EXPERIMENT–5

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

Apparatus :

 A”U”-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) 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. Repeatsteps (6) 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 Newton‟s 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
Newton‟s Second law of motion gives us,

Net force on the mass= Mass × acceleration.

∆PA- hAρg - RAdh/dt = 2ALρ/ 3[d2t/ d h2] (1)

Where,
A=cross sectional area of the manometer tube. [cm2]
P=Applied pressure [gm.force/cm2]
H=Height of liquidabove its steady-state level.[cm]
ρ =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 –Poiseulli‟s
equation can be written as

ΔP = 32µuL/ρgD2 = 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 2ρg/g cand rearranging, it gives,

2L/3g d2h/dt2+ 16µL/ gc D2dh/dt + h =∆ P/ ρg = hi (3)

Here, hiis taken as input pressure in terms of liquid column height to balance that pressure.

Again notice that coefficient of d2h/dt2{L/2g}have dimensions of sec2or (time2).Similarly coefficient of

dh/dt have the dimensions of second or [time] .Thus the coefficient of dh/dt can be replaced by 2ζ as
√L/2g may not be equal to 16µL/gcD2

Thus, equation (3) may be written as

2d2h/dt2+ 2ζ 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/[2s2+ 2ζs + 1 ] (5)

To define equation (5) fully we require value of two parameters ζ and  and it is known as second order
system.

The response of second order system to various forcing functions can be obtained by factorizing
thequadratic term in the denominator into two linear terms that contains its roots S 1 and S2.

For ζ less than on the roots of quadratic equation [2s2+2ζs + 1 ] are given by

S1 = {-ζ/ } + {√ 1- ζ2/ } = a+ib

S2.= {-ζ/ } - {√ 1- ζ2/ } = a-ib (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 [2s2+ 2ζ s + 1 ] (8)

Taking Laplace inverse by making use of partial fractions, we get the response of the second order under
damped system [ζ<1.0] to a step change in forcing function as

Y(t) = 1 - {√ 1- ζ2/ } e- ζt/{ sin[ (√ 1- ζ2)t/  ] + tan-1 {√ 1- ζ2/ } (9)

It may be noted from equation (9), that the response Y(t) has an oscillatory component in it whose
amplitude {√ 1- ζ2/ } e- ζt/goes on decreasing as time increases.

Under damped response is more commonly sought in control systems. Anumber 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 ζ by the expression

Overshoot = e[-ζ/√ 1- ζ2] (10)

It can be noted from equation (10) that over shoot increase as ζ decreases and reaches a limiting value of 1
when ζ = 0 .

Decay ratio: It is defined as the ratio of second peak to first peak. The decay ratio is related to ζ by the
expression.

Decay ratio = e[-2ζ/ √ 1- ζ] (11)

SCHEMATIC DIAGRAM:

OBSERVATION TABLE:

Sr. No Height of Time (Sec) TheoreticalTemp

lower limb y (ºC)
1 0
2
3
4
5
6
7
8
9
10
11
12
13

CALCULATION:

Viscosity=0.015 g/cm S
Density = 13.53 g/cc
D= ____________
L= ____________

=√L/2g
ζ
= (8µ/ρ D2)√2L/g
-ζ/√ 1- ζ2
Theoretical Overshoot = e[ ]
 -2ζ/√ 1- ζ2
Theoretical Decay ratio= e[ ]

