1907609 PROCESS CONTROL LAB DEPT OF EIE

SRM VALLIAMMAI ENGINEERING COLLEGE

(An Autonomous Institution)
Affiliated to Anna University
SRM Nagar, Kattankulathur - 603 203.

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION

ENGINEERING

1907609 - PROCESS CONTROL LABORATORY

LAB MANUAL

2022-2023 EVEN SEMESTER

Prepared by

Mr. C. PRAVEEN KUMAR, M.E., (Ph.D)

ASSISTANT PROFESSOR (SENIOR GRADE)
DEPARTMENT OF EIE

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1907609 PROCESS CONTROL LAB DEPT OF EIE

INDEX PAGE

Date Staff
E.No Name of the Experiment Pg.No
Sign
Characteristics of Pneumatically Actuated Control Valve
1. (with and without Positioner).

Dynamic Characteristics of First & Second Order

2. System with and without transportation lag.

Study and control of flow process using Compact Flow

3. Control Unit.
Tuning of PID Controller for mathematically described
4. processes.

Control of Level and Pressure using Process Control

5. Training Plant.

PID Implementation Issues.

6.
PID Enhancements (Cascade and Feed-forward Control
7 Schemes).
Design and implementation of ON/OFF Controller for the
8 Temperature Process.

9 Dynamic characteristics of P+I+D controller

Design and implementation of Interacting and non-

10 interacting system.

11 Study of AC and DC drives.

Study of Multi-input Multi-output system (MIMO system).

12

ADDITIONAL EXPERIMENTS

1 Simulation of lumped /distributed parameter system.

Mathematical model of a typical industrial process

2
using nonparametric identification methods

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1907609 PROCESS CONTROL LAB DEPT OF EIE

CHARACTERISTICS OF PNEUMATICALLY ACTUATED CONTROL

VALVE (WITH AND WITHOUT POSITIONER)
Ex.No:1
Date:

AIM

To determine the flow – lift characteristics (Internet / Installed) of a control

valve equipped with and without valve positioner.

EQUIPMENT

1. Control valve trainer (with position for varying ΔP across the valve) - 1 No

2. Flow meter - 1No

THEORY
Control valve
In most of the industrial process control systems control valve is the final
control element. The control valve consists of two major components, namely,
Actuator and valve. The actuator is made up of flexible diaphragm: spring and
spring tension adjustments, plate, stem and lock nut housing. The valve is made
up of body, plug, stem, and pressure tight connection.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

The function of a control valve is to vary the flow of fluid through the
value by means of a change of pressure to the valve top. The relation (or lift) is
called the valve characteristic. There are three main types of valve
characteristics. The types of valve characteristics can be defined in terms of the
sensitivity of the valve, which is simply the fraction change in flow to the
fractional change in stem position for fixed upstream and downstream pressures.
Mathematically
Sensitivity = dm / dx
In terms of valve characteristics, valve can be classified in to three types:
1. Linear.
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1907609 PROCESS CONTROL LAB DEPT OF EIE

2. Increasing sensitivity.
3. Decreasing sensitivity.
For the linear type valve characteristics, the sensitivity is constant and the
characteristic curve is a straight line (e.g. linear valve). For increasing
sensitivity type, the sensitivity increases with flow (e.g.) Equal percentage or
logarithmic valve). In practice, the ideal characteristics for linear and equal
percentage valves are only approximated by commercially available valves.
These discrepancies cause no difficulty because the inherent characteristics are
changed considerably when the valve is installed in a line having resistance to
flow, a situation that usually prevails in practice.
VALVE POSITIONER
The valve positioner is an instrument working on force balance principle
to position the control valve stem in accordance to a pneumatic signal received
from a controller or manual loading station, regardless of packing box friction,
actuator hysteresis or unbalanced forces on the valve plug. Thus the positioner
ensures a reliable and accurate operation of control valve. The instrument signal
is applied to the signal diaphragm. An increasing signal will drive the
diaphragm and flapper-connecting stem to the right. The flapper- connecting
stem will then open the supply flapper admitting supply pressure in to the
output, which is connected to the actuator diaphragm. The exhaust flapper
remains closed when the flapper-connecting stem is deflected to right. The
effect of increasing signal is to increase the pressure in the actuator. This
increased pressure in the actuator drives the valve stem downwards and rotates
the positioned lever clockwise. This clockwise rotation of the lever results in a
compression of range spring through cam. When the valve stem reaches the
position called for by the controller, the compression in the range spring will
give a balance force resulting the closure of both the flapper. If the control
signal is decreased the force exerted by the signal diaphragm will also decrease
and the force from the range spring will push the flapper-connecting stem to the
left, opening the exhaust flapper. This causes a decrease in actuator diaphragm
pressure and allows the valve stem to move upward until a new force Balance is
established.
Control valve (Linear) - Type: Pneumatic; Size: 1/2", Input: 3–15 psig, Air to
open.
Control valve (equal %) - Type: Pneumatic; Size: 1/2", Input: 3–15 psig,
Action: Air to close.
Control valve (quick opening) - Type: Pneumatic; Size: 1/2", Input: 3–15 psig,
Air to open.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

MODEL GRAPH

FRONT PANEL DESCRIPTION

Power ON/OFF switch : Switch ON/OFF the unit.

Pump ON : Switch ON/OFF the pump.
Pump Indicator : To indicate the pump power.
HV1 : Bypass hand valve.
HV2 : Inlet regulating valve for quick opening valve.
HV3 : Inlet regulating valve for equal percentage
valve.
HV4 : Inlet regulating valve for linear valve.
HV5 : Pressure supplying valve for quick opening
valve.
HV6 : Pressure supplying valve for equal percentage
valve.
HV7 : Pressure supplying valve for linear valve.
HV8 : Vent valve

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1907609 PROCESS CONTROL LAB DEPT OF EIE

G1 : To measure the pressure drop across the control

valve
G2 : To measure the actuator pressure
G3 : To measure the supply pressure for positioner
CV1 : Quick opening valve.
CV2 : Equal percentage valve.
CV3 : Linear valve

FRONT PANEL DIAGRAM

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1907609 PROCESS CONTROL LAB DEPT OF EIE

PROCEDURE:

➢ Before conducting the experiment, make sure that availability of water in

reservoir tank. Fill
clean and soft water in the reservoir
➢ Connect air supply pipe to regulator. Confirm there is no loose
connection.
➢ Control valve positioned should be in “bypass” mode.
➢ Hand valve settings for linear control valve characteristics study;
HV4(the regulating
valve, which is provided at the inlet of control valve) and HV7 should be
fully open.

