INSTRUMENTATION

PROCESS DYNAMICS &

CONTROL LAB
MANUALS

Department of Petroleum Engineering and Petrochemical Engineering

University College of Engineering Kakinada (A), JNTUK Kakinada
 Department of Petroleum Engg. & Petrochemical Engg.

LIST OF EXPERIMENTS
S.No. Name of the Experiment Remarks
1 i). To study the step and impulse response of single tank level system
ii). To study the impulse response of single tank level system
i). To study the step response of two tank non interacting liquid level system
2 ii). To study the impulse response of two tank non interacting liquid level
system
i). To study the step response of two tank interacting liquid level system
3
ii). To study the impulse response of two tank interacting liquid level system
4 To study the step response of thermometer without thermal well
5 To study the hysteresis of control valves
6 To study the inherent characteristics of various control valves
7 To study the step response of u-tube water manometer
Temperature Control Trainer
1. Study of open loop response (Manual control)
2. Study of ON-OFF control in Temperature Control Trainer
8
3. Tuning of Controller in Temperature Control Trainer
4. Study of P-controller in Temperature Control Trainer
5. Study of PID-controller in Temperature Control Trainer

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

1. i). TO STUDY THE STEP RESPONSE OF SINGLE TANK LEVEL SYSTEM

Aim: To study the step response of single tank level system and to obtain the time
constant of the process.
Apparatus: Single tank liquid level system apparatus and stop watch.
Description: The setup is designed to study dynamic response of single and multi-
capacity process when connecting in interacting and non-interacting mode. It is
combined to study,
1. Single tank capacity process.
2. Non-interacting process.
3. Interacting process.
The observed step response of the tank level in different modes can be compared with
mathematically predicted response. The setup consists of supply tank, pump for water
circulation, Rota-meter for flow measure measurement, transparent water tanks with
graduated scales which can be connected in interacting and non-interacting mode. The
components are assembled on frame to form table top mounting.

Fig.1.0. Single tank liquid level system

Theory:
Mathematically the step function of A can be expressed as;
X(t) = A.U(t)

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Department of Petroleum Engg. & Petrochemical Engg.

Where: U(t) is a unit step function.

To study transient response for step function, Consider the system consisting of tank of
uniform cross sectional area A and outlet flow resistance ‘R’, such that as a value q0
volumetric flow rate through the resistance is related to head ‘h’ by a linear relationship,
ℎ
q0 =  (1)
𝑅

Writing a transient mass balance around the tank,

Mass flow in – Mass flow out = Rate of accumulation of mass in tank
( 𝐴𝜌 )𝑑ℎ
𝜌q (t) - 𝜌q0 (t) =
𝑑𝑡
𝐴𝑑ℎ
q (t) – q0 (t) =  (2)
𝑑𝑥

Combining equations (1), (2) to eliminate q0 (t) gives the following linear differential
ℎ 𝑑ℎ
equation: q= = A1𝑑𝑥  (3)
𝑅
𝑑ℎ
Initially the process is operating as steady state which means =0
𝑑𝑥
ℎ𝑠
Eq., (2) becomes; qs = =0  (4)
𝑅
ℎ −ℎ𝑠 𝑑(ℎ−ℎ𝑠 )
q - qs = + A1  (5)
𝑅 𝑑𝑡

Introducing deviation variables: Q = q – qs ; H = h – hs

𝐻 𝑑𝐻
Q = 𝑅 + 𝐴I 𝑑𝑡  (6)

Taking the transform of equation (3) is given by

𝐻 ( 𝑠)
Q(s) = + A1 s [H(s)]  (7)
𝑅

Equation (7) is rearranged into standard form of first order system as

𝐻(𝑠) 𝑅
=  (8)
𝑄(𝑠) 𝜏𝑠 + 1

For a step change of magnitude ‘A’, we can write it as;

𝐴𝑅
Q (t) = A U (t); Q(s) = A/s; H(s) = 𝑠 (𝜏𝑠 + 1)  (9)

By applying Inverse Laplace Transform

−𝑡
We get; H(t) = AR( 1 - 𝑒 𝜏 )  (10)
Procedure:
1. Start the setup.

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Department of Petroleum Engg. & Petrochemical Engg.

2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe into the cover
of the top tank-1. Keep the outlet valves (R1, R2) of both tanks-2 & 3 are fully closed.
3. Switch ON the pump and adjust the flow to at the rate of 80 LPH. Allow the level
of tank-1 to reach at steady state and record the initial flow and steady state levels
of the tank-1.
4. Apply the step change with increasing Rotameter flow at rate of 20 LPH.
5. Record the levels of tank-1 at the interval of 5 or 10 seconds, until the level reaches
the steady state.
6. Record the final flow and steady state level of tank-1.
7. Carryout the calculations as mentioned in calculation part and compare the
predicted and observed values of the tank level.
8. Repeat the experiment by throttling outlet valve to change resistance.
Observations:
1. Diameter of tanks = 92 mm
2. Initial flow rate = 80 LPH
3. Initial steady state liquid level of tank 1 = mm
4. Final flow rate = 100 LPH
5. Final steady state liquid level of tank 1 = mm

Tabular form:

Time Height in tank-2 H(t) Observed H(t) Predicted

S. No.
(sec) (mm) (mm) (mm)
1
2
3
4
5
6

Formulae:
𝜋
Area of tank-1, A = 4 𝑑2

H (t)observed = ( Level at ‘t’ – Level at t=0 )

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Department of Petroleum Engg. & Petrochemical Engg.

−𝑡
H(t)predicted= AR2 [ 1 – 𝑒 𝜏 ]

Where: H(t) is the level of tank -1 predicted at time ‘t’ in mm.; A is magnitude of step
change in input;
𝑑𝐻
Time constant, τ = AR; Outlet valve resistance, R = ;
𝑑𝑄

Time constant, τ = A1R

Model Calculations:

Graph: Level of the tank response H(t, mm) Vs Time (t, sec)

Precautions:
1. Readings should be taken without parallax error.
2. Note the time properly with the help of stop watch.

Result: The step response of single tank liquid level system was studied and the time
constant for this process τ, is ___ sec.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

1.ii). TO STUDY THE IMPULSE RESPONSE OF SINGLE TANK LIQUID LEVEL

SYSTEM

Aim: To study the impulse response of single tank level system and to obtain the time
constant of the process.
Apparatus: Single tank liquid level system apparatus and stop watch
Description: The setup is designed to study dynamic response of single and multi-
capacity process when connecting in interacting and non-interacting mode. It is
combined to study,
1. Single tank capacity process.
2. Non-interacting process.
3. Interacting process.
The observed impulse response of the tank level in different modes can be compared with
mathematically predicted response. The setup consists of supply tank, pump for water
circulation, Rota-meter for flow measure measurement, transparent water tanks with
graduated scales which can be connected in interacting and non-interacting mode. The
components are assembled on frame to form table top mounting.

Fig.1.0. Single tank liquid system apparatus

Theory:
Mathematically the impulse function of A can be expressed as
X ( t ) = A Tm( t )  (1)

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Department of Petroleum Engg. & Petrochemical Engg.

Where: Tm (t) is a unit impulse function.