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 Overshoot Decay ratio

Graphical value
theoretical value

CONCLUSIONS:
 EXPERIMENT–6
DATE:
ON-OFF LEVEL AND TEMPERATURE CONTROLLER
1. ON-OFF LEVEL CONTROLLER
1.1. OBJECTIVE
To study the basic design and operation of an On-Off level controller
1.2 THEORY
• On-Off Control is a special case of proportional control in which the valve will move from one extreme
position to the other, if the process value deviates from the set point.
• This very sensitive action is called on-off action because the valve is either fully open (on) or fully
closed (off); i.e., the valve acts like a Switch.
• The Valve, which acts with respect to On-Off Control, is called as Shut-Off Valve (SOV).
• In the given "On-Off" Level Control (LIC001) model, a feed liquid is passing through a vessel V-001
that is provided with an On-Off Level Control.
• At design condition, the level is maintained at 50.17 % of the tank level such that the outlet flow
matches the inlet flow.
• By Manipulating the O/L Valve HIC001 to 30 %, the user can see the behavior of On-Off Level
Controller LIC001 & LIC002.
• Since the Outlet flow is changed, the outlet flow doesn't match with the inlet flow and the liquid level
will start to rise.
• Initially "High Set" (LIC001) is at 80% & "Low Set” (LI0002) is at 40%.
• When the liquid level reaches 80 % of the tank level, the Shut-Off valve closes so that the liquid level
starts to decrease.
• When the liquid level decreases and attains 40 %, the Shut-Off Valve (SOV) opens, so that the inlet
starts to flow.
• By this way, the On-Off Controller works. Thus, without going in for a costly PID controller, level is
allowed to remain in the non-alarm condition, with the help of an On-Off controller.

1.3. PROCEDURE
 Observe the effects on the level by, altering the valve HIC001 position in outlet line.
 Find the set value of ON-OFF control valve (i.e., at what level of tank the inlet valve will Open and
Close) by the following procedure:
a) Change the "High Set” (LIC001) and "Low Set" (L1C002) (For Eg: 70% & 30%),
b) Decrease the globe valve HIC001 position by 10%.
c) The Shut Off valve will Close when PV of LIC001 reaches 70% and it opens when PV of LIC001
reaches 30%.
d) Observe and note the PV of LIC001 (i.e., the level change) and PV of F1001 (i.e., Flow inlet to
tank) in every time interval of 60 seconds.
e) Plot the graph Time Vs. PV.
f) Result is substantiated from the graph plotted.
2. ON-OFF TEMPERATURE CONTROLLER
2.1. OBJECTIVE
This course is designed to teach the graduate engineers the basic design and operation of an On-Off control
of a thermal process.
2.2. THEORY
• When On-Off Control deals with the Temperature of the process, the On-Off control is called as On-
Off Temperature Control.
• In the given On-Off Temperature Control model, a vessel V-001 is provided with a steam coil.
• The steam coil helps to maintain the temperature of the oil bath within the range of 75 to 85 ºC to
maintain the fluidity of the oil, which is meant for a Compressor.
• The lube oil tank temperature is controlled by means of an On-Off Controller TIC001/002. The On-Off
Controller algorithm compares the tank temperature with the desired value 80 ºC.
• If it is less than the set point (i.e,) below 80 ºC, the algorithm sends a maximum output set point to
“Shut Off Valve” (open fully) by TIC001/002, causing the valve to allow full steam flow to the tank.
• Initially “High Set”(TIC001) is at 85ºC & “Low Set”(TIC002) is at 75ºC.
• By manipulating the steam I/L Valve HIC003 to 70 %, the user can see the behavior of On-Off
Temperature Controller TIC001.
• When the tank temperature reaches a preset maximum value 85ºC, the algorithm supplies a minimum
output to allow full cooling by closing the steam valve (“Shut-Off Valve” closes fully).
• When the tank temperature reaches a preset minimum value 75ºC, the “Shut-Off Valve” opens fully.
• The On-Off Temperature Controller Behavior can be seen in varying of the flow rate of the Oil Inlet
FI001, Oil Outlet FI002 and Steam Inlet FI003 by manipulating the Valves HIC001, HIC002 and
HIC003 respectively.

2.3. PROCEDURE
2.3.1.Observe the effects on the heating system by
 Altering the inlet flow rate of the steam (Alter the MV in HIC003).
 Altering the inlet flow rate of oil (Alter the MV in HIC001).
 Altering the outlet flow rate of oil (Alter the MV in HIC002).
2.3.2. Find the set value of ON-OFF control valve (i.e., at what temperature of the L-1 outlet the inlet
steam valve of TIC001 will Open and Close) by the following procedure:
 Change the “High Set” and “Low Set” ( For Eg: 90ºC & 80ºC),
 Decrease the inlet lube oil flow (or) Increase the outlet lube oil flow (or) Increase the steam
inlet flow by altering the respective globe valve positions.
 The Shut Off valve will Close when PV of TIC001 reaches 90% and it opens when PV of
FI003 reaches 80%.
 Observe and note the PV of TIC001 (i.e., the Temperature change) and PV of FI003 (i.e.,
Steam Flow inlet to tank) in every time interval of 30 seconds.
 Plot the graph Time Vs. PV.
 Result is substantiated from the graph plotted.

