SARDAR VALLABHBHAI NATIONAL INSTITUTE OF

TECHNOLOGY
SURAT

LABORATORY JOURNAL
OF

Process Control
B.Tech IV (7th Semester)

CHEMICAL ENGINEERING DEPARTMENT

Name :_____________________________________
Class : _____________ Admn/Roll No._________
Academic Year :____________________________

INDEX
Sr.
Experiment Title
No
1. FIRST ORDER LIQUID LEVEL
2.
3.

SYSTEM
LINEARIZATION
SECOND ORDER SYSTEM (NON-

4.

INTERACTING TANKS)
SECOND ORDER SYSTEM

Date

Page
No.

Signature

(INTERACTING TANKS)
5. RESPONSE OF THERMOMETER
6. MANOMETER
7. HEAT EXCHANGER
8. CATALYTIC REFORMER
9. BINARY DISTILLATION
10. DIGITAL ANEMOMETER
11. TACHOMETER
12. TURBIDITY METER
13. THERMOCOUPLE CALIBRATION
14. DISSOLVED OXYGEN METER

EXPERIMENT 1
DATE:

FIRST ORDER LIQUID LEVEL SYSTEM

AIM :- To study the response of first order liquid level system to step change.

APPARATUS :- Tank with input and output arrangement, Centrifugal pump , Stop
Watch , Measuring Scale.
PROCEDURE :1) Start the centrifugal pump and set the flow rate into the graduated tank.
2) Allow the system to reach the steady state for this flow rate. Measure the incoming
flow rate and outgoing flow rate. Ensure that input and output flow rates are same
within the experimental accuracy. Note down the initial flow rate and height.
3) Once steady state is achieved the flow rate of liquid into the level tank is disturbed
by changing the input flow rate. (Flow may be cut off). Time, t is set to zero.
4) Note down the time taken by the liquid level in the test tank to fall by one
centimeter.
5) Repeat step (4) for every centimeter fall in the liquid level in the test tank.
6) Allow sufficient time for level in the test tank to attain a new steady state under the
new reduced flow rate condition.
7) Once the new steady state is achieved the final flow rate is measured and final
steady state height is noted.
THEORY: A tank of uniform cross sectional area A has a flow resistance R attached,
such as a valve, a pipe or a weir. For volumetric flow rate
q0 = h/R...(i)
This is a case of linear resistance.
If qs and hs are steady state values, we define,
Q = q-qs
H = h-hs ..........................(ii)
= AR (iii)
Introducing step change of H value , (H = hs1 - hs2)
H(t) = H (1- e-(t/))
Or
H(t) = (qs1- qs2)R(1- e-(t/))
OBSERVATIONS :Cross-Sectional area of tank , A =
1)
Initial flow rate , qsi =
2)
Final flow rate, qsf =
3)
Initial Steady state height hsi=
4)
Final Steady state height hsf=
5)
OBSERVATION TABLE:Sr No.

Time, t (s)

Height (observed)

Height (theoretical)

hobs ( cm )

hthe ( cm )

SAMPLE CALCULATIONS:1) Initial Resistance, Ri = hsi / qsi =

2) Final Resistance, Rf = hsf / qsf =
3) H = hsi - hsf Or H = (qsi -qsf ) * R =
4) Time constant = ARi =
5) Predicted Height or theoretical Height, htheoretical
h theoretical hsi H (1 e t / ) (Valid for step change)
GRAPH : Plot the following curves in single graph for comparison.

1. hobs vs time
2. hthe vs time
RESULT :-Comment on the Nature of the Graph.

CONCLUSION :-

EXPERIMENT 2
DATE:

LINEARIZATION
AIM: To study the response of linearization.
APPARATUS: A trapezoidal system tank equipped with i/p & o/p arrangement with

fluid circulating, centrifugal pump, measuring cylinder, stop watch.