To study transient response for step function, Consider the system consisting of tank of
uniform cross sectional area A and outlet flow resistance ‘R ‘such that as a value q 0
volumetric flow rate through the resistance is related to head ‘h’ by a linear relationship.
ℎ
q0 = 𝑅  (2)

Writing a transient mass balance around the tank,

Mass flow in – Mass flow out = Rate of accumulation of mass in tank
(𝐴𝜌)𝑑ℎ
𝜌q (t) - 𝜌q0 (t) =
𝑑𝑡
𝐴𝑑ℎ
q (t) – q0 (t) =  (3)
𝑑𝑡

Combining equations (2), (3) to eliminate q0 (t) gives the following linear differential
ℎ 𝑑ℎ
equation: q = 𝑅 = A 𝑑𝑥  (4)
𝑑ℎ
Initially the process is operating as steady state which means: = 0;
𝑑𝑥
ℎ𝑠
Eq (3) becomes; qs = =0  (5)
𝑅
ℎ−ℎ𝑠 𝑑(ℎ−ℎ𝑠 )
q - qs = + A1  (6)
𝑅 𝑑𝑡

Defining deviation variables; Q = q – qs ; H = h – hs

𝐻 𝑑𝐻
Q = 𝑅 + 𝐴I 𝑑𝑡  (7)

Taking the transform of equation (4) is given by

𝐻 ( 𝑠)
Q(s) = + A1s [H(s)]  (8)
𝑅

Equation (8) is rearranged into standard form of first order system as:
𝐻(𝑠) 𝑅
=  (9)
𝑄(𝑠) 𝜏𝑠 + 1

For a impulse change of magnitude V (added volume), we can write it as;

𝐻(𝑠) 𝑉𝑅
= (10)
𝑄(𝑠) 𝜏𝑠 + 1

By applying Inverse Laplace Transform,

−𝑡
𝑉𝑅
We get, H(t) = 𝑒𝜏  (11)
𝜏

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Department of Petroleum Engg. & Petrochemical Engg.

Procedure:
1. Start the setup.
2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe into the cover
of the top tank-1. Keep the outlet valves (R1, R2) of both tank-2 & 3 are fully closed.
3. Switch ON the pump and adjust the flow to at the rate of 80 LPH. Allow the level
of tank-1 to reach at steady state and record the initial flow and steady state levels
of the tank 1.
4. Apply the impulse input by adding 0.5 liter of water in tank-1.
5. Record the levels of tank-1 at the interval of 5 or 10 seconds, until the level reaches
the steady state.
6. Record the final flow and steady state level of tank-1.
7. Carryout the calculations as mentioned in calculation part and compare the
predicted and observed values of the tank level.
8. Repeat the experiment by throttling outlet valve to change resistance.
Tabular form:
Time Height in tank-2 H(t) Observed H(t) Predicted
S. No.
(sec) (mm) (mm) (mm)
1
2
3
4
5
6

Observations:
Diameter of tanks = 92 mm;
Initial flow rate = LPH
Initial steady state liquid level of tank-1 = mm
Volume of liquid (water) added in tank = 500 ml
Final steady state level of tank 1 = mm

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Department of Petroleum Engg. & Petrochemical Engg.

Formulae:
𝜋
Area of tank-1, A = 𝑑2
4

H(t)observed = ( level at t=‘t’ – level at t=0 )

𝑡
𝑉𝑅
H(t)predicted = 𝑒 −(𝜏),
𝜏

Where V is magnitude of impulse change in input;

H (t) is the level of tank-1 predicted at time ‘t’
Time constant, τ = AR;
𝑑𝐻
Outlet valve resistance, R = 2 𝑑𝑄 ; τ = A1 R

Model Calculations:

Graph: Impulse Response of level of tank H (t, mm) Vs Time (t, Sec)
Precautions:
1. Readings should be taken without parallax error.
2. Note the time properly with the help of stop watch.
Result: The impulse response of single tank liquid level system was studied and the time
constant of the process τ, is ____sec.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

2. i). TO STUDY THE STEP RESPONSE OF TWO TANK NON INTERACTING

LIQUID LEVEL SYSTEM

Aim: To study the step response of two tank non interacting liquid level system and to
obtain the time constants of the process.
Apparatus: Two tank non interacting liquid level system apparatus and stop watch.
Description:
The setup is designed to study dynamic response of single and multi-capacity process
when connected to in interacting and non-interacting mode. It is combined to study,
1. Single tank liquid capacity process.
2. Non-interacting process.
3. Interacting process.
The observed step response of the tank level in different modes can be compared with
mathematically predicted response. The setup consists of supply tank, pump for water
circulation, Rotameter for flow measurement, transparent water tanks with graduated
scales which can be connected in interacting and non-interacting mode. The components
are assembled on a frame to form table top mounting.

Fig. 1.0. Two tank Noninteracting liquid level systems Apparatus

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Theory: In non -interacting system, we assume the tanks have uniform cross -sectional
area and the flow resistance in linear. To find out the transfer function of the system that
reaches H2 and q, a mass around the tank, we proceed as follows unsteady state balance,
𝑑ℎ1
For tank-1, q – q1 = A1  (1)
𝑑𝑡
𝑑ℎ2
For tank-2, q – q2 = A2  (2)
𝑑𝑡

Steady state balance, qs – q1s = 0  (3)

q1s –q2s = 0  (4)
Introducing deviation variables, Q = q – qs; Q1 = q1 – q1s; Q2 = q1s – q2s;
The flow head characteristics for the two linear resistances in non- interacting system are
𝐻1 𝐻2
given by the following expressions: q1 = 𝑅1  (5) & q2 = 𝑅2  (6)
𝑄1 (𝑠) 1
From equations (1), (3), (5): = ; (𝜏1 = A1R1)
𝑄(𝑠) 𝜏1 𝑠 +1

𝐻2(𝑠) 𝑅2
From equations (2), (4): = ; (𝜏2 = A2R2)
𝑄1(𝑠) 𝜏2 𝑠 +1

Overall transfer function can be calculated as follows;

𝐻2 (𝑠) 𝑅2
=
𝑄(𝑠) (𝜏1 𝑠 + 1)(𝜏2 𝑠 + 1)
𝐴
For a step change of magnitude’ A’, Q (s) = 𝑠

𝐴𝑅2
𝐻2 (𝑠) =
𝑠(𝜏1 𝑠 + 1)(𝜏2 𝑠 + 1)
H2 at time ‘t’ is given by applying inverse Laplace transform:

  t 
t

   1 2  e 1 e  2 
H 2 (t )  AR2 1     
 
  1 2  2  1 
  
Procedure:
1. Start the setup;
2. A flexible pipe is provided at the Rota-meter outlet. Insert the pipe into the cover
of the top tank-1. Keep the outlet valves (R1, R2) of both tanks-1& 2 slightly closed
ensure that the valve R3 between tank 2 & tank 3 is fully closed.

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Department of Petroleum Engg. & Petrochemical Engg.

3. Switch ON the pump and adjust the flow to at the rate of 80 LPH. Allow the level
of both tanks (1&2) to reach at steady state and record the initial flow and steady
state levels of the both tanks.
4. Apply the step change with increasing Rota-meter flow at rate of 20 LPH.
5. Record the levels of tank-2 at the interval of 10 seconds, until the level reaches the
steady state.
6. Record the final flow and steady state level of tank-1
7. Carryout the calculations as mentioned in calculation part and compare the
predicted and observed values of the tank level.
8. Repeat the experiment by throttling outlet valve to change resistance.
Observations:

1. Diameter of tank = 92 mm
2. Initial flow rate = LPH
3. Initial steady state level of tank-1 = mm
4. Initial steady state level of tank 2 = mm
5. Final flow rate = LPH
6. Final steady state level of tank 1 = mm
7. Final steady state level of tank 2 = mm
Tabular form:

Time Height in tank-2 H(t) Observed H(t) Predicted

S.NO.
(sec) (mm) (mm) (mm)
1
2
3
4
5
6

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Formulae:
𝜋
Area of tank (1 & 2) = A1 = A2= 4 𝑑2

H(t)observed = ( level at ‘t’ – level at t=0 )

−𝑡 −𝑡
τ1 τ2 𝑒 τ1 𝑒 τ2
H(t)predicted = AR2 [ 1 –( τ1−τ2 ) ( τ2 - )]
τ1

Where: H (t) is the level of tank 2 predicted at time‘t’

𝑑𝐻1 𝑑𝐻2
τ1 = A1R1 & τ2 = A2R2; R1 = & R2 =
𝑑𝑄 𝑑𝑄

Model Calculations:

Graph: Response of level of tank H(t, mm) Vs Time (t, Sec).

