1.

1 Introduction

Figure 1 The CE117 Process Trainer

The CE117 Process Trainer is a fully integrated self-contained bench top process control
apparatus. For safety reasons water is used as the working fluid. The equipment allows
practical student investigations into a wide range of strategies for the control of:
• Flow
• Level
• Temperature
• Pressure

1
 TecQuipment CE117 Process Trainer

Support Material

CE2000 Control Software

Figure 2 Sample Screenshot of the CE2000 Control Software

The CE117 Process Trainer is supplied with Windows® based CE2000 Control Software that
allows,
• Controller design and implementation
• Supervisory control
• Data acquisition, storage and display
• The setting of control parameters and gains
• Real time trend display

2
1.2 General Description
The CE117 Process Trainer hardware is supplied in two main parts,
• The Experiment Module
• The Control Module

Two multi-way leads (supplied) connect the two modules together. Section 1.3 provides
full installation information for the CE117 Process Trainer.

The Experiment Module

Figure 3 The Experiment Module

The Experiment Module is a bench-mounting unit that supports all of the process
control hardware of the CE117 on its front panel. This module also contains the power
supplies for each of the devices and circuits of the CE117, as well as the power amplifiers
for the actuators and signal conditioning circuits for the transmitters. The CE117
Process Trainer includes two separate flow circuits - a Process/Cooler Flow Circuit and a
Heater Flow Circuit.

3
Process/Cooler Flow Circuit

The Process/Cooler Flow Circuit includes:

• A Process Vessel with a Drain Valve and an Air Vent
• A Reservoir
• A variable speed d.c. motor driven pump (Pump 2)
• A Cooler comprising a radiator and a variable speed fan
• A servo-controlled Proportional Valve
• A Process Loop Bypass Valve

All these parts are joined by colour coded pipework to form the complete Process Flow
Circuit.

Air Vent Flow Temperatur

Transmitter e
Transmitter
TT4

Level Transmitter LT

Process Vessel

Cooler

Drain Bypass Valve

Valve

Reservoir
Pump 2

4
Heater Flow Circuit

The Heater Flow Circuit comprises:

• A Heater Tank
• A Heat Exchanger Coil mounted in the base of the Process Vessel
• A variable speed d.c. motor driven pump (Pump 1)

Thermal Switch

Heater Tank
Heat
Sight Glass Exchanger

Flow Transmitter

Pump 1

Figure 5 The Heater Flow Circuit

5
The Control Module

Figure 6 The Control Module

The Control Module provides access to all of the actuator and transmitter circuits
contained in the Experimental Module. It also provides the interface between the CE117
Process Trainer and the PC for up to 4 channels of analogue-to-digital conversion (AD) and
eight channels of digital-to-analogue conversion (DA).

The Control Module Mimic Panel

The front panel of the Control Module includes a Mimic Panel that provides schematic
detail of the layout and functionality of the complete CE117 Process Trainer. It also
provides the means to physically access the inputs and outputs of the transmitters and
actuators of the CE117.

VENT H
VALVE

D/A1 A/D1 A/D5

CE117
PROCESS TRAINER D/A2 ADA A/D2 A/D6

PT PROCESS
VESSEL D/A3 A/D3 A/D7

D/A4 A/D4 A/D8

FT2
LT

HEATER
TANK
COOLER
HEAT
EXCHANGER TT4
TT5
S

TT1 FAN

STIRRER
PROPORTIONAL
VALVE

ELECTRIC
HEATER
OFF
TT2
ON
H DRAIN
VALVE

TT3

BYPASS
VALVE
FT1
H

EXT E R NA L MANUAL
RESERVOIR

PUMP 1 PUMP2

KEY
TT1 -- HEATER TANK
TEMPERATURE TRANSMITTER
TT2 -- HEAT EXCHANGER OUTPUT
MANUAL TEMPERATURE TRANSMITTER MANUAL
TT3 -- PROCESS LOOP COOLER INLET
TEMPERATURE TRANSMITTER
TT4 -- PROCESS LOOP COOLER OUTLET
TEMPERATURE TRANSMITTER HEATER TANK
M TT5 -- PROCESS T ANK M
TEMPERATURE TRANSMITTER LOW LEVEL
FT1 -- HEATER LOOP

6
FLOW TRANSMITTER RESERVOIR TANK
FT2 -- PROCESS LOOP LOW LEVEL
EXTERNAL FLOW TRANSMITTER EXTERNAL
LT -- PROCESS VESSEL
LEVEL TRANSMITTER
PT -- PROCESS VESSEL
PRESSURE TRANSMITTER
Figure 7 The Control Module Mimic Panel

7
Process Vessel Section

VE NT H
VALVE

D/ A1

D/ A2

PT PROCESS
D/ A3
VESSEL

D/ A4

FT2
LT

HE AT
EX CHA NG E R
TT5

STI RRE R
PROP O RTI O NAL
VALVE

OFF

ON
H DRAI N
VALVE

Figure 8 Process Vessel Section of the Mimic Panel

This section of the Mimic Panel includes sockets for the:

• Input to the Proportional Valve (S) to control its degree of opening - open, closed or
some intermediate setting
• Output signal from the Pressure Transmitter (PT)
• Output signal from the Level Transmitter (LT)
• Output signal from the Temperature Transmitter (TT5)
• Output signal from the Flow Transmitter (FT2) measuring the flow rate into

the Process Vessel A toggle switch labelled ON/OFF controls the Stirrer mounted

in the base of the Process Vessel. Cooler Section

A/ D4 A/ D8

COOLER

TT4

FAN

AL

TT3

BYP ASS
VALVE
H

Figure 9 The Cooler Section

This section of the Mimic Panel includes sockets for the:

• Output signal from the Temperature Transmitter (TT3), located at the input to the Cooler
• Output signal from the Temperature Transmitter (TT4), located at the output of the Cooler
8
A rotary potentiometer is included to allow the speed of the cooling fan to be varied from
zero to maximum, and hence control the heat transfer rate achieved by the Cooler.

Heater Tank Section

HEATER
TANK

TT1

ELE CTRI C
HE ATE R

TT2

FT1

EXTERNAL MANUAL

Figure 10 Heater Tank Section

This section of the Mimic Panel includes sockets for the:

• Output signal from the Temperature Transmitter (TT1), located in the side of the
Heater Tank to provide a measure of the temperature of the water inside the Tank
(the outflow temperature)
• Output signal from the Temperature Transmitter (TT2) located in the return pipework
to measure of the temperature of the water re-entering the Heater Tank from the
Process Vessel (the inflow temperature)

A 2 mm socket and a potentiometer provide control over the delivery of Pump 1 in the
Heater Flow Loop. A toggle switch selects whether the pump speed is controlled
manually (Manual), or whether it is controlled using an external source (External).

Reservoir Section

TT3

BYP ASS
VALVE
FT1
H

RESERVOIR

PUMP2

KE Y
TT1 -- HEATER TANK
TEMPER ATU RE TR AN SM IT T ER
TT 2 -- H EAT EXC H AN GER OUT PU T
TEM PER ATU RE TR AN SM IT T ER MANUAL
TT 3 -- PROC ESS LOOP C OOLER IN LET
TEMPER ATU RE TR AN SM IT T ER
TT 4 -- PROC ESS LOOP C OOLER OUT LET
TEMPER ATU RE T R AN SM ITT ER
TT 5 -- PROC ESS T AN K M
TEM PER ATU RE TR AN SM IT T ER
FT 1 -- HEAT ER LOOP
FLOW TR AN SM IT TER
FT 2 -- PROC ESS LOOP
FLOW T RAN SMITTER
AL EXTE RNAL
LT -- PROC ESS VESSEL
LEVEL T RAN SMITTER

Figure 11 The Reservoir Section

This section of the Mimic Panel includes:

• A 2 mm socket and a potentiometer to provide control over the delivery of Pump 2 in
9
 the Process Flow Loop.
• A toggle switch to select whether the pump speed is controlled manually (Manual),
or whether it is controlled using an external source (External).

Low Water Level Switches and Indicators

HEATER TANK
LOW LEVEL

RESERVOIR TANK
LOW LEVEL

Figure 12 Low Water Level Indicators

The bottom right-hand corner of the Control Module includes two LED indicators.

If the level of water in either the Heater Tank or the Process Vessel falls below a minimum
level, then the Float Level Switches included in both tanks will open and disable the
respective pump (Pump 1 or 2 respectively). The specific action will be indicated by the
relevant indicator LED illuminating. The Heater in the Heater Tank is also turned off if the
water level becomes too low.

Once the level in the tank increases above the minimum, then the Float Level Switch closes,
the pump supply is re-enabled and the LED indicator goes out.

The ADA Section

D/A1 A/D1 A/D5

D/A2 ADA A/D2 A/D6

D/A3 A/D3 A/D7

D/A4 A/D4 A/D8

Figure 13 The ADA Section

The ADA Section of the Mimic Panel is the interface between the transmitters and
actuators of the CE117 Process Trainer and a PC running the CE2000 Control Software
supplied. It provides all of the facilities required to be a multi-channel data acquisition
and control system.

The ADA facilities provided are;

10
• 8 A-D Inputs - 12 bit, ±10 V.
• 4 D-A Outputs - 12 bit, ±10 V.

it is normal to use the abbreviations ‘AD’ and ‘DA’ for analogue to digital
NOTE
and digital to
analogue conversion.

A serial connection is included at the rear of the Control Module. The serial lead
provided allows the CE117 to be connected to a suitable port of the host computer.

0 V signal input and output

reference sockets for other
controllers.