Regulating valves of other control valves should be fully closed.

➢ Initially, set the output pressure of air regulator to 15 Psi by varying the
knob. Thelinear valve is fully open.
➢ Keep partially open the vent valve (HV8), when air regulator lifts to its
maximumrange.
➢ Switch on the unit.
➢ Set the maximum flow in the rotameter by adjusting the bypass valve
(HV1) and inletregulating valve (HV4).
➢ Maintain the pressure drop across the control valve in pressure gauge
(G1)(e.g. 1/1.5/2Psi) remains constant varying the bypass valve (HV4).
Note the pressure drop acrossthe valve at fully open (G1).
➢ Never disturb the hand valve (HV4), once it is adjusted for particular
opening.
➢ Observe flow and inlet pressure variations. Note down the air regulator
pressure (G2),rotameter flow, and stem position in control valve.
➢ Decrease the pressure in air regulator to 12 Psi, at same time, pressure
across thecontrol valve slightly increases, adjust bypass valve (HV1) to
maintain predefinedpressure in G1.
➢ Note the flow in rotameter and stem position in control valve, air
regulator pressure.
➢ Slowly decrease/increase the air pressure regulator for achieving different
stempositions till the valve is fully closed/open.
➢ Tabulate the rotameter flow, air regulator pressure and stem position.
➢ Plot the graph between rotameterflow in the y-axis and stem position in
x-axis.

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TABULATION

∆Pressure drop across control valve (∆p)=

Actuator pressure (Psi) Stem position (%) Rotameter flow (LPH)

Calculate the control valve co-efficient from the table,

RESULT

Thus, the characteristics of linear valve without positioner were studied.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

DYNAMIC CHARACTERSITICS OF FIRST & SECOND ORDER

SYSTEM WITH AND WITHOUT TRANSPORTATION LAG
Ex.No:2
Date:

AIM

To determine the dynamic characteristics of first order and second order system
with and without transportation lag.

EQUIPMENT

1. Simulation kit

2. CRO

3. Patch Chords

4. PC with Matlab software

THEORY
FIRST ORDER SYSTEM

It is characterized by only one pole with or without a zero. In this case, consider only the pole
and it is assumed that there is no more complex zeros available. Eg. For such
transfer function are a pure integrator a single time constant (u) the pole is either
at the origin or at the negative real axis.
The transfer function for a pure integrator is C(s) / R(s) = K/S

For step input R(s) = 1/s

C(s) = K/S2
Taking Inverse Laplace Transform C(t) = kt
For a step input provided in the input the pure integrator gives the ramp
response. The transfer function of a single time constant process is given
C(s) / R(s) = K/1+ts = 1/s X 1/1+ts
C(t) = K(1-e-t/z)

Here the time constant is defined as the time taken by C(t) to reach 63.3% of the
final steady state value. In general, first order system with dead time is
represented by the following transfer function
C(s) / R(s) = K/s e-tds for pure integrator
C(s) / R(s) = K e-tds / 1+ ts for single time constant process
Here td is the transportation lag or dead time.

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SECOND ORDER SYSTEM

A second order system is represented in the standard form as

C(s) = wn2 / s2 + 2zwns + wn2
Z – damping ratio
Wn – undamped natural frequency

Depending on the value of “z” of the pole of the system may be repeated or
complex conjucate.

a) UNDERDAMPED SYSTEM (0 < z < 1)

C(t) = 1 – e-zwnt √ 1-z2 sin (wdt + ∅ )

Where, wd = wn √ 1-z2
It is the natural frequency of damped oscillation.
∅ = tan-1 √ 1-z2 / z

b) CRITICAL DAMPED ( z = 1)

C(t) = 1 – e-zwnt

c) OVERDAMPED SYSTEM ( z > 1)

C(t) = 1 + wn / 2 √ z2-1 { e-zt / z – e-z2t/ 2z }

Where, z = z + √ z2 + wn
z = z - √ z2 + w n
In general 2 nd order system with dead time is presented by

C(s) = wn2e-Qds / s2 + 2zwns + wn2

PROCEDURE:

➢ Choose the input square wave of suitable frequency and amplitude say
(30Hz, 2.5V)
➢ For the process of order 1, P is provided with a toggle.
➢ Provide the input supply as in step and analyses and second the response
using a CRO or DSO
➢ Plot the graph.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

MODEL GRAPH

FIRST ORDER SYSTEM (WITH AND WITHOUT DELAY)

SECOND ORDER SYSTEM (WITH AND WITHOUT DELAY)

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RESULT

Thus, the response of first order and second order system with and without
transportation lag was obtained and the dynamic characteristics were studied.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

CLOSED LOOP RESPONSE OF FLOW CONTROL LOOP

Ex.No: 3
Date:

AIM:
To obtain the closed loop response of flow control loop for servo and regulator
Operation.