1.4 RESULTS AND DISCUSSION-

 EXPERIMENT–7
DATE:
P AND PI CONTROLLER
1. P & PI CONTROL ON FLOW
1.1. OBJECTIVE
To compare the effects of PI with P controller on flow control loop.
1.2. THEORY
In this simulated model the instrumentation details incorporated in the controller action are discussed.
• A flow controller FIC001 & FIC002 are located in a pipeline carrying fluid from Unit A to Unit B.
• FIC001 is Proportional Integral controller and FIC002 is proportional controller.
• The flow controller is initially provided with only a Proportional Control. The proportional controller
computes its output as a result of the error between the process variable and the set point. Its output
changes in proportion to a change in the measured error.
• The greater the error, the greater the control effort; and as long as the error remains, the controller will
continue to try to generate a corrective effort.
• Simulated model is disturbed by means of opening a drain valve, located in the pipeline. The Process
Value (PV) is now different, and the controller is finding an error in the flow.
• The control valve opens further from its existing position in proportion to the error signal. But the valve
does not close when the Process Value (PV) exceeds the Set Value (SV).
• The problem with a controller having only proportional control is to settle on the wrong corrective
effort. It can be measured in the proportional controller FIC002.
• As a result, it will generally leave a steady state error (offset) between the set point and the process
variable after it has finished responding to a set point change or a load.
• In the same controller, the addition of the integral action in the process makes the controller more
effective. It can measured the dynamic change in the controller FIC001.
• Specifically, a controller that contains its own integral action or acts on a process with inherent integral
action will generally not permit a steady-state error.
• The student can be asked to give a value for the Integral action by comparing with proportional
controller and repeat the same exercise. He can now see the effect of both Proportional cum Integral
actions on the process.
1.3. PROCEDURE
1.3.1. Change the design condition by
  Altering the drain valve position.
 Altering UNIT A and UNIT B pressures.
 Altering the SV of the controller.
1.3.2. Find the suitable P and I values from the two different set of values for the flow controller
when there is a disturbance to achieve the set flow by following the procedure:
 Note the design flow from unit A to unit B, the controller output (MV) of FIC001,
Differential pressure across the orifice, the flow transducer O/P, SDBT O/P, SLPC O/P and
I/P converter O/P.
 Open the drain valve(HIC001) to 10%
 Observe and note the flow & the corresponding valve opening (MV) of FIC001 and FIC002.
 Observe and note the flow & the differential pressure across the orifice
 Observe and note the flow & the flow transmitter O/P
 Observe and note the flow & SDBT O/P
 Observe and note the flow & SLPC O/P
 Observe and note the flow & I/P converter O/P.
 Plot the two graphs Time Vs. Flow, Valve opening MV (or) controller output of FIC001 and
FIC002.
2. RESULTS AND DISCUSSION-
 EXPERIMENT–8
DATE:
ADVANCE CONTROL 1 (CASCADE AND SPLIT RANGE)
1. DIRECT AND CASCADE CONTROL
1.1. OBJECTIVE
To study the operation of Cascade Control on Level Process.
1.2. THEORY:
In the given Direct and Cascade model, the comparison of cascade control to direct control can be
observed.
• Direct Control Measures any one of the process variables (Temperature, pressure, flow, level) by
getting input signals (process value) from those process variables, comparing with the set point given
and controlling those variables directly by the output signal that send to the valve from the controller.
• Cascade Control Measures any two-process variables at a time.
• A Cascade structure has two controllers with the output of the primary (or master) controller changing
the set point of the secondary (or slave) controller.
• The output of the secondary Controller goes to the valve.
• There are two purposes for cascade control - to eliminate the effects of some disturbances, to improve
the dynamic performance of the control loop.
• In the given Direct and Cascade model, the comparison of cascade control to direct control can be
observed.
• The liquid feed flows into two vessels.
• The liquid level in the first vessel V-001 is under the direct control of LIC001.
• The liquid level in the second vessel V-002 is under cascade control of LIC002 with FIC001, where
LIC002 is configured to control the set point of FIC001.
• By introducing a step change in the feed to both vessels by manipulating feed valve HIC001 between
20 – 70 %, the user can see the behavior of both Direct LIC001 and Cascade Control LIC002-FIC001.

