EMM 3502

CONTROL SYSTEM
ENGINEERING

LAB MANUAL

Created on September 2016 (by KFAB)

 Department of Mechanical & Manufacturing Engineering
Faculty of Engineering, Universiti Putra Malaysia

M
M
3
7. PI- PRESSURE CONTROL SYSTEM 5
0
2

Objective: C
O
N
To study the effect parameter of Proportional (P) and Integral (I) component value to the T
performance of pressure control system. R
O
L
Introduction: S
Y
Nowadays modern plants, processes are controlled to achieve desired objectives. In this case, S
pressure measurement are used in many area such as taken in tank storage, pumps, compressors, T
E
furnaces, reactors, heat exchangers, etc. or from the connecting piping to or from the M
equipment. To prevent and minimize major erroneous a control system is required for the
equipment to perform at its best. By tuning the P, I and D parameters, the controller is able to
rapidly correct it output in response to a step change in the error. The correction is to be
performed without excessive overshooting of the controlled variables. Therefore, a good trial -
and-error method may be apply and follow a geometrical progression in the search for optimal
parameters.

Apparatus:
Pressure Control SM529PC

Procedure:

Tuning with the trial and error method

First for startup, check all piping lines and each component (valve, sensor, tank storage, etc.) in the pressure
control is working function and in good condition.

1. On the machine system and pump system (green light).

2. Open the DAQ Software in the computer and press the connect button. Make sure the
pump is not running.
3. Right click at the left box of the software panel on the TK1 (pressure control) and click
run all parameters.
4. In the right box of software panel, scroll down to Parameter 2 section. Then, set the SV
setting value of the pressure desired to run (Max Range: 40)
5. Adjusting the P element
a. With the controller in manual mode (parameter 2), turn off the integral and
derivative action by setting the value to 0.
b. Set a value on the P controller gain to an arbitrary but small value such as 10.
c. Click on run and log button in the software to record the data.
d. Start the pump for the water to pressurize the tank.
e. Observe the response from the graph. The set value and preset value point
change should be typical of the expected use of the system.
f. Increase the P controller gain by a factor of 2 and make another step change
in the set point to see the effect on the response of the controlled variable. The
objective is to find the value of P gain at which the response becomes
underdamped and oscillatory. This is the ultimate controller gain. Once the
ultimate controller gain is reached, revert back to the previous value of P gain.
Now the P gain value is set well enough to add another control action if
required.
6. Adjusting the I element
a. Start bringing in integral action by setting the integral time at an arbitrarily
high value (for example: 10). Decrease by factors of 2, making a set point
change after each setting. Do so until it reach a value at which the response of
the controlled variable becomes underdamped and oscillatory. At this point
revert back to the previous value by increase twice its value.
b. Then, the I gain value is now set and can proceed to the adjustment of the D
action if required.
7. Record the graph obtain after the process of optimal tuning by trial and error method
by click the stop button in the software. Make sure to save as image and also in excel
csv format for future reference.
 Department of Mechanical & Manufacturing Engineering
Faculty of Engineering, Universiti Putra Malaysia

M
M
3
Results: 5
0
1. Show all the result obtain and finalized for optimal result after tuning process by 2

trial and error method. C
2. Observe the increase/decrease of the P and I controller parameter for the response. O
N
T
R
Discussion: O
L
1. Discuss the trial and error method for obtain best approach. S
2. Describe the error encounter during the experiment performed. Y
S
3. Recommend other method if possible. T
E
M
 Department of Mechanical & Manufacturing Engineering
Faculty of Engineering, Universiti Putra Malaysia

M
M
8. PID- PRESSURE CONTROL SYSTEM 3
5
0
2
Objective:
C
O
To study the effect parameter of Proportional (P), Integral (I) and Derivative (D) component value to N
the performance of pressure control system. T
R
O
Introduction: L
S
Nowadays modern plants, processes are controlled to achieve desired objectives. In this case, Y
pressure measurement are used in many area such as taken in tank storage, pumps, compressors, S
T
furnaces, reactors, heat exchangers, etc. or from the connecting piping to or from t he E
equipment. To prevent and minimize major erroneous a control system is required for the M
equipment to perform at its best. By tuning the P, I and D parameters, the controller is able to
rapidly correct it output in response to a step change in the error. The correction is to be
performed without excessive overshooting of the controlled variables. Therefore, a good trial -
and-error method may be apply and follow a geometrical progression in the search for optimal
parameters.

Apparatus:
Pressure Control SM529PC

Procedure:

Tuning with the trial and error method

First for startup, check all piping lines and each component (valve, sensor, tank storage, etc.) in the pressure
control is working function and in good condition.

1. Follow the procedure in Experiment 7 (PI- Pressure Control System) from 1 to

6. Make sure the set value pressure is per assigned.
2. Adjusting the D element
a. Start bringing in derivation action by setting the derivative time at an
arbitrarily low value (for example: 5). Increase by factors of 2, making a
set point change after each setting. Do so until it reach a value that gives
the fastest response without amplifying the overshooting or creating
oscillation.
b. The D element is now set.
3. Fine tuning of the parameters until the requirements regarding the response
time and overshooting of the controlled variable are satisfied
4. Record the graph obtain after the process of optimal tuning by trial and error
method by clicking the stop button in the software. Make sure to save as image
and also in excel csv format for report purpose.

Results:

1. Show all the result obtain and finalized for optimal result after tuning process by
trial and error method.
2. Observe the increase and decrease for the P and I controller parameter.