EQUIPMENT:
1. Flow process station with all accessories - 1 No
2. Analog / Digital PID controller - 1 No
3. Recorder - 1 No

THEORY:
Flow process controller is used to perform the control action on flow
process. A Differential pressure transmitter is used to measure the flow of the
fluid through orifice plate. Pump discharges the water from reservoir tank and
give it to control valve. Computer acts as an error detector and controller.
According to the error signal, that it develops a control signal.
This control signal is given to I/P Converter that operates the control
valve. It controls the flow of the fluid in pipeline by varying stem position of the
control valve. By pass line is provided to avoid the pump overloading. Data
Acquisition card(Data Acquisition System) having ADC and DAC, section so
that it acts an effective link between the process plant and the controller.
The level sensing element is a metal probe which is inserted vertically
into the medium from the top of the tank. If the tank is a conductor it is used as
a ground reference. In insulated tanks the probe is enclosed by a concentric
electrode to serve as capacitance change.
When the tank is empty, the probe and inner wall of the tank are
separated by air space. As the level of the medium increases the capacitance
between the insulated probe and the tank wall increases. The change in
capacitance is sensed and converted into a current signal in the range of 4-20
mA for transmission.
The I/P convertor is also called the electro pneumatic convertor, is used
where a4 to 20 mA signal current is to be converted to 3-15 psi pressure signal.
Essentially the convertor needs two inputs, viz. a fixed 20 psi air at its air inlet
and a variable 4 to 20mA at its current input. It consists of 3 basic parts:
• Pick up system
• Convertor
• Pneumatic relay

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The pickup system consists of a voice coil situated in the air gap of
permanent magnet. The convertor consists of a nozzle, the restrictor and the
baffle plate on the beam, which is mounted on low friction fulcrum. The
pneumatic relay consists of a diaphragm, a valve seat, a needle, and a capillary
tube.

EXERCISE: 1

Closed – loop connection is made in the flow process station.

PROCESS DESCRIPTION:

The block diagram and schematic diagram for Closed – loop connection
is made in the flow process station as shown in fig. given below.

FRONT PANEL DIAGRAM

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 1907609 PROCESS CONTROL LAB DEPT OF EIE

FRONT PANEL DESCRIPTION

Power ON/OFF Switch - It is used to switch ON/OFF the unit.
Pump Speed regulator - It is used to vary the speed of the pump.
G1 - It is used to indicate output pressure of air
regulator.
G2 - It is used to indicate the I/P converter output.
PV - Test points for flow transmitter output (4-
20mA).
CO - Test points for Controller output (4-20mA)

EXERCISE: 2

The flow controller (P+I) is tuned using any one of the tuning techniques.

PROCEDURE:

i. Ensure the availability of Air & Water.

ii. Interface the PC with process and Data Acquisition System.
iii. Maintain Gauge (G1) pressure at 20 Psi by using air regulator knob.
iv. Position the Hand valve HV1 in partially open position.
v. Patch CO & PV terminals through Patch chords.
vi. Switch ON the Data Acquisition System with PC.
vii. Invoke Process Control Software.
viii. Using PI control mode to met the desired flow

EXERCISE: 3
The response of the control loop is obtained for changes in the set point.

PROCEDURE:
i. Procedure for exercise-1 is repeated upto viii.
ii. By changing the various set point, the response for corresponding set
point plotted.

PI Controller Set Point---------- Kp----- Ki--------

-
Time in Sec Controller output in Process variable (lph)
percentage

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EXERCISE: 4

The response of the control loop is obtained for changes in the load
variable.

PROCEDURE:

i. Procedure for exercise-1 is repeated up to viii.

ii. By varying HV1 (Disturbance), the response for corresponding
disturbance plotted.

PI Controller Set Point---------- Kp----- Ki--------

-
Time in Sec Controller output in Process variable (lph)
percentage

EXERCISE: 5

The Exercise 3 and 4 are repeated for different controller modes and settings.

RESULT:

Thus the closed loop response of flow process for Servo and Regulator
operation was obtained.
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TUNING OF PID CONTROLLER FOR MATHEMATICALLY DESCRIBED

PROCESS
Ex.No: 4
Date:

AIM
To study of various controller tunings using MATLAB software.

APPARATUS REQUIRED
MATLAB Software,PC

THEORY
Controller tuning is the process of determining the controller parameters
which produce the desired output. Controller tuning allows for optimization of a
process and minimizes the error between the variable of the process and its set
point.
Types of controller tuning methods include the trial and error method,
and process reaction curve methods. The most common classical controller
tuning methods are the Ziegler-Nichols and Cohen-Coon methods. These
methods are often used when the mathematical model of the system is not
available. The Ziegler-Nichols method can be used for both closed and open
loop systems, while Cohen-Coon is typically used for open loop systems.

I) TRIAL AND ERROR METHOD

The trial and error tuning method is based on guess-and-check. In this method,
the proportional action is the main control, while the integral and derivative
actions refine it. The controller gain, Kc, is adjusted with the integral and
derivative actions held at a minimum, until a desired output is obtained.
II) PROCESS REACTION CURVE
In this method, the variables being measured are those of a system that is
already in place. A disturbance is introduced into the system and data can then
be obtained from this curve. First the system is allowed to reach steady state,
and then a disturbance, Xo, is introduced to it. The percentage of disturbance to
the system can be introduced by a change in either the set point or process
variable.

III) ZIEGLER-NICHOLS METHOD

Ziegler and Nichols devised two empirical methods for obtaining controller
parameters. Their methods were used for non-first order plus dead time
situations, and involved intense manual calculations.

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Ziegler-Nichols closed-loop tuning method

The Ziegler-Nichols closed-loop tuning method allows one to use the ultimate
gain value, Ku, and the ultimate period of oscillation, Pu, to calculate Kc . It is a
simple method of tuning PID controllers and can be refined to give better
approximations of the controller.
To find the values of these parameters, and to calculate the tuning constants, use
the following procedure:
Closed Loop (Feedback Loop)
1. Remove integral and derivative action. Set integral time (Ti) to a largest
value and set the derivative controller (Td) to zero.
2. Create a small disturbance in the loop by changing the set point. Adjust
the proportional, increasing and/or decreasing, the gain until the
oscillations have constant amplitude.
3. Record the gain value (Ku) and period of oscillation (Pu).
4. Plug these values into the Ziegler-Nichols closed loop equations and
determine the necessary settings for the controller. Closed-Loop
Calculations of Kc, Ti, Td
Ziegler-Nichols open-loop tuning method or process reaction method
This method remains a popular technique for tuning controllers that use
proportional, integral, and derivative actions. The Ziegler-Nichols open-loop
method is also referred to as a process reaction method, because it tests the
open-loop reaction of the process to a change in the control variable output.
This basic test requires that the response of the system be recorded, preferably
by a plotter or computer. Once certain process response values are found, they
can be plugged into the Ziegler-Nichols equation with specific multiplier
constants for the gains of a controller with either P, PI, or PID actions.
IV) COHEN-COON METHOD
The Cohen-Coon method of controller tuning corrects the slow, steady-state
response given by the Ziegler-Nichols method when there is a large dead time
(process delay) relative to the open loop time constant; a large process delay is
necessary to make this method practical because otherwise unreasonably large
controller gains will be predicted. This method is only used for first-order
models with time delay, due to the fact that the controller does not
instantaneously respond to the disturbance (the step disturbance is progressive
instead of instantaneous).
The Cohen-Coon method is classified as an 'offline' method for tuning, meaning
that a step change can be introduced to the input once it is at steady-state. Then
the output can be measured based on the time constant and the time delay and
this response can be used to evaluate the initial control parameters.
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V) Other Methods
There are other common methods that are used, but they can be complicated and
aren't considered classical methods.

