Estimation of optimum range of set-points and two level & four level
control for a closed loop quadruple tank pilot plant through PLC
Shrinivas Shirnewar1
Abstract Nearly all process industries exhibit nonlinear
characteristics and have complex dynamic properties. Some of
these industries are highly coupled. Most industries are MIMO
i.e. multi-input multi-output sytems or multivariable systems.
Multivariable systems which involve a number of control loops
which interact with each other where and where one input not
only affects its own output but also affects to other outputs
of the system. The quadruple tank system is a benchmark to
understand the non-ideals of such industrial process.
I. INTRODUCTION
The quadruple tank pilot plant on which this experiment
is performed consists of four interconnected water tanks,
four level transmitters, two pumps, and two control valves.
The inputs of the system are the voltages to the pumps, the
outputs being the water levels in the lower two tanks and
the control valve opening acting as disturbance signals to
the system. Tank 1 and tank 2 are placed below the tank
3 and tank 4 respectively, which make them to receive the
water flow by the action of gravity. As the lower two tanks
are having continuous drainage at their respective bottoms
so a reservoir of 200 liters is placed at the bottom of these
two tanks. The pumps are used to transfer water from the
reservoir to the tanks based on the valve opening. Pump 1
delivers water to tank 2 and tank 4 via a 3-way control valve
1 (CV1) and pump 2 delivers water to tank 1 and tank 3 via
control valve 2 (CV2).
Due to gravitational forces the lower tanks receive water
from their corresponding upper tanks. The system aims at
controlling the liquid levels in all the four tanks. So in
order to measure the liquid levels in corresponding tanks,
level transmitters are placed at the bottom of each tank. The
control valve positions give the ratio in which the water is
split into the diagonally placed upper and lower tanks. The
flow to the tanks can be manipulated by either varying the
speed of pumps or by changing control valves opening. The
pumps are driven by a 3-phase induction motors those are
controlled by a variable frequency drive (VFD). This system
is thus used to demonstrate coupling effects and performance
limitations in multivariable control systems.
The quadruple tank system is used in understanding the
dynamic interactions as the operation of the system can be
is in two phases, viz, minimum phase and non- minimum
phase.Minimum phase system is a system in which all poles
and zeros are located to the left half of S-plane where as
non-minimum system is the one with atleast one pole or
1 Shrinivas Shirnewar is students of the department of Instrumentation
and Control, College of Engineering Pune - 411 005, Maharashtra, India
shirnewarshri@gmail.com
zero to the right half os S-plane.The non-minimum phase
characteristics of a system has several limitations on system
design. In the linearized model of the quadruple-tank plant
a multivariable zero occurs, the location of which can be
varied on either the left or the right half-plane by varying
openings a valve. Both the location and the direction of a
multivariable zero are important for control design. They
have direct physical interpretations of the quadruple-tank
process, which make the process suitable to use in control
education.
II. M OTIVATION
There does not, however, seem to exist any laboratory
processes that demonstrate multivariable zero location and
direction in an illustrative way. This was one of the main
motivations for the development of the quadruple-tank pro-
cess.
III. N EED OF PILOT PLANT
Preliminary process design and economic analysis to
guide research programs and to determine the economic
viability of a project.
The need to pilot at a meaningful scale before moving
to a commercial scale will always be a requirement. The
risk is too great in not piloting a new process, because
there are always surprise.
Lab work, computer models and pilot plants all have an
important role to play in process development.
Fundamental lab work will always be needed and a
model can screen which potential new processes should
be piloted because people want to see data. They want
to see proof. Although, if you could develop a good
kinetic model based on your pilot-plant data, then you
might not need to run the plant all the time to generate
estimates for customers or to revamp studies.
The mathematical model adds value at all stages of the
design process from early conceptual design through the
ultimate operation of the facility.
IV. P ROBLEM STATEMENT
The main aim of this project is to design and implement
advanced control strategy that will control all the four levels
in a quadruple tank pilot plant present at Advanced Process
Instrumentation laboratory, Department of Instrumentation &
Control, COEP.
 V. M ETHODOLOGY
It refers that the first stage started with the testing and
commissioning of the pilot plant. Simultaneously, different
control strategies were studied for implementation. Lastly,
the pilot plant would be operated and controlled through 2
different modes- local and remote. Remotely the plant can
be again accessed by 4 different controllers- remote PLC,
remote DCS, VLAB (VPLC/VDCS) & MATLAB.
A. Hardware and software required
1) Hardware:
Local PLC (Micrologix 1400)
Remote PLC (ControlLogix 1756)
Remote DCS (Emerson Delta V)
Sensors, valves, motor etc.