CHEMICAL: Ethylene glycol.
PROCEDURE:
1. Start the centrifugal pump and set the flow rate into the graduated tank.
2. Allow the system to reach the steady state for this flow rate. Measure the
incoming flow rate and outgoing flow rate. Ensure that input and output flow
rates are same within the experimental accuracy. Note down the initial flow rate
and height.
3. Once steady state is achieved the flow rate of liquid into the level tank is
disturbed by changing the input flow rate. (Flow may be cut off). Time, t is set
to zero.
4. Note down the time taken by the liquid level in the test tank to fall by one
centimeter.
5. Repeat 4) for every centimeter fall in the liquid level in the test tank.
6. Allow sufficient time for level in the test tank to attain a new steady state under
the new reduced flow rate condition.
7. Once the new steady state is achieved the final flow rate is measured and final
steady state height is noted.
THEORY:
For a liquid of constant density & tank of uniform cross sectional area, a material balance
around the tank gives,
q(t) q0(t) = A dh ..(2)
dt
In this Non-linear tank, if the fluid is flowing through linear resistance,
q0(t) = h/R
q - q0(s) = (h-hs) = A dh ..(3)
R1
dt
At steady state q0 = q0(s)
Q = q-qs
H = h-hs
= AR (4)
Introducing step change H, (H = hs1 - hs2)
H(t) = (H (1- e-(t/))
Or H(t) = (qs1- qs2)R(1- e-(t/))
ht hsi H (1 e t / ) ................(5)

(Valid for step change)

OBSERVATIONS :-

1)
2)
3)
4)
5)

Cross-Sectional area of tank (at the average height of hsi and hfi ), A =
Initial flow rate , qsi =
Final flow rate, qsf =
Initial Steady state height hsi=
Final Steady state height hsf=

OBSERVATION TABLE:Sr No.

Time, t (s)

Height (observed)

Height (theoretical)

hobs ( cm )

hthe ( cm )

CALCULATIONS :Initial Resistance, Ri = hsi / qsi =

1)
Final Resistance, Rf = hsf / qsf =
2)
H = hsi - hsf Or H = (qsi -qsf ) * R =
3)
Time constant = ARi =
4)
Predicted Height or theoretical Height, htheoretical
5)
h theoretical hsi H (1 e t / ) (Valid for step change)

GRAPH : Plot the following curves in single graph for comparison.

3. hobs vs time
4. hthe vs time

RESULT :-Comment on the Nature of the Graph.

CONCLUSION :-

EXPERIMENT 3
DATE:

SECOND ORDER SYSTEM (NON-INTERACTING TANKS)

AIM :- To study the response of a non-linear, non-interacting second order critically
damped system.
APPARATUS :- A two tank non-interacting system , Centrifugal Pump , Measuring

Scale, Stop Watch

PROCEDURE :1) Start the centrifugal pump and set the flow rate into the graduated tank.
2) Allow the system to reach the steady state for this flow rate.
3) Once steady state is achieved the flow rate of liquid into the level tank is changed,
and time, t is set to zero.
4) Now, for each 5 min change in height of liquid in the second tank time is noted.
5) Once the new steady state is achieved the final flow rate is measured and the pump
is switched off.
THEORY: For a critically damped second order system the response expression is given
by,
Y(t) = 1- (1+t/) e-t/ .(i)
The assumption made above are, A1 = A2, R1 = R2 = R and 1 = 2 = .
The response when plotted, is non oscillatory.
= (12)
= 1 + 2/2
H2(t) = K
OBSERVATION :-

Tank -1
1)
2)
3)
4)
5)
1)

Cross-Sectional area of tank , A1 =

Initial flow rate , qsi1 =
Final flow rate, qsf1 =
Final height, hsf1 =
Resistance, R1 = hsi / qsi =
Time constant 1 = AR1

Tank 2
1)
2)
3)
4)
5)

Cross-Sectional area of tank , A2 =

Initial Height , hsi2 =
Final height, hsf2 =
Initial Resistance, R2 = hsi / qsi =
Time constant 2 = AR2

OBSERVATION TABLE:Sr No.

Time, t (s)

Height in the
Second Tank (obs.)

hobs ( cm )

Height theoretical hthe

( cm )

CALCULATIONS :1)
2)
3)

= (12) =
H for second Tank: H = hsi - hsf Or H = (qsi -qsf ) * R=
Predicted Height or theoretical Height, htheoretical
h theoretical hsi 2 H [1 {1 (t / )}e t / ] (if 1 = 2)

(Valid for step change)

GRAPH: Plot the following curves in single graph for comparison.

1. hobs vs time
2. hthe vs time

RESULT:-Comment on the Nature of the Graph.

CONCLUSION:-

EXPERIMENT 4
DATE:

SECOND ORDER SYSTEM (INTERACTING TANKS)

Aim : To study response of second order over damped system consisting of two
interacting tank in series.
Apparatus : Two interacting tank system, stop watch, scale, measuring cylinder etc.
Chemicals : Ethylene Glycol.