a. INTERNAL MODEL CONTROL

The Internal Model Control (IMC) method was developed with robustness in
mind. The Ziegler-Nichols open loop and Cohen-Coon methods give large
controller gain and short integral time, which isn't conducive to chemical
engineering applications. The IMC method relates to closed-loop control and
doesn't have overshooting or oscillatory behavior. The IMC methods however
are very complicated for systems with first order dead time.
b. AUTO TUNE VARIATION
The auto-tune variation (ATV) technique is also a closed loop method and it is
used to determine two important system constants (Pu and Ku for example).
These values can be determined without disturbing the system and tuning values
for PID are obtained from these. The ATV method will only work on systems
that have significant dead time or the ultimate period, Pu, will be equal to the
sampling period.
PROCEDURE

Type the program using matlab software in matlab editor .

Given transfer function

Gp(S) = 5/(14s3 +78S2+11S+1)

Gp(S) = 6/(48s3 +44S2+12S+1)

TUNING METHOD:

ZIEGLER NICHOLS OPEN AND CLOSE LOOP

n=[5]

d=[1478 11 1]

y=tf(n,d)

[gm,pm,wpc,wgc] = margin(y)

gm =

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12.05

pm =

31.4

ω pc =
0.25

ω gc =

0.88

From the program we got the above values, using the formulas we find the P,I
and D values.

gm=ku

P=ku/1.7

FOR P CONTROLLER=12.05

Pu=2 x3.14(pi) / ω pc

ω pc =0.25

Pu = 25.12

FOR I CONTROLLER = Pu/8 = 3.14

FOR D CONTROL = Pu/2= 12.56

n=[6]

d=[48 44 12 1]

y=tf(n,d)

[gm,pm,wpc,wgc] = margin(y)

gm =
1.6667
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pm =

17.7247

ω pc =
0.5000

ω gc =

0.3906

From the program we got the above values, using the formulas we find the P,I
and D values.

gm=ku

P=ku/1.7

FOR P CONTROLLER=0.97

Pu=2 x3.14(pi) / ω pc

ω pc =0.5

Pu = 12.36

FOR I CONTROLLER = Pu/8 = 1.545

FOR D CONTROL = Pu/2= 6.18

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For closed loop Response apply the values in MATLAB SIMULINK.

Now the controller parameters are calculated using the table below,

Kp Ti Td
P Ku/2
PI Ku/2.2 Pu/1.2
PID Ku/1.7 Pu/2 Pu/8
Now using the PID values again implement the Simulink Model to get the
response of Ziegler Nichols Closed Loop responses.
Output Response

ii) CLOSE LOOP RESPONSE OF I ORDER SYSTEM WITH DELAY USING COHEN
COON TUNNING METHOD IN MATLAB CODING:
2
Gp (s) = 𝑒 −2𝑠
10𝑠+1
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PROCEDURE

1. Write a coding or simulink for a open loop I order process and observe
the response.
2. Draw a tangent line in the graph.
3. Find k,τ,td from a graph.
4. After that find the controller values using k,τ,td in cohen coon tuning
method.
5. Then we write a coding for a close loop system.
6. Observe the close loop response of P, PI and PID controllers.
OPEN LOOP RESPONSE

K=B/A
𝜏 = B/Slope
Slope= opposite / adjacent
td=Delay Time
n=[2]
d=[10 1]
[n1,d1]=pade(2,1)
n2=conv(n,n1)
d2=conv(d,d1)
t=[0:0.5:25]
y=step(tf(n2,d2))
subplot(2,2,1)
plot(y)
kp=2.67

[n3,d3]=cloop(kp*n2,d2)
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y1=step(tf(n3,d3))
subplot(2,2,2)
plot(y1)
kp=2.56
n4=[6.96 1]
d4=[6.96 0]
[n5,d5]=cloop(kp*conv(n2,n4),conv(d2,d4))
y2=step(tf(n5,d5))
subplot(2,2,3)
plot(y2)
kp=3.33
n6=[3.18 4.547 1]
d6=[0 4.547 0]
[n7,d7]=cloop(kp*conv(n2,n6),conv(d2,d6))
y3=step(tf(n7,d7))
subplot(2,2,4)
plot(y3)
CLOSED LOOP RESPONSE

2 1.5

1.5
1
1
0.5
0.5
0
0

-0.5 -0.5
0 50 100 150 200 250 0 50 100 150

1.5 1.5

1
1
0.5
0.5
0
0
-0.5

-0.5 -1
0 50 100 150 0 50 100 150

RESULT :
Thus the different tuning methods were studied using MATLAB software.

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CLOSED LOOP RESPONSE OF LEVEL CONTROL LOOP

Ex No: 5 (a)
Date:

LEVEL CONTROL IN PROCESS CONTROL TRAINING PLANT

AIM
To obtain the closed loop response of level control loop for servo and regulator
operation.

APPARATUS REQUIRED
1. Level Process Analyser
2. Data Acquisition System.
3. PC with Process Control software.
4. Patch chords.

EXERCISE: 1

Closed loop connection is made in the level process station.

FRONT PANEL DIAGRAM

FRONT PANEL DESCRIPTION

Power ON/OFF Switch - It is used to switch ON/OFF the unit.

