Chen4352 PDC Lab Manual

Course Code:
CHEN4352
Process
Dynamics and
Control
College of Applied Sciences / Sohar
2015 2016
LABORATORY MANUAL
Semester: Fall 15
Tutor: Dr. Kumar
Engineering Department(Chemical)
Engineering Department
PREFACE
This lab manual hand out is intended to provide you with a concise guide in respect of
CHEN4352 PROCESS DYNAMICS AND CONTROL. This is intended to present the basics
involved in this subject and it remains as a course guide to achieve the objectives.
This module introduces the concepts and procedures used in the process industries
including the selection and design of controllers for process systems. Particular emphasis is
given to electronic control systems, pneumatic actuators, control valves, control loop
adjustments and process control software.
Dr. Kumar
CHEN4352 Process Dynamics and Control
Academic Year 2015-16
Semester: Fall
P2 | P a g e
age 1
LABORATORY DETAILS:
Associated Module
Code & Name
Level & Semester
CHEN4352
Academic Year
2015-16
Laboratory Name
Process Dynamics and Control Lab
Level 4 & Semester-Fall
Room No. (A/A21)/T006

Weightage for
report and
presentation
lab 20% (Lab report 10% + Lab presentation 5% + Lab Exam 5%)
Assessment
Deliverable
Written Laboratory Report, Lab Presentation and Lab Exam
Submission Time
29/11/15
Objectives
Ability to understand, operate and acquire hands on experience on

P,PI,PID flow controller, PI level controller, open loop controller,
temperature & pressure controller and Bode plots
Semester: Fall
P3 | P a g e
age 1
CONTENTS
EXPT NO.
1
TITLE OF THE EXPERIMENT
PAGE NO.
THE EFFECT OF P CONTROLLER ON FLOW CONTROL
SYSTEM
2
THE EFFECT OF PI and PID CONTROLLERS ON FLOW
CONTROL SYSTEM
3
THE EFFECT OF PI CONTROLLER ON LEVEL PROCESS
13
OPEN LOOP CONTROL SYSTEM USING SINUSOIDAL INPUT
15
STUDY ON BODE PLOTS USING OPEN LOOP SYSTEM
17
THE EFFECT OF P CONTROLLER ON PRESSURE CONTROL
19
LOOP
7
THE EFFECT OF PI CONTROLLER ON PRESSURE CONTROL
21
LOOP
8
THE EFFECT OF P CONTROLLER ON TEMPERATURE
23
CONTROL LOOP
9
THE EFFECT OF PI CONTROLLER ON TEMPERATURE
25
CONTROL LOOP
Semester: Fall
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Distribution of Experiments through First semester of AY (2015/2016)

General Plan
Lab A021/T006 (Process Dynamics and Control)
Title of Experiment
Date
Lecture
First Week
Safety Instructions
Second week
The effect of P controller on flow control
Third week
system
4
The effect of PI and PID controllers on
Fourth week
flow control system

5
The effect of PI controller on level
Fifth week
process
6
Open loop control system using
Sixth Week
sinusoidal input
7
Study on bode plots using open loop
Seventh Week
system
8
The effect of P controller on pressure
Eighth Week
control loop
9
The effect of PI controller on pressure
Ninth Week
control loop
10
The effect of P controller on temperature
Tenth Week
control loop
11
The effect of PI controller on temperature Eleventh Week

control loop
12
Presentation
Thirteenth week
13
Report submission
Fourteenth week
14
Lab Practical Exam
Fifteenth week
Semester: Fall
P5 | P a g e
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The Device PCT-100 includes the following elements:

