CHEMICAL ENGINEERING LAB III 
  
 

LAB REPORT   
  
   

  EXPERIMENT  9: TEMPERATURE
CONTROL
 
  

   
GROUP: 4G  
  
NO   NAME    MATRIC ID   

1   ABDUL CARIM COMANDA MOMADE     25563   

2   FARRAH ATIKAH ABD RAHMAN    25312   

3   SITI NUR FATIHAH BINTI ADNAN    25398   

4   NASRIN FATINI BINTI AHMAD FAUZI    17005968   

5   MUHAMMAD ANWAR BIN HAIZAL    25202   

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TABLE OF CONTENTS

1.0 ABSTRACT......................................................................................................................................3

2.0 INTRODUCTION ...........................................................................................................................4

3.0 METHODOLOGY ..........................................................................................................................6

4.0 RESULT AND DICUSSION ..........................................................................................................7

5.0 CONCLUSION ..............................................................................................................................11

6.0 REFERENCES ..............................................................................................................................12

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1.0 ABSTRACT

The Air Temperature Control experiment is carried out to investigate the characteristic of
Proportional Only Control(P), Proportional Band and Integral Action (PI), and Proportional
Band, Integral Action and Derivative Action (PID) on a temperature process control loop. This
experiment was conducted whereby 6 bar of air compressed air stored in air receiver, V-102
then the air is regulated to about 4 bar before heated by air heater to 150ºC. This process is
controlled using microprocessor-based controller which value of Proportional (P), Integral(I)
and Derivative (D) are specified based on the mode of the controller. This controller received
signal from Resistance Temperature Detector (RTD), TIC-102. When the setpoint are stable at
100ºC, disturbance by new setpoint of 150ºC are introduced and the response of P, PI, PID
controller respectively recorded in control chart. The characteristics of P, PI and PID are
analysed and discuss in the report. Based on result of the experiment, PID controller is suitable
for Air Temperature Control as it eliminates offset, minimise overshoot when the disturbance
introduced and lagging, and converge to the setpoint much faster than PI, P controller exhibit
during the experiment. As temperature control provide rapidly changes of energy, PID
controller seem appropriate since it can handle frequent load changes however proportional,
integral and derivative should be tuned separately before combine in the controller.

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2.0 INTRODUCTION

Temperature control refers to a process that is aimed at maintaining the temperature in

a given area at certain maximum or minimum level or within a certain range. This process is
commonly used in all parts of the world. Globalization and industrialization have further
necessitated the need for Temperature Control applications in various daily industrial activities
(Emmanuel, 2011). Homes and Industries among other areas have parts of operation that must
be maintained within a certain temperature for process to work successfully, otherwise, the
processes would not work or would not be as efficient. Automatic temperature control is the
best method in any application because the temperature is usually controlled automatically
without human intervention (Yugal et al., 2016).

In this experiment an Air Temperature Control has been designed on how a temperature
loop for an exchanger can be controlled using a microprocessor-based controller. The control
panel is connected to a Distributed Control System (DCS), which can remotely control the
process plant using supervisory control mode (SCADA) or direct digital control mode (DDC).
The Air Temperature Control Module is an air process where 6 bar(g) compressed air is
charged into the air receiver tank V-102 and regulated to about 4 bar(g) by the air regulator.

The PID which stands for proportional–integral–derivative controller maintains the output
to the process plant such that there is zero error between process variable and set point or
desired output by a closed loop or feedback loop mechanism. According to Astrom (1995), The
behaviour of the 3 controllers can be characterized as follows:

1. P controller, known as proportional control, is designed to eliminate the cycling

associated with on-off control. A proportional controller decreases the average power
supplied to the heater as the temperature approaches set point. This has the effect of
slowing down the heater so that it will not overshoot the set point but will approach the
set point and maintain a stable temperature.