Precautions:
1. Readings should be taken without parallax error.
2. Note the time properly with the help of stop watch.

Result: The step response of two tank non interacting liquid level system was studied
and the time constants are τ1 = _____ sec and τ2 = ____ sec.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

2.ii). TO STUDY THE IMPULSE RESPONSE OF TWO TANK NON INTERACTING

LIQUID LEVEL SYSTEM

Aim: To study the impulse response of two tank non interacting liquid level system and
to obtain the time constants of the process.
Apparatus: Two tank non interacting liquid level system apparatus and stop watch.
Description:
The setup is designed to study dynamic response of single and multi-capacity process
when connected to in interacting and non-interacting mode. It is combined to study,
1. Single tank liquid capacity process.
2. Non-interacting process.
3. Interacting process.
The observed impulse response of the tank level in different modes can be compared with
mathematically predicted response. The setup consists of supply tank, pump for water
circulation, Rotameter for flow measurement, transparent water tanks with graduated
scales which can be connected in interacting and non-interacting mode. The components
are assembled on a frame to form table top mounting.

Fig. 1.0. Two tank Noninteracting liquid level systems Apparatus

Theory:
Mathematically, the impulse function of magnitude A is defined as: y (t) = 𝑉 𝑇𝑚 (𝑡)

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Department of Petroleum Engg. & Petrochemical Engg.

Where: Tm(t) is unit impulse function.

In non-interacting system, we assume the tanks have uniform cross sectional area and the
flow resistance in linear. To find out the transfer function of the system that reaches H2
and q, a mass around the tank, we proceed as follows unsteady state balance,
𝑑ℎ1
For tank-1, q – q1 = A1 𝑑𝑡  (1)
𝑑ℎ2
For tank-2, q – q2 = A2 𝑑𝑡  (2)

Steady state balance: qs – q1s = 0  (3)

q1s – q2s = 0  (4)
Introducing deviation variables; Q = q – qs; Q1= q1 – q1s; Q2= q1s – q2s
The flow head characteristics for the two linear resistances in non -interacting system are
𝐻1 𝐻2
given by the following expressions: q1 = 𝑅1  (5) & q2 = 𝑅2  (6)
𝑄1 (𝑠) 1
From equation (1), (3), & (5); = (𝜏1 = A1R1)
𝑄(𝑠) 𝜏1𝑠 +1

𝐻2(𝑠) 𝑅2
From equation (2), (4); = (𝜏2 = A2R2)
𝑄1(𝑠) 𝜏2𝑠 +1

Overall transfer function can be calculated as follows,

𝐻2 (𝑠) 𝑅2
=
𝑄(𝑠) (𝜏1𝑠 + 1)(𝜏2 𝑠 + 1)
For a step change of magnitude V; Q ( t) = 𝑉 𝑇𝑚 (𝑡) ; Q (s) = V
𝑉𝑅2
H2 (s) =
(𝜏1𝑠 + 1)(𝜏2 𝑠 + 1)
−𝑡 −𝑡
𝑒 𝜏1 −𝑒 𝜏2
H2 at time ‘t’ is given by; 𝐻2 (𝑡) = 𝑉𝑅2 [ ]
𝜏1−𝜏2

Procedure:
1. Start the setup
2. A flexible pipe is provided at the Rota-meter outlet. Insert the pipe into the cover
of the top tank 1. Keep the outlet valves (R1, R2) of both tanks 1 and 2 slightly closed.
3. Ensure that the valve (R3) between two bottom tanks (2 and 3) is fully closed.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

4. Switch ON the pump and adjust the flow to at the rate of 90 LPH. Allow the level
of both tanks (1,2) to reach at steady state and record the initial flow and steady
state levels of the both tanks.
5. Apply the impulse input by adding 0.5 lit of water in tank 1.
6. Record the levels of tank 2 at the interval of 10 seconds, until the level reaches the
steady state.
7. Record the final flow and steady state level of tank 1 and tank 2.
8. Carryout the calculations as mentioned in calculation part and compare the
predicted and observed values of the tank levels.
9. Repeat the experiment by throttling outlet valve to change resistance.

Observations:
1. Diameter of tank = 92 mm
2. Initial flow rate = LPH
3. Initial steady state level of tank 1 = mm
4. Initial steady state level of tank 2 = mm
5. Volume of water added in tank = 500 ml
6. Final steady state level of tank 1 = mm
7. Final steady state level of tank 2 = mm
Tabular form:
Time Height in tank-2 H(t) Observed H(t) Predicted
S.NO.
(sec) (mm) (mm) (mm)
1
2
3
4
5
6

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Formulae:
𝜋
Area of tank (1 and 2) = A1 = A2 = 4 𝑑 2

H(t)observed = ( level at t sec – level at 0 sec)

−𝑡 −𝑡
𝑒 𝜏1 −𝑒 𝜏2
H(t)predicted = VR 2 [ ]
𝜏1−𝜏2

Where: H(t) is the level of tank 2 predicted at time ‘t’;

τ1 = A1R1 , τ2 = A2R2
𝑑𝐻1 𝑑𝐻2
R1 =2 𝑑𝑄 , R2 =2 𝑑𝑄 .

Model Calculations:

Graph: Response of level of Tank H(t, mm) Vs Time (t, Sec)

Precautions:
1. Readings should be taken without parallax error.
2. Note the time properly with the help of stop watch.
Result:
The Impulse response of two tank non interacting liquid level system was studied and
the time constants are τ1 = ____ sec and τ2 = ___ sec.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

3.i). TO STUDY THE STEP RESPONSE OF TWO TANK INTERACTING LIQUID

LEVEL SYSTEM

Aim: To study the step response of two tank interacting liquid level system and to obtain
the time constants of the process.
Apparatus: Two tank interacting liquid level system apparatus and stop watch.
Description:
The setup is designed to study dynamic response of single and multi-capacity process
when connected to in interacting and non-interacting mode. It is combined to study,
1. Single tank liquid capacity process.
2. Non-interacting process.
3. Interacting process.
The observed step response of the tank level in different modes can be compared with
mathematically predicted response. The setup consists of supply tank, pump for water
circulation, Rotameter for flow measurement, transparent water tanks with graduated
scales which can be connected in interacting and non-interacting mode. The components
are assembled on a frame to form table top mounting.

Fig. 1.0 Two tank Interacting liquid level systems Apparatus

Theory:
Assuming the tanks of uniform cross-sectional areas and valves with linear flow
resistance, the transfer function of interacting system can be written as

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Department of Petroleum Engg. & Petrochemical Engg.