Pump Speed regulator - It is used to vary the speed of the pump.
G1 - It is used to indicate output pressure of air regulator.
G2 - It is used to indicate the I/P converter output.
PV - Test points for Level transmitter output (4 - 20mA).
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EXERCISE: 2 & 3

The level controller (P+I) is tuned using any one of the tuning techniques
The response of the control loop is obtained for changes in the set point.

PROCEDURE

* Ensure the availability of Air & Water.

* Interface the PC with process and Data Acquisition System.
* Maintain Gauge (G1) pressure at 20 Psi by using air regulator knob.
* Position the Hand valve HV1 in partially open position.
* Patch CO & PV terminals through Patch chords.
* Switch ON the Data Acquisition System with PC.
* Invoke Process Control Software.
i. In PC select “Start →Menu → All Programs → Process Control”
The following window will be appeared,
CO - Test points for Controller output (4 - 20mA).
ii. Select the “file>>Start” menu. The menu will be shown below,
• The port setting window will open Select the COM port number, Baud
rate (38400) and keep the
• remaining boxes as it is and click OK button
• The Port opened successfully window will appear. Then click OK
button.
• To select the appropriate control and set the parameters like Set point,
Kp, Ki &Kdvalues
• Switch ON the pump and vary the speed control knob.
• Enter the parameters and observe the responses.
• Switch OFF the pump.
• Save the response and conclude the behavior of Level process.
• Load the file and analysis the graph

PI Controller Set Point---------- Kp----- Ki---------

Time in Sec Controller output in Process variable
percentage

RESULT
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Thus, the performance of PI controller on Level process was studied.

EXERCISE: 4

The response of the control loop is obtained for changes in the load variable.

PROCEDURE
By applying disturbance using corresponding control valve

PI Controller Set Point---------- Kp----- Ki---------

Time in Sec Controller output in Process variable

percentage

EXERCISE: 5

The step 3 and step 4 are repeated for different controller modes and settings.

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Ex No: 5 (b)
Date:

PRESSURE CONTROL IN PROCESS CONTROL TRAINING PLANT

AIM
To obtain the closed loop response of pressure control loop for servo and
regulator operation.

APPARATUS REQUIRED
1. Pressure Process Analyser.
2. Data Acquisition System.
3. PC with Process Control software.
4. Patch chords.

THEORY

EXERCISE: 1

Closed loop connection is made in the pressure process station.

FRONT PANEL DIAGRAM

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1907609 PROCESS CONTROL LAB DEPT OF EIE

FRONT PANEL DESCRIPTION

Power ON/OFF Switch - It is used to switch ON/OFF the unit.
Pump Speed regulator - It is used to vary the speed of the pump.
G1 - It is used to indicate output pressure of air regulator.
G2 - It is used to indicate the I/P converter output.
PV - Test points for pressure transmitter output (4 - 20mA).
CO - Test points for Controller output (4 - 20mA).

EXERCISE: 2 & 3

The level controller (P+I) is tuned using any one of the tuning techniques
The response of the control loop is obtained for changes in the set

PROCEDURE
* Ensure the availability of Air.
* Interface the PC with process and Data Acquisition System.
* Maintain Gauge (G1) pressure at 20 Psi by using air regulator knob.
* Position the Hand valve HV1 in partially open position.
* Patch CO & PV terminals through Patch chords.
* Switch ON the Data Acquisition System with PC.
* Invoke Process Control Software.
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Precautions:

1. Check the air inlet pressure to the process station as 100 – 150 psi.
2. Check whether the I/P converter inlet pressure is 20 psi.
3. Let hand valves HV2, HV4 and HV6 be fully closed position.
4. Keep the hand valves HV1 and HV3 connected tank 1 slightly opened.
5. Keep the outlet valve HV5 of tank 1 slightly opened.
6. Check whether there is any leakage in air path.
7. Switch off the mains before making the connections.

PI Controller Set Point---------- Kp----- Ki---------

Time in Sec Controller output in Process variable

percentage

EXERCISE:4

The response of the control loop is obtained for changes in the load variable.

PROCEDURE
By applying disturbance using corresponding control valve

PI Controller Set Point---------- Kp----- Ki---------

Time in Sec Controller output in Process variable
percentage

RESULT
Thus the closed loop response of pressure process for Servo and
Regulator operation was obtained.
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1907609 PROCESS CONTROL LAB DEPT OF EIE

PID IMPLEMENTATION ISSUES

Ex.No 6
Date:

AIM
To obtain the response of integral windup, anti integral windup, proportional kick,
anti proportional kick, derivative kick, anti derivative kick controllers using MATLAB
software.

APPARATUS REQUIRED
PC with MATLAB Software.

THEORY
Industrial PID control usually comes in a packaged form, and before attempting a
tuning exercise, it isinvaluable to understand how the PID controller has been implemented.
This usually means a detailedexamination of the manufacturer’s User Manual, and possibly a
meeting and discussion with thecontroller manufacturer’s personnel. Even then, many of the
manufacturer’s innovations in PID controlmay remain commercially sensitive, since for a
number of the problems arising in industrialPIDcontrolmanufacturers have introduced
customized features, and details of these may not be available tothe user or installer.
However, there are several common problems in the implementation of the terms ofthe PID
controller and it is useful to examine general solutions and terminology even if specific
industrialdetails are not available. Table 1.6 shows some common process control problems
and the appropriatePID implementation solution.To performwell with the industrial process
problems of Table 1.6, the parallel PID controller requiresmodification. In this section,
detailed consideration is given to the bandwidth-limited derivative term,proportional and
derivative kick, anti-windup circuit design and reverse acting control.
Table 1.6 Process control problems and implementing the PID controller.

Process control problem PID controller solution

Measurement noise Noise signals look like high frequency
Significant measurement noise on process signals
variable in the feedback loop. Replace the pure derivative term by a
Noise amplified by the pure derivative term. bandwidth limited derivative term.
This prevents measurement noise
amplification.