2) Software:
RSLogix 500
RSLogix 5000
Factory talk view
MATLAB 2013

VI. L ITERATURE S URVEY

A. Quadruple Tank Process with an adjustable zero
A new laboratory process named quadruple tank system Fig. 1. Schematic diagram of pilot plant
is designed to illustrate performance limitations due to zero
location in multivariable control systems isdescribed in. A
nonlinear model for the quadruple-tank process based on
physical data is derived. The model is linearized and then
this linear model is validated using experimental data. The
location and the direction of a multivariable zero of the
linearized model for the quadruple system is also derived.
The valve positions of the system uniquely determine if the
system is minimum phase or non minimum phase.
The relative gain array (RGA) of the process is a measure
of interaction in multivariable control systems. RGA of
the quadruple tank process is also derived. The properties
of the nonlinear model of the quadruple-tank process are
concerned mainly by the nonlinear zero dynamics and steady
state conditions. Some nonlinear design methods usually
require that the zero dynamics are stable. The nonlinear
zero dynamics can be made stable or unstable by simply
changing the valve position. The quadruple tank process is
thus suitable to illustrate how sensitive a nonlinear design
method is to the stability of the zero dynamics. A schematic
diagram of the process is shown in 1.
Proportional integral (PI) control of the quadruple-tank pro-
cess is tuned manually on simulators using the physical
model. The controller parameters are manually tuned to give
good closed loop performance. But it is found that the system
is difficult to control in non-minimum phase than in the
minimum phase. Fig. 2. Experimental set-up

B. Control Strategies on quadruple tank till date

Decentralized proportional integral (PI) controller Internal model controller
Decentralized PI controller with sliding mode features Model predictive controller
Decoupled PID controller Quantitative feedback controller
 H controller Manufacturer: Triplex Power Sprayer
Non-linear model predictive controller Pressure: 28 kg/cm2
Gain scheduling control Capacity: 2160 lph
Linear parameter varying control Speed: 950 rpm
Input-output feedback linearization control HP: 3.0
Fractional PID controller Specifications of the 3 phase induction motors
VII. OVERVIEW OF THE SYSTEM Manufacturer: Laxmi Hydraulics and Pvt. Ltd.
It consists of a water reservoir which is of capacity 200 Type: Squirrel Cage AC IM
liters. Here the water is stored to 95% of its capacity. The Type of connection: Star connection
water from this reservoir is pumped to the 4 tanks through Output: 0.75 to 1.00 (kW/HP )
a combination of 2 positive displacement pumps and control Max Current: 2.2 A
valves viz pump 1 and control valve 1 (CV1), and Pump 2 Max Speed: 950 rpm
and control valve 2 (CV2). The control valve used here is Max Voltage: 415 V
a 3-way control valve, ie, 1 inlet and 2 outlets, so that the Max Frequency: 50 Hz
water pumped can be split into diagonally placed upper and Specifications of the VFD
lower tanks. The purpose of doing so is to add disturbance Manufacturer: ABB
by changing the valve positions. The quadruple tank is made Model No: AS355
highly interactive by continuously draining them at their Max voltage: 415 V
bottoms. This provision is done by introducing 1 hole at the Max Current: 2.2 A
bottom of each of the 4 tanks of diameter approximately 1cm Max Speed: 950 rpm
(exact 0.9cm) whereas the inlet pipe diameter discharge to Max Frequency: 50 Hz
the tanks are approximately of diameter 2cm approx (2.1cm
2) Actuating Unit The 3-way control valve and current to
exact). The levels in each of the tank is measured by level
pressure converter together act as an actuating assem-
transmitters that are labeled as shown in 1.
bly. Control valve is having 1 inlet and 2 outlets. It is
A. Function of important components a diaphragm valve which is pneumatically operated.
The instrumentation components in the quadruple tank So, to convert the electrical 4-20 mA signal from
pilot plant can be divided in the following groups: the controller to 3-15 psi we have a I/P converter. It
converts the corresponding current to pressure required
Sensors and transmitters
to operate the control valve.
Final control elements
Specifications of the control valves
1) Sensors and transmitters
The transducer measures a process variable in the plant Manufacturer: PNEUCON Valves Pvt. Ltd
while the transmitter produces an output signal, often Model no: PVP-1
in the form of a 4-20 mA electrical current signal. Supply: 2.5 kg/cm2
Level Transmitters The level is measured in each of the Output: 0.2-1.0 kg/cm2
tanks by specific level transmitters which give output Specifications of I/P Converter
in the form of 4-20 mA which is in the range of 0- Manufacturer: Forbes Marshall
100%. Output: 0.2-1.0 kg/cm2
Manufacturer: WIKA Input: 4-20 mA
Model no.: S-11
The quadruple plant can be operated in 3 different phases:
Input: 0-1 bar
Output: 4-20 mA Minimum phase experiment
2) Final control elements Non-minimum phase experiment
Pseudo random binary sequence experiment
Final control element is a physical device whose activation
or movement causes a change in dynamic process as
commanded by the controller. Following are the final VIII. M ATHEMATICAL MODELING OF QUADRUPLE TANK
control elements used in the plant. SYSTEM