Theory :
Taking material balance across the tanks ,
q q1 = A1dh1 /dt

.(1)

q1 q2 = A2 dh2/dt.(2)
q1 = 1/R1 (h1 -h2) ..(tank 1) .(3)
q2 = h2/ R2(tank 2)(4)
At steady state,equation (1) & (2) becomes
q(s) q1(s) = 0.(5)
q1(s)- q2(s) = 0.(6)
Equations 1,2,5 and 6
Q - Q1 = A1dh1 /dt (7)
Q1- Q2 = A2 dh2/dt(8)
Q1 = (H1 - H2)/ R1.......................................................................................(9)
Q2 = H2/ R2...............................................................................................(10)
H2(S)/ Q(S) = R2/{ 1 2 s2 + (1 + 2 + A1R2 ) s + 1}
For both tanks to be interacting with 1 = 2
Q2 (S)/ Q(S) = 1/(2 s2 + 3 s+1)
Q2 (S)/ Q(S) = 1/(0.38s+1)(2.62s+ 1)
For step disturbance:
Taking inverse of Laplace transform
Q2 (t) = 1+ 0.17 e-t/0.38 - 1.17 e-t/2.62
H2(t) = R2 [1+ 0.17 e-t/0.38 - 1.17 e-t/2.62 ]
Procedure:
Start flow of liquid, measure the flow rate and attain steady state.
Note down initial height and flow rate readings.
When steady state is attained, give step /impulse disturbance (e.g. plug one of two inlets).
Note down the reading at each 5 mm drop of liquid level in second tank, till the second
steady state is achieved.
Observation:

Tank -1
1.

Cross-Sectional area of tank , A1 =

2.
3.
4.
5.
6.

Initial flow rate , qsi1 =

Final flow rate, qsf1 =
Final height, hsf1 =
Resistance, R1 = hsi / qsi =
Time constant 1 = AR1

Tank 2
Cross-Sectional area of tank , A2 =
Initial Height , hsi2 =
8.
9. Final height, hsf2 =
10. Initial Resistance, R2 = hsi / qsi =
11. Time constant 2 = AR2
Observation Table:
7.

Sr.No.

Height Observed in
second tank, hobs (cm)

Calculation:
(1 )1 = A1R1
(2)2 = A2R2
(3) =

Time (sec)

Theoretical height
hthe (cm)

For step disturbance:

H2(t) = R2 [1+ 0.17 e-t/0.38 - 1.17 e-t/2.62 ]
4)

So, h(t) = hinitial H [1+ 0.17 e-t/0.38 - 1.17 e-t/2.62 ] (if 1 = 2)

(Valid for step change)

GRAPH: Plot the following curves in single graph for comparison.

1. 1. hobs vs time
2. hthe vs time

RESULT:-Comment on the Nature of the Graph.

CONCLUSION:-

EXPERIMENT 5
DATE:

RESPONSE OF THERMOMETER
AIM: To measure positive step change of measuring thermometer.
APPARATUS: Thermometer, beaker, burner, stand etc.

CHEMICAL: Ethylene glycol.

PROCEDURE:
Take sufficient amount of ethylene glycol or oil in a vessel. Heat it using burner upto
90C. Now, dip thermometer in it. Allow temperature to increase to steady state of 90C.
Now immediately take thermometer out of the bath and note down the time for every 5
C fall.
THEORY: Assumption made for analysis of response of mercury bulb thermometer:
(1) All the resistance to heat transfer reside in the film surrounding the bulb.
(2) All the thermal capacity is in the mercury.
(3) The glass wall containing the mercury does not expand or contract during the
transient response.
Applying unsteady state energy balance,
h As (x-y) = mc dy ..(i)
dt
For steady sate h As (xs - ys) = 0 .(ii)
Now,
X = x - xs
Y = y - ys
From (i)-(ii)
Y(s) =
1
X(s)
s + 1
Where = mc/h As
For step change,

A =ysi - ysf
Y(t) = A(1-e-(t/))
y (Theo. Temp) = yinitial A(1- e-t/)
OBSERVATIONS:
1. Room temperature (Initial temp indicated by thermometer) =

OBSERVATION TABLE:
Sr. No
1

Temperature
Experimental
(C)

Time
(sec)

Theoretical Temp
y (C)