1. Process tank
10. 2/2 Proportional drain valve
2. Sump tank
11. Needle valve
3. Cooler Unit
12. Pressure relief valve
4. Sump tank Temperature sensor (PRT)
13. Heater
5. Variable speed pump with filter and
14. Level sensor
pressure switch
15. Pressure transducer
6. 3/2 Diverter valve
16. Float switch
7. 2/2 Proportional control valve
17. Overflow/Vent valve
8. Flow rate sensor
18. Digital LCD displays
9. One way check valve
19. Indicator lights
Semester: Fall
P6 | P a g e
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EXPERIMENT NO. 1
THE EFFECT OF P CONTROLLER ON
FLOW CONTROL SYSTEM
AIM:
To study the effect of P controller on flow control system
Device:
A PCT-100, Process Control Technology model is a bench-top system which
implements several continuous fluid processes. The main elements of the PCT-100 are the
process rig and control module. The rig includes the following elements: sump, pump,
turbine flow meter, process tank, sensor for level, vent pipe, needle drain valve, proportional
drain valve, pressure transducer, float switch, check valve, forced air cooler and proportional
valve.
THEORY:
In any automation process, controllers are required for process control. The parameter
to be controlled may be temperature, pressure, flow rate, level etc. The difference between
the reference signal and the feedback signal is error signal. The error signal drives a control
valve or a damper to control, the process variables like tank level, fluid flow, pressure or
temperature to the set point.
The performance of the control systems is determined by the nature of the process, the
characteristics of the controller, the location and magnitude of the disturbance. Sometimes the
performance of feedback control system will be unsatisfactory because of large uncontrolled
load changes, hence other control schemes can be considered.
PROCEDURE:
P Controller
1. Before beginning the experiments ensure the vent valve at the top of the process tank
is open.
2. Go to the menu click flow controller
3. Keep Set Point (SP) as constant value of 2
4. Vary the Proportion Gain(PG) value from 0.5 to 10
5. Set study state input signal
Semester: Fall
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6. Start the set up and do the necessary arrangements to operate the control system
through computer system.
7. Record the steady state value and comment your observations in the tabular column
8. Keep the proportional gain value constant as 1 and vary the set point value from 0.6 to
3.4.
10. Study the response, record the steady study value and comment your observations
TABULAR COLOUMN:
Constant SP with different PG
S. No.
SP(l/min)
PG
Constant PG with different SP

Steady
State
SP(l/min)
PG
Steady
State
Calculate Experimental offset and Theoretical offset

Theoretical offset
SP
1 PG
GRAPH: Flow rate vs Time
CALCULATION AND REPORT:
Semester: Fall
P8 | P a g e
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EXPERIMENT NO. 2
THE EFFECT OF PI AND PID CONTROLLERS ON
FLOW CONTROL SYSTEM
AIM:
To study the effect of PI and PID controllers on flow control system
THEORY:
Integral or reset action combined with Proportional control gives us a controller which
will always act to maintain the controlled variable at its desired value (the set point). The
combination of proportional plus reset (PI) is most popular on application such as flow
control, pressure control and level control, where the process has little lags but required a
wide proportional band for stability. The small process lag permits the use of a large amount
of integral action.
A Proportional plus Derivative (PD) controller properly fitted and adjusted to a process
acts to prevent the controlled variable from deviating excessively and reduces the time
require to stabilize. Because the process lags can be compensated by the anticipatory nature
of derivative action. When all three control effects are combined together, we obtain the
benefits of each control action and moreover the effect duplicates the action of a good human
operator on a control application. A three mode controller (PID) contains the stability of
proportional control and the ability to eliminate offset because of reset control and the ability
to provide an immediate correction for the magnitude of a disturbance because of rate
control.
The performance of the control systems is determined by the nature of the process, the
characteristics of the controller, the location and magnitude of the disturbance. Sometimes the
performance of feedback control system will be unsatisfactory because of large uncontrolled
load changes, hence other control schemes can be considered. The best way of using an
additional controller to decrease upsets is to use the scheme called cascade control. The
Semester: Fall
P9 | P a g e
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output of the primary controller is used to adjust the set point of the secondary controller,
which in turn sends a signal to the control valve. The process output is fed back to the
controller, and a signal from an intermediate stage of process is fed back to secondary
controller. The main advantage of the cascade control is that the performance is better for all
types of load changes. For disturbance that enters near the beginning of the system, the
secondary controller starts corrective action before the process output shows any deviation.
PROCEDURE:
PI Controller
is open.
2. Go to the menu click flow controller
3. Keep Set Point (SP) as constant value of 2
5. Keep the proportional gain value constant as 1
6. Start flow loop experiment with addition of an element of Integral(I) action after
about ten seconds
8. Repeat this process several times and each time increase the amount of integral action
(I)
9. Record the final steady state flow value (if the flow actually does settle) and your
main observations as to the nature of the response.
PID Controller
10. Follow the instructions 1-5 and include Derivative(D) and to investigate the effect of
derivative action by running a flow experiment with SP= 1, PG=1 and vary the I and
D values
11. Inference the observations
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PI Controller
S. No.
SP(l/min)
PID Controller
S. No.
SP(l/min)
PG
PG
Steady State
Steady
State
Observations
Observations
PI:
Calculate Experimental offset and Theoretical offset (Assume first
order tank system)
Theoretical offset
SP
1 PG
Calculate Time constant ()