Figure 15 Back View of Control Module

Ite Analogue Conversion Details

m Signal
PRT T 0 - 10 VDC 10°C per
Temperature T1 Output Volt 0 V
Transmitters T Linear = 0°C
(Platinum T2
10 V = 100°C
Resistance T
Thermometer T3
s) T
T4
T
T5

11
 Flow FT 0 - 10 VDC 1 L/min
Transmitters 1 Output per Volt 0
FT V = No
2
flow
Level LT 0 - 10 VDC 0 V = Empty
Transmitter Output Vessel 10 V =
Non Maximum
Linear Level
Pressure PT 0 - 10 VDC 100 mbar
Transmitter Output per Volt 0 V =
0 mbar
(gauge)
Electric Heater 0 - 10 VDC 75 W per
Input Volt 0 V =
Heater Off
10 V = 750 W Maximum
Power (Nominal)
Proportional S 0 - 10 VDC 0V=
Valve Input Closed
10 V =
Open
Pump 1 0 - 10 VDC 0 V = No Flow
Pump 2 Input 10 V =
Maximum Flow

Table 1 Analogue Signal Sockets on the Mimic Panel

12
Experiments
VENT H
VALVE

D/A1 A/D1 A/D5

CE117
PROCESS TRAINER D/A2 ADA A/D2 A/D6

PT PROCESS
D/A3 A/D3 A/D7
VESSEL

D/A4 A/D4 A/D8

FT2
LT

HEAT ER
TANK
COOL ER
HEAT
EXCHA NGE R TT4
TT5
S

TT1 FAN

STIRRER
PROPORTIONAL
VALVE

ELECTRI C
HEATE R
OFF
TT2
ON
H DRAI N
VALVE

TT3

BYPASS
VALVE
FT1
H

EXTERNAL MANUAL
RESERVOIR

PUMP 1 PUMP2

KEY
TT1 -- HEATER TANK
TEMPERATURE TR ANSM ITT ER
TT2 -- H EAT EXCH ANGER OUT PUT
MANUAL TEMPERATURE TRAN SMITTER MANUAL
TT3 -- PROCESS LOOP C OOLER IN LET
TEMPERATURE TR ANSM ITT ER
TT4 -- PROCESS LOOP C OOLER OUTLET
TEMPER ATURE TRAN SMITTER HEATER TANK
M TT5 -- PROCESS TANK M
TEMPERATURE TRANSMITTER LOW LEVEL
FT1 -- HEATER LOOP
FLOW TRAN SMITTER
RESERVOIR TANK
FT2 -- PROC ESS LOOP LOW LEVEL
EXTERNAL FLOW TRANSMITTER EXTERNAL
PROCESS VESSEL
LT --
LEVEL TR ANSMITTER
PT -- PR OCESS VESSEL
PRESSUR E TRANSMITT ER

Figure 38 Connections for Experiment 1 Procedure 2.

Figure 39 Screenshot of Experiment 1 Procedure 2

Proportional Valve

FT
Process Vessel
(Stirred Tank)
Flow Transmitter

Drain Valve

Pump 2

Reservoir

Figure 40 Schematic of Experiment 1 Procedure 2

Page 34 of 35
Procedure 2 - Process Loop Pump and Valve Characteristics

1) Create two blank results tables similar to Table 4 and Table 5.

2) Start the CE2000 software

3) Close the process loop bypass valve, fully open the process vessel drain valve and
open the air vent valve.

4) Connect the CE117 Mimic Panel as shown in Figure 38. Set Pump 2 switch to
‘External’. Analogue signals will pass from the ADA section to Pump 2, the
proportional valve S and from flow transmitter FT2. The software will display the
flow through the process loop.

Pump Characteristic

5) On the software, set the pump voltage to 0 V and apply a full 10 V to the valve
(fully open). Run the software. In 1 V steps, increase the pump voltage from 0 to 10 V.
After each voltage increase, wait for the flow to stabilize, the chart will help. Use
your blank table to record the corresponding flow transmitter voltages. You may
also use the record button on the software to record your readings.

6) Convert the flow transmitter voltage into flow rate in Litre per minute. Table 1 on page
10 gives details of voltage and flow rate conversions.

7) Draw a block diagram of the control system. Create a chart of Flow (volt) on the
vertical axis against Pump (volt) on the horizontal axis. You may use the CE2000
software to do this for you. Your curve is the pump flow characteristic.

Valve Characteristic

8) On the software, set the valve voltage to 0 V and apply a full 10 V to the pump
(full flow). Run the software. In 1 V steps, increase the valve voltage from 0 to 10 V.
After each voltage increase, wait for the flow to stabilize, the chart will help. Use
your blank table to record the corresponding flow transmitter voltages. You may
also use the record button on the software to record your readings.

9) Convert the flow transmitter voltage into flow rate in Litre per minute. Table 1 on page
10 gives details of voltage and flow rate conversions.

10) Draw a block diagram of the control system. Create a chart of Flow (volt) on the
vertical axis against Valve (volt) on the horizontal axis. You may use the CE2000
software to do this for you. Your curve is the valve characteristic.