H2 (S) R2
=
Q(S) τ1 τ2 S + (τ1 + τ2 + A1 R 2 )S + 1
2

1 1 A 1 R2 −b −b 2 1 −b −b 2 1
Let: 𝑏= +τ + ; α = ( 2 ) + √( 2 ) − τ ; β = ( 2 ) − √( 2 ) − τ
τ1 2 τ 1 τ2 1 τ2 1 τ2

eαt eβt
( − )
α β
For a step change of magnitude A; H2 (t) = AR 2 [1 − 1 1
]
( − )
α β

In terms of transient response, the interacting system is more sluggish than the non-
interacting system.
Procedure:
1. Start the setup.
2. A flexible pipe is provided at the Rota-meter outlet. Insert the pipe into the cover
of the top tank 3. Keep the outlet valves (R2, R3) of both tanks 2 and 3 slightly
closed.
3. Switch ON the pump and adjust the flow to at the rate of 80 LPH. Allow the level
of both tanks (2 & 3) to reach at steady state and record the initial flow and steady
state levels of the both tanks.
4. Apply the step change with increasing Rota-meter flow at rate of 20 LPH.
5. Record the levels of tank 2 at the interval of 10 seconds, until the level reaches the
steady state.
6. Record the final flow and steady state level of tank-3.
7. Carryout the calculations as mentioned in calculation part and compare the
predicted and observed values of the tank level.
8. Repeat the experiment by throttling outlet valve to change resistance.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Tabular form:

Time Height in tank-2 H(t) Observed H(t) Predicted

S.NO.
(sec) (mm) (mm) (mm)
1
2
3
4
5
6

Observations:
1. Diameter of tank = 92 mm
2. Initial flow rate = LPH
3. Initial steady state level of tank 2 = mm
4. Initial steady state level of tank 3 = mm
5. Final flow rate = LPH
6. Final steady state level of tank 2 = mm
7. Final steady state level of tank 3 = mm
Formulae:
𝜋
Area of tank (2 & 3) = A2 = A3 = 4 𝑑 2

H(t)observed = ( level at ‘t’ – level at t=0 )

𝑒𝛼𝑡 𝑒𝛽𝑡
( − )
𝛼 𝛽
H(t)predicted = 𝐴𝑅2 [1 − 1 1 ]
( − )
𝛼 𝛽

−𝑏 −𝑏 2 1 −𝑏 −𝑏 2 1 1 1 𝐴1 𝑅2
Where: 𝛼 = ( 2 ) + √( 2 ) − 𝜏 ; 𝛽 = ( 2 ) − √( 2 ) − 𝜏 ;𝑏= +𝜏 +
1 𝜏2 1 𝜏2 𝜏1 2 𝜏1 𝜏2

𝑑𝐻1 𝑑𝐻2
τ 1 = A1R1, τ2= A2R2; R1= , R2 =
𝑑𝑄 𝑑𝑄

Model Calculations:

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Department of Petroleum Engg. & Petrochemical Engg.

Graph: Response of level of Tank, H (t, mm) Vs Time (t, Sec)

Precautions:
1. Readings should be taken without parallax error.
2. Note the time properly with the help of stop watch.
Result:
The step response of two tank interacting liquid level system was studied and the
time constants of the process are τ1 = _____ sec and τ2 = _____ sec.

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3.ii). TO STUDY THE IMPULSE RESPONSE OF TWO INTERACTING LIQUID

LEVEL SYSTEM

Aim: To study the impulse response of two tank interacting liquid level system and to
obtain the time constants of the process.
Apparatus: Two tank interacting liquid level system apparatus and stop watch.
Description:
The setup is designed to study dynamic response of single and multi-capacity process
when connected to in interacting and non-interacting mode. It is combined to study,
1. Single tank liquid capacity process.
2. Non-interacting process.
3. Interacting process.
The observed step response of the tank level in different modes can be compared with
mathematically predicted response. The setup consists of supply tank, pump for water
circulation, Rotameter for flow measurement, transparent water tanks with graduated
scales which can be connected in interacting and non-interacting mode. The components
are assembled on a frame to form table top mounting.

Fig. 1.0. Two tank Interacting liquid level systems Apparatus

Theory:
Impulse function is described as: 𝑋(𝑡) = 𝐴𝑇𝑀 (𝑡)

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Assuming the tanks of uniform cross-sectional areas and valves with linear flow
resistance, the transfer function of interacting system can be written as:

𝐻2 (𝑆) 𝑅2
= 2
𝑄(𝑆) 𝜏1 𝜏2 𝑆 + (𝜏1 + 𝜏2 + 𝐴1 𝑅2 )𝑆 + 1

For an impulse change of magnitude V (volume added to the system)

VR2
Q(t)=V(Ωt) ; Q(s)=V; H2 (s) = τ 2
1 τ2 S +(τ1 +τ2 +A1 R2 )S+1

VR
For impulse change of H2 at time‘t’ is given by; H2 (t) = (α−β)τ2 [eαt − eβt ]
1 τ2

−b −b 2 1 −b −b 2 1 1 1 A1 R2
Let: α = ( 2 ) + √( 2 ) − τ ; β = ( 2 ) − √( 2 ) − τ ; b= +τ +
1 τ2 1 τ2 τ1 2 τ1 τ2

Considering non-linear valve resistance, the resistance at outlet of both tanks can be
2𝐻1 2𝐻2
calculated as; R1= & R2=
𝑄 𝑄

Procedure:
1. Start the setup
2. A flexible pipe is provided at the Rota-meter outlet. Insert the pipe into the cover
of the tank 3. Keep the outlet valves (R2, R3) of both tanks 2 and 3 slightly closed.
3. Ensure that the valve (R1) between top tanks 1 is fully closed.
4. Switch ON the pump and adjust the flow to at the rate of 90 LPH. Allow the level
of both tanks (2, 3) to reach at steady state and record the initial flow and steady
state levels of the both tanks.
5. Apply the impulse input by adding 0.5 lit of water in tank 1.
6. Record the levels of tank 2 at the interval of 10 seconds, until the level reaches the
steady state.
7. Record the final flow and steady state level of tank 2 and tank 3.
8. Carryout the calculations as mentioned in calculation part and compare the
predicted and observed values of the tank levels.
9. Repeat the experiment by throttling outlet valve to change resistance.

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Observations:
1. Diameter of tank = 92 mm
2. Initial flow rate = LPH
3. Initial steady state level of tank 2 = mm
4. Initial steady state level of tank 3 = mm
5. Volume of water is added = 500 ml
6. Final steady state level of tank 2 = mm
7. Final steady state level of tank 3 = mm
Tabular form:
Time Height in tank-2 H(t) Observed H(t) Predicted
S. No.
(sec) (mm) (mm) (mm)
1
2
3
4
5
6

Formulae:
𝜋
Area of tank (2 and 3) = A2 = A3 = 𝑑2
4

H(t)observed = ( level at ‘t’ – level at t=0 )

(𝑉𝑅2 )
H(t)predicted = 𝜏 [𝑒 𝛼𝑡 − 𝑒 𝛽𝑡 ]
1 𝜏2 (𝛼−𝛽)

Where; H (t) is the level of tank 2 predicted at time‘t’

−𝑏 −𝑏 2 1 −𝑏 −𝑏 2 1 1 1 𝐴1 𝑅2
𝛼 = ( 2 ) + √( 2 ) − 𝜏 ; 𝛽 = ( 2 ) − √( 2 ) − 𝜏 ;𝑏= +𝜏 +
1 𝜏2 1 𝜏2 𝜏1 2 𝜏1 𝜏2

𝐻2 𝐻3
τ1= A2R2, τ2= A3R3 & R2=2 , R3 =2
𝑄 𝑄

Model Calculations:

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Graph: Response of level of tank H (t, mm) Vs Time (t, Sec)

Precautions:
1. Readings should be taken without parallax error.
2. Note the time properly by the help of stop watch.
Result:
The Impulse response of two tank interacting liquid level system was studied and The
time constants of the process are τ1 = _____ sec and τ2 = ____ sec.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

4. TO STUDY THE STEP RESPONSE OF THERMOMETER WITHOUT THERMAL

WELL

Aim: To study the step response of Thermometer without thermal well.

Apparatus: Thermometer, heater, heating bath, Timer, Beeper.
Installation requirement: water supply, electric supply, support table.
Theory: The thermometer bulb is at first order system, where response can be described
by first order linear differential equation. The dynamic response of first order type
instruments to a step change can be represented by
𝑑𝜃
𝜏 𝑑𝑡 + 𝜃 = 𝜃f

Where: 𝜃 = Temperature indicated by thermometer; 𝜃 f = final steady state of

temperature; t = Time; 𝜏 = Time constant
The linear first order differential has the particular solutions for given initial conditions,
−𝑡
𝜃
=1-𝑒𝜏
𝜃𝑓

This represents a single exponential response as shown below.

