MANUAL FOR LEVEL CONTROL

MANUAL FOR LEVEL CONTROL

INTRODUCTION: THE SYSTEM
Aim

: To study level control using 1-element (level) single loop PID

Control System : It consist of the following in feedback

LT11- Level, Open or closed Tank T11
LIC11- Loop 1, PID 1 of LIC/FIC11
LCY11/PP/LCV11 - Control valve at Inflow pipe, complete with
current-Air, (IP) converter and Positioner,
(PP)
Special Remark : LIC11 FIC11 is in the 1-element position 1: LIC11.
LIC11, Loop 1, PID 1 is in Auto (A) mode.
Display LIC11
Key Process Variable: Level of tank T11
EXPERIMENTAL PROCEOURES
These procedures assume you have gone through the start-up check list and
preliminary exercises.
Procedure 0: Start up
1. Do not switch on pumps PI3/P14/P15 as there is no necessity to operate the
product flow system.
Do not turn on the heaters as there is no necessity for heating. Switch off both
the heaters, for tanks T11 and T12.
2. Do a final check that the Instrument air supply (IAS) is set according to the
pressure indicated at the air pressure regulator (IAS), and the overflow Drain
valve and the Vent at tank T11 are opened.
Inflow to tank T11 can be from the top or bottom. Open the top manual valve
for Inflow to enter tank T1I from the top but shut the bottom Inflow manual
valve to T11.
3. Fill tank T12 with water till its level reaches the overflow Drain pipe outlet
(D). Check and top up later when T11 is about half-full.
4. Turn on the main power supply switch at the electrical cubicle. The control
panel instruments lit up. The PANEL, SCADA/DDC switch should be in the
"PANEL, SCADA" position.
5a) Locate the following external selector switches mounted near the panel
controllers LIC/FIC11 and LIC1/FIC12.

1-2-3 position (element) selector switch is for controller LIC/FIC11.

1-2
position (element) selector switch is for controller LIC1/FIC12.
b) Set the two panel controllers to Manual (M) mode.
Make sure LIC/FIC11 is in 1-Element position 1: LIC11 to operate only
LIC11, PID1, loop 1. Display LIC11 and switch in to Manual (M) mode.
Manually adjust the output (MV) of LIC11 to above MV = 35%. By pass i.e.
DO NOT USE THE POSITIONER (PP). visually check the steam position of
LCV11. it should read less than 35% open without the positioner (PP).
c) Switch ON the positioner (PP) at LCV11 i.e. USE THE POSITIONER (PP).
Note that LCV11 is now approximately 35% opened with the position (PP)
connected. Let the positioner (PP) remain on and connected at LCV11
throughout this experiment unless stated otherwise.
d) Display TIC11 and switch it to Manual (M) mode. Manually adjust the
output of TIC11 to about 35%. Visually check that the steam position is
about 35% with the position (EP TCY11) always controlling.
6)

Start the inflow pumping P12 and quickly verify from its by-pass that it is
pumping. Shut the by-pass valve and note the change of the water level in tank
T11 from the sight glass. Check that the inflow manual valve entering tank T11
at the top is opened, but shut the bottom Inflow manual valve to T11.

7)

Open the Other Demand valve fully and keep it opened throughout the
experiment. It is at the outflow pipe upstream of control valve TCV11. when
the level in tank T11 is about 50%, start the outflow pump P11. Verify P11 is
pumping through the Heat Exchanger by visually checking its discharge into
tank T12.
WHWNEVER ANY ANNUNCIATOR IS ACTIVATED, PRESS THE
ACKNOWLEDGE BUTTON TO SILENCE THE BUZZER BUT THE
PARTICULAR ALARM LIGHT REMAINS LIT AS LONG AS ITS ALARM
CONDITION EXISTS.

8a) Start the recorder LFTR11 and its chart drive by pressing ON the RCD
pushbutton at the front of the recorder with its swing cover opened.
b) Display both controllers LIC11 and TIC11, making sure that both are in
Position 1 at their respective external selector switches. Manually regulated
both LCV11 and TCV11 from their controllers LIC11 and TIC11 (in Manual
mode) so that the water level in tank T11 remains almost steady at 500 mm
(50%). This is an exercise of controlling level manually, and is done by
balancing the inflow and the outflow. Observe the Inflow (FT12, green pen )
and Outflow (FT11, blue pen) at the recorder LFTR11.
Do not allow the water level to fall below 30% (300mm) or rise above 90%
(900mm). Note the Inflow and Outflow rates at LFTR11. They should be
approximately equal when the level is steady.

c) Note the following displays at LIC/FIC11 and at LFTR11.