Page 34 of 35
 Pump Flow Transmitter Flow Rate
(Volt) (Volt) (Litre/minute)
0
1
2
3
4
5
6
7
8
9
10

Table 4 Blank Results Table for Pump Flow Characteristics

Valve Flow Transmitter Flow Rate

(Volt) (Volt) (Litre/minute)
0
1
2
3
4
5
6
7
8
9
10

Table 5 Blank Results Table for Valve Characteristics

Page 34 of 35
 VENT H
VALVE

D/A1 A/D1 A/D5

CE117
PROCESS TRAINER D/A2 ADA A/D2 A/D6

PT PROCESS
D/A3 A/D3 A/D7
VESSEL

D/A4 A/D4 A/D8

FT2
LT

HEAT ER
TANK
COOL ER
HEAT
EXCHA NGE R TT4
TT5
S

TT1 FAN

STIRRER
PROPORTIONAL
VALVE

ELECTRI C
HEATE R
OFF
TT2
ON
H DRAIN
VALVE

TT3

BYPASS
VALVE
FT1
H

EXTERNAL MANUAL
RESERVOIR

PUMP 1 PUMP2

KEY
TT1 -- HEATER TANK
TEMPER ATURE TR ANSM ITTER
TT2 -- H EAT EXCH ANGER OUT PUT
MANUAL TEMPERATURE TRANSMITTER MANUAL
TT3 -- PROCESS LOOP C OOLER IN LET
TEMPER ATURE TR ANSM ITTER
TT4 -- PROCESS LOOP C OOLER OUTLET
TEMPER ATURE TRAN SMITTER HEATER TANK
M TT5 -- PROC ESS TAN K M
TEMPERATURE TRANSMITTER LOW LEVEL
FT1 -- HEATER LOOP
FLOW TR ANSM ITT ER RESERVOIR TANK
FT2 -- PROC ESS LOOP
EXTERNAL FLOW TRANSMITTER EXTERNAL LOW LEVEL
LT -- PROCESS VESSEL
LEVEL TRANSMITTER
PT -- PR OCESS VESSEL
PRESSUR E TRAN SMITTER

Figure 41 Connections for Experiment 1 Procedure 3.

Figure 42 Screenshot of Experiment 1 Procedure 3

Heater Tank

TT

Temperature
Transmitter

Page 34 of 35
Figure 43 Schematic of Experiment 1 Procedure 3

Page 34 of 35
 Procedure 3 - Heater Control

1) Start the CE2000 software.

2) Connect the CE117 Mimic Panel as shown in Figure 41. Set the heater switch to
‘External’. Analogue signals will pass from the ADA section to the heater and from
temperature transmitter TT1. The software will display the temperature rise in the
heater tank.

3) Run the software and apply a full 10 V to the heater (full power).

4) Note how quickly the heater tank reaches the maximum temperature of approximately
60°C. The chart on the software will show the temperature rise against time.

5) Turn the heater voltage down to 0 V (power off).

VENT H
VALVE

D/A1 A/D1 A/D5

CE117
PROCESS TRAINER D/A2 ADA A/D2 A/D6

PT PROCESS
VESSEL D/A3 A/D3 A/D7

D/A4 A/D4 A/D8

FT2
LT

HEATER
TANK
COOLER
HEAT
EXCHA NGE R TT4
TT5
S

TT1 FAN

STIRRER
PROPORTIONAL
VALVE

ELECTRIC
HEATE R
OFF
TT2
ON
H DRAIN
VALVE

TT3

BYPASS
VALVE
FT1 H

EXTERNAL MANUAL
RESERVOIR

PUMP 1 PUMP2

KEY
TT1 -- HEATER TANK
TEMPERATURE TRANSMITTER
TT2 -- HEAT EXCHANGER OUTPUT
MANUAL TEMPERATURE TRANSMITTER MANUAL
TT3 -- PROCESS LOOP COOLER IN LET
TEMPERATURE TRANSMITTER
TT4 -- PROCESS LOOP COOLER OUT LET
TEMPERATURE TRANSMITTER HEATER TANK
M TT5 -- PROCESS T ANK M LOW LEVEL
TEMPERATURE TRANSMITTER
FT1 -- HEATER LOOP
FLOW TRANSMITTER
RESERVOIR TANK
FT2 -- PROCESS LOOP
FLOW TRANSMITTER LOW LEVEL
EXTERNAL EXTERNAL
LT -- PROCESS VESSEL
LEVEL TRANSMITTER
PR OCESS VESSEL
PT --
PRESSURE TRANSMITTER

Figure 44 Connections for Experiment 1 Procedure 4

Page 34 of 35
Figure 45 Screenshot of Experiment 1 Procedure 4

Process Vessel LT
(Stirred Tank)
Level Transmitter

Drain Valve

Pump 2

Reservoir

Figure 46 Schematic of Experiment 1 Procedure 4

Page 34 of 35
Procedure 4 - Level Transducer Characteristic and Calibration

1) Create a blank results table similar to Table 6.

2) Start the CE2000 software. Make sure that the reservoir water level is correct.

3) Connect the CE117 Mimic Panel as shown in Figure 44. Analogue signals will pass
from the ADA section to the valve and from level transmitter LT. The software will
display the level rise in the process vessel.

