TEMPERATURE CONTROL SYSTEM

Objectives:
To design PID controller based on Open loop method and to apply it on a temperature control
system.

Block Diagram:

SP
TT

Controller

Thyristor
Heater

Flow meter

Input flow

Specifications:

Temperature sensor:
Type
RTD PT-100
Mounting
BSP
Temperature transmitter:
Type
RTD PT-100
Output 0-5V DC
Range
0-1000C
Process tank:
Capacity
0.5 lit
Material
SS 304

Heater:
Capacity

1.5 KW

Rotameter:
Range
Make

100 LPH
Eureka
Overall size:
500L 700D 500H
Weight(approximate):
30 Kg
Control panel: All extruded with switches, power supply, indicators make presidents.

ADC/DAC card: 12 bit resolution

Software: for experimentation, PID control, data logging, trend plot, offline analysis and
pricing

Theory:
In the reaction curve method of controller design, one needs to open the control loop just
before the final control element and create a small sudden step change in process input. From
the shape of the resulting reaction curve obtained, the controller parameters are calculated by
simple equations. From the curve, Slope (R) and Dead time (L) are calculated. Where R is the
slope of line drawn tangent to the point of inflection and L is the time between the step change
and the point where tangent line crosses the initial value of the controlled variable.

Procedure:

Condition the equipment, set the water flow to the apparatus as 40 LPH by using
rotameter control.

Switch on the control module and switch on the computer also.

Open the temperature control trainer, select suitable port and start the process.

Select the control (Open loop)

The controller mode is selected as manual mode

Log on and enter the filename

Change the output (give a step change) by changing the corresponding field.

Press F3 key to display the trend.

Wait till steady state conditions achieved

Press F6 key to record the process response values on time basis in computer in present
file

Give a step change to process by changing the output (by say 30-40% which is taken as
P) by using the following keys
For 10% change
For 1% change

Page up or Page down

+ or -

For 0.1% change

Insert or Delete

After the process value becomes steady, press F6 key to stop the data logging in
computer

Come out from the online mode.

Now, choose offline mode, open the file in which the data is stored. Press F4 key to see
the table.

Plot the graph of Process variable Vs time.

Find out the slope of the tangent drawn at the point of inflection and find the value of
dead time also.

Process reaction curve method suggests the following values for PID parameters using R,
L and P. (P is the step change applied in % i.e. initial output-final output of the
controller)

Mode

Proportional

Integral

100 RL/P

P+I

110 RL/P

0.3/L

P+I+D

83 RL/P

0.5/L

Derivative

0.5L

Select the controller in the PID mode and the control in closed loop and check the
process response for a step change in the set point.

Observations:
Tabulate the experimental values as shown below. Take the readings till the process variable
settles to a finite a value (in a band).
Sl. No.

Time

Process variable

Calculations:
The dead time and the slope of the tangent are found out. The values are
Dead time, L

Slope of tangent, R

Process output change, P

Model Graph:

Summary and Conclusions:

PID controller settings are calculated based on open loop data. The controller is loaded with the
PID values and the process is run with a step change in the set point. It is seen that the process
variable tracks the set point.