2
3
4
5
6
7
8
9
10
11
12
13
SAMPLE CALCULATION:
A = ys(initial) - ys(final)
= ___________(time at 63.2% Response, from graph of observed temperature vs time)

yt (Theo. Temp) = yinitial A(1- e-t/)

GRAPH: Plot the following curves in single graph for comparison.
1. Temperature experimental v/s Time
2. Temperature theoretical (Predicted) v/s Time
RESULT:
1. Time constant for 63.2% response, [from Graph of Temp.(exp.) v/s t] _____________
CONCLUSION:

EXPERIMENT 6
DATE:

MANOMETER
Aim: To find out the dynamic response of a second order under damped system to a step
change in the input variable. To determine overshoot and decay ratio from the response
and to compare it with theoretical values.

Apparatus :

AU-tube manometer of sufficient inside diameter, filled with mercury.

A compressed air supply at 1 atm. gauge pressure.
A pressure regulating valve to control the out put pressure of compressed air.

Procedure:
1. Apply the regulated compressed air pressure to one side of the manometer by using the
manometric tubing provided for the pressure.
2. Allow sufficient time for the manometer reading to stabilize. Note down the height of
mercury thread in one of the limbs of the manometer.
3. At time T=0 with draw the air pressure and note down the height of the mercury thread
in the same limb where the reading was taken earlier. Remember that the mercury
thread will move very fast and the reading has to be taken in very short time.
4. Repeat (3) and (4) but now take the reading for the trough in the thread height if earlier
reading was taken for peak in the thread height.
5. Go on taking the readings of subsequent peak and though heights of mercury thread.
6. Repeat steps (6) to (7) for minimum three different step sizes of pressures.
Theory:
Consider a U tube manometer. The transfer function can be developed, by
considering a force balance on manometric fluid and applying Newtons law of
motion to it. To simplify the matter, the frictional pressure drop due to motion of fluid
through U tube, will b assumed to be proportional to the velocity of the fluid and all
the fluid mass is assumed to accelerate uniformly. Again it will be assumed that the
cross-sectional area of manometer tube A remains constant all through.
After this an additional pressure of magnitude P is applied .As a consequence to
this manometric fluid starts rising in the right hand side and dropping by
corresponding magnitude in the left side. This rise in the height of the liquid will
create back pressure and will try to resist movement of manometric fluid. Similarly
viscous pressure drop will also try to resist the movement of the fluid. Applying the
Newtons Second law of motion gives us,
Net force on the mass= Mass acceleration.
AP - 2hAg/gc - RAdh/dt = AL/ gc [d2 t / d h2 ]
Where,
A = cross sectional area of the manometer tube. [cm2]
P = Applied pressure [gm.force/cm2]
H = Height of liquid above its steady-state level.[cm]

(1)

 = Density of the manometric fluid [gm.mass/cm3]

R = Frictional resistance of the fluid for flow [gm.force sec/cm3]
With the above given assumption of frictional pressure drop proportional to h t velocity
Hagen Poiseullis equation can be written as
P = 32uL/ gc D2

Ru

(2)

Where,
L = Length of the manometric fluid in the manometer. [cms]
D = Inner diameter OF U tube. [cms]
Sub. Equation (2) in equation (1) and dividing by 2g/gc and rearranging, it gives,
{L/2g}d2h /dt 2

+ {16 L / gc D2 } dh/dt + h = P gc / 2g

hi

(3)

Here, hi is taken as input pressure in terms of liquid column height to balance that
pressure.
Again notice that coefficient of d2h /dt 2 {L/2g}have dimensions of sec2 or (time2).
Similarly coefficient of dh/dt have the dimensions of second or [time] .Thus the
coefficient of dh/dt can be replaced by 2 as L/2g may not be equal to 16 L / gc D2
Thus, equation (3) may be written as
2 d2h /dt 2 + 2 dh/dt + h = hi

(4)

Taking Laplace transform on both the sides and noting that h as well as dh/dt are zero at
t=0, and rearranging, we get
H(s)/H2(s) = 1/[2 S

+ 2 S + 1 ]

(5)

To define equation (5) fully we require value of two parameters and and it is known as
second order system.
The response of second order system to various forcing functions can be obtained by
factorizing the quadratic term in the denominator into two linear terms that contains its
roots S1 and S2.
For less than on the roots of quadratic equation [2 S
S1 = {- / } + { 1- 2/ } = a+ib
S2.= {- / } - { 1- 2/ } = a-ib