4) Switch Pump 2 to ‘Manual’ control and set its control to minimum. Run the
software and apply a full 10 V to the valve (fully open). Close the process loop
bypass valve and the process vessel drain valve. Open the air vent valve.

5) Use the manual control of Pump 2 to slowly increase the level in the process vessel.
At each 10 mm step, record the level transmitter reading (in volt). The reservoir slowly
empties, so as the process vessel level reaches a level of around 180 mm, the
reservoir low water level switch will operate and stop the pump.

6) Plot a chart of Level Transmitter Output on the vertical axis against the water level of
the process vessel on the horizontal axis. Your curve is the characteristic of the level
transmitter.

Water Level Level Transmitter

inside the Output (V)
Process
Vessel (mm)
0
10
20
30
40
50
60
70
80
90
10
0
11
0
12
0
13
0

Page 34 of 35
 14
0
15
0
16
0
17
0
18
0
19
0
20
0

Table 6 Blank Results Table for Experiment 1 Procedure 4

Figure 53 Screenshot of Experiment 2 Procedure 1

Flow Proportional Valve

Transmitter

FT
Process Vessel
(Stirred Tank)

FC
Flow
Drain Valve Controller

Pump 2
Reservoir

Figure 54 Schematic of Experiment 2 Procedure 1

Page 34 of 35
4.1 Experiment 2: Basic Proportional Control - Flow Control by Valve
Object

To investigate the use of the proportional valve position to control flow rate in the process
loop.

Procedure

1) Start the CE2000 software.

2) Close the loop bypass valve, fully open the process vessel drain valve and the air vent.

3) Connect the CE117 Mimic Panel as shown in Figure 52. Set Pump 2 switch to
‘External’. Analogue signals will pass from the ADA section to Pump 2, the
proportional valve S and from flow transmitter FT2.

4) On the software, the block titled ‘PID’ is a three term controller that controls the
valve voltage. You may adjust the controller’s values of Proportional gain, Integral
and Derivative. Set the PID controller to:

Proportional gain -
0.5 Integral - 0.5
Derivative - 0
(zero)

5) Run the software and use it to record the flow response. Adjust the flow setpoint to
0.5 V and Pump 2 voltage to 6 V and wait for the flow to stabilize.

6) Increase the flow setpoint in steps of 0.5 V up to a maximum of 3 V. At each step

change, allow the flow to stabilize (should take less than 20 seconds). Adjust the
flow setpoint back to 0.5 V and wait for the flow to stabilize (should take less than 20
seconds). You may use the software to record and create a chart of the results.

NOTE This experiment does not control level, so at setpoints above 2 V the reservoir
can run low and
switch off the pump. To avoid this, perform this part of the experiment as
quickly as possible.

7) Increase the flow setpoint to 2 V and wait a few seconds for the flow to stabilize.

8) Part-open the process loop bypass valve to reduce the loop flow. Close the bypass
valve, wait for the flow to stabilize. Reduce the pump voltage by 2 V to reduce the
flow.

9) Draw a block diagram of the control system.

Page 34 of 35
 VENT H
VALVE

D/A1 A/D1 A/D5

CE117
PROCE SS TRAINER D/A2 ADA A/D2 A/D6

PT PROCESS
D/A3 A/D3 A/D7
VESSEL

D/A4 A/D4 A/D8

FT2
LT

HEATER
TANK
COOLER
HEAT
EXCHANGER TT4
TT5
S

TT1 FAN

STIRRER
PROPORTIONAL
VALVE

ELECTRIC
HEATER
OFF
TT2
ON
H DRAIN
VALVE

TT3

BYPASS
VALVE
FT1
H

EXT E R NA L MANUAL
RESERVOIR

PUMP 1 PUMP2

KEY
TT1 -- HEATER TANK
TEMPERATURE TRANSMITTER
TT2 -- HEAT EXCHANGER OUTPUT
MANUAL TEMPERATURE TRANSMITTER MANUAL
TT3 -- PROCESS LOOP COOLER INLET
TEMPERATURE TRANSMITTER
TT4 -- PROCESS LOOP COOLER OUTLET
TEMPERATURE TRANSMITTER HE A TE R T AN K
M TT5 -- PROCESS T ANK M LOW LEVEL
TEMPERATURE TRANSMITTER
FT1 -- HEATER LOOP
FLOW TRANSMITTER RESERVOIR TANK
FT2 -- PROCESS LOOP LOW LEVEL
EXTERNAL F LO W T R AN S M IT T E R EXTERNAL
PROCESS VESSEL
LT --
LEVEL TRANSMITTER
PT -- PROCESS VESSEL
PRESSURE TRANSMITTER

Figure 55 Connections for Experiment 3 Procedure 1

Figure 56 Screenshot of Experiment 3 Procedure 1

FT
Process Vessel Flow
(Stirred Tank) Transmitter

FC
Flow
Drain Valve
Controller

Pump 2
Reservoir

Figure 57 Schematic of Experiment 3 Procedure 1

Page 34 of 35
4.2 Experiment 3: Flow Control by Pump
Objects
• To investigate the use of the pump speed for control of flow rate in the process loop.
• To demonstrate the effect of derivative action and the importance of the ‘washout’ filter.

