VELAMMAL ENGINEERING COLLEGE:: CHENNAI-66.

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

ACADEMIC YEAR 2013-2014

EVEN SEMESTER
LAB MANUAL

SUB CODE: EI 2356

SUB NAME: PROCESS CONTROL SYSTEMS LABORATORY

PREPARED BY

APPROVED BY

S.N.SIVARAJ

Dr.N.BHARATHI

AP-2/EIE

HOD/EIE

LIST OF EXPERIMENTS

CYCLE-I
1. Closed loop response of flow control loop
2. Closed loop response of level control loop
3. Closed loop response of temperature control loop
4. Closed loop response of pressure control loop
5. Operation of interacting system
6. Operation of non interacting system
7. Characteristics of control valve with and without positioner

CYCLE-II

8. Study of mat lab

9. Study of cascade control system
10. Tuning of controllers using Ziegler -Nichols method
11. Tuning of controllers using Cohen coon method
12. Response of different order process with and without transportation lag
13. Study of ratio control system
14. Study of feed-forward control system

EXPT NO: 1

CLOSED LOOP RESOPNSE OF FLOW CONTROL LOOP

AIM:
To obtain the closed loop regulatory response of flow process station for PID and ONOFF mode of control actions.
APPARATUS REQUIRED:
1. Flow process station, 2.Data acquisition system, 3.Personal computer, 4.Compressor

PROCEDURE:
1. Ensure the flow process station is connected as per the P&I diagram.
2. Keep the valve HV1 10% open and close the valve placed in the orifice line connected
with manometer tube.
3. Ensure the connection between PC, data acquisition system and flow process station.
4. In the PC select the ICON flow process station by double clicking on it.
5. Switch on the pump after ensuring the storage tank is filled with water up to overflow
mark
6. Switch on the compressor and regulate the air filter regulators of the flow process station
to the required values
7. In the software select the control action mode as on-off.
8. Configure the controller with its parameters and define the set point.
9. Put the process in run mode by selecting start ICON in the software and observe the
response.
10. After the control action produce satisfactory (i.e., process variable settles in the set point)
response click stop to stop the process.
11. Save the response as a file by selecting save icon by giving a file name.
12. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
13. Compare the results.

RESULT:
The closed loop response for flow process station with nominal disturbance for various
modes of control action was obtained and the process performances for various modes were
inferred.

P&I DIAGRAM
S.P
FIC

D.P.T

AFR

ORIFICE

ROTAMETER
CV

RESERVOIR
TANK
PUMP

BLOCK DIAGRAM OF FLOW CONTROL SYSTEM

SET POINT
(S.P)

CO

e=S.P-P.V

+-

M.V

CONTROLLER

F.C.E

ON-OFF/PID

CONTROL VALVE

P.V

TRANSMITTER
ORIFICE + D.P.T

P.V
PROCESS

FLOW

TABULATION:
S.P=______________LPH; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs

S.No

TIME

PV

(SECS)

(ENGG UNITS=LPH)

MODEL GRAPH
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE

SET POINT

FLOW IN LPH

LOWER LIMIT

TIME IN SECS

FLOW IN L.P.H

P MODE & PD MODE

SET POINT

TIME

FLOW IN L.P.H

PI & PID MODE

SET POINT

TIME

EXPT NO: 2

CLOSED LOOP RESOPNSE OF LEVEL CONTROL LOOP

AIM:
To obtain the closed loop regulatory response of level process station for PID and ONOFF mode of control actions.
APPARATUS REQUIRED:
1. Level process station, 2.Data acquisition system, 3.Personal computer, 4.Compressor

PROCEDURE:
1.
2.
3.
4.
5.