Also a access the following data in LIC/FIC11 at the I/O Data
X1
Level LTI11, % of 0 1000 mmWG.
X2
Inflow FT12, % of 0 7 m3/hr.
X3
Otflow FT11, % of 0 7 m3/hr.
X4
Temperature TE11/TIT, % of 0 100 C.

Level
(LT11)
Inflow
(FT12)
Outflow
(FT11)

LFTR11
Pen
Digital
0-100 mmH2O
Red (%)
Channel 1
0 -7 m3/hr
Green (%)
Channel 1
0 -7 m3/hr
Blue (%)
Channel 1

LIC11

LIC/FIC11
FIC11
I/O Data

PV1

X1

PV2

X2

X3

10) Set Proportional (P) and Integral control into LIC11 (Loop 1, PID 1) using the
following first (I) trial values for LIC11 i.e. PID 1.
First (I) trial PID values: PID1 for LIC11
PB1 = 20%
TI1
= 30 secs
TD1 = 0 sec
11) Observe the level PVi at LIC11. Adjust its set point SV1 = 500 mm. with LIC11
in Manual (M) mode, adjust its output MV so that the level PV1 is near to 500
mm. Press the Auto (A) button to switch LIC11 to Auto (A) mode.
12) The recorder LFTR11 should be at fast speed (500 mm/hr). Observe the control
response (red pen) of the level at LFTR11 unit it shows consistent response for
two cycle, or when the response is almost steady.
WRITE THE SET POINT AND PID VALUES ON THE RECORDER CHART
PAPER BESIDE ITS RESPONSE (RED PEN). THESE CHART
RECORDINGS CONSTITUTE THE REASULTS OF YOUR EXPERIMENT.
13) Step increase or decrease the set point SV1 by about 50 mm to 550 or 450 mm
and watch the control response of the level at LFTR11 (red pen).
AT ALL TIME, DO NOT OPERATE THE LEVEL SEPOINT BELOW
30% (300mm) (THE SACTION PIPE IF PUMP P11 EXTENDS INSIDE
TANK T11 AND WILL BE SUCKING AIR OTHERWISE) OR ABOVE
90% (900mm).
AVOID OPERATING AT TO LOW INFLOW AND OUTFLOW
BECAUSE OF THE LOW FLOW RANGEABILITY OF THE FLOW
METER, WHEN ACCURACY DETERIORATE.

14) With some experience now, repeat the above procedures with a second (II) set
of trial PID values at LIC1l as shown below. The level setpoint SV1 = 500 mm.
After the change of new PID values, disturb the setpoint SV1 by 50 mm and
watch the level response (red pen) until it is almost steady or consistent for two
cycle.
Second (II) trial PID values: PID1 for LIC11
PB1 = 10%
TI1
= 20 sec
TD1 = o sec

Note that a smaller PB and TI has higher ..Oscillatoryand less damped, i.e.
10%/20 sec/Osec is faster, more oscillatory and less damped than 20%/30

sec/O sec.
Note that the manipulated variable i.e. Inflow (green pen) maybe
fluctuating but the level (red pen) can be steady because level has a
capacity to "buffer" the flow fluctuation. Flow process has negligIole
capacity compared to level process.

15a) Repeat with a few other Pill values (within the range shown below) but use the
same level setpoint SVI = 500 mm. Apply a step level setpoint disturbance of
50 mm to 450 or 550mm. Return the level setpoint to 500mm after the test.
PBI = 2-100%

b)

TI I = 0-9999 secs
TDI = 0 always i.e. no Derivative (D) control for level
Otherwise, try a combination of the first (I) and second (II) trial Pill values, or
use a higher PB1 for more damping i.e.
LIC11
PB1
TI1
TD1

First (I) Trial

Value
20 %
30 secs
0

Second (II)Trial
Value
10 %
20 secs
0

First/Second
Combine
30 to 40%
25 secs
0

16) Test Disturbances

Try different ways, one at a time as shown below, to disturb the level process,
using any of the above PID trial values at LIC11. The level setpoint SV1 must
remain at 500 mm
a) Step increase the level setpoint SV1 as above in 15, from 500 to 550 mm. This
approximates a step setpoint disturbance. Observe the effect of this disturbance
until the level is almost steady or consistent for two cycles.
Repeat with a step decrease in level setpoint back to 500 mm
b) Open 1-turn, hold for 5 seconds and then close the by-pass manual valve around
the Inflow pump Pl2 to disturb the Inflow. This approximates a pulse load
disturbance at the Inflow.