1.3. PROCEDURE
1.3.1. Vary the design condition by
 Altering the outlet pressure(PIC001).
 Altering the globe valve(HIC001) at the inlet.
 Altering the SV of the controller in Auto mode (LIC001/002).
 1.3.2. Compare the control action on level by the direct control and the cascade control by the
following procedure:
 Note the level of the vessel V-001, LIC001 controller output (or) Valve position.
 Note the level of the vessel V-002, LIC002 controller output and FIC001 controller output
(or) valve position.
 Alter the outlet pressure (PIC001) in-between 2 to 8 Kg/cm2.
 Observe and note the level of vessel V-001, LIC001 controller output (or) Valve position.
 Observe and note the level of vessel V-002, LIC002 controller output and FIC001 controller
output (or) valve position.
 Plot two graphs Time Vs. other parameters noted for two tanks.

2. SPLIT RANGE PRESSURE CONTROL

2.1. OBJECTIVE
To study the basic design and operation of Split Range pressure control.
2.2. THEORY
• Split Range Pressure Control controls the pressure in the pressure vessel by controlling the two Valves
that one Valve is on the process line and the other one is on the flare line.
• Based on the set point (pressure) given to the controller, the two valves opens or closes by signals from
the controller.
• In the given Split Range Pressure Control (PIC001) model, the Feed gas comes from Unit A to the
vessel V-001 and goes out to destination Unit B.
• There is provision to take the gas to flare. One valve is on the Unit B inlet line and the other is on the
Flare line.
• The pressure in a vessel V-001 is controlled by Split Range Pressure Controller PIC001 acting on two
separate valves namely XV001 and XV002.
• The signal from the pressure controller PIC001 is split into two and sent to the two valves.
• The initial signal from 0 to 50 %( MV of PIC001) is sent to the control valve on the Unit B line.
Further signals will facilitate the opening of the flare valve.

2.3. PROCEDURE
2.3.1. Observe the effects on the drum pressure by,
  Altering the inlet flow rate of the gas by either decreasing or increasing the valve position.
 Increasing/ Decreasing the SV of the controller PIC001
2.3.2. Find the range of controller output splitted to the two control valves by the following procedure:
 Note the design PIC001 controller output (MV), design XV001 valve opening (PV) and
design XV002 valve opening (PV).
 Increase the inlet gas flow by increasing the position of HIC001 to 80%.
 Observe and note the changes in controller PIC001 output (MV), XV001 valve opening (PV)
and XV002 valve opening (PV) in every time interval of 30 seconds.
 Plot the graph Time Vs. changes in controller output (MV), XV001 valve opening (PV) and
XV002 valve opening (PV).
 Result is substantiated from the graph plotted.
2.3.3. How to ensure the flow in flare without altering the design value of the inlet valve HIC001
 Decrease the SV of the controller.

3. RESULTS AND DISCUSSION-

 EXPERIMENT–9
DATE:
ADVANCE CONTROL 2 (RATIO AND FEED BACKWARD-FORWARD)
1. RATIO CONTROL
1.1. OBJECTIVE
To study the basic design and operation of ratio control.
1.2. THEORY
• Ratio control controls the flow of one stream say B based on the set point (ratio) of two streams say A:
B given to the controller.
• It takes up signal from both the streams, makes it as process value (ratio) and corresponding signal is
given to the controller.
• In the given Ratio control (RC001) model, the Stream A enters as a pure solution of component A at 40
ºC and stream B enters as a pure solution of component B at 50 ºC.
• The ratio of 4:2 of component A and B enters the reactor (R-001) for mixing at design conditions.
• The two fluids are mixed in the reactor and the composition of A and B in the outlet mixture is
indicated by AI001 and AI002.
• The level of the tank is at 44.04 % indicated by LI001.
• The set point ratio of A to B is maintained by ratio controller RC001 by Controlling the component B
stream to the tank.
• By manipulating the HIC001 Valve between 40% – 70 %, the user can see the behavior of the Ratio
Controller RC001.