Ensure the level process station is connected as per the P&I diagram.
Keep the valve HV1 and HV2 10% open
Ensure the connection between PC, data acquisition system and level process station.
In the PC select the ICON level process station by double clicking on it.
Switch on the pump after ensuring the storage tank is filled with water up to overflow
mark
6. Switch on the compressor and regulate the air filter regulators of the level process station
to the required values
7. In the software select the control action mode as on-off.
8. Configure the controller with its parameters and define the set point.
9. Put the process in run mode by selecting start ICON in the software and observe the
response.
10. After the control action produce satisfactory (i.e., process variable settles in the set point)
response click stop to stop the process.
11. Save the response as a file by selecting save icon by giving a file name.
12. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
13. Compare the results.

RESULT:
The closed loop response for level process station with nominal disturbance for various
modes of control action was obtained and the process performances for various modes were
inferred.

P&I DIAGRAM
S.P
LIC

AFR

SENSOR

HV1

CV
PROCESS TANK

RESERVOIR
TANK

HV2
TO RESERVOIR

PUMP

BLOCK DIAGRAM OF LEVEL CONTROL SYSTEM

SET POINT
(S.P)

CO

e=S.P-P.V

+-

M.V

P.V

CONTROLLER

F.C.E

PROCESS

ON-OFF/PID

CONTROL VALVE

LEVEL

P.V

TRANSMITTER
D.P.T

TABULATION:

S.P=______________cm; Kc=___________;

Ki=_______________ Secs-1;Kd=____________Secs

S.No

TIME

PV

(SECS)

(ENGG UNITS=cm)

MODEL GRAPH:
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE

SET POINT

LEVEL IN CM

LOWER LIMIT

TIME IN SECS

LEVEL IN C.M

P MODE & PD MODE

SET POINT

TIME

LEVEL IN C.M

PI & PID MODE

SET POINT

TIME

EXPT NO: 3 CLOSED LOOP RESOPNSE OF TEMPERATURE CONTROL LOOP

AIM:
To obtain the closed loop regulatory response of temperature process station for PID and
ON-OFF mode of control actions.
APPARATUS REQUIRED:
1. Temperature process station, 2.ON-OFF/PID controllers, 3.Stop clock
PROCEDURE:
1. Ensure the temperature process station is connected as per the P&I diagram.
2. Keep the valve HV3 and HV2 100% open
3. Switch on the pump after ensuring the storage tank is filled with water up to overflow
mark and pump the water into overhead tank and regulate the water in to process vessel
through the valve HV2 select
4. Select the mode of control action either ON-OFF or PID by following the steps given
below
ON-OFF mode
5. Select the control action mode as on-off using toggle switch
6. Connect the node A and CO through a patch cord
7. Configure the controller with its parameters and define the set point with indicating meter
switch at SV
PID mode
4. Select the control action mode as on-off using toggle switch
5. Connect the node A and CO through a patch cord
8. Configure the controller with its parameters and define the set point with indicating meter
switch at SV
6. Switch on the stirrer and heater
7. Turn the meter switch to PV mode
8. Note down the temperature for every 30 seconds till the control action produce
satisfactory (i.e., process variable settles in the set point) response
9. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
10. Compare the results.
RESULT:
The closed loop response for temperature process station with nominal disturbance for
various modes of control action was obtained and the process performances for various modes
were inferred.

P&I DIAGRAM

12V

SW

OVER HEAD TANK

STIRRER

HV 3

To sump

ON/OFF
HV2

RTD SIGNAL
CONDITIONE
R

T1

T2

INTEGRAL
TIME

RTD
SENSOR
GND

80%
P
PUMP
TRIGGER
40%
SCOPE

TO DRAIN
OFF

EXT
SVD

INT
SVD

0%

B
100%

T4
80%

40%A

0% C

100%

ON

DERIVATIVE
TIME3

THYRISTOR POWER
CONTROL

BLOCK DIAGRAM OF TEMPERATURE CONTROL SYSTEM

SET POINT
(S.P)

THYRISTOR
POWER
CONTROL
UNIT

ON-OFF/PID
CO

e=S.P-P.V

+-

CONTROLLER

TEMPERATURE
M.V

F.C.E

P.V

TRANSMITTER
R.T.D

P.V
PROCESS

TABULATION:
S.P=______________C; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs

S.No

TIME

PV

(SECS)

(ENGG UNITS= C )

MODEL GRAPH:
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE

SET POINT

TEMP IN DEG C

LOWER LIMIT

TIME IN SECS

TEMP IN C

PID MODE

SET POINT

TIME

EXPT NO: 4

CLOSED LOOP RESOPNSE OF PRESSURE CONTROL LOOP

AIM:
To obtain the closed loop regulatory response of pressure process station for PID and
ON-OFF mode of control actions.
APPARATUS REQUIRED:
1. Pressure process station, 2.Data acquisition system, 3.Personal computer, 4.Compressor

PROCEDURE:
1.
2.
3.
4.
5.

Ensure the pressure process station is connected as per the P&I diagram.
Keep the valve HV5 and HV6 100% open AND HV3 and HV4 10% open
Ensure the connection between PC, data acquisition system and pressure process station.
In the PC select the ICON level process station by double clicking on it.
Switch on the compressor and regulate the air filter regulators of the pressure process
station to the required values
6. In the software select the control action mode as on-off.
7. Configure the controller with its parameters and define the set point.
8. Put the process in run mode by selecting start ICON in the software and observe the
response.
9. After the control action produce satisfactory (i.e., process variable settles in the set point)
response click stop to stop the process.
10. Save the response as a file by selecting save icon by giving a file name.
11. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
12. Compare the results.

RESULT:
The closed loop response for pressure process station with nominal disturbance for
various modes of control action was obtained and the process performances for various modes
were inferred.

P&I DIAGRAM

AIR INLET
150 PSI

G2

AT1

AT2

G3

PR1
I
P

G1
PRESSURE
TRANSMITTER
G4

RV1

PR2

AIR MUFFLER
HV5

PROCESS TANK
1

HV1

HV3
RV2

G5
CONTROL
VALVE

HV6

PROCESS TANK
2
HV2
HV4

BLOCK DIAGRAM OF PRESSURE CONTROL SYSTEM

SET POINT
(S.P)

CO

e=S.P-P.V

+-

M.V

P.V

CONTROLLER

F.C.E

PROCESS

ON-OFF/PID

CONTROL VALVE

PRESSURE

P.V

TRANSMITTER
CAPACITIVE PROBE

TABULATION:
S.P=______________PSI; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs

S.No

TIME

PV

(SECS)

(ENGG UNITS=PSI )

MODEL GRAPH:

ON-OFF CONTROL MODE

UPPER LIMIT
NEUTRAL ZONE

SET POINT

PRESSURE IN PSI

LOWER LIMIT

PRESSURE IN P.S.I

TIME IN SECS

P MODE & PD MODE

SET POINT

TIME

PRESSURE IN P.S.I

PI & PID MODE

SET POINT

TIME

EXPTNO: 5

OPERATION OF INTERACTING SYSTEM

Aim:
To study the operation of two tank interacting system.
Apparatus Required;
1. Interacting system station, 2.Stop clock
Procedure:
1. Ensure to maintain the water level in storage tank is always kept fully filled up to the
overflow level.
2. Switch on and run the Pump and continuously to fill the overhead tank up to its
overflow level
3. Keep the valves HV5, HV2 at fully open and HV3 at 10% open condition.
4. Set a constant flow rate of X LPH through the Rota meter with the help of valve HV1
5. Note down the readings in tank 1 and tank 2 for every 30 seconds till steady is
reached in both the tanks
6. Plot the graph
Result:
The behavior of two tank interacting system was studied.