PID:
Experimental values for the following

Rise time (tr)
Peak time (tp)
Settling time (ts) =

Decay ration
Semester: Fall
P11 | P a g e
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Consider second order tank system and find theoretically tf and tp

tf
tp
2 1
sin 1 ( )
2
1
1 2
Decay ratio exp
2
1 2
Semester: Fall
P12 | P a g e
age 1
EXPERIMENT NO. 3
THE EFFECT OF PI CONTROLLER ON LEVEL PROCESS
AIM:
To study the effect of PI controller on level process for various Integral values but
constant SP and PG values.
THEORY:
Integral or reset action combined with Proportional control gives us a controller which
will always act to maintain the controlled variable at its desired value (the set point). The
combination of proportional plus reset (P+I) is most popular on application such as flow
control, pressure control and level control, where the process has little lags but required a
wide proportional band for stability. The small process lag permits the use of a large amount
of integral action.
The Proportional-Integral (PI) algorithm computes and transmits a controller output
(CO) signal every sample time, T, to the final control element (e.g., valve, variable speed
pump). The computed CO from the PI algorithm is influenced by the controller tuning
parameters and the controller error, e(t).
Integral action enables PI controllers to eliminate offset, a major weakness of a P-only
controller. Thus, PI controllers provide a balance of complexity and capability that makes
them by far the most widely used algorithm in process control applications.
PROCEDURE:
is open.
2. Open the tank valve to drain manual controller
3. Close again the valve
4. Go to the menu click level controller
5. Remove the tick mark of automatic controller
Semester: Fall
P13 | P a g e
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6. Keep set point(SP) as constant value of 30%

7. Keep the Proportion Gain(PG) value as constant (for example 5)
8. Vary the Integral(I) values from 999 to 1
11. Study the response, record the steady state values and comment your observations in
the tabular column
12. Drain the water manually for each set of reading
TABULAR COLOUMN:
S.No.
SP (Volume %)
PG
Steady State
Observations
Calculate Experimental offset and Theoretical offset (Assume first order

tank system)
Theoretical offset=
SP
1 PG
Calculate Time constant ()
GRAPH: Flow Level vs Time

Semester: Fall
P14 | P a g e
age 1
EXPERIMENT NO. 4
OPEN LOOP CONTROLLER FLOW SYSTEM USING SINUSOIDAL INPUT
AIM:
To study the performance of open loop controller flow system using sinusoidal input
THEORY:
An open-loop controller, also called a non-feedback controller, is a type of controller
that computes its input into a system using only the current state and its model of the system.
A characteristic of the open-loop controller is that it does not use feedback to determine if its
output has achieved the desired goal of the input. This means that the system does not
observe the output of the processes that it is controlling. Consequently, a true open-loop
system cannot engage in machine learning and also cannot correct any errors that it could
make. It also may not compensate for disturbances in the system.
An open-loop controller is often used in simple processes because of its simplicity and low
cost, especially in systems where feedback is not critical. A typical example would be a
conventional washing machine, for which the length of machine wash time is entirely
dependent on the judgment and estimation of the human operator
PROCEDURE:
1. Before beginning the experiments ensure the vent valve at the top of the process
tank is open.
2. Go to the menu and click open loop controller
3. Set sinusoidal input signal with minimum 30 % and max 80% to derive the pump
4. Vary the periods from 0.5 to 100 seconds
Semester: Fall
P15 | P a g e
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TABULAR COLOUMN:
S.No.
Period
(s)
Observations
Calculate:
Input amplitude=A
Output amplitude
A
1 ( ) 2
Amplitude ratio= Input amplitude/Output amplitude