c) Disturb the Outflow by shutting and opening fully the Other Demand valve.
This approximates an impulse load disturbance at the outflow. Keep the Other
Demand valve opened.
d) Switch LIC11 Manual (M) mode and manually step change its control output
MV to LCV11 by about 10%. Quickly switch LIC11 back into Auto (A) model.
This step load disturbance at the Inflow.
17) Closed tank T11
Make sure the level is controlled by LIC11 at SV1 = 500mm, in Auto (A) mode, using
either the First (I) or Second (II) trial PID values. Shut the Vent and overflow Drain
valve at the top of tank T11. Pressurize the top space of tank T11 by opening the air
supply valve at the top of tank T11, beside the regulator AR1, to a few psig (see
pressure gauge PG11). Do not exceed 2.5 psig which corresponds to approximately
1760 mm Water Gauge. Check if there is any difference to the level measurement
using LT11 and the level sight glass. Tank T11 is now a closed Tank.
The level transmitter LT11 has been installed and set up to measure the tank level,
irrespective whether the tank is Opened or Closed. However, no correction is made
for temperature effect on the liquid density - i.e. water temperature variation and
difference in water temperature inside the tank and inside the wet leg connecting the
top of the tank to the low pressure chamber of LT11.
Shut the pressurising air supply; open the overflow Drain valve and then the Vent
after this test, to restore T11 as an Open tank again.
18) Controller LIC11 tunin2
Refer to the various Controller tuning methods (see Appendix section) and try the
Closed Loop method. This method is done with the Controller in Auto (A) mode
using only proportional (P) control to obtain uniform oscillation i.e. constant
amplitude oscillation. If uniform oscillation cannot be obtained, make a note and
proceed with the Open Loop method.
Try the Open Loop method which is done with the Controller in Manual (M) mode.
Note that the Level process here is integrating and non-self regulating. A stepdisturbance will give an integrating (ramping) response without a steady-state i.e. the
level can overflow or run dry. Also, try a pulse disturbance to see the effect on the
Level. The Open Loop test should proceed only when the Controlled Variable (level)
is steady as follows:

When the level is held constant in Auto (A) mode at a level setpoint of say SVI =
500 mm, switch LICII to Manual (M) mode. Note the MY value of LIC 11. The
level must remain steady at the recorder level trend. Quickly proceed to the next
procedure.

Mark on the time axis on the recorder level trend and at the same instant, increase
the MV by about 10%. Note the new MV and therefore the applied MV change.

The level will rise in a straight line. Switch LIC11 back to Auto (A) when the
level is about 750 mm, so that the level will not overflow. There is sufficient data
to tune the loop.
The effective Dead Time (DT) and Response rate (RR) can be established by
drawing the steepest tangent to response curve. In this case the tangent is the
straight line response it self. Refer to Ziegler formulae (see appendix section) to
the determine the approximate PI value.

100%
0.9

, TI 3.3DT, TD 0 (i.e.no Derivative (D) action

PB% DTxRR
In one such test, the PI values were found to be PB =30%, TI = 25 secs.
PLEASE REVER TO THE APPENDIX FOR SOME COMMENTS ON
CONTROLLER TUNING. THE PROCEDURES TO OBTAIN THE OPEN LOOP
RESPONSE AND THE DETERMINATION OF THE RESPONSE RATE (RR)
AND DEAD TIME (DT) IS IMPORTANT. USE THE ZIEGLER AND NICHOLS
FORMULAE TO DETERMINE PB% AND TI SECONDS. TD SHOULD BE 0 FOR
LEVEL. USE ONLY PI ACTION FOR LEVEL CONTROL.
19) When a good set of PID values have been established giving reasonably damped
response with minimum overshoot and fast recovery to setpoint, do the following
additional exercises:
a) Level control with and without Derivative (D) action

