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CHAPTER 2
2.1 INTRODUCTION
In this chapter, the lab scale non-linear conical tank level process in
which the level of liquid to be maintained at a constant value is described.
The time constant and gain of the selected process vary as a function of level.
The non-linear mathematical model, process input-output characteristics,
linearisation and process reaction curves obtained in various regions are
discussed.
tank level process, whose time constant and gain are functions of the process
variable, becomes suitable for the present work.
The schematic diagram of the hardware set-up is shown in the
Figure 2.1. The set-up consists of a process tank, submersible pump, float
sensor arrangement, overhead sump, inlet valve, outlet valve, level indicator
and interfacing card. The process tank is in the shape of an inverted cone
fabricated from a sheet metal. Provisions for liquid inflow and outflow are
provided at the top and bottom of the tank respectively. Metal rods are welded
around the circumference for support. The height of the process tank is 80 cm
and top radius of the tank is 20 cm. The submersible pump used here is
capable of discharging liquid at the rate of 300 cm3/seconds. The pump is
immersed in the overhead tank and a flexible hosepipe is connected to the
pump to supply the inflow into the tank. A gate valve is used in this path to
give disturbance input. The minimum voltage applied to the pump for
discharge is 104 volts (AC). A float sensor is used here to sense the water
level in the process tank. The arrangement consists of a float made up of light
stainless steel material. It is tied to a nylon thread through a pulley
arrangement. The other end of the thread is tied to a calculated weight. A
rotary potentiometer is attached to the center of the pulley shaft to obtain
electrical output.
R r
tan (2.2)
H h
1 dh dA
Hence, Fin b h A h (2.4)
3 dt dt
dA
dh
3 Fin b h h
dt
(2.5)
dt R 2 h 2
H2
The time constant and gain of the process change as the level
changes. This is obvious from the mathematical model given by equation
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(2.5). The simulink model developed to simulate the conical tank level
process is shown in Figure 2.4. The process steady state input-output
characteristic obtained from the real time setup with inflow variations from 7
cm 3 / seconds to 300 cm3 / seconds is shown in Figure 2.5. The characteristic
shows the non-linear behaviour of the process. To obtain a linear model the
characteristic is divided into six different linear regions as shown in Figure
2.6. A first order mathematical model is then obtained for each region using
process reaction curve method and the reaction curves for regions 1 to 4 are
shown in Figures 2.7 to 2.10. The gain (K), dead time (td) and time constant
(τ) are measured from the reaction curves and are given in the Table 2.1. It is
found practically that the dead time is 2 seconds in all the regions due to 2
seconds sampling time.
Figure 2.7 Reaction curve for first region when step change in inflow
from 10 cm3 / seconds to 25 cm3 / seconds is applied to the
process
Figure 2.8 Reaction curve for second region when step change in inflow
from 25 cm3 / seconds to 48 cm3 / seconds is applied to the
process
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Figure 2.9 Reaction curve for third region when step change in inflow
from 48 cm3 / seconds to 80 cm3 / seconds is applied to the
process
Figure 2.10 Reaction curve for fourth region when step change in inflow
from 80 cm3 / seconds to 140 cm3 / seconds is applied to the
process
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Level A B K τ
Inflow range
range (input (output at (Steady
Time constant
(cm3/seconds)
(cm) change) steady state) state gain) (seconds)
10-25
7-22 15 22 1.46 35
(I Region)
25-48
22-38 23 38 1.65 80
(II Region)
48-80
38-50 32 50 1.56 146
(III Region)
80-140
50-64 60 64 1.06 245
(IV Region)
140-210
64-72 80 72 0.9 475
(V Region)
210-275
72-80 65 80 0.8 750
(VI Region)
From the Table 2.1, it is observed that, the gain of the system varies
from 1.46 to 0.8 and the time constant varies from 35 seconds to 750
seconds as the level increases from 0 to 80 cm.
During the normal operation of the process, the outlet valve is kept
in the middle position. The corresponding valve constant ‘b’ for that position
is obtained experimentally as b = 2.2. When the valve is nearly completely
closed, the respective valve co-efficient experimentally obtained is b = 1.32.
Similarly for the completely opened position, the valve co-efficient
experimentally obtained is b = 4.4. Hence, the valve co-efficient is changing
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from 4.4 to 1.32. when the valve motion is changed from completely opened
to merely closed position. The change in process characteristics for these
valve positions are shown in Figure 2.11.
2.4 Conclusion
Thus the process parameters are obtained using the process
reaction curve method in various linearised regions. Using these
parameters of the linearised models and controller tuning methods ,
it is proposed to design conventional controller first for the control
of the level process, that is discussed in the next chapter.