Phase lag tan 1 ( )
Phase lag
T
360
(In terms of time unit)
CACLUATION AND REPORT:
Semester: Fall
P16 | P a g e
age 1
EXPERIMENT NO. 5
STUDY ON BODE PLOTS USING OPEN LOOP SYSTEM
AIM:
To conduct the open loop experiment and estimate the gain and phase angle
THEORY:
Bode plots are the most widely used means of displaying and communicating
frequency response information. It is a graph of transfer function of a linear, time-invariant
system versus frequency, plotted with a log-frequency axis, to show the system's frequency
response. It is usually a combination of a Bode magnitude plot, expressing the magnitude of
the frequency response gain, and a Bode phase plot, expressing the frequency response phase
shift
All in all, Bode' plots are widely used, not just to specify or show a frequency response, but
they also give useful information for designing control systems. Stability criteria can be
interpreted on Bode' plots and there are numerous design techniques based on Bode' plots.
PROCEDURE:
1. Before beginning the experiments ensure the vent valve at the top of the process
tank is open.
2. Go to the menu click open loop controller
3. Set sinusoidal input signal with minimum 30 % and max 80% to derive the pump
4. Vary the periods from 0.5 to 100 seconds
7. Draw bode gain and bode phase plots
Semester: Fall
P17 | P a g e
age 1
TABULAR COLOUMN:
S. No.
Period
(s)
Frequency (Hz)
Gain
Gain by
max. Gain
Phase angle
()
Calculate phase lag/angle theoretically and draw the following graphs

(a) Bode gain vs Frequency
(b) Bode phase vs Frequency
Gain = (Maximum Flow Rate - Minimum Flow Rate) / 50%
Experimental phase angle
T
x 360o (where T is the time interval, how
P
much time passes from the moment the input reaches a peak (or trough) until
the output reaches the corresponding peak (or trough)
GRAPH: Bode gain vs Frequency and Bode phase vs Frequency

CACULATION AND REPORT:
Semester: Fall
P18 | P a g e
age 1
EXPERIMENT NO. 6
THE EFFECT OF P CONTROLLER ON PRESSURE CONTROL LOOP
AIM:
To study the effect of P controller on pressure control loop for a change in SP and PG
DEVICE:
The PCT-M3 consists of a reservoir tanks; a compressor; a control valve; a
pressure sensor and two needle valves. Control is achieved using a pump, solenoid
valve and a pressure transducer to measure the results. A controller fitted to the unit
is linked to the PC using a USB connection. The objective is to control the pressure
level in the tank using the pump and valve and the measured value from the
pressure transducer.
THEORY:
Although proportional control is simple to understand, it has drawbacks. The largest
problem is that for most systems it will never entirely remove error. This is because when
error is 0 the controller only provides the steady state control action so the system will settle
back to the original steady state (which is probably not the new set point that we want the
system to be at). To get the system to operate near the new steady state, the controller gain,
Kc, must be very large so the controller will produce the required output when only a very
small error is present. Having large gains can lead to system instability or can require
physical impossibilities like infinitely large valves.
The output of a proportional controller (or the portion of the output of a two or three
term controller contributed by its proportional term) is proportional to the error between the
set point (SP) and the measured valve (MV).
PROCEDURE:
1. Set Integral to off (un check box)
2. Set Derivative off (un check box)
3. Set Period to 30 and select sinusoidal input.
4. Run the loop experiment using proportional only control with constant SP max/min
as constant (1.5/0.5) and vary PG values.
5. Repeat the same experiments with constant PG values and vary the SP max/min
values
Semester: Fall
P19 | P a g e
age 1
TABULAR COLOUMN:
P Controller
S. No.
SP(max/min) PG