The time constant Τ is the time required to indicate 63.2% of the complete change. The
time constant 𝜏 is numerically equal to the product of resistance and capacitance

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Fig. 1.0. First order system apparatus

Procedure:
1. Prepare the setup.
2. Fill the heating bath with water.
3. Switch ON the beeper and set beep interval to 30 sec.
4. Ensure that the cycle time is set to 30 sec ON time and 30 sec OFF time. Switch ON
mains to heat the water in heating bath to its boiling point and switch OFF the
mains
5. The water in the heating bath is near to its boiling point; now insert the
thermometer in water bath.
6. Note the thermometer readings at each beep interval till the temperature reaches
steady state.
7. Switch OFF the beeper and note the readings.

Tabular form:
(For 𝑻𝒂𝒄𝒕𝒖𝒂𝒍 , 𝑻𝒕𝒉𝒆𝒐𝒓𝒆𝒕𝒊𝒄𝒂𝒍 v/s time)
S. No. Time(sec) Actual temperature(0c) Theoretical Temperature(C0)
1
2
3
4
5
6
7
8

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(For process reaction curve i.e.,𝒀(𝒕) v/s time)

𝑻 − 𝑻𝒊
S.NO. Time(sec) 𝒀(𝒕) =
𝑻𝒇 − 𝑻𝒊
1
2
3
4
5
6
7
8

Observations:
Initial temperature ( Ti) = 0C ;
Final temperature (Tf) = 0C

Model Calculations:
1. Step change (∆T) = Final temperature - initial temperature = = 0C

2. Value of 63.2% step change = ( 0.632 x ∆T ) + Ti =

3. Plot the graph of actual temperature v/s time and the value of time at 63.2% of

step change .This value is observed as time constant of the thermometer

4. Time corresponding to 63.2 % of step change is τ = sec

5. Calculate the theoretical temperature by using the following equation

𝑡
−( )
6. Theoretical temperature = Initial temperature + [ (step change)* ( 1 --𝑒 𝜏 )
7. Plot the graph of theoretical temperature v/s time on the same graph plotted

above.
8. Also, plot a graph between Y(t) and time, t which is termed as the “process

reaction curve”.
𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑎𝑡 𝑡𝑖𝑚𝑒 𝑡 − 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐼𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑇−𝑇𝑖
Where: 𝑌(𝑡) = =𝑇
𝐹𝑖𝑛𝑎𝑙 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓 −𝑇𝑖

9. From the process reaction curve;

Time constant of the system is τ = ____sec
Transportation lag is τd = ____sec

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Graphs: (i). Temperature (T, 0C) Vs Time (t, Sec)

(ii). Response of thermometer, y(t) Vs Time (t, Sec)

Precautions:
1. Handle thermometer carefully while doing experiment.
2. Readings should be taken without parallax error.
Result:
1. The Step response of thermometer without thermal well is studied.
2. A graph is plotted between actual temperature, theoretical temperature and
time.
3. From the graph of actual temperature v/s time,
Time constant 𝜏 = sec.
𝑇−𝑇𝑖
From the process reaction curve i.e., graph between 𝑌(𝑡) = 𝑇 v/s time,
𝑓 −𝑇𝑖

Time constant 𝜏 = sec.

Transportation lag τd = sec.

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5. TO STUDY THE INHERENT CHARACTERISTICS OF CONTROL VALVES

Aim: To study the inherent characteristics of following control valves:

1. Equal percentage control valve
2. Quick-opening control valve
3. Linear control valve.
Apparatus: Control valve Apparatus, Mini-Compressor, Submerged pump, Stop watch

Theory:
A control valve regulates the flow rate in a fluid delivery system. Control valve is
a valve with a pneumatic, hydraulic, electric (excluding solenoids) or other externally
powered actuator that automatically, fully or partially opens or closes the valve to a
position dictated by signals transmitted from controlling instruments. Most commonly
pneumatic actuators are used for control valves. A pneumatic valve is an air operated valve
which controls flow through an orifice by positioning approximately a plug. The plug is
attached at the end of a stem which is supported on a flexible fabric reinforced Elastomers
diaphragm, the stem moves down and consequently the plug restricts the flow through
the orifice. It is known as “Air-to-close” or “Equal % valve”. If air pressure is applied on the
bottom side of the diaphragm, the stem moves up and consequently the plug frees the flow
through the orifice. It is known as “Air-to-open ”or “Linear valve”.
The amount of fluid passing through the valve at any time depends upon the
opening between the plug and seat. Hence there is a relation between the flow through the
valve and valve position (lift) is called valve characteristics.

In general the flow through the control valve from specific fluid at given
temperature can be expressed as:
Q = 𝑓1 (L, P0, P1)
Where: Q is volumetric flow rate; L is stem position or lift; P0 & P1 are upstream and
downstream pressures

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Inherent characteristics of control valve are the relation between the flow and the
valve travel at constant pressure drop across the valve (fixed upstream and downstream
pressures).
Hence, inherent characteristics are Qmax =𝑓2 (L)

𝑄 𝐿
It can be written as m=𝑄 ; m =𝑓 (𝐿 ); m=f (x)
𝑚𝑎𝑥 𝑚𝑎𝑥

Where: Qmax is the maximum flow when the valve stem is at its max lift Lmax (valve is full
𝑄
open); m is fraction of maximum flow; and 𝑄 is fraction of maximum lift.
𝑚𝑎𝑥

Description:
The setup is designed to understand the control valve operation and its flow
characteristics. This setup contains three control valves with pneumatic actuators. One
control valve is with linear characteristics (air to close type) and the other two are with
quick-opening and linear characteristics (air to open type). Water from receiving tank is
pumped to supply tank to supply tank and re-circulated. Water from supply tank flows
through the control valve and water flow can be measured using rotameter and the water
inlet pressure at the control valve can be measured in terms of water column. The outlet of
control valve is open to atmosphere. The control valve stem travel can be adjusted by air
regulator resulting change in flow through the control valve. A scale is also provided to
measure the stem travel (in mm) from fully open to fully close.

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Fig.1.0. Control valve Apparatus & process flow diagram

Procedure:
1. Start up the set up. Open the flow regulating valve of the control valve to be studied
(Linear/ Equal%/quick opening).
2. Open the respective hose cock for pressure indication. (Close the flow regulating
valves and hose cocks of other control valves.)
3. Ensure that pressure regulator outlet is connected to the valve actuator of the control
valve under study. Keep the control valve fully open by adjusting air regulator.
4. Adjust the regulating valve and set the flow rate. (Set 400 LPH flow for
linear/equal% valve or 600 LPH for quick opening valve).
5. Note for measuring flow rates below rotameter minimum range use measuring jar.
6. Note the pressure drop at control valve at full open condition.
7. Slowly increase/decrease air pressure by regulator and close the control valve to
travel the stem by 4mm. Note the pressure drop at control valve and corresponding
flow rate.
8. Repeat the above step and take the readings at each 4mm-stem travel till the valve is
fully closed.

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9. Using necessary formulae, calculate the valve flow coefficients for all the three
valves.

Tabular form:
Equal % control valve:
Lift Flow ΔP (mm of ΔP Valve
S.NO
(mm) Q(LPH) H2O) (bars) Coefficient ,CV
1 0
2 4
3 8
4 12
5 16
6 20
7 24
8 28

Quick opening control valve:

Lift Flow ΔP (mm of ΔP Valve
S.No.
(mm) Q(LPH) H2O) (bars) Coefficient ,CV
1 0
2 4
3 8
4 12
5 16
6 20
7 24
8 28

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Linear control valve:

Lift Flow ΔP (mm of ΔP Valve
S.NO
(mm) Q(LPH) H2O) (bars) Coefficient ,CV
1 0
2 4
3 8
4 12
5 16
6 20
7 24
8 28

Model calculations:
G
Valve coefficient (Cv ) = 1.16 × Q × √∆P

Where, G = Specific Gravity = 1 for Water

∆P(mm of H2 O)×1.01325
ΔP = Pressure drop across valve (bar) = = 10,336

𝑚3 𝑄(𝐿𝑃𝐻)
Q = Flow-rate ( ℎ𝑟 ) = 1000

Graphs:
1. Lift position (mm) Vs Flow coefficient (Cv)
2. x/xmax Vs q/q max
3. Lift position (mm) Vs Flow (Q, LPH)
4. Lift position (mm)Vs Delta P

Precautions:
i. Readings should be taken without parallax error.
ii. While operating one valve, other valves should be kept closed.