Procedure 1 - Flow Control with Proportional and Integral Action

1) Start the CE2000 software.

2) Close the loop bypass valve, fully open the process vessel drain valve and the air vent.

3) Connect the CE117 Mimic Panel as shown in Figure 55. Set Pump 2 switch to
‘External’. Analogue signals will pass from the ADA section to Pump 2, the
proportional valve (S) and from flow transmitter (FT2).

4) On the software, the block titled ‘PID’ is a three term controller that controls the
pump voltage. You may adjust the controller’s values of Proportional gain, Integral
and Derivative. Set the PID controller to:

Proportional gain -
0.5 Integral - 0.5
Derivative - 0
(zero)

5) Run the software and use it to record the flow response. Adjust the Setpoint to 1 V
and the valve voltage to 8 V and wait for the flow to stabilize.

6) Increase the flow setpoint in steps of 0.5 V up to a maximum of 3 V. At each step

change, allow the flow to stabilize (should take less than 30 seconds). Adjust the
flow setpoint back to 1 V and wait for the flow to stabilize (should take less than 30
seconds). You may use the software to record and create a chart of the results.

NOTE This experiment does not control level, so at setpoints above 2 V the reservoir
can run low and
switch off the pump. To avoid this, perform this part of the experiment as
quickly as possible.

7) Increase the flow setpoint to 2 V and wait a few seconds for the flow to stabilize.

8) Part-open the process loop bypass valve to reduce the loop flow. Close the bypass
valve, wait for the flow to stabilize. Reduce the valve voltage by 2 V to reduce the
flow.

9) Draw a block diagram of the control system.

Page 34 of 35
 VE NT H
VA LV E

D/ A1 A/ D1 A/ D5
CE117
PROCESS TRAINER D/ A2 ADA A/ D2 A/ D6

PT PROCESS
D/ A3 A/ D3 A/ D7
VESSEL

D/ A4 A/ D4 A/ D8

FT2
LT

HEATER
TANK
COOLER
HE AT
EX CHA NG E R TT4
TT5

TT1 FAN

S TI RRE R
PROP O RTI O NAL
VALVE

ELE CTRI C
HE ATE R
O FF
TT2
ON
H DRAI N
VA LV E

TT3

BYP ASS
VALVE
FT1
H

EXTE RNAL MANUAL

RESERVOIR

P UMP 1 P UMP 2

KE Y
TT1 -- H EATER T AN K
TEMPER ATU RE TR AN SMITT ER
TT 2 -- H EAT EXC H AN GER OUT PU T
MANUAL TEM PER ATU RE TR AN SMIT T ER MANUAL
TT 3 -- PROC ESS LOOP C OOLER IN LET
TEMPER ATU RE T R AN SM ITT ER
TT 4 -- PROC ESS LOOP C OOLER OUT LET
TEMPER ATU RE T R AN SM ITT ER
HEATER TANK
M TT 5 -- PROC ESS T AN K M
TEM PER ATU RE TR AN SMIT T ER LOW L EVEL
FT 1 -- H EAT ER LOOP
FLOW TR ANSMITT ER
RESERVOIR TANK
FT 2 -- PROC ESS LOOP
EXTE RNAL FLOW TR ANSMITT ER EXTE RNAL LOW L EVEL
LT -- PR OC ESS VESSEL
LEVEL TR AN SM IT TER
PT -- PR OC ESS VESSEL
PR ESSU RE TR AN SMIT T ER

Figure 58 Connections for Experiment 3 Procedure 2

Figure 59 Screenshot of Experiment 3 Procedure 2

Page 34 of 35
Procedure 2 - Demonstration of Derivative Action

1) Start the CE2000 software.

2) Close the loop bypass valve, fully open the process vessel drain valve and the air vent.

3) Connect the CE117 Mimic Panel as shown in Figure 58. Set Pump 2 switch to
‘External’. Analogue signals will pass from the ADA section to Pump 2, the
proportional valve (S) and from flow transmitter (FT2).

4) On the software, a three term controller is made from three individual (P, I and D)
blocks that control the pump voltage. Set the blocks to:

Proportional
gain - 2 Integral -
0.5 Derivative - 0
(zero)

5) Run the software and use it to record the flow response, the error and the derivative
action (D_action). Adjust the Setpoint to 3 V and the valve voltage to 10 V (fully open)
and wait for the flow to stabilize.

6) Increase the flow setpoint by 1 V. Note that the output from the derivative block
(D_action) does not change. Decrease the setpoint by 1 V and again note that there
is no output from the D block.

7) Stop the software and change the D block gain to 5 and its Washout gain to 5.
Make sure that the Washout ‘Enabled’ check box is ticked. Run the software and
allow it to stabilize.