+ 2 S + 1 ] are given by

(6)

When the forcing function is a unit step function, then its Laplace transform is given by
X(s) = 1/S
(7)

Thus, Y(s) = 1/S [2 S

+ 2 S + 1 ]

(8)

Taking Laplace inverse by making use of partial fractions, we get the response of the
second order under damped system [<1.0] to a step change in forcing function as
Y(t) = 1 - { 1- 2/ } e- t/ { Sin[ ( 1- 2)t/ ] + tan-1 { 1- 2/ }

(9)

It may be noted from equation (9), that the response Y(t) has an oscillatory component in
it whose amplitude { 1- 2/ } e- t/ goes on decreasing as time increases.
Under damped response is more commonly sought in control systems. A number of terms
are used to describe the under damped system. The most useful of them are as given
below.
Overshoot: It is a measure of how much the response exceeds the ultimate value
following a step change in the forcing function and is expressed as ratio of excess
response to the step size.
The overshoot for a unit step change is related to by the expression
Overshoot = e[-/ 1- 2]

(10)

It can be noted from equation (10) that over shoot increase as decreases and reaches a
limiting value of 1 when = 0 .
Decay ratio: It is defined as the ratio of second peak to first peak. The decay ratio is
related to by the expression.
Decay ratio = e[-2/ 1- ]

(11)

OBSERVATION TABLE:
Sr. No
1
2
3
4
5
6

Height of
lower limb

Time (Sec)
0

Theoretical Temp
y (C)

7
8
9
10
11
12
13
Calculation:
Viscosity=0.015 g/cm S
Density = 13.53 g/cc
D= ____________
L= ____________

=L/2g

= (8/ D2)2L/g
Theoretical Overshoot = e[-/ 1- 2]
Theoretical Decay ratio= e[-2/ 1- 2]
GRAPHS :
Plot the graph of manometer readings of one limb versus time.

RESULT :
From the graph, determine the value of overshoot and decay ratio, and compare graphical
value with the theoretical value.
Type of Value
Graphical value
theoretical value

CONCLUSIONS:

Overshoot

Decay ratio

EXPERIMEN 7
DATE:

HEAT EXCHANGER
Aim : To study the Digital Control System for Heat Exchanger.
Theory

: The Digital Control System is the recent development in Chemical

Engineering Branch. In this practical, the stream is taken from the 7 th tray and it is at
higher temperature and the temperature has to be lowered so we are using heat exchanger
.The hot fluid flows into the tube side and the cold fluid (water) flows into the shell side.
When the hot fluid comes out its temperature decreases and the temperature of cold fluid
increases. Now vary the flow rate of hot fluid, cold water and note down various
parameters that vary proportionally respectively.
Also vary the temperature of hot stream, cold stream, and take down the readings.
The logic behind this is that all the flow rate varies due to the proportional control
attached to it .For having the temperature of the stream leaving the heat exchanger and
entering the fractionator and at higher.
Process Description :

The objective in training a student on this system is to explore the control system tied up
with non-linear process behavior.
The purpose of Heat Exchanger in this model is to control the temperature profile of
FCCU fractionator. This is accomplished by cooling the TPA (Top Pump
Around),entering the 4th tray to 105 Deg C. The TPA comes from the 8 th tray of FCCU
fractionator at150-200 Deg C. The temperature controller regulates the flow through heat
exchanger & by-pass, thereby controlling the temperature of the mixed stream to
maintain desired set point (105 Deg C)
HEAT EXCHANGER PROCESS DESCRIPTION:
The model uses standard Shell & Tube Heat Exchanger, with water on tube side & TPA
entering the shell side .The temperature of the TPA entering the shell is controlled by the
flow of cold water whose temperature varies from 15 to 50 Deg C, depending upon the
malfunction value. The temperature of the TA, entering the shell, ranges from 150 Deg C,
depending upon the malfunction value.
SIGNIFICANT OPERATING VARIABLES:
The most important controller is Temperature Controller that is used to control the TPA
return temperature to desired set point. Flow controllers for TPA entering Shell Side &
cold water entering tube side are also provided for controlling the plant in fully automatic
mode.
Training Exercises:
The exercises begin with the program operating at the normal condition, following a
Design Start. If any difficulties arise in the midst of work, reinitialize the program and
continue without getting bogged down in by manipulation of the controls.
Exercise 1: Temperature Control
Action: Decrease the set point of temperature controller TIC-01
Result: The controllers output decreases, controller output increases temp will settle at
lower value than design.
Discussion: The decrease in set-point shall demand more cold TPA from shell side of heat
exchanger as compared to the TPA through by-pass which causes the temperature
controller to increase the cold TPA through by-pass.
Exercise 2 : FIC-01
Action : Increase setting of FIC-01
Result : Output of FIC-01 increases thereby increasing flow of cold water through tube
side of heat exchanger.