Result: The inherent characteristics of Equal, Quick-Opening and Linear control valves
were studied.

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6. TO STUDY THE HYSTERESIS OF CONTROL VALVES

Aim: To study the Hysteresis of following control valves:

i. Equal percentage control valve
ii. Quick-opening control valve
iii. Linear control valve

Apparatus: Control valve Apparatus, Mini-Compressor, Submerged pump, Stop watch

Theory:
A control valve regulates the flow rate in a fluid delivery system. Control valve is
a valve with a pneumatic, hydraulic, electric or other extremely powered actuator that
automatically, fully or partially opens or closes the valve to a position dictated by signals
transmitted from controlling instruments. Most commonly, pneumatic actuators are used
for control valves. A pneumatic control valve is an air operated valve which controls the
flow through an orifice by positioning appropriately a plug. The plug is attached at the
end of the stem which is supported on a flexible fabric reinforced elastomeric diaphragm
at the other end. If air pressure is applied on the upper side of the diaphragm, the stem
moves down and consequently the plug restricts the flow through the orifice. It is known
as “Air- to-close” or “Equal % valve”. If air pressure is applied on the bottom side of the
diaphragm the stem moves up and consequently the plug frees the flow through the
orifice. It is known as “Air-to-open” or “Linear valve”.
Hysteresis is a predictable error resulting from the differences in a transfer
functions when a reading is taken from above and below the valve to be measured. In
case of control valves for same actuator signal, different stem travel (hence valve
coefficients) are obtained depending upon the direction of change in the signal.

The maximum error in stem travel (or valve coefficient) expressed in percentage
for same actuator pressure while opening and closing the valve is indicated as hysteresis.
The friction in the packing and guiding surfaces of a control valve will exhibit hysteresis.

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Presence of hysteresis is not desirable since it produces cycling and causes wear of the
valve plug and seat.

Description of setup:
The setup is designed to understand the control valve operation and its flow
characteristics. This setup contains three control valves with pneumatic actuators. One
control valve is with linear characteristics (air to close type) and the other two are with
quick-opening and linear characteristics (air to open type). Water from receiving tank is
pumped to supply tank to supply tank and re-circulated. Water from supply tank flows
through the control valve and water flow can be measured using rotameter and the water
inlet pressure at the control valve can be measured in terms of water column. The outlet
of control valve is open to atmosphere. The control valve stem travel can be adjusted by
air regulator resulting change in flow through the control valve. A scale is also provided
to measure the stem travel (in mm) from fully open to fully close.

Fig.1.0. Control valve Apparatus & process flow diagram

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Procedure:
1. Start up the setup for air- to-close control valve.
2. Adjust the regulatory valve at the inlet of the control valve to maintain the flow at
400LPH.
3. Set actuator pressure to 3psig.
4. Note the flow rate and pressure at the inlet of control valve.
5. Gradually increase the actuator pressure in steps from 0psig to 18psig and note
the readings.
6. Gradually decrease the actuator pressure in steps from 18psig to 0psig and note
the readings.
7. Calculate valve flow coefficient for actuator pressure for every reading.
8. Calculate hysteresis as the ratio of maximum difference between flow coefficients
at same actuator pressure to that of maximum flow coefficients.
9. Repeat the same experiment for quick-opening and linear control valve.

Tabular form:
Equal % Control valve:
Increasing Pressure Decreasing Pressure
Actuator Pressure
Valve Pressure Valve
S. NO Pressure Flow drop Flow Hysteresis
coefficient drop (mm coefficient
(psig) (LPH) (mm of (LPH)
(Cv) of H2O) (Cv)
H2O)
1 0
2 3
3 6
4 9
5 12
6 15
7 18

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Quick –Opening Control valve:

Increasing Pressure Decreasing Pressure
Actuator Pressure
Valve Pressure Valve
S. NO Pressure Flow drop Flow Hysteresis
coefficient drop (mm coefficient
(psig) (LPH) (mm of (LPH)
(Cv) of H2O) (Cv)
H2O)
1 0
2 3
3 6
4 9
5 12
6 15
7 18

Linear Control valve:

Increasing Pressure Decreasing Pressure
Actuator Pressure
Valve Pressure Valve
S. NO Pressure Flow drop Flow Hysteresis
coefficient drop (mm coefficient
(psig) (LPH) (mm of (LPH)
(Cv) of H2O) (Cv)
H2O)
1 0
2 3
3 6
4 9
5 12
6 15
7 18

Formulae:
G
1. Valve coefficient (Cv ) = 1.16 × Q × √∆P

Where: G = Specific Gravity = 1 for Water

∆P(mm of H2 O)×1.01325
ΔP =Pressure drop across valve (bar) = 10,336

m3 Q(LPH)
Q = Flow-rate ( hr ) = 1000
(CV at decreasing pressure−CV at increasing pressure)
2. Hysteresis% = × 100
Maximum CV

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Model Calculations:

Graphs:
1. Actuator Pressure Vs Valve flow coefficient (Equal % Valve
2. Actuator Pressure Vs Valve flow coefficient (Quick opening Valve)
3. Actuator Pressure Vs Valve flow coefficient (Linear Valve)

Precautions:
1. Reading should be taken without parallax error.
2. While using one valve, the remaining should be kept closed.

Result: The hysteresis behavior of above control valves were observed and also the
percentage of hysteresis were calculated.
1. Average hysteresis % for equal percentage control valve is .
2. Average hysteresis % for quick-opening control valve is .
3. Average hysteresis % for linear control valve is .

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7. TO STUDY THE STEP RESPONSE OF U-TUBE MERCURY

MANOMETER
Aim: To study the transient response of U-tube mercury manometer when a step input
is given to the system.

Apparatus: U-tube manometer setup, compressor, scale and stop watch.

Theory:
The dynamic response of second order system to step change can be described by a
second order differential equation.
The solution to above equation involve 3 laws: (i) an under damped condition (ξ< 1), (ii)
critically damped condition (ξ = 1), (iii) over damped condition (ξ > 1)
The response of under damped system is (ξ <1) can be written as:
−𝑡𝜉 ( √(1 − 𝜉 2 ))𝑡 𝜉 ( √(1 − 𝜉 2 ))𝑡
𝑌 (𝑡) = 𝐾𝑀 [ 1 − 𝑒 𝜏 ( 𝑐𝑜𝑠 + 𝑠𝑖𝑛 )]
𝜏 √(1 − 𝜉 2 ) 𝜏

Fig.1.0. U- tube Mercury manometer apparatus

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In case of manometer;
Y(t) = Response of any time after step change; K = gain factor = 1; M = magnitude of step
8𝐿𝜇 2𝑔
change; Damping coefficient , ξ = 𝜌𝑔𝐷2 √ 𝐿

Where: L = column length (m); 𝜇 = Dynamic viscosity (kg / ms); D = diameter of tube
(m); 𝜌 = density of manometric fluid (kg / 𝑚3 ); g = gravitational acceleration (m / 𝑠 2 )
Characteristics time (τ) = 2π in sec.
𝜔𝑛√(1−𝜉 2 )
Frequency of damped oscillation (f) = in cps;
2𝜋

2𝑔
(Where Natural frequency 𝜔n = 2𝜋√ 𝐿 in rad / sec)

Performance characteristics for the step response of an under damped system is shown
in fig.2.0.