8) Increase the flow setpoint by 1 V. Note the output from the derivative block
(D_action). Decrease the setpoint by 1 V and again note the D block output
(D_action).

9) Stop the software and make sure that the Washout ‘Enabled’ check box is not ticked.
Run the software and allow it to stabilize. Repeat step 8.

10) While the software runs, enable and disable the washout filter.

Page 34 of 35
gure 63 Connections For Experiment 4 Procedure 2

Figure 64 Screenshot of Experiment 4 Procedure 2

Level
Transmitter
LT
Process Vessel
(Stirred Tank)
Level
Controller
LC
Drain Valve

Pump 2
Reservoir

Figure 65 Schematic of Experiment 4 Procedure 2

Page 34 of 35
Procedure 2 - Level Control by Pump Speed

1) Start the CE2000 software.

2) Close the loop bypass valve, fully open the process vessel drain valve and the air vent.

3) Connect the CE117 Mimic Panel as shown in Figure 63. Set Pump 2 switch to
‘External’. Analogue signals will pass from the ADA section to Pump 2, the
proportional valve (S) and from level transmitter (LT).

4) On the software, the block titled ‘PID’ is a three term controller that controls the
pump voltage. You may adjust the controller’s values of Proportional gain, Integral
and Derivative. Set the PID controller to:

Proportional gain
- 10 Integral - 0.5
Derivative - 0
(zero)

5) Run the software. Adjust the Setpoint to 6 V and the valve voltage to 10 V (fully
open) and wait for the level to stabilize.

6) Increase the setpoint by 0.5 V and use the software to monitor the level until it
becomes stable. Compare the response with the open loop test of Procedure 1.

7) Reduce the setpoint back to 6 V and let the system stabilize. Repeat the procedure with
PID values:

A (Gain Only) B (Integral

Only)
Proportional gain - Proportional gain -
20 5
Integral - 0 Integral - 0.5
Derivative - 0 (zero) Derivative - 0 (zero)

8) Note how well the system responds.

9) Draw a block diagram of the system.

Page 34 of 35
 VE NT H
VA LV E

D/ A1 A/ D1 A/ D5
CE117
PROCESS TRAINER D/ A2 ADA A/ D2 A/ D6

PT PROCESS
D/ A3 A/ D3 A/ D7
VESSEL

D/ A4 A/ D4 A/ D8

FT2
LT

HEATER
TANK
COOLER
HE AT
EX CHA NG E R TT4
TT5

TT1 FAN

S TI RRE R
PROP O RTI O NAL
VALVE

ELE CTRI C
HE ATE R
O FF
TT2
ON
H DRAI N
VA LV E

TT3

BYP ASS
VALVE
FT1
H

EXTE RNAL MANUAL

RESERVOIR

P UMP 1 P UMP 2

KE Y
TT1 -- H EATER T AN K
TEMPER ATU RE TR AN SMITT ER
TT 2 -- H EAT EXC H AN GER OUT PU T
MANUAL TEM PER ATU RE TR AN SMIT T ER MANUAL
TT 3 -- PROC ESS LOOP C OOLER IN LET
TEMPER ATU RE T R AN SM ITT ER
TT 4 -- PROC ESS LOOP C OOLER OUT LET
TEMPER ATU RE T R AN SM ITT ER
HEATER TANK
M TT 5 -- PROC ESS T AN K M
TEM PER ATU RE TR AN SMIT T ER LOW L EVEL
FT 1 -- H EAT ER LOOP
FLOW TR ANSMITT ER
RESERVOIR TANK
FT 2 -- PROC ESS LOOP
EXTE RNAL FLOW TR ANSMITT ER EXTE RNAL LOW L EVEL
LT -- PR OC ESS VESSEL
LEVEL TR AN SM IT TER
PT -- PR OC ESS VESSEL
PR ESSU RE TR AN SMIT T ER

Figure 66 Connections For Experiment 4 Procedure 3

Figure 67 Screenshot of Experiment 4 Procedure 3

Page 34 of 35
Procedure 3 - ON/OFF Control of Level

1) Start the CE2000 software .

2) Close the loop bypass valve, fully open the air vent and open the process vessel
drain valve to approximately 45°.

3) Connect the CE117 Mimic Panel as shown in Figure 66. Set Pump 2 switch to
‘External’. Analogue signals will pass from the ADA section to Pump 2, the
proportional valve (S) and from level transmitter (LT). The relay block in the software
turns the proportional valve fully on and fully off, so that it acts like a standard
solenoid valve.

4) On the software, the ‘P’ block is a simple gain device for the relay control voltage.

Set the blocks to: Proportional gain 1

Pump Voltage to 5 V
Setpoint to 6 V
Set the relay to ‘Switch on at’ 0.5 V with a Hysteresis of 1 V

5) Run the software. Wait for the level to stabilize into a simple oscillation. Use the
software to record the level, the valve voltage and the setpoint over at least two
cycles.