Put in Derivative (D) control of level into LIC11. Try the following trial PID
values using a level setpoint SV1 = 500 mm.
PB1
: 20 % (or your best value)
TI1 : 30 secs (or your best value)
TD1
: 30 secs i.e. with Derivative (D) control for level.
Disturb the Inflow by opening/closing the by-pass manual valve of pump P12 as
in 16(b). When the Inflow oscillates with large amplitude, it will also cause the
level to oscillate. Double the PB1 of LIC11 to damp out the oscillation and
observe the level response (red pen). (If the oscillation persists, increase PB1
again). Observe that even though the oscillation may be damped out, the response
becomes very slow and sluggish.
When the oscillation is damped, apply the load test disturbance as in 16(b) again
for a retest. Observe the level response (red pen)
Finally restore the PID1 values in LIC11, back to its first (I) trial values i.e. PB1
20%, TI1 30 secs, TD1 = 0 sec. Applied the load test disturbance again as in 16(b)
and observe.With TD1 = 0, there is no Derivative (D) control action. It is best not
to use Derivative (D) action for level control, since level loops are usually noisy.

b) Limit-cycling without a valve positioner (PP) and use of a control valve

positioner (PP)

With LIC11 still in Auto (A) mode, set the best PID values in LIC11 or use
the first (I) trial values PB1 = 20%, TI1 = 30 secs and TD = 0. Wait till the
level is steady at it setpoint SV1 of 500mm. with LIC11 still in Auto (A)
mode, by-pass the positioner (PP) at LCV11 i.e. DO NOT USE THE
POSITIONER (PP)
Observe the level (red pen) response at the recorder patiently. Watch also the
Inflow FT12 through the control valve LCV11 which is the recorder green pen
(Inflow). (Disturb the Inflow FT12 slightly if it is stable). If the Inflow
oscillates with large amplitude causing the level to oscillate, double PB1 to
increase the damping and observe patiently the oscillation pattern. (Disturb
the Inflow slightly again if the level becomes stable, for further observation).
Without the Positioner (PP), the Inflow will limit-cycle with almost constant
amplitude, due to the stem packing and actuator spring friction at the control
valve LCV11. The Inflow (green pen) oscillation may sometime show a
smooth rise, then flatten into a plateau and may fall more sharply at the
trailing end for smaller amplitude oscillation.

The smooth rise starts again and the oscillation persists with almost constant
amplitude. The level (red pen) oscillates with the Inflow (green pen), and may
develop into a triangular oscillation.
Also note that the actuator spring in LCV11 is 7-15 psig and not 3-15 psig.
This means that without a positioner, LCVII can be fully stroked from 7-15
psig (i.e. an input signal change of 8 psig) instead of 3-15 psig (i.e. 12 psig
change). This is a major cause of the oscillation because of the higher valve
gain of 100% (instead of 100%).
8 psi
12 psi
Thus without the Positioner (PP) at LCV11, high gain (due to the 7-15 psig
actuator spring) and friction have been introduced into the control loop,
causing limit cyling oscillation. Oscillation pattern induced by mechanical
friction usually looks perculiar and different from process oscillation.

Try doubling PBI again for further damping and observe patiently the
oscillation pattern. The oscillation will not completely go away. The Inflow
and level may oscillate more sluggishly with longer period. The Inflow may
sometime oscillate with flat-top plateaus.
Restore back the first (I) trial PID values and observe further the oscillation
pattern.
Then connect back the positioner (PP) at LCV11. Observe both the Inflow
(green pen) and level (red pen) patiently.
Limit-cycling caused by friction at the control valve can be minimized
with a positioner which helps to overcome the friction. Damping it with a
larger PB%, is not effective against friction-induced limit cycling.

20a) If the Self Tuning STC1 of LIC11 has been at DISPLAY mode (STC: DISP),
check the PID1 values (PA1, IA1, DA1) at the STC1 page of controller LIC11.
These are the PID values established by the controller self tuning and are
displayed but not implemented, unless STC1 is put to ON mode.
b) Try the controller Self-Tuning (switch STC: ON) to establish and implement its
own P, I and D, if time and opportunity permit. Refer to the manufacturers
Manual for Self-Tuning theory and procedures. Consult your Instructor for
assistance.

EXPERIMENT NO. 2B

Aim

: To study level control using 2-Element (Level-Inflow) PID

Cascade control.

Control System : It consists of the following in feedback and cascade.

PRIMARY LOOP
LT11 - Level, Open or Closed tank T11
LIC11 - Loop 1, PID 1 of LIC/FIC11
SECONDARY LOOP
FT12 - Inflow, Vortex flowmeter
FIC11 - Loop 2, PID 2 of LIC/FIC11
LCY11/PP/LCV11 - Control valve at Inflow pipe, complete with
Current-Air (IP) converter and Positioner
(PP).
Special Remarks : LIC11/FIC11 is in the 2-Element Position 2: Cascade
LIC11- FIC11.
LIC11, Loop1, PID1 in Auto (A) mode.
FIC11, Loop2, PID2 in Cascade (C) mode.
Display LIC11.
Key Process Variable : Level of tank T11
EXPERIMENTAL PROCEOURES
*The previous procedures from 1-20 of Experiment No. 2A are applicable here.
Please continue.
21a) Set the following first (I) trial Pill values into LIC11 and FIC11, using a level
setpoint SVI = 500 mm, throughout this Experiment.