Fig.2.0. Characteristics for the step response of an under damped system

1. Rise time = tr is the time the indicated value takes to first reach the new steady
state value.
2. Time to first peak = tp is the time required for the indicated value to reach its first
maximum value.
3. Response/settling time = ts is defined as the time required for the indicated value
to reach and remain inside a band whose width is equal to +/-5% of the total

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change in θ. The term 95% response time sometimes is used to refer to this case.
Also, values of +/-1% sometimes are used.
4. Decay ratio (DR) = c/a (Where c is the height of the second peak).
−2𝜋𝜉
DR = exp ( );
√(1−𝜉 2 )

5. Overshoot (OS) = a/b =√DR

6. Period of oscillation = P is the time between two successive peaks or two
2𝜋
successive valleys of the response. Period of oscillation (P) =
𝑤𝑛 √(1−𝜉 2 )

Formulae:
2𝜋
1. Characteristic time (t) = 𝜔𝑛 insec

𝜔𝑛√(1−𝜉 2 )
2. Frequency of damped oscillation (f) = in cps;
2𝜋

2g
3. Natural frequency = 𝜔n = 2𝜋√ 𝐿 in rad / sec;

−2𝜋𝜉
4. Decay ratio = exp ( );
√(1−𝜉 2 )

5. Overshoot =√𝐷𝑒𝑐𝑎𝑦𝑅𝑎𝑡𝑖𝑜;
2𝜋
6. Period of oscillation(P) =
𝑤𝑛 √(1−𝜉 2 )

Procedure:

1. Ensure that mercury levels in manometer are set to zero on the scale.
2. Close the vent valve on base plate for mercury manometer.
3. Rotate the valve to deflect the mercury levels to 200 mm, 150 mm and 100mm from
zero level.
4. Note mercury level readings and quickly open the vent valve to apply step change.
Note the top peak and bottom peak readings also simultaneously note the time at
that peaks.
5. Repeat process 2-3 times for different step changes.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Tabular form:
Case –(i) : STEP INPUT = 100 mm

Time H(t)observed H(t)predicted

S.NO.
(sec) (mm) (mm)
1
2
3
4
5
6

Case-(ii): STEP INPUT = 150 mm

Time H(t)observed H(t)predicted

S.NO.
(sec) (mm) (mm)
1
2
3
4
5
6

Case-(iii) : STEP INPUT = 200 mm

Time H(t)observed H(t)predicted

S.NO.
(sec) (mm) (mm)
1
2
3
4
5
6

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Observations:
1.Manometer fluid: Mercury;
2.Dynamic viscosity = 0.016 kg/m.sec
3.Mass density = 13550 kg/m3
4.Column length = 0.4 m;
5.Tube diameter = 0.0016 m

Model Calculations:
8𝐿𝜇 2𝑔
1. Damping coefficient (ξ ) = √
𝜌𝑔𝐷 2 𝐿

2𝑔
2. Natural frequency (𝜔n ) = 2𝜋√ 𝐿

𝑤𝑛 √(1−𝜉 2 )
3. Frequency of oscillation (f) = 2𝜋
2𝜋
4. Characteristic time (t) = 𝑤
𝑛

−2𝜋𝜉
5. Decay ratio = exp ( )
√(1−𝜉 2 )

6. Over shoot =√𝐷𝑒𝑐𝑎𝑦𝑅𝑎𝑡𝑖𝑜

2𝜋
7. Period of oscillation (P) =
𝑤𝑛 √(1−𝜉 2 )

−𝑡𝜉 ( √(1 − 𝜉 2 ))𝑡 𝜉 ( √(1 − 𝜉 2 ))𝑡

𝑌(𝑡) 𝑇ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 = 𝐾𝑀 [ 𝑒 𝜏 ( 𝑐𝑜𝑠 + 𝑠𝑖𝑛 )]
𝜏 √(1 − 𝜉 2 ) 𝜏

Where: K = Gain factor =1; M = Magnitude of step input

Graphs:
1. Response of U-tube water manometer (100 mm, y(t)) Vs Time (t, sec)
2. Response of U-tube water manometer (100 mm, y(t)) Vs Time (t, sec)
3. Response of U-tube water manometer (100 mm, y(t)) Vs Time (t, sec)

Precautions:
1. Readings should be taken without parallax error.
2. Control the valve such that the manometric fluid does not come outside of the
manometer

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Result:
The step responses of u-tube mercury manometer were studied.
Decay ratio = ;
Overshoot = ;
Period of oscillation = sec;
For step input = 100 mm:
Rise time (tr) = sec;
Time to first peak (tp) = sec;
Setting time (ts) = sec.
For step input = 150 mm:
Rise time (tr) = sec;
Time to first peak (tp) = sec;
Setting time (ts) = 24.7 sec.
For step input= 200 mm:
Rise time (tr) = sec;
Time to first peak (tp) = sec;
Setting time (ts) = sec.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

8. TEMPERATURE CONTROL
TRAINER
Instrumentation and Process Control Laboratory
Department of Petroleum Engg. & Petrochemical Engg.

1. Study of open loop response (Manual control)

Aim: To study of open loop response in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup including
water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature control
principles. The process setup consists of heating tank fitted with SSR controlled heater
for on-line heating of the water. The flow of water can be manipulated and measured by
Rota-meter. Temperature sensor (RTD) is used for temperature sensing. The process
parameter (Temperature) is controlled by microprocessor based digital indicating
controller which manipulates heat input to the process. These units along with necessary
piping and fitting are mounted on support frame designed for tabletop mounting. The
controller can be connected to computer through Ethernet port for monitoring the process
in SCADA mode or Apex process trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select open loop Experiment (click on “Change Expt.” Button, click on “Change”, Click
on “Open Loop” button.)
3. Close the control valve by increasing the controller output to 100%.
4. Apply the step change by 10% to controller output in manual mode, wait for the level
to reach the steady state value.
5. Repeat the above step until the controller output reaches to minimum i.e. 0%.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Table:
S. No. Controller output in % Process value in %
1 0
2 10
3 20
4 30
5 40
6 50
7 60
8 70
9 80
10 90
11 100
Observations:
1. From the above data, note the output required for maintaining the temperature at
desired set points. (For particular drain valve opening).
2. Set the output of the controller to the noted value and at steady state applies the
load change to the process. Load change can be given by slightly varying the drain
valve. Observe new steady state process value.
Result: The open loop responses in temperature control trainer were identified.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

2. Study of ON-OFF control in Temperature Control Trainer

Aim: To study of response of ON-OFF Control in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup including
water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature control
principles. The process setup consists of heating tank fitted with SSR controlled heater
for on-line heating of the water. The flow of water can be manipulated and measured by
Rota-meter. Temperature sensor (RTD) is used for temperature sensing. The process
parameter (Temperature) is controlled by microprocessor based digital indicating
controller which manipulates heat input to the process. These units along with necessary
piping and fitting are mounted on support frame designed for tabletop mounting. The
controller can be connected to computer through Ethernet port for monitoring the process
in SCADA mode or Apex process control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select “On-Off mode” option for the control from software. (Click on “Change Expt.”
Button, click on “Change”, Click on “On-Off mode” button.)
3. Change Hysteresis value to 5%.(Range 0.1-10%)
4. Change the values of the set point and observe the On-Off control operation.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Table:

S. No. Set point value in % Process value in % Output value in %

1
2
3
4
5
6
7
8
9
10

Observations:
 Observe that if process value exceeds the set point and increases above the
value of (0.5x Hysteresis), control valve is fully closed and if process value
decreases below the set point by (0.5 x Hysteresis), the control valve opens fully
i.e. controller operates like On/Off switch.