Steady
State
SP(max/min) PG
Steady
State

Theoretical offset
SP
1 PG
GRAPH: Pressure vs Time
Semester: Fall
P20 | P a g e
age 1
EXPERIMENT NO. 7
THE EFFECT OF PI CONTROLLER ON PRESSURE CONTROL LOOP
AIM:
To study the effect of PI controller on pressure control loop keeping in SP and PG
constant and vary I
THEORY:
Integral Control Term
The integral control term is often used to remove proportional offset errors. It determines a
component of controller output based upon the history of the error. It is calculated by
multiplying the net area under the error curve, e(t), by PG divided by the integral action time
(IAT) in seconds.
A proportional-integral-derivative controller (PID controller) is a generic control loop
feedback mechanism (controller) widely used in industrial control systems. A PID controller
calculates an "error" value as the difference between a measured process variable and a
desired set point. The controller attempts to minimize the error by adjusting the process
control inputs.
The PID controller calculation algorithm involves three separate constant parameters,
and is accordingly sometimes called three-term control: the proportional, the integral and
derivative values, denoted P, I, and D. Simply put, these values can be interpreted in terms of
time: P depends on the present error, I on the accumulation of past errors, and D is a
prediction of future errors, based on current rate of change. The weighted sum of these three
actions is used to adjust the process via a control element such as the position of a control
valve, a damper, or the power supplied to a heating element.
In the absence of knowledge of the underlying process, a PID controller has
historically been considered to be the best controller. By tuning the three parameters in the
PID controller algorithm, the controller can provide control action designed for specific
process requirements. The response of the controller can be described in terms of the
responsiveness of the controller to an error, the degree to which the controller overshoots the
set point, and the degree of system oscillation. Note that the use of the PID algorithm for
control does not guarantee optimal control of the system or system stability.
Semester: Fall
P21 | P a g e
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Some applications may require using only one or two actions to provide the
appropriate system control. This is achieved by setting the other parameters to zero. A PID
controller will be called a PI, PD, P or I controller in the absence of the respective control
actions.
PI controllers are fairly common, since derivative action is sensitive to measurement
noise, whereas the absence of an integral term may prevent the system from reaching its
target value due to the control action
PROCEDURE:
1. Set Derivative to off (un check box)
2. Set integral on (check box)
3. Set Period to 30 and select sinusoidal input.
4. Run the loop experiment using PI controller with constant SP max/min and PG
values as constant and vary I values
PI Controller
S. No.
SP(max/min)
PG
Steady State
Observations
Assuming second order, calculate the experimental and theoretical values

for the following
Calculate tr, tp, phase lag, lag
Period and Overshoot
GRAPH: Pressure vs Time
Semester: Fall
P22 | P a g e
age 1
EXPERIMENT NO. 8
THE EFFECT OF P CONTROLLER ON
TEMPERATURE CONTROL LOOP
AIM:
To study the effect of P controller on temperature control loop for a change in SP, PG
and I
DEVICE:
The PCT-M4 consists of a Heating Element (TE), Three PT100 PRT Sensors
and a Disturbance. Control is achieved using a Peltier Heating Element, and PRT
Sensors to measure the output. A controller fitted to the unit is linked to the PC
using a USB connection. The objective is to control the Temperature level in the
system using the Peltier Heater and measured value from the PRTs.
THEORY:
Temperature control is a process in which change of temperature of a space (and
objects collectively there within) is measured or otherwise detected, and the passage of heat
energy into or out of the space is adjusted to achieve a desired average temperature. PI
controllers are fairly common, since derivative action is sensitive to measurement noise,
whereas the absence of an integral term may prevent the system from reaching its target value
due to the control action
Home thermostat is an example of a closed control loop: It constantly assesses the
current room temperature and controls a heater and/or air conditioner to increase or decrease
the temperature according to user-defined setting(s). A simple (low-cost, cheap) thermostat
merely switches the heater or air conditioner either on or off, and temporary overshoot and
undershoot of the desired average temperature must be expected.
A more expensive thermostat varies the amount of heat or cooling provided by the
heater or cooler, depending on the difference between the required temperature (the "set
point") and the actual temperature. This minimizes over/undershoots. This method is called
proportional control.
PROCEDURE:
1. Set Integral to off (un check box)
2. Set Derivative off (un check box);
Semester: Fall
P23 | P a g e
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3. Set temperature to 30 and select step input.

