TITLE OF EXPERIMENT

Temperature Process Control

OBJECTIVES

-To understand the characteristic of proportional (P), proportional-integral (PI) and

proportional-integral-derivative (PID) controller in a temperature control loop.

-To observed the different types of temperature responses to P, PI, and PID controller.

INTRODUCTION

A feedback control loop which is also known as a closed-loop control is a basic

component found in the industrial process control system. A closed-loop control is
able to pass information of the process continuously around the loop, thus creating an
automatic feedback. It consists of interconnecting elements such as the process, the
measurement, the controller and the final control element. The feedback is utilised for
decision making of changes to the control signal that drives the system. 3 types of
control are introduced in this experiment which are the proportional controller (P),
proportional-integral controller (PI) and the proportional-integral-derivative controller
(PID).

A P controller response to the magnitude and the direction of the error in an

attempt to stabilise a system. It calculates the offset which is the error between
measurement and set point, amplifies the signal and adjust the final control element to
reduce the error. The magnitude of both corrective action and error is proportional.
When a process upset occur, the offset must be calculated to change the valve position
in order to adjust the controlled variable back to the set point. The proportional band
(PB) is expressed in percentage and represents the relationship between the output and
the width of measurement span. The PB should not be too narrow as it will result in
cycling. On the other hand, it should not be too wide as it causes the system to be
insensitive.

The PI controller response to the duration, magnitude and direction of error.

The Integral action helps to avoid offset formed by the P control by adjusting the output
back to the set point. When an error is found, the integral control mode either increases
or decreases the output to reduce error. Given an error, the controller’s integral time
sets the speed of the integral action.
 The PID controller responds to all expect errors in a process. It responds to the
direction, magnitude, duration and rate of change. The derivative action allows an
increase in the proportional gain. While integral action increases the cycling period,
derivative actions tends to decrease them, thus producing responds of the same speed
as proportional action without the offset. In this experiment, we are able compare and
observe how the temperature responses to P, PI and PID controller in a temperature
control loop.

MATERIALS AND EQUIPMENTS

Control Panel Plate heat exchanger

Control Valve
Cold water tank

Hot water tank

Figure 1: Temperature Control Unit

RESULTS

Table 1a: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C, P = 100%, I = 600s, D = 0s, SV = 45 ˚C

Time TT01 (°C) Set Point (°C) Output (°C)

Interval(s)
30 44.9 45 14.2
60 45.0 45 14.1
90 45.5 45 13.6
120 45.0 45 14.1
150 44.7 45 14.3
180 45.5 45 13.6
210 45.2 45 13.9
240 44.7 45 14.4
270 45.5 45 13.8
300 45.2 45 13.8
330 44.7 45 14.3
360 45.3 45 13.7
390 45.4 45 13.6
420 44.7 45 14.3
450 45.3 45 13.7
480 40.1 45 19.0
510 39.3 45 20.1
540 43.8 45 15.9
570 45.6 45 14.0
600 45.9 45 13.7
630 45.3 45 14.2
660 45.1 45 14.4
690 45.8 45 13.7
720 45.4 45 14.1
750 45.2 45 14.3
780 45.8 45 13.6
810 45.7 45 13.7
840 44.9 45 14.5
870 45.7 45 13.7
900 46.0 45 13.4
930 45.2 45 14.1
960 45.4 45 13.9
990 45.8 45 13.5
 Graph of temperature against time
P=100%, I=600s, D=0s, SV=45°C
48 25

46
20
44
Temperature (°C)

Output (%)
42 15

40 10
38
5
36

34 360 0
30
60
90
120
150
180
210
240
270
300
330

390
420
450
480
510
540
570
600
630
660
690
720
750
780
810
840
870
900
930
960
990
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 1a: Graph of temperature against time with SV of 45 ˚C.

Table 1b: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 50 ˚C

P = 100%, I = 600s, D = 0s , SV = 50 ˚C, Time Interval: 1 unit = 30s

Time Interval (s) TT01 (°C) Set Point Output (°C)

(°C)
30 49.5 45 45.8
60 50.3 45 45.0
90 50.5 45 44.7
120 44.2 45 51.2
150 43.9 45 51.8
180 49.5 45 46.3
210 49.9 45 46.0
240 49.7 45 46.2
270 50.1 45 45.8
300 49.2 45 46.7
330 49.8 45 46.1
360 49.8 45 46.1
390 50.3 45 45.6
420 50.6 45 45.3
450 49.8 45 46.1
480 50 45 45.9
510 50.4 45 45.5
540 49.3 45 46.6
570 49.8 45 46.2
600 50.3 45 45.6
630 49.9 45 46.0
660 49.9 45 46.0
 Graph of temperature against time
P=100%, I=600s, D=0s, SV=50°C
52 54

50 52

50
Temperature (°C)

48

Output (%)
48
46
46
44
44

42 42

40 40

300
30
60
90
120
150
180
210
240
270

330
360
390
420
450
480
510
540
570
600
630
660
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 1b: Graph of temperature against time with SV of 50 ˚C.