Proportional and derivative kick Move the proportional and derivative terms
P- and D-terms used in the forward path into feedback path.
Step references causing rapid changes and This leads to the different forms of PID
spikes in the control signal. controllers which are found in industrial
Control signals are causing problems or applications.
outages with the actuator unit.
Nonlinear effects in industrial processes Use anti-windup circuits in the integral term

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Saturation characteristics present in of the PID controller.

actuators. These circuits are often present and used
Leads to integral windup and causes without the installer being aware of their use.
excessive overshoot.
Excessive process overshoots lead to plant
trips as process variables move out of range.
Negative process gain Use the option of a reverse acting PID
A positive step change produces a wholly controller structure.
negative response.
Negative feedback with such a process gives
a closed-loop unstable process.

Proportional Kick

The Problem

Proportional kick is the term given to the observed effect of the proportional term in the usual
parallel PIDstructure on rapid changes in the reference signal.Recall first the parallel PI
controller structure as shown in Figure 1.15.

Using Figure 1.15, if the process is under control and the outputs of the system are steady
then the error signal E(s) =R(s) −Y(s)will be close to zero.Consider now the effect of a step
change in the reference input R(s).This will cause an immediate step change in E(s) and the
controller will pass this step change directly into the controller output Uc(s) via the
proportional term kPE(s). In these circumstances, the actuator unit will experience a rapidly
changing command signal that could be detrimental to the operation of the unit; the actuator
will receive a proportional kick. A typical sharp spike-like change in the control signal is seen

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in Figure 1.16, which shows output and control signals for thisproportional kick problem

Figure 1.16 Process output and control signals showing proportional kick effects due to unit
step change in reference signal at t = 1.

The Remedy

The remedy for proportional kick is simply to restructure the PI controller, moving the
proportional term into the feedback path, as shown in Figure 1.17.

Figure 1.17 Restructured PI controller removing proportional kick effects.

The step response and control signal for this modified PI structure typically look like those of
Figure 1.18. The spike on the control signal has been removed and the control signal is no
longer an aggressive- looking signal.Meanwhile, the process output signal is now a little
slower.

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Figure 1.18 Typical output and control signals for the restructured PI controller (removing
proportionalkick).

The equation for the restructured form of the PI controller is

This structure shows the integral (I) term to be on the setpoint error signal and the
proportional (P)term to be on the measured output or process variable signal. This has lead to
the industrial terminology where this structure is called I–P,meaning I on error and P on
process variable. Clearly, a new set of PID controllers is possible by restructuring the
controller in this way.

Derivative Kick
The Problem
Derivative kick is very similar to proportional kick (Section 1.3.2). Figure 1.19 shows
a parallel ID–Pcontrol system. This structure is read as “integral (I) and derivative (D) on
error and proportional (P)on process variable”. The derivative term is also the modified
derivative term from Section 1.3.1. Thuswith this particular form of three-term controller, the
proportional (P) on process variable has eliminatedproportional kick and the presence of the
modified derivative term has reduced high-frequencynoise amplification.

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If the output of the process is under control and steady then the setpoint error signal E(s)
=R(s) −Y(s)will be close to zero.A subsequent step change in the reference signal R(s) will
cause an immediate stepchange in the error signal E(s). Since the proportional term of the
controller operates on the processoutput,proportional kickwill not occur in the control signal;
however,the output of the derivative term

must be considered. Differentiating a step change will produce an impulse-like spike in the
control signal and this is termed derivative kick. Figure 1.20 shows typical output and control
signals for this problem.Note the very sharp spike-like change in the control signal.This
control signal could be driving a motor or a valve actuator device, and the kick could create
serious problems for any electroniccircuitry used in the device.
The Remedy
If the derivative term is repositioned so that the reference signal is not differentiated, then
derivativekick is prevented. The ID–P controller transfer function is

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Figure 1.20 Output and control signals showing derivative kick in the control signal (unit
step changein reference at t = 1).
and hence removing the operation of the derivative term on the reference gives

This new I-PD controller is shown in Figure 1.21. In this case, the I-PD terminology denotes
Integral term on error and Proportional and Derivative terms on process variable or measured
output.

Figure 1.21 Three-term I-PD control for preventing derivative kick (and proportional kick).

Typical step response and control signals for themodified I-PD control structure are shown in
Figure 1.22. In the figure, it can be seen that the spike on the control signal due to derivative
kick has been removed and that no proportional kick is present either.

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Figure 1.22 Typical output and control signals for the three-term I-PD controller showing
that derivativekick has been removed.
Integral windup in PID controller: Integral windup refers to the situation in a PID
controller where a large change in setpoint occurs (say a positive change) and the integral
terms accumulates a significant error during the rise (windup), thus overshooting and
continuing to increase as this accumulated error is unwound (offset by errors in the other
direction). The specific problem is the excess overshooting.This problem can be addressed
by:
• Initializing the controller integral to a desired value.
• Increasing the set point in a suitable ramp.
• Disabling the integral function until the to-be-controlled process variable (PV) has
entered the controllable region.
• Limiting the time period over which the integral error is calculated.
• Preventing the integral term from accumulating above or below pre-determined
bounds.
PROCEDURE
PROPORTIONAL KICK & ANTI PROPORTIONAL KICK STRUCTURE

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DERIVATIVE KICK &ANTI DERIVATIVE KICK STRUCTURE

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INTEGRAL WINDUP AND ANTIWINDUP STRUCTURE

RESULT

Thus the response of integral windup, anti-integral windup, proportional kick, anti-
proportional kick, derivative kick, anti-derivative kick action was studied using MATLAB
software.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

PID ENHANCEMENTS (CASCADE AND FEED-FORWARD

CONTROL SCHEMES)
Ex.No: 7
Date:
AIM
To study the perform Feed Forward Control System and Cascade Control
System using MATLAB software.

APPARATUS REQUIRED:
1. Matlab software
2. Printer

THEORY
FEED FORWARD CONTROL

A feed forward control law is used to compensate for the effect that
measured disturbance variable’s may have on the controlled variable. The basic
idea is to measure a disturbance directly and take control action to eliminate its
impact on the process output. How well the scheme will work depends on the
accuracy of the process and disturbance models used to describe the system
dynamics.