First (I) Trial Value for

LIC11 (Loop1, PID1)
PB1
20 %
TI1
30 secs
TD1
0

First (I) Trial Value for

FIC11 (Loop2, PID2)
PB1
150 %
TI1
6 secs
TD1
0

Switch ON the positioner (PP) at the control valve LCV11 i.e. USE THE
POSITIONER (PP) throughout this experiment unless stated otherwise.
b) Make sure TIC11 is in Manual (M) mode, with its MV = 35% throughout the
Experiment. The Other Demand valve at the Outflow pipeline upstream of
control valve TCV11 remains fully opened, throughout the Experiment.
22) Turn the 1-2-3 Element selector switch located near LIC/FIC11 to the 2-Element
Position 2: CASCADE LIC11- FIC11. Make sure LIC11 (loop1) is in Auto (A)
and FIC11 (Loop 2) is in Cascade (C) mode throughout this Experiment 2B.
If this causes a process bump observe the response of the level (red pen) at the
recorder LFTR11 until it stabilises, or show consistent response for two cycles.
The level setpoint SV1 is 500 mm.
23) Test Disturbances
When the level is almost stable, introduce a process upset at the Inflow. This is
done at (a) and (b) as follows, with the level setpoint SV1 at 500 mm.
a) Open 1-turn, hold for 5 seconds and then shut the by-pass manual valve
around the Inflow pump P12.
b) Switch LIC11 to Manual (M) mode, apply a 10% change at its MV and then
quickly switch LIC11 back to Auto (A) mode.
Observe the level (red pen) and Inflow (green pen) control responses at LFTR11.
If the level (red pen) does no oscillate excessively but dumped out after
two three cycles, then the selected PID values for LIC11 and FIC11 are
able to provide satisfactory damping.
If the Inflow (green pen) is too oscillatory, damp it out with a higher PB2
(at PID 2, FIC11) of say 250% but it is important to not that the target
variable to be controlled is level, not the Inflow. If the level is well
controlled, slight Inflow oscillation is acceptable. Higher Inflow damping
will slow down the level response.
24) Repeat with a few other PID values for both LIC11 and FIC11 (within the range
shown in the Table below). After the change of new PID values, disturb the
Inflow as in 23(a), (b) and watch the level response (red pen) until it is almost
steady or consistent for two cycles.
PB1
TI1
TD1

LIC1(Loop 1, PID 1)
2-100 %
0-100 secs
0 sec

PB2
TI2
TD2

FIC11 (Loop 2, PID 2)

10-400 %
1-30 seca
0 sec

25) - Otherwise use the best PID 2 values established in Experiment No. 1 flow flow
control by FIC11. Use the best PID 1 values established in Experiment No. 2A
for 1-Element level control by LIC11.
- Or else use the second (II) trial PID values as follows, bearing in mind that the
lower PB% and TI secs will be more oscillatory.
Remember to disturb the Inflow as in 23(a), (b) after the change of new PID
values. The level setpoint SV1 remains at 500 mm.
Second (II) Trial Values
for LIC11 (Loop 1, PID1)
PB1
10%
TI1
20 secs
TD1
0 sec