Table 2a: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C

P = 100%, I = 1s, D = 0s , SV = 45 ˚C

Time Interval (s) TT01 (°C) SetPoint Output (°C)

(°C)
30 45.0 45 9.8
60 44.9 45 9.4
90 45.0 45 15.7
120 45.4 45 12.4
150 44.8 45 12.8
180 45.3 45 14.1
210 44.8 45 10.9
240 44.7 45 12.8
270 44.9 45 16.1
300 42.5 45 22.6
330 44.5 45 72.8
360 44.4 45 80.5
390 49.1 45 13.6
420 44.5 45 0
450 45.1 45 11.8
480 44.7 45 7.5
510 45.2 45 15.1
540 45.2 45 13.9
570 44.9 45 9.6
600 44.9 45 13.6
630 45.3 45 11.3
660 45.0 45 10.0
690 44.7 45 13.3
720 45.2 45 13.7
750 44.9 45 9.2
780 45.1 45 6.9
810 44.9 45 15.0
840 45.2 45 13.6
 Graph of temperature against time
P=100%, I=1s, D=0s, SV=45°C

50 90
80
48
70
Temperature (°C)

46 60

Output (%)
50
44
40
42 30
20
40
10
38 0
90

540
30
60

120
150
180
210
240
270
300
330
360
390
420
450
480
510

570
600
630
660
690
720
750
780
810
840
Time (s)

TT01 (°C) SetPoint (°C) Output (%)

Figure 2a: Graph of temperature against time with I = 1s.

Table 2b: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C

P = 100%, I = 100s, D = 0s , SV = 45 ˚C

Time Interval (s) TT01(°C) Set Point (°C) Output (°C)

30 45.3 45 9.9
60 44.8 45 10.4
90 44.4 45 10.9
120 45.1 45 10.2
150 44.9 45 10.4
180 44.5 45 11.0
210 45.2 45 10.4
240 45.4 45 10.0
270 39.2 45 17.4
300 39.4 45 19.0
330 45.4 45 13.7
360 46.0 45 12.9
390 45.4 45 13.3
420 45.1 45 13.6
450 45.8 45 12.7
480 45.5 45 12.7
510 45.0 45 13.2
540 45.7 45 12.4
570 45.4 45 12.5
600 45.0 45 12.9
630 45.6 45 12.2
660 45.4 45 12.2
690 44.7 45 12.9
720 45.3 45 12.3
750 45.5 45 12.0
 Graph of temperature against time
P=100%, I=100s, D=0s, SV=45°C
48 20
18
46
16
44 14
Temperature (°C)

Output (%)
12
42
10
40
8

38 6
4
36
2
34 0
30
60
90
120
150
180
210
240
270
300
330
360
390
420
450
480
510
540
570
600
630
660
690
720
750
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 2b: Graph of temperature against time with I = 100s.

Table 2c: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C

P = 100%, I = 600s, D = 0s , SV = 45 ˚C

Time Interval (s) TT01 (°C) Set Point (°C) Output (°C)
30 44.8 45 12.5
60 45.5 45 11.9
90 45.2 45 12.2
120 44.3 45 13.1
150 39.5 45 18.1
180 39.7 45 18.2
210 39.3 45 18.8
240 45.0 45 13.3
270 45.7 45 12.6
300 45.4 45 12.8
330 44.9 45 13.3
360 45.6 45 12.6
390 45.6 45 12.5
420 44.9 45 13.2
450 45.5 45 12.7
480 45.5 45 12.7
510 44.8 45 13.3
540 45.4 45 12.7
570 45.8 45 12.2
600 45.3 45 12.7
630 44.8 45 13.3
660 45.4 45 12.6
690 45.7 45 12.3
 Graph of temperature against time
P=100%, I=600s, D=0s, SV=45°C
48 20
18
46
16
14
Temperature (°C)

44

Output (%)
12
42 10
8
40
6
4
38
2
36 0
30
60
90
120
150
180
210
240
270
300
330
360
390
420
450
480
510
540
570
600
630
660
690
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 2c: Graph of temperature against time with I = 600s.