Exercise 3 : FIC-02
Action : Increase setting of FIC-02.
Result : Output of FIC-02 increases thereby increasing flow of TPA.

EXPERIMENT 8
DATE:

CATALYTIC REFORMER
Aim : To study the Digital Control System with the Catalytic Reformer.
Theory :
The Catalytic Reformer Plant converts feed stocks into high Octane gasoline. A byproduct of the process is hydrogen. To avoid catalytic poisoning, the feed is first
desulfurised to extremely low limits of sulfur, using some of the hydrogen produced by
the reforming reactions.
Catalytic Reforming involves both cracking and isomerisation .Straight-run gasoline and
light naphthas usually have very low octane numbers. By sending this fraction to a
reforming unit and giving them a light crack their octane number may be increased
.This upgrading is probably due primarily to isomerisation. The plant is divided into main
sections as regards chemical reactions. The first of these is the desulphurization section,
and the second is the reforming section. The Simulator will be considering reforming
section only. Reforming section includes one reactor, one furnace and one feed effluent
heat exchanger.(whereas plant has three sets of these equipment ) .

The plant is divided into main sections as regards chemical reactions. The first of these is
the desulphurization section, and the second is the reforming section. The Simulator will
be considering reforming section only. Reforming section includes one reactor, one
furnace and one feed effluent heat exchanger (where as plant has three sets of these
equipment).
In simulator, feed flow is simulated by simply opening feed valve and opening feed valve
and recycle gas. Composition of feed flow and recycle gas can be changed from
Instructor console. The reactor pressure is assumed to be constant at 31kg/cm2 G .

Training Exercises:
FIRST SET EXERCISES:
Ex.1. Reactor Inlet Temperature.
ACTION: The student changes the temperature set point of temperature controller TIC
104.
RESULT: Temperature of combined feed brings to its new set point.
DISCUSSION: Temperature controllers regulate the fuel gas flow.
Ex.2.Reformer Feed Control.
ACTION: Student varies the set point FIC-101.
RESULT: Feed rate changes to new set point value of FIC-101.
DISCUSSION: Notice finally now this change is reflected to the throughput to reactor
i.e. flow to the reaction section changes.
Ex.3. Recycle Gas Flow Rate.

ACTION: Student varies the setting of HC 101.

RESULT: Circulation of hydrogen to the reactors is changed.
DISCUSSION: Note indicator FI-102, Discuss why a change in the flow rate is not
particularly upsetting the reformer flash drum pressure control system.
SECOND SET EXERCISES :
EX.1. Reformer Charge Rate.
ACTION: Student varies the set point FIC-101.
RESULT: Essentially all flow rate in the plant change.
DISCUSSION: Eventually, the fresh feed rate settle out to a value, which satisfies
demand, set on FIC-101.Furnace firing rates change, to satisfy the reacting requirement
represented for above reason by setting FIC-`101.More or less hydrogen is produce. So
the reformer flash drum pressure controller reacts. The recycle gas compressor system
stay at set values, thus changing some basic operating ratios in the plant.
Note also how much time is required for steady conditions become established after a
change of FIC-101 set point. This is a special significant feature of the plant and deserves
special notice.

EX.2. Reformer reaction Temperature Control.

ACTION: The student changes the set point of TIC-104.
RESULT: All temperatures in the reformer section change.
DISCUSSION: Take note how all the temperatures change, how much time it takes for
conditions to settle out, 7 briefly note the fact that hydrogen production rate is change.
EX.3. Recycle gas control.
ACTION: Student varies the setting of HC-101
RESULT: The circulation of hydrogen to reactor is changed.
DISCUSSION: Note the indicator FI-102 , discuss why a change this flow rate is not
particularly upsetting to the reformer flash drum pressure control system.
Major Equation Used in Models:
The catalytic reactor model is considering the following reactions :
1.
2.
3.
4.