4. Run the experiment using proportional only control with constant SP values and
vary PG values.
5. Repeat the same experiments with constant PG values and vary the SP values
7.
TABULAR COLOUMN:
P Controller
S. No.
SP(0C)
PG

Steady
State
SP(0C)
PG
Steady
State
Calculate Experimental offset and Theoretical offset (Assume first order)

Theoretical offset=
SP
1 PG
GRAPH: Temperature vs Time

Semester: Fall
P24 | P a g e
age 1
EXPERIMENT NO. 9
THE EFFECT OF PI CONTROLLERS ON
TEMPERATURE CONTROL LOOP
AIM:
To study the effect of PI controller on temperature control loop for a change in I and
keeping SP and PG as constant
THEORY:
Temperature control is a process in which change of temperature of a space (and
objects collectively there within) is measured or otherwise detected, and the passage of heat
energy into or out of the space is adjusted to achieve a desired average temperature. PI
controllers are fairly common, since derivative action is sensitive to measurement noise,
whereas the absence of an integral term may prevent the system from reaching its target value
due to the control action
Home thermostat is an example of a closed control loop: It constantly assesses the
current room temperature and controls a heater and/or air conditioner to increase or decrease
the temperature according to user-defined setting(s). A simple (low-cost, cheap) thermostat
merely switches the heater or air conditioner either on or off, and temporary overshoot and
undershoot of the desired average temperature must be expected.
A more expensive thermostat varies the amount of heat or cooling provided by the
heater or cooler, depending on the difference between the required temperature (the "set
point") and the actual temperature. This minimizes over/undershoots. This method is called
proportional control. Further enhancements using the accumulated error signal (Integral)) and
the rate at which the error is changing (Derivative) are used to form more complex.
PROCEDURE:
1. Set Derivative off (un check box)
2. Set integral on
3. Set temperature to 30 and select step input.
4. Keep SP and PG values as constant and vary the I values
Semester: Fall
P25 | P a g e
age 1
PI Controller
S. No.
SP(0C)
PG
Steady State
Observations

Theoretical offset=
SP
1 PG
GRAPH: Temperature vs Time
Semester: Fall
P26 | P a g e
age 1

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Tutor: Dr. Kumar

CHEN4352 Process Dynamics and Control

Academic Year 2015-16

Process Dynamics and Control Lab

Level 4 & Semester-Fall

Room No. (A/A21)/T006

Written Laboratory Report, Lab Presentation and Lab Exam

Ability to understand, operate and acquire hands on experience on

CHEN4352 Process Dynamics and Control

Academic Year 2015-16

TITLE OF THE EXPERIMENT

THE EFFECT OF P CONTROLLER ON FLOW CONTROL

THE EFFECT OF PI and PID CONTROLLERS ON FLOW

THE EFFECT OF PI CONTROLLER ON LEVEL PROCESS

OPEN LOOP CONTROL SYSTEM USING SINUSOIDAL INPUT

STUDY ON BODE PLOTS USING OPEN LOOP SYSTEM

THE EFFECT OF P CONTROLLER ON PRESSURE CONTROL

THE EFFECT OF PI CONTROLLER ON PRESSURE CONTROL

THE EFFECT OF P CONTROLLER ON TEMPERATURE

THE EFFECT OF PI CONTROLLER ON TEMPERATURE

CHEN4352 Process Dynamics and Control

Academic Year 2015-16

Distribution of Experiments through First semester of AY (2015/2016)

The effect of P controller on flow control

The effect of PI and PID controllers on

flow control system

The effect of PI controller on level

Open loop control system using

Study on bode plots using open loop

The effect of P controller on pressure

The effect of PI controller on pressure

The effect of P controller on temperature

The effect of PI controller on temperature Eleventh Week

Lab Practical Exam

CHEN4352 Process Dynamics and Control

Academic Year 2015-16

The Device PCT-100 includes the following elements:

10. 2/2 Proportional drain valve

11. Needle valve

12. Pressure relief valve

4. Sump tank Temperature sensor (PRT)

5. Variable speed pump with filter and

14. Level sensor

15. Pressure transducer

6. 3/2 Diverter valve

16. Float switch

7. 2/2 Proportional control valve

17. Overflow/Vent valve

8. Flow rate sensor

18. Digital LCD displays

9. One way check valve

19. Indicator lights

CHEN4352 Process Dynamics and Control

Academic Year 2015-16

Academic Year 2015-16

Constant PG with different SP

Calculate Experimental offset and Theoretical offset