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2. PI controller, known as Proportional-Integral, as its name suggests is a combination of
Proportional and Integral control. Due to limitation of p-controller where there always
exists an offset between the process variable and set point, I-controller is needed, which
provides necessary action to eliminate the steady state error. It integrates the error over
a period of time until error value reaches to zero. It holds the value to final control
device at which error becomes zero.

3. PID controller, known as Proportional-Integral-Derivative controller is a combination

of all 3 controllers. Since the I-controller doesn’t have the capability to predict the
future behaviour of error. So, it reacts normally once the set point is changed. D-
controller overcomes this problem by anticipating future behaviour of the error. Its
output depends on rate of change of error with respect to time, multiplied by derivative
constant.

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3.0 METHODOLOGY
General Start-up Procedure
1. Compressor had beem started to build enough air pressure in air receiver tank, V-102
until it reached 6 bar.
2. Main instrument at control panel switched on.
3. Pens with ink installed on the recorder and checked for its functionality.
4. Controller was set to manual mode with setpoint 100ºC.
5. HV 115 and HV 117 were closed while HV 111,112,113,114 were opened.
6. Volumetric flow rate was adjusted to 35 m3/hr.
7. Precaution should be taken during handling the experiment as surface air heater is
hot.

Proportional and Integral and Derivative Control

1. TIC-102-1 was set to manual mode with setpoint of 100ºC.
2. The output was gradually adjusted for the TT 102 matches the set point
3. Values PB = 100, I =180, D=60 entered to the controller.
4. Disturbance was introduced by setpoint was changed to the 150ºC.
5. Controller was set to auto mode.
6. The response of the system was recorded in control chart until it reaches near to the
setpoint.

Closed Loop PI Control

1. TIC-102-1 was set to manual mode with setpoint of 100ºC.
2. The output was gradually adjusted for the TT 102 matches the set point.
3. Values P= 20, I = 180, D = 0 entered to the controller.
4. Disturbance was introduced by setpoint was changed to 150ºC
5. The controller was set to auto mode.
6. The response of the system was recorded in control chart until it reaches near to the
setpoint.

Closed Loop Proportional Control

1. Values PB = 100, I = 9999 and D = 0, were entered to the controller.
2. Disturbances was introduced by setpoint changed to the 100ºC.
3. The controller was set to auto mode.
4. The response of the system was recorded in control chart for 5 minutes.

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4.0 RESULT AND DICUSSION
Experiment 10.1 Closed Loop Proportional Control

Figure 10.1.1 Graph of Closed Loop Proportional Control for Temperature Control
The proportional controller is set when the integral value and derivative value of the
PID controller being set to 0. In this experiment, an infinity(large) value for integral and 0 for
derivative has been used to ensure it as a proportional only control of temperature control. The
error for P controller could be calculated from the formula of 𝑒(𝑡) = 𝑦𝑠𝑝 − 𝑦𝑚 . By this
formula, the error from the obtained value and the setpoint could be calculated. However, to
calculate the offset, the transfer function of P control can be used along with the final value
theorem (FVT). The final value theorem will set the ‘s’ approaching 0 and the remaining of the
value left is the offset of the system. The function of the P control is per describe below:

𝑝(𝑡) = 𝑝𝑠𝑠 + 𝑘𝑐 𝑒(𝑡)

Where the Kc is the controller gain and p(t) is the controller output meanwhile the p ss is the
bias value at steady state. Based on the graph, the setpoint value was set to the 100℃ and the
manipulated variable was adjusted in auto mode to have the desired setpoint value. However,
as mention earlier, the P control will introduce the offset to the system. Hence, the system will
produce a behaviour where it will have a steady state error and never meet the setpoint value.
The system shows an oscillatory response in early stages but managed to produce a steady
response at the end as the system being corrected by the controller. The oscillatory might
because of the lag or dead time consists in the system. The oscillations occur make it possible
to calculate the natural period between two successive crest or valleys. By calculating the
natural period, the time taken for the system to complete one cycle will be known. But since
there are no disturbance introduced to the system. There will be no natural period calculated
for this P controller.