6) Click on the P (gain) block and change the gain to 2. Again, wait for the level to
stabilize into a simple oscillation. Again, use the software to record the results over
at least two cycles.

7) Repeat with the gain set to 4.

Page 34 of 35
 VENT H
VALVE

D/A1 A/D1 A/D5

CE117
PROCE SS TRAINE R D/A2 ADA A/D2 A/D6

PT PROCESS
D/A3 A/D3 A/D7
VESSEL

D/A4 A/D4 A/D8

FT2
LT

HEATER
TANK
COOLER
HEAT
EXCHANGER TT4
TT5
S

TT1 FAN

STIRRER
PROPORTIONAL
VALVE

ELECTRIC
HEATER
OFF
TT2
ON
H DRAIN
VALVE

TT3

BYPASS
VALVE
FT1
H

EXTERNAL MANUAL
RESERVOIR

PUMP 1 PUMP2

KEY
TT1 -- HEATER TANK
TEMPERATURE TRANSMITTER
TT2 -- HEAT EXCHANGER OUTPUT
MANUAL TEMPERATURE TRANSMITTER MANUAL
TT 3 - - P R OC E S S LO O P C O O LE R IN LE T
T E M P E R AT UR E T R AN S M I TT E R
TT4 -- PROCESS LOOP COOLER OUTLET
TEMPERATURE TRANSMITTER HE A TE R TA N K
M TT5 -- PROCESS T ANK M LOW LEVEL
TEMPERATURE TRANSMITTER
FT1 -- HEATER LOOP
FLOW TRANSMITTER RESERVOIR TANK
FT2 -- PROCESS LOOP LOW LEVEL
EXTERNAL FLOW TRANSMITTER EXTERNAL
LT -- PROCESS VESSEL
LE V E L TR A N S MI TT E R
PT -- PROCESS VESSEL
PRESSURE TRANSMITTER

Figure 68 Connections for Experiment 5

Figure 69 Screenshot of Experiment 5

Page 34 of 35
 Heater Tank Process Vessel

TT Cooler

TC
Drain Valve

Pump 1 Pump 2

Reservoir

Figure 70 Schematic of Experiment 5

Page 34 of 35
4.3 Experiment 5: Temperature Control of the Heater Tank
Object

To control the temperature in the heater tank by adjustment of the heater power.

Procedure

• Ambient temperature changes will affect this experiment. Do this

experiment in a temperature stable environment, or at a time of day
NOTE
when the temperature remains constant.
• This experiment may take up to two hours to perform.

Page 34 of 35
1) Start the CE2000 software.
2) Connect the CE117 Mimic Panel as shown in Figure 68. Analogue signals will pass to
the ADA section from the temperature transmitter TT1. The software will instruct
the ADA section to pass 10 V to the proportional valve to keep it fully open. The
software will display the temperature in the heater tank and the flow in the heater
loop.

3) On the software, the block titled ‘PID’ is a three term controller that controls the
heater voltage. You may adjust the controller’s values of Proportional gain, Integral
and Derivative. Set the PID controller to:

Proportional
gain - 1 Integral -
0.01 Derivative -
0 (zero)

4) Close the loop bypass valve, fully open the process vessel drain valve and the air vent.

5) On the Mimic Panel, set the heater switch to ‘Manual’ and turn the control down to
minimum (heater off). Set Pump 1 and Pump 2 switches to ‘Manual’. Turn Pump 1
control to minimum, turn Pump 2 control to maximum. Switch on the process vessel
stirrer and set the cooler fan to maximum speed.

6) Run the software.

7) On the Mimic Panel carefully adjust Pump 1 to give a low heater loop flow of
approximately 1 L/min and allow the system to stabilize. Refer to Table 1 on page
18 of this guide for the voltage to flow conversion of the flow transmitters.

8) Wait until the temperature of the water in the heater tank stabilizes to an ambient
level (remember that the heater is still off). Note the temperature (voltage) of the
water in the heater tank. This is the ‘reference temperature’. Refer to Table 1 on
page 18 of this guide for the voltage to temperature conversion of the temperature
transmitters.

9) Adjust the setpoint so that it is equal to the reference temperature.

10) Switch the heater to ‘External’ and use the software to record the heater tank
temperature, the flow in the heater loop, the setpoint and the output to the heater
(controller output).

The reservoir level will drop during this experiment and the low level circuit
NOTE
will switch off
Pump 2 for a few seconds. This is normal and does not affect the experiment.

11) Adjust the setpoint to correspond to a temperature increase of 2°C above the reference
temperature.

12) Note how long the system takes to adjust to the new heater tank temperature
Page 35 of 35
 (it should be less than 30 minutes).

13) On the Mimic Panel, increase the speed of Pump 1 to maximum. Allow the
system to stabilize (this should take less than 20 minutes). Note how the
system changes the heater power to compensate. Adjust Pump 1 back to the
flow of approximately 1 L/min and wait for the system to stabilize.

14) Reduce the setpoint an amount that corresponds to 2°C and note how the system
responds.

15) Draw a block diagram of the system.

Page 35 of 35