PB2
TI2
TD2

Second (II) Trial Values

for FIC11 (Loop 2, PID 2)
100%
6 secs
0 sec

The above two sets of PID values of lower PB% and TI secs are of higher gain
than those used in 21 previously.
If the level (red pen) does not oscillate excessively but damped out after two or
three cicles, the the selected PID values are able to provide satisfactory damping.
If the cause persisten oscillation, try increasing the PB% and TI secs i.e. Use the
first (I) trial values. (If the Inflow (reen pen) is still oscillatory, increase PB2 (at
PID2, FIC11) to 250% as in 23 previously). But note that the controlled variable
is the level, not the Inflow.
Note that whenever the external selector switch for LIC/EIC11 is turned back to
1-Element Position 1 the control system becomes 1-Element with LIC11
controlling LCV11 directly in single loop, without FIC11. For this Experiment 2B
using level-flow Cascade control, the selector switch must remain in 2-Element
Position 2 with FIC11 in Cascade (C) mode and LIC11 in Auto (A) mode.
26) Limit-Cycling a Valve Positioner (PP) and Use of a Control Valve Positioner
(PP)
Restore the first (I) trial PID values in LIC11 and FIC11. Make sure the external
selector switch for LIC/FIC11 is in Position 2 with LIC11 in Auto (A) mode and
FIC11 in Cascade (C) mode. Wait till the level is steady at its setpoint SV1 = 500
mm.
By-pass the positioner (PP) at the control valve LCV11 i.e. DO NOT USE THE
POSITIONER (PP). Refer to Experiment No. 2A, and follow Procedures 19(b)
Limit-Cycling without a Valve Positioner (PP) and Use of a Control Valve
Positioner (PP), but note that LIC11 is now cascading FIC11. Take this
opportunity to observer patiently any perculiar oscillation pattern, caused by the
mechanical friction at the control valve LCV11. Remember to double PB1 (at
LIC11) or even PB2 (at FIC11) to see whether the limit cycling oscillation can be
damped out.

After this test, connect back the positioner (PP) to the control valve LCV11
and restore back the First (I) PID trial values. Observe if limit cycling can be
reduced with the positioner (PP) acting to overcome the control valve friction.
Limit cycling cannot be damped out with PID tuning.

*NOTE THAT IN TURNING CASCADE LOOPS, THE SECONDARY LOOP (I.E.

FLOW LOOP) SHOULD BE TURNED FIRST AS AN INDEPENDENT LOOP,
WITH ITS OWN OPERATOR SETPOINT. THEN SWITCH THE CONTROLLER
TO 2-ELEMENT CASCADE MODE AND TUNE THE PRIMARY LOOP (I.E.
LEVEL LOOP) WITH ITS OWN OPERATOR SETPOINT. THE SECONDARY
LOOP IS THEN TREATED AS JUST A CONTROLER ELEMENT IN THE
PRIMARY LOOP.

EXPERIMENT NO. 2C

Aim

: To study level control using 3-element (level-Inflow-Outflow) PID

control

Control System : It consist of the following arranged in feedback, cascade and feed
forward.
LT11
: Level, Open or closed Tank T11
LIC11
: Loop 1, PID 1 of LIC/FIC11
FE11
: Outflow orifice plate
FT11
: Outflow DP flow transmitter with
Adder Block : LIC11 Output + FT11
FT12
: Inflow and Vortex flow meter
FIC11
: Loop2, PID 2 of LIC/FIC11
LCY11/PP/LCV11 - Control valve at Inflow pipe, complete with
current-Air, (IP) converter and Positioner, (PP)
Special Remarks: LIC11 FIC11 is in the 3-element position 3: feedforward.
LIC11, Loop 1, PID 1 is in Auto (A) mode
LIC11, Loop2, PID 2 in Cascade (C) mode
Display LIC11
The third element is the outflow FT11. FT11 is added to the
control output of LIC11 and the output of the adder is the
remote setpoint cascaded to FIC11.
FT11 is the feedforward signal of the outflow disturbance.

Key Process Variable : Level of tank T11, measured by LT11

EXPERIMENTAL PROCEOURES
*The previous procedures from 1 to 26 of Experiment No. 2B are applicable here.
Please continue.

27a) Set the following first (I) trial Pill values into LIC11 and FIC11, using a level
setpoint SV1 = 500 mm throughout this Experiment.

First (I) Trial Value for LIC11

(Lopp1 and PID 1)
PB1
20 %
TI1
30 secs
TD1
0 sec

First (I) Trial Value for LIC11 (Lopp2

and PID 2)
PB2
150%
TI2
6 secs
TD2
0 sec

Switch ON the positioner (PP) at the control valve LCV11 i.e. USE THE
POSITIONER (PP).
b) Make sure TIC11 is in Manual (M) mode with its MV = 35%. The Other
Demand valve at the Outflow pipeline upstream of the control valve
TCV11 is fully opened throughout the Experiment.
28) Turn the 1-2-3 Element selector switch located near LIC1/FIC11 to the 3Element Position 3: FEEDFORWARD. LIC11 (Loop 1) is in Auto (A) mode
and FIC11 (Loop 2) in Cascade (C) mode throughout this Experiment 2C.
If this causes a process bump, observe the respotfse of the level (red pen) at
the recorder LFTR11 until it stabilizes, or show consistent response for two
cycles. The level setpoint SV1 is 500 mm.
29) Test Disturbance
a) When the level is almost stable, introduce the following process disturbances
consecutively, one after the other, as if the control system is hit by a series of
disturbance. Use a level setpoint SV1of 500 mm (50%) throughout. Observe
the level response (red pen) at LFTR11 until it stabilizes or show consistent
response for two cycles.