P N + H2
N A+ H2
P + H2 LHC
N + H2 LHC

P = Paraffines
N=Naphthenes
A=Aromatic
H2 = Hydrogen
LHC = Light Hydrocarbon

EXPERIMENT 9
DATE:

BINARY DISTILLATION
Aim : To study the Digital Control System for Binary Distillation.
Theory : In Binary Distillation, Distillation of Benzene and Toluene occurs Benzene
comes out from the top and toluene comes from the bottom and we have to note down the
reflux flow rate that varies proportionally.
The steam flow rate is varied and accordingly reflux, distillate, and residue rate is varied.
Then various readings for varying top head pressure is changed and result on the other
parameter is seen. Then we will close the discharge valve and then we will note down the
effect.
The DISTILLATION TOWER OPERATIONS Program has to do with conventional
bubble cap plate distillation tower. These are so named because they have a number of
horizontal plates or trays, which are usually equally spaced in the upright tower shell.
These bubble plates provide time for mixing and interchange of vapor and liquid flows
required for carrying out distillation separation. The relatively large number of trays used

generally produces tall and upright structure, and is the reason for the terms column or
tower.
The temperature of the boiling liquid is fixed by ht column pressure and liquid
composition and heat balance is always maintained. For the continuous balanced
operation, the sensible heat of the liquid and vapor flows into the plate plus the latent heat
of the condensing vapour must equal the sensible heat of the liquid and the vapor flow
out, plus the heat loss and the heat of mixing. Since the temperature change from one
plate to another is usually small, the heat balance effectively reduces the balance between
the heat given up by condensing vapor and the heat requires to vaporize the liquid leaving
the plate. And heat of vaporization and condensation have similar values; the vapour rate
out of the plate is nearly equal to the vapor rate into the plate.
Liquid enters the bottom part of the tower from the bottom plate down flow pipe. The
more vapour produced, the richer the bottom liquid becomes, in high material. Therefore
for constant column pressure, the bottom plate temperature can be used to adjust the
fraction of high boiling material in the bottom product flow. Increasing the bottom plate
temperature will increase the bottom fraction of boilers.
The reflux rate effectively determines the time that the feed materials remain in the
column. A large reflux rate means high portion of the overhead vapors are returned to the
column giving the material a longer time exposure to the separation operation, making it
richer in low boiling material. A smaller reflux flow will produce a less pure overhead
product.

EXPERIMENT 10
DATE:

DIGITAL ANEMOMETER
AIM:

To measure of wind velocity using digital anemometer.

APPARATUS: Digital anemometer.

PROCEDURE:

Turn on the instrument.

Place the hub of the instrument containing vanes against the wind.
Note down the reading in m/s unit.
Take 3-4 reading of different velocity.

THEORY:
Anemometer is device used for measuring wind velocity. The digital
anemometer contains hub with deflecting vanes. It shows reading in
different units directly by adjusting the knob.Different types of anemometer
are available e.g cup anemometer, deflecting vane anemometer, hot wire
anemometer, etc:

SCHEMATIC REPRESENTATION :

OBSERVATION TABLE:
Sr. No

Location

Velocity of
wind
m/s

1.
2.
3.
4.

RESULT:
CONCLUSION:

EXPERIMENT 11
DATE:

TACHOMETER
AIM:

To study measurement of rotational speed using digital tachometer with

contacting and non contacting methods.

APPARATUS: Digital tachometer, rotating object.

PROCEDURE:

For noncontacting measurement place the tachometer on the top edge of

stirrer.
Measure the speed.
For the same speed measure the speed using laser beam.
Take 3-4 reading of different speeds.
SCHEMATIC REPRESENTATION:

THEORY:
This is a handy and widely used instrument for the measurement of
rotational speed of shaft. In tachometer the input shaft having a rubber cap at its
front of magnet induced voltage into cup which thereby produces voltage

circulations, eddy current in the cup materials. This eddy current interact
with magnetic field to produce a torque, on the cup on proportion to relative
velocity of magnet. This causes the cup to turn through an angle is directly
proportional to the inject rotational speed. This is non-conducting type of speed
measuring instrument. The light is directly fall on rotating member. A reference
line is marked on the rotation member which serve as a tangent.
OBSERVATION TABLE:
Sr. No

Object

Tachometer
Reading
r.p.m.
(contacting)

1.
2.
3.
RESULT:
CONCLUSION:

EXPERIMENT 12
DATE:

TURBIDITY METER
AIM:

To measure the turbidity of given sample.