Discussion:

1. Discuss the trial and error method for obtain best approach.
2. Describe the error encounter during the experiment performed.
3. Explain the influence of D element in the controller.
4. Recommend an improvement or other method if possible.
 Department of Mechanical & Manufacturing Engineering
Faculty of Engineering, Universiti Putra Malaysia

M
M
9. PI- LEVEL/FLOW CONTROL SYSTEM 3
5
0
2
Objective:
C
O
To study the effect parameter of Proportional (P) and Integral (I) component value to the N
performance of level/flow control system. T
R
O
Introduction: L
S
Nowadays modern plants, processes are controlled to achieve desired objectives. In this case, Y
pressure measurement are used in many area such as taken in tank storage, pumps, compressors, S
T
furnaces, reactors, heat exchangers, etc. or from the connecting piping to or from the E
equipment. To prevent and minimize major erroneous a control system is required for the M
equipment to perform at its best. By tuning the P, I and D parameters, the controller is able to
rapidly correct it output in response to a step change in the error. The correction is to be
performed without excessive overshooting of the controlled variables. Therefore, a good trial -
and-error method may be apply and follow a geometrical progression in the search for optimal
parameters.

Apparatus:
Pressure Control SM529PC

Procedure:

Tuning with the trial and error method

First for startup, check all piping lines and each component (valve, sensor, tank storage, etc.) in the pressure
control is working function and in good condition.

1. On the machine system and pump system (green light).

2. Open the DAQ Software in the computer and press the connect button. Make
sure the pump is not running.
3. Right click at the left box of the software panel on the TK1 for level control
(TK2 for flow control) and click run all parameters.
4. In the right box of software panel, scroll down to Parameter 2 section. Then,
set the SV setting value of the level desired to run (Max Range: 6)
5. Adjusting the P element
a. With the controller in manual mode (parameter 2), turn off the integral and
derivative action by setting the value to 0.
b. Set a value on the P controller gain to an arbitrary but small value such as
5.
c. Click on run and log button in the software to record the data.
d. Start the pump for the water to enter the tank.
e. Observe the response from the graph. The set value and preset value point
change should be typical of the expected use of the system.
f. Increase the P controller gain by a factor of 2 and make another step change
in the set point to see the effect on the response of the controlled variable.
The objective is to find the value of P gain at which the response becomes
underdamped and oscillatory. This is the ultimate controller gain. Once the
ultimate controller gain is reached, revert back to the previous value of P
gain. Now the P gain value is set well enough to add another control action
if required.
6. Adjusting the I element
a. Start bringing in integral action by setting the integral time at an arbitrarily
high value (for example: 5). Decrease by factors of 2, making a set point
change after each setting. Do so until it reach a value at which the response
of the controlled variable becomes underdamped and oscillatory. At this
point revert back to the previous value by increase twice its value.
b. Then, the I gain value is now set and can proceed to the adjustment of the
D action if required.
7. Record the graph obtain after the process of optimal tuning by trial and error
method by click the stop button in the software. Make sure to save as image
and also in excel csv format for future reference.
 Department of Mechanical & Manufacturing Engineering
Faculty of Engineering, Universiti Putra Malaysia

M
M
3
5
Results: 0
2

1. Show all the result obtain and finalized for optimal result after tuning process C
by trial and error method. O
2. Observe the increase and decrease for the P and I controller parameter. N
T
R
O
Discussion: L
S
1. Discuss the trial and error method for obtain best approach. Y
S
2. Describe the error encounter during the experiment performed. T
3. Recommend other method if possible. E
M
 Department of Mechanical & Manufacturing Engineering
Faculty of Engineering, Universiti Putra Malaysia

M
M
10. PID- LEVEL/FLOW CONTROL SYSTEM 3
5
0
2
Objective:
C
O
To study the effect parameter of Proportional (P), Integral (I) and Derivative (D) component value to N
the performance of level/flow control system. T
R
O
Introduction: L
S
Nowadays modern plants, processes are controlled to achieve desired objectives. In this case, Y
level/flow measurement are used in many area such as taken in tank storage, pumps, S
T
compressors, furnaces, reactors, heat exchangers, etc. or from the connecting piping to or from E
the equipment. To prevent and minimize major erroneous a contr ol system is required for the M
equipment to perform at its best. By tuning the P, I and D parameters, the controller is able to
rapidly correct it output in response to a step change in the error. The correction is to be
performed without excessive overshooting of the controlled variables. Therefore, a good trial -
and-error method may be apply and follow a geometrical progression in the search for optimal
parameters.

Apparatus:
Level/Flow Control SM213PB

Procedure:

Tuning with the trial and error method

First for startup, check all piping lines and each component (valve, sensor, tank storage, etc.) in the pressure
control is working function and in good condition.

1. Follow the procedure in Experiment 9 (PI- Level/Flow Control System) from 1

to 6. Make sure the set value level is per assigned.
2. Adjusting the D element
a. Start bringing in derivation action by setting the derivative time at an
arbitrarily low value (for example: 1). Increase by factors of 2, making a
set point change after each setting. Do so until it reach a value that gives
the fastest response without amplifying the overshooting or creating
oscillation.
b. The D element is now set.
3. Fine tuning of the parameters until the requirements regarding the response
time and overshooting of the controlled variable are satisfied
4. Record the graph obtain after the process of optimal tuning by trial and error
method by clicking the stop button in the software. Make sure to save as image
and also in excel csv format for report purpose.

Results:

1. Show all the result obtain and finalized for optimal result after tuning process
by trial and error method.
2. Observe the increase and decrease for the P, I and D controller parameter.

Discussion:

1. Discuss the trial and error method for obtain best approach.
2. Describe the error encounter during the experiment performed.
3. Explain the influence of D element in the system
4. Recommend other method if possible.