Table 3a: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C

P = 100%, I = 600s, D = 10s

Time Interval (s) TT01 (°C) Set Point (°C) Output (°C)
30 44.7 45 13.2
60 45.5 45 12.4
90 45.4 45 12.7
120 44.7 45 13.4
150 45.2 45 12.5
180 40.0 45 18.6
210 39.2 45 19.3
240 39.3 45 19.2
270 44.8 45 12.9
300 45.9 45 12.8
330 45.3 45 13.6
360 45.3 45 13.1
390 45.9 45 12.6
420 45.9 45 13.1
450 45.2 45 13.6
480 45.3 45 13.0
510 45.8 45 12.8
540 45.7 45 12.7
570 45.5 45 13.3
600 45.0 45 13.5
630 45.6 45 12.6
660 45.7 45 13.0
690 45.1 45 13.5
720 45.5 45 12.8
 Graph of temperature against time
P=100%, I=600s
48 25

46
20
44
Temperature (°C)

Output (%)
15
42

40
10

38
5
36

34 0
30
60
90
120
150
180
210
240
270
300
330
360
390
420
450
480
510
540
570
600
630
660
690
720
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 3a: Graph of temperature against time with I = 600s.

Table 3b: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C

P = 100%, I = 600s, D = 50s , SV = 50 ˚C

Time Interval (s) TT01 (°C) Set Point (°C) Output (°C)
30 45.3 45 13.7
60 45.2 45 12.7
90 45.7 45 11.8
120 45.5 45 13.2
150 45.0 45 13.6
180 44.9 45 15.3
210 40.4 45 22.1
240 39.7 45 19.4
270 44.2 45 8.3
300 45.0 45 12.8
330 45.0 45 13.3
360 45.5 45 12.5
390 45.3 45 14.0
420 45.3 45 13.0
450 45.7 45 12.3
480 45.6 45 13.7
510 45.0 45 14.5
540 45.3 45 12.7
570 45.3 45 13.6
600 44.9 45 14.1
630 45.4 45 12.5
660 45.3 45 13.6
690 45.0 45 13.7
720 45.0 45 12.4
 Graph of temperature against time
P=100%, I=600s,D= 50s, SV=45°C
47 25
46
45 20
44
Temperature (°C)

43

Output (%)
15
42
41
10
40
39
38 5

37
36 0
30
60
90
120
150
180
210
240
270
300
330
360
390
420
450
480
510
540
570
600
630
660
690
720
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 3b: Graph of temperature against time with D = 50s.

Table 3c: Data of temperature change in TT01 and percentage of output with
respective time interval.

Target Set Point: 45 ˚C

P = 100%, I = 600s, D = 100s , SV = 45 ˚C

Time Interval (s) TT01 (°C) Set Point Output (°C)

(°C)
30 45.2 45 12.6
60 45.7 45 11.7
90 45.3 45 14.2
120 45.2 45 13.4
150 45.6 45 11.9
180 45.3 45 13.9
210 40.9 45 26.9
240 40.3 45 21.9
270 43.9 45 8.2
300 44.7 45 10.8
330 44.7 45 13.8
360 44.9 45 13.0
390 45.4 45 12.2
420 45.0 45 14.8
450 45.0 45 13.9
480 45.4 45 12.7
510 45.1 45 14.6
540 44.9 45 14.4
570 45.4 45 12.8
600 45.6 45 12.9
630 45.1 45 15.1
660 45.1 45 13.6
690 45.4 45 13.3
 Graph of temperature against time
P=100%, I=600s,D= 100s, SV=45°C
47 30
46
25
45
44
Temperature (°C)

20

Output (%)
43
42 15
41
10
40
39
5
38
37 0
30
60
90
120
150
180
210
240
270
300
330
360
390
420
450
480
510
540
570
600
630
660
690
Time (s)
TT01 (°C) SetPoint (°C) Output (%)

Figure 3c: Graph of temperature against time with D = 100s.

DISCUSSION

This experiment was carried out to understand the characteristic of

proportional (P), proportional-integral (PI) and proportional-integral-derivative (PID)
controller in a temperature control loop. It is also to observe the different types of
temperature responses to P, PI and PID controller. The experiment was carried out by
varying either proportional, integral or derivative and fix the other 2 variables. The
data were obtained for every 30 seconds for each sets of experiment. From the results
obtained, TT01 represents the process variable, where it indicates the temperature of
the cold water outlet. The set point is the set point temperature of the cold water outlet,
where as the output indicates the opening of the valve that controls the flowrate of the
hot water.