Feed forward control actually offers the potential for perfect control.
However, because of Plant Model Mismatch (PMM) and unmeasured /
unknown disturbances this is rarely achieved in practice. Consequently, feed
forward control is normally used in conjunction with feedback control. The
feedback controller is used to compensate for any model errors, unmeasured
disturbances etc. and ensure offset free control.
Feed forward control is always used along with feedback control because
a feedback control system is required to track set point changes and to suppress
unmeasured disturbances that are always present in any real process.
Feed forward control is distinctly different from open loop control
and teleoperator systems. Feed forward control requires a mathematical model
of the plant (process and/or machine being controlled) and the plant's
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relationship to any inputs or feedback the system might receive. Neither open
loop control nor teleoperator systems require the sophistication of a
mathematical model of the physical system or plant being controlled. Control
based on operator input without integral processing and interpretation through a
mathematical model of the system is a teleoperator system and is not considered
feed forward control.

Designing a Single Loop Control System with a PI Controller

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PROCEDURE
Feed Forward System
1. Draw a simulink program for a given transfer functions for feed forward
control system.
2. Find kp, Ti, Td values using auto tuning techniques.
3. Observe the responses for with and without feed forward system.

CASCADE CONTROL
A cascade control configuration can be used in cases where there are one
manipulated variable and more than one measurement. It is clear that with a
single manipulation only one output can be controlled. Therefore the
performance of single feedback control is improved by changing it into cascade
control which consists of two loops.
1) Primary loop
2) Secondary loop
In cascade control disturbances arising within the secondary loop are
corrected by the secondary controller before they can affect the value of the
primary controlled output. That is the closed loop response of the primary loop
is influenced by the dynamics of the secondary loop.
BLOCK DIAGRAM
Cascade control is mainly used to achieve fast rejection of disturbance before it
propagates to the other parts of the plant. The simplest cascade control system
involves two control loops (inner and outer) as shown in the block diagram
below.

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Controller C1 in the outer loop is the primary controller that regulates the
primary controlled variable y1 by setting the set-point of the inner loop.
Controller C2 in the inner loop is the secondary controller that rejects
disturbance d2 locally before it propagates to P1. For a cascade control system
to function properly, the inner loop must respond much faster than the outer
loop.

In this example, you will design a single loop control system with a PI
controller and a cascade control system with two PI controllers. The responses
of the two control systems are compared for both reference tracking and
disturbance rejection.

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MATLAB SIMULINK PROGRAM FOR CASCADE CONTROL SYSTEM

Result:

Thus the feedforward and cascade control system was implemented using
Matlab software.

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OPERATION OF ON-OFF CONTROLLED THERMAL PROCESS

Ex.No: 8
Date:

AIM
To obtain the operation of on-off controlled thermal process using filled
in system thermometer.

APPARATUS REQUIRED

1. Temperature process set up

2. stop watch

EXPERIMENTAL SET UP

DESCRIPTION

The temperature is converted in to a mechanical motion caused by pressure or

expansion, and this is measured. The instruments working with this principal
are much simpler ones. The thermal system of a filled system thermometer
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comprises the thermometer bulb, an expansion element, such as a Bourdon

tube, diaphragm, capsule or bellows and a capillary tube connecting the bulb
and the expansion element.

Study of on/off controller

PROCEDURE

1. Switch ON the trainer.

2. Adjust the required set temperature in standard temperature controller.
3. Put the sensors both the filled system thermometer temperature response bulb
as well as standard temperature controller thermocouple in to the furnace.
4. The digital display of temperature controller shows the furnace
temperature.The corresponding temperature is also displayed in the filled
system thermometer temperature dial.

MODEL GRAPH
.

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Tabular Column:

S.No Time in sec Temperature in 0C

.
◦C Temperature

◦C

RESULT
Thus the operation of on-off controlled thermal process using filled in system
thermometer was studied.

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DYNAMIC CHARACTERSITICS OF PROPOTIONAL PLUS

INTEGRAL PLUS DERIVATIVE CONTROLLER
Ex.No:9
Date:

AIM

To determine the dynamic characteristics of Proportional plus Integral plus

Derivative controller.

EQUIPMENT

1. Simulation kit

2. CROs

3. Patch chords
THEORY
Proportional control mode :

In this control mode, a smooth, linear relationship exists between the controller
output and the error.

For each value of error input, the controller gives out unique controller output
in one-to-one correspondence.

Proportional band :

The range of error to cover the 0% to 100% controller output is called the
proportional band, because the one-to-one correspondence exists only for
errors in this range. The Proportional mode can be expressed by

P =  ep

P = Kpep + p0

where

Kp = proportional gain between error and controller output (% per %)

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P0 = controller output with no error (%)

Characteristics of proportional mode :

1. If the error, ep is zero, then the controller output p = (Kp x 0) + P0  a

constant P0.
2. For every 1% of error, a correction of Kp percent is added or subtracted from
P0, depending on the sign of the error.
3. There is a band of error about zero of magnitude PB within which the output
is not saturated at 0% or 100%
Integral - control mode :

This mode is otherwise called as reset mode as the offset error in

proportional mode can be reset to zero. In the proportional mode, offset error
occurs because the controller cannot adapt to changing loads (external
conditions). The zero error output is a fixed value. The problem is eliminated
by the integral mode as the controller adapts to changing loads (external
conditions) by changing the zero - zero output.
Integral action is provided by summing the error overtime, multiplying
that sum by a gain, and adding the result to the present controller output. If the
error becomes positive or negative for an extended period of time, the integral
action will begin to accumulate and make changes to the controller output.
The integral mode is represented by the equation,

.
Derivative - control mode :

Derivative controller is otherwise called as rate controller or anticipating

controller.

The derivative mode is represented by the equation.

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where KD = Derivative gain

Fig. Experimental Setup

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TABULATION

P CONTROLLER

Propotional Rise Time Peak Peak Settling Offset (V)

Band (ms) Time (ms) Overshoot (V) Time (ms)

PI CONTROLLER

Propotional Rise Time Peak Time Peak Settling Time

Band (ms) (ms) Overshoot (V) (ms)

PID CONTROLLER

Propotional Rise Time Peak Time Peak Settling Time

Band (ms) (ms) Overshoot (V) (ms)

RESULT

Thus, the dynamic characteristics of Proportional plus Integral plus Derivative

controller were studied.
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1907609 PROCESS CONTROL LAB DEPT OF EIE

OPERATION OF NON-INTERACTING SYSTEMS

Ex.No 10 (a)
Date:

AIM:

To study the operation of Non Interacting System and find its transfer function.