1.3. PROCEDURE
1.3.1. Change the design condition by
 Altering the inlet valve position (HIC001) of component A.
1.3.2. Calculate at what ratio the Component A and B are mixed by the following procedure:
 Note the design Component A flow rate, Component B flow rate and Component A and B
composition at the outlet line.
 Increase the inlet valve position of component A line.
 Note the Component A flow rate.
 Observe and note the Component B flow rate and also the component A and B composition
in every time interval of 10 seconds till the steady state is reached.
  Plot the graph Time Vs. Component B flow rate, and Composition of A and B.
 Result is substantiated from the graph plotted.

2. FEED BACKWARD AND FORWARD CONTROL

2.1. OBJECTIVE
To study the principle and advantage of a Feed Forward Control over Feed Backward control in a heater.
2.2. THEORY
• Feed Backward control is the control that uses a process variable that is affected by the control output.
• Feedback control has nothing to do with the physical location of the measurement point and the control
point in the process; often the measurement point is after the control point.
• An example of feedback control is direct or cascade control. Feed Forward control is the control that
compensates for a disturbance before its effect is felt in the output.
• It is based on a model that relates the output to the input where the disturbance occurs.
• An example of feed forward control is ratio control.
• The given Feed Backward and Forward Control model demonstrates the advantage of a Feed Forward
Control over Feed Backward control in a heater based on the accuracy in Control tuning loop.
• In this model, Feed oil at same flow and temperature enters two symmetrical heaters F-001 and F-002.
The heater F-001 Coil Outlet Temperature (COT) TIC001 is controlled by a Feed Backward Control.
• But in the case of heater F-002, the Coil Outlet Temperature TIC002 is controlled by Feed Backward
control and Feed Forward Control.
• In the heater F-001, when the feed flow is altered, the controller TIC001 takes action only when the
COT temperature changes.
• In heater F-002, when the feed flow is altered, a corresponding signal from the summer & multiplier is
sent to the valve, which is controlling the fuel, and required action is taken before there is considerable
change in the COT.
• It can be demonstrated by introducing step change in the Feed Oil by manipulating the HIC001 Valve
between 30 – 50 %.

2.3. PROCEDURE
2.3.1. Observe the effects by
 Altering the globe valve (HIC001) at the inlet.
  Alter the SV of the controllers (TIC001/002) in Auto mode.
2.3.2. Compare the control action on the temperature by feed forward and feedback controllers by
following procedures:
 Note the design outlet temperatures from both the heater and also the controller output or
valve positions of the two controllers TIC001 and TIC002.
 Decrease the inlet valve HIC001 position to 10%.
 Observe and note down the temperature at the outlet of heater F-001 and the controller output
(or) valve position of TIC001.
 Observe and note down the temperature at the outlet of heater F-002 and the controller output
(or) valve position of TIC002.
 Plot the graphs for the heater F-001 and F-002 Time Vs. other parameters observed.