*For each disturbance applied, think of the immediate control action, even
through it is LIC11 in feedback that eventually brings the level to its setpoint.
Note the feedforward control system equation:
Outflow FT11 (feedforward) + LIC11 (feedback) = Setpoint to FIC11 (cascade)

Setpoin upset

Step change the level setpoint SV1 by 50 mm to 450

or 550 mm. Hold for 5 seconds and then step change
SV1 back to 500 mm (50%) to simulate a pulse
setpoint disturbance.
*(Level: LIC11 in level feedback control, cascading
FIC11)

Inflow upset

Open 1-turn, hold for 5 seconds and then shut the bypass manual valve around the Inflow pump P12, to
simulate an Inflow pulse disturbance.
*(h1flow: FIC11 in Inflow feedback control, with
cascaded setpoint from LIC11: LIC11 in level
feedback control).

Inflow upset from the :

controller

Put the controller LIC11 in Manual (M) mode and

quickly step change by 10% its control output (MV)
to the control valve. Quickly put the controller
LIC11 back into Auto (A) mode. Check that FIC11
is still in Cascade (C) mode. This simulates a step
disturbance at the Inflow.
*(Inflow: FIC11 in Inflow feedback control, with
cascaded setpoint from LIC11. LIC11 in level
feedback control).

Outflow upset from the :

controller

With TIC11 in Manual (M) mode, step change its

MV from 35% to 45% for step increase in Outflow.
This simulates a step disturbance at the Outflow.

Shut then Open fully the Other Demand manual

valve simulating an impulse disturbance at the
Outflow.
When this valve is opened, it represents additional
process demand for Outflow in other parts of the
plant. In a typical boiler where the Outflow is steam
the Other Demand could represent the steam
turbine for power generator. It could also represent
Other Demand like heating, drying and
sterilization processes. The Other Demand valve
should remain fully opened after this test
*(Outflow FT11: feedfoward signal
Outflow FT11 + LIC11 Outflow = Setpoint to FIC11

Observe the level control response (red pen) at LFTR11.

If the Inflow (green pen) is to oscillatory, damp it out with a higher PB2 (PID2,
FIC11) of say 25% but it is important to note that the target variable to be
controlled is level, not the Inflow.
b) - When the level is steady, switch the 1-2-3 Element Selector Switch to Position
1: LIC11, for single loop level control. LIC11 must be in Auto (A) mode. With
TIC11 still in Manual (M) mode, step change its MV back to 35%. Wait for the
level to be steady at its setpoint SV1.
- Apply consecutive one after the other, the disturbances described previously in
29(a) and observe the level (red pen) response. The idea is to observe the level
response using Single loop level control (1-Element) when subjected to similar
type of disturbances.
- REMEMBER to switch back the level control to 3-Element Position 3:
FEEDFORWARD with LIC11 in Auto (A) mode and FIC11 in Cascade (C)
mode.

30) Repeat 29(a) with other PID values for both LICll and FICll as shown in the Table
below.
PB1
TI1
TD1

LIC11 (Loop1, PID1)

10%, 20%, 30%, 40%
20, 25, 30 secs
0 secs

PB2
TI2
TD2

LIC11 (Loop2, PID2)

75%, 100%, 150%, 200%, 250%
6 secs
0 secs

Or else use the best sets of PID values established in Experiment 2B. Otherwise
use the second (II) set of trial values as follows:LICll: PB1 = 10%, TI1 = 20 secs, TD1 = 0 sec
FIC11: PB2 = 100%, T12 = 6 secs, TD2 = 0 sec
If the level response is oscillatory, use a higher PB2 and/or PB1 as in the First (I)
trial PID values. Otherwise the second (II) trial PID values with a smaller PB1 and
PB2 are able to provide satisfactory damping.
Remember that the controlled variable is the level, not the Inflow.