Effect of Load Change on the Temperature Control System

In every experiment with P, PI or PID controller, the flow rate of cold water
was set to 5 LPM. After getting a few sets of data, the flow rate of cold water was
changed to 10 LPM for 1 minute to obtain 2 sets of data. By referring to all graphs
obtained, as the flow rate of cold water increased, the value of output varied. The
increasing trend can be observed in every graphs obtained as the effect of load change
on temperature control system. The effect of load change is the biggest in figure 2a
which the output increased 22.6% to 72.8%. The output percentage indicates the
percentage of the opening of control valve which control the water flow rate of hot
water flows into the heat exchanger in the temperature control system. As the flow rate
of cold water increased, the flow rate of hot water increased as well to maintain the
desired set point temperature by increasing the output percentage. As the flow rate
decreased to 5 LPM, the temperature in the heat exchanger increased instantly. To
control the temperature at desired temperature, the output percentage decreased again.
A new steady state was achieved after a load change was applied.

Effect of Set Point Change on the Temperature Control System

From the first experiment, the proportional, integral and derivative controller
were fixed at 100%, 600s and 0s respectively, while the set point of the temperature
was varied from 45°C to 50°C. When the set point increases, the value of the output
increases. When the desired temperature increases from 45°C to 50°C, the opening of
the valve at the hot water flow will be increased. This is to increase the amount of
energy passing through which will increase the temperature to the desired set point
value.

Effect of Tuning of PI & PID Controller on the Process Response

Tuning is a process to set the optimal gains for P, I and D to obtain an ideal
response from the control system (National Instruments, 2011). According to Table 2a,
2b, and 2c, when the experiment of PI controller was carried out, the value of
proportional controller was set to 100%, whereas the value of integral controller was
varied at 1s, 100s, and 600s. As the integral increases, the readings of the process
variable, TT01 are closer to the set point value of 45°C, where the readings are within
a range of ±1°C as compared to the set point value. When the integral variable was set
at 1s, the output value fluctuated, but the output remained relatively constant when the
integral controller was set at 100s and 600s. If the integral value is too low, the stability
will be low, which results in the fluctuation of the output. Theoretically, when the
integral variable increases, the offset will decrease, and the time required to achieve
steady state will be faster.

When conducting the experiment of PID, the value of proportional controller

and integral controller were fixed at 100% and 600s respectively, while the derivative
controller was varied from 10s to 50s and 100s. According to Table 3a, 3b, and 3c, as
the derivative variable increases, the values of TT01 obtained were relatively constant
and the values are within the range of ±1°C from the set point value of 45°C. Similarly,
the values of the output were relatively constant as the integral variable increases.
Theoretically, when the derivative variable increases, the system will react to the
disturbance faster, which decreases the time needed to achieve steady state.

Comparison of PI &PID Controller on the Temperature Control System

Figure 4: Comparison of System Response to a Process Upset with PI and PID

Control
 Theoretically, by referring to the graph above, the addition of derivative action
to a proper adjusted PI controller will cause the period to complete a cycle become
shorter than only with PI controller. Therefore, PID controller should be better than PI
controller in this case. In this experiment, overshoot percentage is one of the criteria
to compare the three types of controllers. By comparing figure 2a, 2b and 2c, figure 2a
shows that the values of temperature of cold water are the nearest to the setpoint after
the system had stabilized, forming lowest overshoot percentage. The value of I used
in figure 2a is the lowest among the 3 sets of data which is 1s. Low overshoot
percentage indicates that the situation with I=1s was the most stable system. In addition,
by comparing figure 3a,3b and 3c, the difference between the overshoot percentage is
not obvious. It might due to the inaccuracy of the temperature control system. The
overshoot percentage should be lower as the value of D increases. Theoretically, PID
controller should give a better result compared to PI. However, the results we obtain
from PI and PID controller have no big differences, meaning the PID controller this
experiment might not be performing well to show accurate result.

Precautions

Firstly, it was ensured that the water pump was not switched on when there is
no water in the tank or the water level is low. Besides that, not more than 0.4MPa of
pressure was applied to the electro-pneumatic proportional valve. Other than that, the
setting of the control valve and sensor were not change. Lastly, the apparatus was
switched off when there is any leakage.

Recommendations

The instrument used in this experiment should be well-insulated to prevent

any heat loss to the surrounding. The water level should also be checked from time to
time, the water pump should be turned off when the water level is too low.

CONCLUSION

In this experiment, the characteristic of proportional (P), proportional-integral

(PI) and proportional-integral-derivative (PID) controller in a temperature control loop
were studied. The different types of temperature responses to P, PI, PID controller
were also observed and analysed.
REFERENCE
National Instruments. (2011, March 29). PID Theory Explained. Retrieved from National
Instruments: http://www.ni.com/white-paper/3782/en/