3. RESULTS AND DISCUSSION-

 EXPERIMENT–10
DATE:
DISTILLATION OPERATION
1. OBJECTIVE
The primary objective of PS2001 Distillation Column Program is to teach trainees the operating
fundamentals of a distillation system using dynamic simulation.
ProSimulator provides opportunities to identify the main equipments associated with distillation systems,
to describe the operation of Depropanizer column, how to startup and shutdown the process using
documented procedures, how to respond safely and efficiently to disturbances and malfunctions in the
process, understand how temperature and pressure affect the operation of a distillation tower.
2. THEORY
The distillation plant receives hydrocarbon feed and separates into two fractions:propane, and butane,
from the heavier natural gasoline components by the process ofdistillation.
The following paragraphs describe the process flow through the simulated plant.
2.1 DEPROPANIZER COLUMN
• The raw feed is transferred by pump to the inlet of the Depropanizer column, at tray18.
• The feed enters the column through a control valve, FIC001 and is distributed via astaggered lateral
inlet.
• Saturated steam circulation supplies heat for the distillation process by circulationthrough the tube
side of the kettle type bottoms reboiler, E-001.
• The liquid inlet to the reboiler is taken from tray 1 of the column, a total draw-offtray with two
nozzles.
• The hot vapor from the reboiler returns to the column below tray 1, while thereboiled liquid flows
by gravity directly to the base of the column.
• The column temperature at tray 5 determines the reboiler heat input.
• The temperature controller, TIC001, at tray 5 acts on cascade flow control, FIC002, to regulate the
supply of saturated steam to the reboiler.
• The tray 5 temperature therefore, controls the column bottoms product composition.
• The bottoms column liquid is transferred without a pump, on level control, LIC001, to the inlet of
debutanizer column.
• The pressure differential existing between the two columns is the driving force for the flow.
 • The overhead vapor product of the depropanizer is cooled and partially condensed by passing the
entire vapor through an air fan condenser,E-002, which consists of four fin-fans.
• The degree of condensation is a function of the column pressure, which is controlled by a split-
range pressure controller, PIC001.
• This pressure is controlled at the tower top by adjusting the variable pitch of the cooler fans.
• If the air fans cannot provide sufficient cooling, the pressure controller acts on splitrange control on
a vent valve to the flare system.
• The condensed overhead product then enters the reflux drum, where vapor/liquid gravity separation
occurs.
• The liquid phase from the reflux drum is returned to the column as reflux. The reflux is pumped
back to the column by reflux pump above the top tray, tray 40, through a spray pipe distributor.
• The reflux return to the column is controlled by FIC003, which allows the reflux ratio to be altered
so as to maintain the top product purity.
• Level control, LIC002, of the reflux drum is achieved by cascade control of the top product flow,
FIC004. The vapor phase of the drum is the overhead product of the Depropanizer column.
• Care should be taken between each flow adjustment to allow ample time for the columns to adjust
to the new flow rates.
• It is important to maintain the proper product purities at all times.
3. PROCEDURE
 Increase the Feed Rate
 Increase Feed Temperature Feed
 Decrease Reboiler Temperature
 Decrease Reflux drum level
• Decrease Steam I/L Pressure

4. RESULTS AND DISCUSSION-

 EXPERIMENT–11
DATE:
CSTR IN SERIES
1. OBJECTIVE
The primary objective of Continuous Stirred Tank Reactor – PS2008 Program is to teachtrainees the
operating fundamentals of a CSTR using dynamic simulation.
PROSIMULATOR provides opportunities to study the CSTR, to describe the operation of aCSTR, how to
startup and shutdown the process using documented procedures, how to respondsafely and efficiently to
disturbances and malfunctions in the process.
2. THEORY
The continuous flow Stirred Tank Reactor in series (CSTR) is commonly used in manyindustrial
applications. The CSTR assumes that the feed is instantaneously mixed as it enters thereactor vessel. As the
reaction is exothermic, heat is generated to a great extent. To reduce thistemperature, each reactor is
surrounded by a cold water jacket. Temperature controller TIC01 andTIC02 regulates the flow of cooling
water to this jackets and maintains the temperature at 40 C and 45ºC in R001 and R002 respectively. Level
in the reactors are maintained by controlling the productoutlet flow by LIC01 and LIC02 in each reactors
respectively.

3. PROCEDURE
• Vary RC001 in the range of 0-2 (i.e. 1.5)
• Vary TIC01 in the range of 0-100 (i.e. 30)
• Vary LIC01 in the range of 0-100 (i.e. 60)
• Vary LIC01 in the range of 0-100 (i.e. 40)
• Vary TIC02 in the range of 0-100 (i.e. 35)

4. RESULTS AND DISCUSSION-

 EXPERIMENT–12
DATE:
PLUG FLOW REACTOR
1. OBJECTIVE
To study the basic design and operating fundamentals of PFR using dynamic simulation.
PROSIMULATOR provides opportunities to study the PFR, to describe the operation of a PFR, how to
startup and shutdown the process using documented procedures. How to respond safely and efficiently to
disturbances and malfunctions in the process.
2.THEORY
 The PFR is commonly used in many industrial applications.
 Mainly it is used in the manyfacture of gasoline additives.
 Here normal butane is converted in to isobutene in the PFR. Further the isobutene will be converted
into the isooctane.
 Here the reaction is carried out adiabatically in the liquid case under high pressure using essentially
trace amounts of a liquid catalyst which gives a specific reaction rate.
 The feed is entering at the temperature of 330 K and here we are considering isothermal condition
also in the PFR.