APPARATUS: Digital turbidity meter. Quette test tube.

CHEMICAL: Distilled water, turbid samples (0.5% & 1% starch solution) etc
PROCEDURE:
Allow sufficient warm up period after switching on the instrument.
Take the test tube holder and close the test tube holder cover.
Select required range for the instrument.
Adjust the display to 0.00 by adjusting set zero knob.
After calibration measure the turbidity of given sample.
SCHEMATIC REPRESENTATION

THEORY:

Quality of water sample is important in producing product distillate for

human consumption and in many more variety of products. Turbidity in water sample is
caused by suspended matter such as clay, slit, finely divided organic and inorganic matter,
sulfur colored organic compound and other microscopic organisms. Distill water is taken
as standard medium with turbidity as low as 0.02 ppm.
OBSERVATION TABLE:

RESULT:

CONCLUSION:

EXPERIMENT 13
DATE:

THERMOCOUPLE CALIBRATION
AIM:

To calibrate a given thermocouple.

APPARATUS: Heater, thermometer.

PROCEDURE:
1. Source Mode: Connect instrument output terminal to the input of digital temperature
indicator. Adjust Sr. No
suitable
Sample
Turbidity
mv signal as required by
using
NTU
high resolution
1.
potentiometer on the
panel &
2.
calibrate
digital
temperature indicator.
2. Measure mode:
(a) mv : Connect the signal to be measured directly to instrument terminal. The display
received
(b) T/C : Connect the thermocouple output to the instrument terminal observing proper
polarity & select thermocouple by means of a selectors.
SCHEMATIC REPRESENTATION:

THEORY: The thermocouple A thermocouple is simply two wires of different metallic composition
welded together to form a junction. The energy of the electrons within each metal is different, and this
energy difference depends upon the temperature of the point where the junction is made. The energy
difference can be measured as a voltage difference by using a very sensitive voltmeter. Since the metal
used in the terminal wires of the voltmeter is different from the thermocouple wires, it is necessary for
high
precision measurements to have two junctions. One junction is placed at a point
where you want to measure an unknown temperature, and the second junction is placed at a reference
temperature (generally 0C). Note: If both junctions are at the same temperature, a zero voltage is
measured. If the junction at an unknown temperature is hotter than the junction at the reference
temperature, a positive voltage is etected. You will use thermocouples made of iron and constantan, a
special alloy of nickel and copper. These metals develop a relatively large EMF compared to other
metals, but the EMF is still so small that a 25C difference is required to yield one millivolt. The
thermocouple has several significant advantages over a glass thermometer that should be emphasized:
1. It measures temperatures over a very broad range between -270C and
+1300C (and higher depending upon the metals used).
2. It is very small and can thus pinpoint temperatures at different locations.
3. Because it involves an electrical measurement, the recording can be
remote from the temperature region.
RESULT:

CONCLUSION:

EXPERIMENT 14
DATE:

DISSOLVED OXYGEN METER

AIM:

To measure the dissolved oxygen in the given sample using digital

dissolved oxygen meter.

APPARATUS: Digital dissolved oxygen meter, quette box.

CHEMICAL: Samples, water, etc.
PROCEDURE:
Put the temperature probe and measuring probe in the water and
calibrate the instrument.
Then dip the probes in the sample.
Note down the reading.
SCHEMATIC REPRESENTATION:

THEORY:

Dissolved oxygen meter designed to provide measurements for the most

critical water quality parameter. Digital readout provides mg/L, and
temperature readings by selecting a mode. Meter comes packaged in a
convenient
carrying
case
with
2
replacement
membrane
cartridges,
electrolyte, and protective probe storage bottle. A dissolved oxygen meter is
an electronic device that converts signals from a probe that is placed in the
water into units of DO in milligrams per liter. Most meters and probes also
measure temperature. The probe is filled with a salt solution and has a
selectively permeable membrane that allows DO to pass from the stream
water into the salt solution. The DO that has diffused into the salt solution
changes the electric potential of the salt solution and this change is sent by
Electric cable to the meter, which converts the signal to milligrams per liter
on a scale that the volunteer can read.
OBSERVATION TABLE:
Sr. No
1
2
RESULT:
CONCLUSION:

DO of given
sample
mg/l