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Experiment 10.2 Closed Loop PI Control

Figure 10.2.1 Graph of Closed Loop PI Control for Temperature Control

For the closed loop PI Control, the values are set to PB=20, I=180 and D=0. PI
Controller are needed in non-integrating processes where the process returns to the same output
given the same set of input and disturbance ("Dynamics and Control"). PI Controller contains
two components of proportional gain and integral gain where the proportional part is to
establish the system stability and improve transient response. While for the integral part is to
reduce the steady state error (Ganesh & Naik, 2017)

1 𝑡 ′
𝑝(𝑡) = 𝑝̅ + 𝐾𝑐 ⌊𝑒(𝑡) + ∫ 𝑒(𝑡 ) 𝑑𝑡 ′ ⌋
𝜏𝐼 0

Where 𝜏𝐼 is an adjustable parameter and referred to as the integral time constant or reset time,
has units of time. PI Controller is used to eliminate the steady state error that resulting from P
Controller. Based on the graph, when the setpoint is set to 100℃, the system maintains the set
point temperature. After a few minutes, the disturbance is introduced as the setpoint is changed
to 150℃, produces a stable oscillatory respons due to the addition of integral controller. The
steepness of the graph increases when disturbance is introduced, which indicate decrease the
rise time and the fast response of the system.

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Experiment 10.3 Proportional and Integral and Derivative Control
This experiment conducted to observe the characteristic of PID controller towards the
temperature control by using different value of P, I and D which are 100, 180 and 60
respectively. The setpoint used for this part is 100ºC and the set point changed to 150ºC as the
disturbance introduced.

Figure 10.3.1 Graph of Closed Loop PID Control for Temperature Control

Based on the graph, the pattern of PID controller can be observed. At the first peak is
where the controller started to adjust the output to the set point and the second peak is where
the disturbance introduced. As illustrated in above graph, the red line which is the heater
temperature was set and the green line, output temperature was stabilize after tuning whereby
it become close to 100°C, which is the set point due to the PID controller consist of Integral
controller which eliminate the offset but still oscillate as it can be seen between temperature
145.5°C to 103.3°C the steady state error is almost zero whereas numerically can be calculated
using 𝑒(𝑡) = 𝑦𝑠𝑝 − 𝑦𝑚 . Besides, as the disturbance of 150°C introduced, the overshoot
occurred then, after time delay to settle approximately 14 minutes, the overshoot is corrected
to its steady set point. Moreover, the graph at disturbance was steeper compared to PI graph
and P graph will always parallel to setpoint which eventually make PID as the optimum
controller because as the steepness increase, the time taken to correct the output to setpoint
decrease. Theoretically, by using Derivative controller together with PI, it will eventually sense
the rate of rise or fall of system temperature and automatically adjusts the proportional band to
minimize overshoot or undershoot, this tuning process will ensure the actual temperature stays
within the set point.

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 Hence, compared to PI and P controller, PID is the most suitable controller for
temperature control as the process has longer time taken for the measured value to increased
or decreased as desired output. Derivative action may be applied for a plant or system has long
time delays between changes in the measured value and their correction (McGeorge, 1998). In
addition, as Integral controller is combined together, steady state error is eliminated by
necessary action, while as Derivative also added together to Proportional controller, phase
advance in the output signal is produced and generate control correction while minimize the
lag sooner than would be possible with proportional action alone (Gray, 2014). Moreover,
because of the simple structure of PID controller, make it the most extensive control method
to be used in industry so far because to achieve optimal control performance, an appropriate
proportional gain (Kp), integral gain (KI), and differential gain (KD) are mainly to be adjusted
(Meshram & Kanojiya, 2012). Therefore, the function of PID controller can be calculated using
formula below:

1 𝑡 𝑑
𝑝(𝑡) = 𝐾𝑝 ⌊𝑒(𝑡) + ∫ 𝑒(𝑡 ′ ) 𝑑𝑡 ′ + 𝑇𝑑 𝑒(𝑡)⌋
𝜏𝐼 0 𝑑𝑡

Where P(t) and e(t) illustrated the control and the error signals respectively, and Kp, Ti and Td
are the parameters to be tuned. The corresponding transfer function is given as:

1
𝐾(𝑠) = 𝐾𝑝 [1 + + 𝑇𝑑 (𝑠)]
𝑇𝑖 (𝑠)

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5.0 CONCLUSION

A temperature control system is used widely in industries. Process control systems are
often hard to control accurately because they are usually nonlinear and quite hard to predict. In
this experiment, The Air Temperature Control has been designed on how a temperature loop
for an exchanger can be controlled using a microprocessor-based controller. Three (3) sub-
experiments were conducted, the first to observe the behaviour of a Closed Loop Proportional
Control, followed by Closed Loop PI Control and lastly, Proportional and Integral and
Derivative Control.

Firstly, from the Closed Loop Proportional Control, it was observed from the
experiment’s resulting data that P control will introduce offset to the system. The system
produced a behaviour where it had a steady state error and never met the setpoint value. The
system showed an oscillatory response in the early stages but produced a steady response at
the end as the system was corrected by the controller.

Secondly, from the Closed Loop PI Control, it was observed from the experiment’s
resulting data that the system first maintains the set point temperature. Once the disturbance is
introduced and the setpoint is changed, a stable oscillatory response is produced due to the
addition of integral controller. Moreover, when the disturbance is introduced it can be noticed
that the steepness of the graph increase, indicating a faster response and a decrease in rise time.

Lastly, from Proportional and Integral and Derivative Control it was observed from the
experiment’s resulting data that the controller adjusts the heater to the set point first, then the
disturbance is introduced. Since PID controller consists of the Integral controller the offset is
eliminated. Furthermore, after the overshoot occurred, the overshoot was corrected to its
steady set point after a time delay of approximately 14 minutes.

To conclude, based on the results from this experiment, after thorough comparisons
between the P, PI and PID controllers, it was found that the PID controller is the most suitable
controller for temperature control because the process takes a longer time for the measured
value to increase or decrease as desired output.

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6.0 REFERENCES
1. Fundamentals of integrating vs. self-regulating processes. (2014, December 3).
Retrieved from https://www.controleng.com/articles/fundamentals-of-integrating-vs-
self-regulating-processes/
2. Dynamics and Control. (n.d.). Retrieved from
https://apmonitor.com/pdc/index.php/Main/ProportionalIntegralControl
3. Ganesh, M. V., & Naik, R. S. (2017). Comparitive Analysis of P-I, I-P, PID and Fuzzy
Controllers for Speed Control of DC Motor. International Research Journal of
Engineering and Technology (IRJET), 04(10), 500–504. Retrieved from
https://www.irjet.net/archives/V4/i10/IRJET-V4I1089.pdf
4. McGeorge, H. D. (1998). Marine auxiliary machinery. Elsevier.
5. Gray, D. (2014). Centralized and automatic controls in ships. Elsevier.
6. Meshram, P. M., & Kanojiya, R. G. (2012, March). Tuning of PID controller using
Ziegler-Nichols method for speed control of DC motor. In IEEE-international
conference on advances in engineering, science and management (ICAESM-2012) (pp.
117-122). IEEE.
7. Astrom K. (1995). PID Controllers: Theory, Design and Tuning. Instrument Society of
America, Research Triangle Park.
8. Emmanuel O. (2011). Temperature Control System. Retrieved from
researchgate.net/publication/293634901_Temperature_Control_System
9. Yugal K., Jayendra K., Keshav K. Pandey, Rohit K. and Bhargav. A. (2016).
Temperature Control System and its Control using PID Controller. International
Journal of Engineering Research and Technology (IJERT), 5(5), 1203–1206. doi:
10.21275/v5i5.nov163686

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