3. PROCEDURE
1. Conversion
 This change must be done in adiabatic reactor.
 Study the effect of conversion on exit temperature, reaction rate, and volume.
 Increase the conversion in steps of 10% (10, 20, 30,40, 50, 60, 70).
 For every change made, note down the the values of the following variables.
a) Exit temperature
b) Reaction rate
c) Volume
2. Order of the reaction
 This change must be done in isothermal reactor.
 Study the effect of order of the reaction on space time, product concentration, and conversion.
 Increase the reaction rate to 1.
  For change made, note down the values of the folloeing variables.
a) space time
b) Product concentration
c) Conversion

3. Feed flow rate

 This change must be done in isothermal reactor.
 Study the effect of order of the reaction on space time, product concentration, and conversion.
 Increase the feed flow rate as (20,22).
 Decreasing the flowrate as (16, 14).
 For change made, note down the values of the folloeing variables.
a) space time
b) Product concentration
c) Conversion
4.RESULTS-

5.CONCLUSIONS-
 EXPERIMENT–13
DATE:
EVAPORATOR
1. OBJECTIVE
The prime objective of Evaporator model is to teach the students about various operating fundamentals
and the design of an Evaporator.
The dynamic Prosimulator creates a virtual environment for the trainees to understand various
functional aspects of the equipment, normal operating conditions and effects of changes in the input
parameters and there corresponding response in the output and design.
2. THEORY
• Evaporator is a heat transfer equipment which is used to evaporate certain proportion of liquid from
a solid-liquid system there by increasing the solid concentration in the system.
• It usually uses steam as the heating medium. In the present model, sugar solution is used as feed and
steam as heating medium.
• The design steps are calculated dynamically and are displayed.
• Using the design steps, the overall heat transfer area and the steam economy are calculated and
displayed.
• A temperature controller (TIC001) is used to regulate the flow of steam depending upon the
temperature of the outlet sugar syrup
• A pressure controller (PIC001) is used to regulate the flow of vapor generated in the equipment.

3. PROCEDURE
3.1. FEED FLOW RATE
 Change the Inlet flow rate by changing the set value on the Hand controller HIC001 and note
down the changes. (i.e. 45%)
3.2. FEED TEMPERATURE
 Change the Steam flow rate by changing the set value of the Temperature controller TIC001
and note down the results. (i.e. 135ºC)
4. RESULTS AND DISCUSSION-
 EXPERIMENT-14
DEMONSTRATION OF CONTROL TRAINER

(LEVEL CONTROL TRAINER, PRESSURE CONTROL TRAINER, TEMPERATURE

CONTROL TRAINER, FLOW CONTROL TRAINER)

LEVEL CONTROL TRAINER

AIM- To study the level control trainer

APPARATUS- Level control trainer

THEORY- Process control trainer demonstrates the control of pressure, flow, level, temperature, and pH
processes. It simulates process control object of life and industrial production truly.

PROCEDURE-
 The setup consists of a process tank fitted with scale in which water enters through a Pneumatic
control valve.
 Water is pumped to process tank from the sump tank by means of a centrifugal pump. The level
transmitter is fitted in the process tank.
 The level of water in process tank is sensed by the transmitter and communicated to the digital
indicating controller.
 This measured variable is compared with the Set Point by controller and output is generated and
given to I/P converter, which in turn supply the 3-15 Psig pressure to vary the opening of the
Pneumatic control valve to eliminate the error observed.
 As the opening of pneumatic control valve varies, the level in the Process Tank gets affected.
 Then change the set point of level.
 Observe how the level is changing to achieve the new set point.
 This process goes on until the set point target is achieved. A rotameter is also provided at the drain
line of the process tank to disturb the system and to observe the effect of disturbance.
 The drain and overflow of the process tanks returns in the sump tank, hence the system operates in
close circuit.
 These units along with necessary piping are supported in a well-designed housing and are fixed on
base plate.
 The process parameter is controlled through computer by micro-processor Controller (SCADA
Model) by manipulating water flow to the process tank.
 In this observe how the pneumatic control valve is changing its position.