P&I DIAGRAM

TABULATION:

TIME

HEIGHT IN TANK-1

HEIGHT IN TANK-1

(SECS)

H1

H2

(CM)

(CM)

S.No

MODEL GRAPH

LEVEL IN TANK-2 ( h2 c.m)

LEVEL IN TANK-I ( h1 c.m)

TANK-I

TANK-2

TIME IN SECS

EXPTNO: 5

OPERATION OF NON-INTERACTING SYSTEM

Aim:
To study the operation of two tank Non-interacting system.
Apparatus Required;
2. Non Interacting system station, 2.Stop clock
Procedure:
7. Ensure to maintain the water level in storage tank is always kept fully filled up to the
overflow level.
8. Switch on and run the Pump and continuously to fill the overhead tank up to its
overflow level
9. Keep the valves HV8 at fully open, HV3, HV4 at 10% open condition and HV2, HV6,
HV5 at fully closed condition.
10. Set a constant flow rate of 10 LPH through the Rota meter with the help of valve
HV1
11. Note down the readings in tank 1 and tank 2 when steady is reached in both the tanks
as H1SS and H2SS
12. After the steady state has reached, increase the flow through the rotameter to 12 LPH
using the valve HV1 and note down the readings in tank 1 and tank 2 for every 30
seconds till a new steady state is reached in both the tanks
13. Plot the graph and calculate the transfer function of the system
Result:
The behavior of two tank non interacting system was studied.

P&I DIAGRAM

TABULATION:

h1 S.S=______________CM; h2 S.S=___________CM;
S.No

TIME

h1

(SECS)

(cm)

MODEL GRAPH

h2
(cm)

H1=h1- h1 S.S

H2=h1- h2 S.S

(cm)

(cm)

LEVEL IN TANK-2 ( h2 c.m)

LEVEL IN TANK-I ( h1 c.m)

TANK-I

TANK-2

TIME IN SECS

EXPT NO: 6

CHARACTERISTICS OF CONTROL VALVE

Aim:
To study the flow-lift characteristics of ON-OFF, linear and equal percentage control
valve with and without positioned.
Apparatus required:
Linear control valve, equal percentage control valve, ON-OFF control valve, compressor,
pressure gauge.
Procedure:
With positioner
1. Fill the storage tank up to the overflow level.
2. Open the control air flow line for linear valve and close the air flow for other control
valves with the help of hand valve
3. Open the water flow line for linear valve and close the water flow line for other control
valve with the help of hand valve HV2, HV3, HV4
4. Set the control pressure signal to 15 P.S.I
5. Note down the flow rate and stem position after maintaining the pressure drop of 1 P.S.I
across the control valve with the help of hand valve connected with linear valve for water
flow control
6. Repeat the above steps for various control signal values till 3 P.S.I
7. Plot the characteristics
8. Repeat the above steps for other control valves.
Without positioner
9. Repeat steps 1 to 8 after bypassing the positioner
Result:
The flow-lift characteristics for control valve with and without valve positioner was
studied

P&I DIAGRAM

TABULATION:
WITH/WITHOUT POSITIONER
Control valve=_____________________ ; S MAX = _______CM;
S.No

Control
signal
(PSI)

Line
pressure
(PSI)

Q MAX =__________LPH

STEM
FLOW
POSITION RATE
S
Q
(CM)
(LPH)

1
15
1
2
12
1
3
9
1
4
6
1
5
3
1
WITH/WITHOUT POSITIONER
Control valve=_____________________ ; S MAX = _______CM;
S.No

Control
signal
(PSI)

Line
pressure
(PSI)

Q MAX =__________LPH

STEM
FLOW
POSITION RATE
S
Q
(CM)
(LPH)

1
15
1
2
12
1
3
9
1
4
6
1
5
3
1
WITH/WITHOUT POSITIONER
Control valve=_____________________ ; S MAX = _______CM;
S.No

1
2
3
4
5

Control
signal
(PSI)
15
12
9
6
3

Line
pressure
(PSI)
1
1
1
1
1

STEM
FLOW
POSITION RATE
S
Q
(CM)
(LPH)

Q MAX =__________LPH

MODEL GRAPH:

2
ON-OFF CONTROL VALVE

Q / QMAX

LINEAR CONTROL VALVE

EQUAL PERCENTAGE CONTROL VALVE

1
S / SMAX