A. Uses of mathematical models

1) Pumping unit The positive displacement pumps are
used to pump water from the reservoir to the tanks.
The speed of these pumps is controlled by 3-phase
induction motors. These motors are directly controlled
by a Variable Frequency Drive (VFD). These VFD's
get signal by a local controller.
Specifications of positive displacement pumps
The most important result of developing a mathematical
model of any engineering system is getting to the root of
the system. This insight enables you to strip away from the
problem the many extraneous confusion factors and to get
to the core of the system. The cause-and-effect relationships
between the variables related can be well studied.
B. Mass balance law ki =Pump parameter
The principle of the conservation of mass when applied ki vi =Flow rate of the pump i
to a dynamic system says: dx
X =
(mass flow into the system)-(mass flow out of system)=time dt
rate of change of mass inside the system A3
1 k 1

T11 0

According to the Mass balance law, mass can neither be 0 A1 T3 0 A1

created or destroyed, ie, the conservation of mass is the A4

2 k 2

T12

0 0 0
main concept behind the mass balance law. Specifically, in dx A2 T4 A2
= x+ u

the case of quadruple tank system the liquid accumulated in dt
(12 )k2
0 0 T13 0 0

the tanks is equal to the liquid entering into the tanks via
A3

the control valve inlet minus the liquid draining from the

bottoms. Mathematically, it can be represented as follows: 0 0 0 T14 (11 )k1
0
A4
(mass at time (t+t)) = (mass at time t)+(mass that entered (6)
from t to (t+t))-(mass that exited from t to (t+t)) kc 0 0 0
y= x (7)
C. Bernoullis law 0 kc 0 0
Bernoullis law describes the behavior of a fluid under The measured level signals are kc h1 and kc h2 .
varying conditions of flow and height. It states,
G(s) = C(sI A)1 B + D
1
P + v 2 + gh = constant (1)
T1 k1 kc 1 T1 k1 kc k2 (12 )

2 A1 (1+sT1 ) k1 A1 (1+sT1 )(1+sT3 )
G(s) = (8)

where,
T2 k1 kc (11 ) T2 k2 kc 2
P=Static pressure (N/m2 ) k2 A2 (1+sT2 )(1+sT4 ) A2 (1+sT2 )
=Fluid density (Kg/m3 )
C1 1 C1 (12 )

v=Velocity of fluid flow (m/s) (1+sT1 ) (1+sT1 )(1+sT3 )
G(s) = (9)

h=height above a reference surface (m)
C2 (11 ) C2 2
The second term in this equation is known as the dynamic (1+sT2 )(1+sT4 ) (1+sT2 )
pressure. The effect described by this law is called the  
Bernoulli effect, and sometimes known as Bernoullis equa- C1 C1 (1 1 )(1 2 )
|G(s)| = (1 + sT 3 )(1 + sT 4 )
tion. 1 2 4i=1 (1s Ti ) 1 2
(10)
A quadruple tank system is a multi-variable, non linear
The system is found to be non-minimum phase if
system. Based on setting of three way control valve, it is
0<(1 +2 )<1
classified as minimum phase system and non minimum phase
And found to be minimum phase if 1<(1 +2 )<2
system. The aim is to control the level in all four tanks with
two pumps. The manipulated variables are the input voltages T1 T2 kp2 1 2
 
