006/CX1206,Operation IM 04L31A01-04E Guide DAQSATION 3 Edition,
rd

3. 4.

5. 6.

Yokogawa, Model BT200 BRAIN Terminal Users Manual, 4th Edition, IM 01C00A11-01E SMC Instruction Manual, 1DG3, Membrane Air Dryer Unit

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