Result: The responses of ON-OFF control in Temperature control trainer were studied.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

3. Tuning of Controller in Temperature Control Trainer

Aim: To study the tuning of controller using auto tuning method in temperature control
trainer
Apparatus: Computer setup and Temperature control trainer equipment setup including
water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature control
principles. The process setup consists of heating tank fitted with SSR controlled heater
for on-line heating of the water. The flow of water can be manipulated and measured by
Rota-meter. Temperature sensor (RTD) is used for temperature sensing. The process
parameter (Temperature) is controlled by microprocessor based digital indicating
controller which manipulates heat input to the process. These units along with necessary
piping and fitting are mounted on support frame designed for tabletop mounting. The
controller can be connected to computer through Ethernet port for monitoring the process
in SCADA mode or Apex process control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

• Adjust the water flow through rotameter is below the 60 LPH.

Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select Autotune option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “Autotune” button.)
3. Wait Till Autotune is complete. (Blinking of green LED stops).
4. Controller automatically finds the PB, IT & DT values.
5. Find out PID values at different set points /flow rates

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Table:

Set point Process Output

S. Proportional Integral Derivative
value in value in value in
No. band time time
% % %
1
2
3
4
5
6
7
8
9
10

Observations:
 The controller has preprogrammed logic for finding “Auto tune” values. Based
on the response of the process the controller calculates PID values or comes out
without finding the “Auto tune” values.
Result: The tuning of controller in temperature control trainer using auto tuning method
at different set point values.
Set point = ____; Proportional band = ____; Integral Time = ___; Derivative time =___.
Set point = ____; Proportional band = ____; Integral Time = ___; Derivative time =___.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

4. Study of P-controller in Temperature Control Trainer

Aim: To study of response of P-controller in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup including
water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature
control principles. The process setup consists of heating tank fitted with SSR controlled
heater for on-line heating of the water. The flow of water can be manipulated and
measured by Rota-meter. Temperature sensor (RTD) is used for temperature sensing. The
process parameter (Temperature) is controlled by microprocessor based digital
indicating controller which manipulates heat input to the process. These units along with
necessary piping and fitting are mounted on support frame designed for tabletop
mounting. The controller can be connected to computer through Ethernet port for
monitoring the process in SCADA mode or Apex process control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Theory: The proportional controller produces an output signal (pressure in the case of a
pneumatic controller, current or voltage for an electronic controller) that is proportional
to the error E. This action may be expressed as
p = K c ϵ + ps

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Where: p = output signal from controller, psig or ma; Kc= gain, or sensitivity;
є = error = (set point - measured variable); ps = constant.
The error є, which is the difference between the set point and the signal from the
measuring element, may be in any suitable units. However, the units of set point and
measured variable must be the same, since the error is the difference between these
quantities.
In a controller having adjustable gain, the value of the gain Kc can be varied by
moving a knob in the controller. The value of ps is the value of the output signal when E
is zero, and in most controllers ps can be adjusted to obtain the required output signal
when the control system is at steady state and є = 0.
Proportional control produces an overshoot followed by an oscillatory response,
which levels out at a value that does not equal the set point; this ultimate displacement
from the set point is the offset.
Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater
 Double click on Apex_Process_Trainers icon on the desktop
 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select P Mode option for control from software. (Click on “Change Expt.” Button, click
on “Change”, Click on “P Mode” button.)
3. Keep the set point to 40%. Change output mode to Manual. Adjust output value so as
to match the process value with set point and apply this output value as bias value to the
controller. Adjust the proportional band to 50%.
4. Switch the controller to Auto mode.
5. Apply step change to set point, step change should be of 2 to 3 % and observe the
response.
6. Switch the controller to Manual mode. Decrease proportional band to half of the
previous value & then shift controller to Auto mode. With each decrease, obtain a new
response of the step change. Ensure that the set point changes are around the same
operating point (@ 2-3% only).
7. Using trial and error approach, find a value of proportional band so that the response
to a step change has at most one overshoot and one undershoot.
8. Set the controller to the settings obtained in the above step and wait for the system to
reach at steady state.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

Table:
Set point Process Output
Proportional Integral Derivative
S. No. value in value in value in
band time time
% % %
1
2
3
4
5
6
7
8
9
10

Observations:
1. Observe steady state error decreases as proportional band decreases.
2. Observe the effect of very low proportional band values (system works in oscillatory
mode).
3. Observe the response of the system to load change. Load change can be given by
slightly varying the inlet flow-rate.

Result: The responses of P-controller in Temperature control trainer were studied.

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

5. Study of PID-controller in Temperature Control Trainer

Aim: To study of response of PID-controller in temperature control trainer
Apparatus: Computer setup and temperature control trainer equipment setup including
water and air supply.
Description:
Temperature control trainer is designed for understanding the basic temperature control
principles. The process setup consists of heating tank fitted with SSR controlled heater
for on-line heating of the water. The flow of water can be manipulated and measured by
Rota-meter. Temperature sensor (RTD) is used for temperature sensing. The process
parameter (Temperature) is controlled by microprocessor based digital indicating
controller which manipulates heat input to the process. These units along with necessary
piping and fitting are mounted on support frame designed for tabletop mounting. The
controller can be connected to computer through Ethernet port for monitoring the process
in SCADA mode or Apex Control trainer software.

Fig. 1.0 Process flow diagram for Temperature control trainer

Theory:
This mode of control is combination of the previous modes and is given by the expression
t
dϵ Kc
p = K c ϵ + K c τD + ( ∫ ϵ dt) + ps
dt τI
0

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

In this case, the controller contains three knobs for adjusting Kc, τI, and τD. The
transfer function for this controller can be obtained from the Laplace transform of above
equation; thus
P(s) 1
= K c (1 + τD s + )
ϵ(s) τI s
The use of PID control combines the beneficial features of PD and PI control.
Integral action, which is present in PI and PID controllers, eliminates offset. The addition
of derivative action speeds up the response by contributing to the controller output a
component of the signal that is proportional to the rate of change of the process variable.
PID control is needed to prevent large overshoot and long settling time.
Procedure:
1. Startup Setup and Startup software;
Startup Setup:
• Switch on electric supply. Switch on Mains.
• Adjust the water flow through rotameter is below the 60 LPH.
Startup software:
• Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Application manager.
• Open “Level Control Trainer” under InTouch Application Manager
• Click “Ignore” under “Window Maker” for License not available
• Click “Select All” and “OK” under “Windows to Open”
• Click on “Runtime” at Top Right corner under “InTouch- Window Maker”
• Click “Ignore” under “Window Viewer” for License not available
• Click “OK” under “Window Viewer” for Demo mode.
(Or)
Startup Setup
 Switch on electric supply. Switch on Mains.
 Adjust rotameter flow rate to 40 LPH.
 Switch on the heater

Instrumentation and Process Control Laboratory

Department of Petroleum Engg. & Petrochemical Engg.

 Double click on Apex_Process_Trainers icon on the desktop

 Select product Temperature Control Trainer (311A), select Controller
Yokogawa (UT35A) and Click Continue.
 For Ethernet port equipment Click Connect
2. Select PID Mode option for control from software. (Click on “Change Expt.” Button,
click on “Change”, Click on “PID Mode” button.)
3. Switch the controller to manual mode.
4. Change the proportional band to the value that estimated in proportional controller.
Set integral time and derivative time based on the responses in previous experiments.
5. Adjust the set point to @ 50 %. Switch the controller to auto mode. Apply step change
of 10%. Observe the process response.
6. Change the proportional band, integral time, derivative time and observe the response
of the process for step change for each change in setting.

Table:
Set point Process Output
Proportional Integral Derivative
S. No. value in value in value in
band time time
% % %
1
2
3
4
5
6
7
8
9
10

Observations: Compare the steady state response of the PID controller with P. PI and PD
controller obtained in the above experiment.

Result: The responses of PID-controller in temperature control trainer were studied.

Instrumentation and Process Control Laboratory