(1 1 )(1 2 )
to the pumps v1 and v2 and the controlled variables are the |G(s)| = 2 4 (1 + sT3 )(1 + sT4 )
a i=1 (1s Ti ) 1 2
level of the two lower tanks y1 and y2 , 1 and 2 represents
the valve openings. To find the both zeros z1 and z2 , we set the term in bracket
to zero,
Equations for a quadruple tank system:
(1 1 )(1 2 )
a1 a3 p 1 k1 (1 + zi T3 )(1 + zi T4 ) = 0, i = 1, 2
h 1 =
p
2gh1 + 2gh3 + v1 (2) 1 2
A1 A1 A1
(1 1 )(1 2 )
a2 a4 p 2 k2 =
h 2 = 1 2
p
2gh2 + 2gh4 + v2 (3)
A2 A2 A2
and solve this quadratic equation for z1 and z2 . Depending
a3 p (1 2 )k2 on the flow ratios 1 and 2 , the introduced parameter
h 3 = 2gh3 + v2 (4) takes values in (0,). Qualitatively then zeros behaves as
A3 A3
like follows:
a4 (1 1 )k1 If <1 (because j are big), the zeros are close to T
1
h 4 =
p
2gh4 + v1 (5) 3
A4 A4 and T14
1 1
where, If =1, and thus 1 +2 =1, the zeros are at 0 to -( T + T )
3 4
hi =Water level in tank i If one zero tends to - and the other to +

ai =Cross-section area of the drainage hole Thus we can say that one of the two zeros is always in the
Ai =Cross-section area of tank i left half-plane, but the other one can be located either in
g=Acceleration due to gravity the left or in the right half-plane. The system is minimum
i =valve settings that controls water sharing between tanks phase (both zeros are in the left half-plane) for <1 and thus
1 +2 >1, and the system is non-minimum phase for >1,
i.e. 1 +2 <1. Let,
f1 f1
h1 . . . h n

f
.. .

A= (he , ue ) = . .
.

h



fn fn
h1 hn
and f1 f1
u1 ... un

f .. ..
B= (he , ue ) = . .

u



fn fn
u1 un
f1 f1 f1 f1

h1 h2 h3 h4
Fig. 3. 2-Level control using PI-PD

f2 f2 f2 f2


h1 h2 h3 h4
f
A= = (11)

f3 f3 f3 f3
h

h1 h2 h3 h4



f4 f4 f4 f4
h1 h2 h3 h4

The result of partial differentiation of the A matrix is given

below:
A3

T11 0 A1 T3 0

A4
T12

0 0 A2 T4

A= (12)


0
0 T13 0

1
0 0 0 T4
f f

1 1
u1 u2

f2 f2 Fig. 4. h1 2 level PI-PD


u1 u2
f
B= = (13)

f3 f3
u

u1 u2



f4 f4
u1 u2

IX. R ESULTS

Fig. 5. h2 2 level PI-PD

Fig. 6. 2-Level control using Interpreted MATLAB Function Fig. 8. h2 Interpreted Matrix function

Fig. 7. h1 Interpreted Matrix function

Fig. 9. 4-Level control using PI
 [6] A. Abdullah and M. Zribi, Control schemes for a quadruple tank
process,International Journal of Computers Communications & Con-
trol,vol. 7, no. 4,pp. 594-605, 2014.

X. C ONCLUSION
2-level control of quadruple tank is easy since manipulated
variables those are voltages to either pump appear as
positive term in both the controlled variables where as it is
difficult to control 4 levels of quadruple tank as
manipulated variables appear as negative term in 2 out of 4
controlled variable. For this reason conventional PI
controllers fail to achieve desired result.

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