31) Limit-cycling without a valve positioner (P) and use of a control valve
positioner (PP)
Restore the First (I) trial PID values in LIC11 and FIC11, in Feedforward
control mode. Make sure the external selector switch for LIC/FIC11 is in
Position 3 with LIC11 in Auto (A) mode and FIC11 in Cascade (C) mode.
Wait till the level is almost steady at its setpoint SV1 = 500 mm.
By-pas,s the positioner (PP) at LCV11 i.e. DO NOT USE THE
POSITIONER.
Watch patiently the Inflow (green pen) which will limit-cycle at almost constant
amplitude, due to the friction at the stem packing and actuator spring of the
control valve LCV 11. Also note that a major cause of the oscillation is also the
higher gain control valve using a 7-15 psig actuator spring (instead of 3-15
psig). Refer to Experiment No. 2A, and follow the Procedures 19(b) LimitCylcing Without a Control Valve Positioner (PP) and Use of a Control
Valve Positioner (PP). Take this opportunity to observe patiently any perculiar
oscillation pattern, caused by the mechanical friction at the control valve
LCV11. Remember to double PB1 (at LIC11) or even PB2 (at FIC11) to see
whether the limit cycling oscillation can be damped out.
After this test, connect back the positioner (PP) to the control valve LCV11
and restore back the First (I) PID trail values. Observe if limit-cycling can be
reduced with the positioner (PP) acting to overcome the control valve friction.
Limit cycling cannot be damped out with PID tuning.

32) PI11 monitors the pressure of the Outflow from tank T11 after the pump P11.
a) When there is no demand for the Outflow produced, i.e. the Other
Demand valve is shut and TCV11 is also shut, the excessive pressure can

be relieved. If necessary, this can be done automatically by setting the

pressure relief valve PRV11 to open, to relieve the Outflow into tank T12.
b) Low alarm Annunciator PAL11 is activated when
Both TCV11 and the Other Demand valve are almost fully opened,
resulting in low pressure at PT11.
When pump PII is OFF.
Check PO7 and PO8 at the PT Register at TIC/FIC12. Refer to previous section on (g)
Data Captured in controllers LIC/FIC11 and TIC11/FIC12 to check the Low
pressure alarm limit and its Dead Band.
RESULTS
The recorder LFTR11 records the results of the experiments.
At each set of PID values, the response of level control is different.
Study and compare the different responses for different PID values.
a) Look for the response that is closest to quarter amplitude damping.
b) Look for a damped response with minimum overshoot, minimum OFFSET and
fast enough recovery to setpoint.
c) Look for the response that gives the minimum total shaded area between its
oscillation around the setpoint and the time axis. This total shade area is the
Integrated Absolute Error (IAE).
d) Look for oscillatory response with inadequate damping (PB% is too low), too
strong Integral action (TI secs is too low) or with Derivative action (TD is not 0).
e) Note also the period of any oscillation.
If any uniform oscillation i.e. oscillation with constant amplitude is obtained, note
the period of oscillation as well as the PID values that cause it. If uniform
oscillation is obtained using only proportional control, the oscillation period is the
uniform natural period (Tn*) and the PB is the ultimate PB*.
f) Examine the response of both the Inflow (green pen) and Outflow (blue pen) for
any limit cycling. Limit cycling can be recognized by an oscillation of almost
constant amplitude that may sometime show a gradual rise in flow and sharp drop
at the trailing end. It is usually repetitive with almost constant amplitude. It is
more likely to appear at the Inflow than the Outflow because the Outflow control
valve at the Outflow pipe is always connected to its positioner.
Also look for limit cycling with triangular waveform at the Level response (red
pen).
g) Examine if the Inflow and Outflow track each other, and whether they become
equal when the level is constant.

RELEVANT PORTIONS OF THE RECORDER CHART RESPONSES

SHOULD BE SUBMITTED AS RESULTS OF THE EXPERIMENT, WITH
THE FOLLOWING PERTINENT DATAS MARKED ON THE
CORRESPONDING CHART RECORDING:
CONTROLLER IN AUTO (A) OR MANUAL (M) MODE, IN SINGLE
LOOP (1), CASCADE (2) OR FEEDFORWARD (3).
SETPOINT.
CONTROLLER IS MANUALLY TUNED OR SELF-TUNED (STC).
PID VALUES AGAINST THE RESPONSE.
ANY ANNUNCIATORS ACTIVATED.
WITHlWITHOUT PP AT LCV11.
WRITE A BRIEF INTERPRETATION OF THE DATAS GATHERED.
NOTE
The period of oscillation and dead time in seconds can be determined from the
recorder chart response using the following relationship:
Time or duration, sec onds

Distance (mm) along the time axis

Recorder chart speed (mm/sec)

The record chart speed is occasionally printed on the chart, for example at 500 mm/Hr
or 7.2 sec/mm.