RESULTS AND CONCLUSIONS-

 PRESSURE CONTROL TRAINER

AIM- To study the pressure control trainer

APPARATUS- Pressure control trainer

THEORY- Pressure control trainer demonstrates the control of pressure process. It simulates process
control object of life and industrial production truly. In this pressure control trainer air pressure in process
tank is sensed by the transmitter and communicated to the digital indicating controller.

PROCEDURE-
 The setup consists of a process tank in which compressed air enters through a Pneumatic control
valve.
 The pressure transmitter is fitted on the process tank. The air pressure in process tank is sensed by
the transmitter and communicated to the digital indicating controller.
 Then change the set point of pressure.
 Observe how the pressure is changing to achieve the new set point.
 This measured variable is compared with the set Point by controller and output is generated and
given to I/P converter, which in turn supply the 3-15 Psig pressure to vary the opening of the
Pneumatic control valve to eliminate the error observed.
 As the opening of pneumatic control valve varies, the pressure in the Process Tank gets affected.
This process goes on until the Set Point target is achieved.
 A ball valve to eliminate the error observed. As the opening of pneumatic control valve varies, the
pressure in the Process Tank gets affected.
 This process goes on until the Set Point target is achieved. A ball valve is also provided in the
process tank to disturb the system and to observe the effect of disturbance.
 These units along with necessary piping are supported in a well-designed housing and are fixed on
base plate.
 The process parameter is controlled through computer by micro-processor Controller (SCADA
Model) by manipulating the pressure in process tank.
 In this observe how the pneumatic control valve is changing its position.

RESULTS-

CONCLUSIONS-
 TEMPERATURE CONTROL TRAINER

AIM- To study the temperature control trainer

APPARATUS- Temperature control trainer

THEORY- Temperature control trainer designed for understanding the basic principles of temperature
control temperature control trainer demonstrates the control of temperature process. It simulates process
control object of life and industrial production truly.

PROCEDURE-
 The setup consists of heating tank fitted with thyristor-controlled heater for on line heating of the
water.
 Water is supplied from laboratory constant head tank and its flow can be manipulated and measured
by provided rotameter.
 The temperature of the heated water is sensed by RTD sensor.
 This measured variable through Temperature Transmitter is communicated to Digital Indicating
Controller.
 Then change the set point of temperature.
 Observe how the temperature is changing to achieve the new set point.
 Error is calculated and output accordingly, is communicated to thyristor controlled heater to achieve
the set Point. These units along with necessary piping are supported in a well-designed housing and
are fixed on base plate.

RESULTS-

CONCLUSIONS-
 FLOW CONTROL TRAINER

AIM- To study the flow control trainer

APPARATUS- Flow control trainer

THEORY- Flow control trainer demonstrates the control of flow process. It simulates process control
object of life and industrial production truly. Flow control trainer is designed for understanding the basic
principles of flow control.

PROCEDURE-
 The present set-up is designed to study a PID Controlled Flow Process in the industry.
 Water is pumped from the sump tank by means of a centrifugal pump to a Pneumatic Control Valve
and after passing thorough the rotameter it return back to the sump.
 The Differential Pressure transmitter with an orificemeter is fitted in the water line.
 The differential Pressure across the orifice in flow line of water is sensed by the transmitter and
communicated to the digital indicating controller.
 Then change the set point of flowrate.
 Observe how the flow is changing to achieve the new set point.
 This measured variable is compared with the Set Point by controller and output is generated and
given to I/P converter, which in turn supply the 3-15 Psig pressure to vary the opening of the
Pneumatic control valve to eliminate the error observed.
 As the opening of pneumatic control valve varies, the flow of water in the line gets affected.
 This process goes on until the Set Point target is achieved. A rotameter is also provided in the
water line to disturb the system and to observe the effect of disturbance. As the water returns in the
sump tank again, the system operates in close circuit.
 These units along with necessary piping are supported in a well-designed housing and are fixed on
base plate.

RESULTS-

CONCLUSIONS-