APPARATUS REQUIRED:
1. Non Interacting system set up.
2. Stop Watch.

EXPERIMENTAL SET UP (NON INTERACTING SYSTEM):

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THEORY:
Consider the two tank system shown in experimental setup. The outlet flow
from tank1 discharges directly into the atmosphere before spilling into tank2
through valve R1. The flow through R1 depends only on h1 (head or level in
tank1) the variation in h2 (head or level in tank2) does not affect the transient
response occurring in tank1. This type of system is referred as non interacting
system.

Assuming the liquid to of constant density and the tanks having uniform cross
sectional area and the flow resistances to be linear, the energy mass balance
equations can be written as follows,

The mass balance equation of tank1 is

(q - q1) = A1(dh1/dt) --------------- (1)
The mass balance equation of tank2 is
(q - q1) = A2(dh2/dt) --------------- (2)
The flow head relationships for the two linear resistances are given by the
expressions,
q1 = h1/R1 ------------------------ (3)
q2 = h2/R2 ----------------------- (4)
Combining the equations (1) & (3) we get the transfer function for tank 1 as,
Q1(s)/Q(s) = 1/τ1s+1
Where,
Q1 = q1 - q1s
Q = q - qs
And τ1 = R1*A1
Combining the equations (2) & (4) we get transfer function for tank2 is,
H2(s)/Q1(s) = R2/ τ1s +1
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Where,
H2 = h2 - h2s
τ2 = R2*A2
The overall transfer function of non interacting system is,
H2(s)/Q(s) = R2/( τ2s+1) ( τ1s+1)

Where,
q=inflow to tank1 in LPH
A1=area of tank1
h1=output variable head of tank1
R1=resistance of valve in the outlet of tank1
q1=inflow to tank1 in LPH
A2=area of tank2
h2=output variable head of tank2
R2=resistance of valve in the head of tank2
q2=outflow of tank2 in LPH
τ1&τ2 =time constants of tank1, 2 respectively

VALVE POSITIONS:
1. Input valve of tank1 fully open
2. Valve between tanks 1&2 partially open
3. Output valve of tank2 partially open
4. All other valves closed

PROCEDURE:
1. Switch on the pump
2. Set the flow rate of liquid at desired flow rate(say 50LPH)by adjusting the
rotameter and wait till the level reaches a steady state in both the two tanks.
3. Record the initial flow rate and initial steady state levels in both tanks.
4. Once the level or reaches a steady state give a small step change in flow rate
and note down the heads h1&h2 of tanks1&2 till tanks reach another steady
state.
5. Note down the final steady state of head in both the tanks.
6. Find out the overall transfer function by finding τ1,τ2, R1, R2 & A1,A2.

TABULATION AND OBSERVATION:

Diameter of tanks (d1 in mm) = 92 mm
Diameter of tanks (d2 in mm) = 92 mm
Initial flow rate (LPH) =
Initial steady state level of tank1 (mm) =
Initial steady state level of tank2 (mm) =
Final flow rate (LPH) =
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Final steady state level of tank1 (mm) =

Final steady state level of tank2 (mm) =

S.No Time (t) sec Height of tank1(h1) mm Height of tank1(h2) mm

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MODEL GRAPH:

CALCULATION:
Area of tank (A1) = π/4(d1)2 in m2
Area of tank (A2) = π/4(d2)2 in m2

R1 = dH1/dQ = (Final steady state level of tank1) - ( Initial steady state level of
tank1)
(Final flow Rate - Initial flow rate)/3600

R2 = dH2/dQ = (Final steady state level of tank2)-( Initial steady state level of
tank2)
(Final flow Rate-Initial flow rate)/3600

τ1=A1*R1
τ2=A2*R2

Transfer function of tank1

Q1(s)/Q(s)=1/τ1s+1
Transfer function of tank2
H2(s)/Q(s)=R2/τ1s+1
Over all transfer function of non interaction system
H2(s)/Q(s)=R2/(τ1s+1)*(τ2s+1)

RESULT:
Thus the response of the non interacting system was studied and transfer
function was found.
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1907609 PROCESS CONTROL LAB DEPT OF EIE

OPERATION OF INTERACTING SYSTEM

Ex.No 10 (b)
Date:

AIM:
To study the operation of Interacting System and find its transfer function.

APPARATUS REQUIRED:
1. Interacting system set up.
2. Stop Watch.

EXPERIMENTAL SET UP (INTERACTING SYSTEM):

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THEORY:
The term interacting is referred as loading. To understand the effect of
interacting, a two tank system is considered in which, the second tank is said to
load the first tank.

The flow through R1 depends on the difference between h1&h2. To obtain the
transfer function of an interacting system, mass balance equation of the tank is
written. The balances on tank1&2 are same the flow head relationship for tank 1
is,
q1 = (h1 - h2)/R1 ---------- (a)

The mass balance equation of tank1 is

(q1 - q1) = A1(dh1/dt) ---------- (1)

The mass balance equation of tank2 is

(q1 - q2) = A2(dh2/dt) ---------- (2)

The flow head relationships for the two linear resistances are given by the
expressions,
q1 = h1/R1---------------------- (3)
q2 = h2/R2---------------------- (4)

At steady state, the flow equation is,

Qs - q1s = 0 -----------------------5
Q1s - q2s = 0 ---------------------6

By solving all the above equations using Laplace transform, we get the transfer
function,

H2(s)/Q(s) = R2/τ1τ2s2+ (τ1+τ2+A1R2)s+1

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Where,
q=inflow to tank1 in LPH
A1=area of tank1
h1=output variable head of tank1
R1=resistance of valve in the outlet of tank1
q1=inflow to tank1 in LPH
A2=area of tank2
h2=output variable head of tank2
R2=resistance of valve in the head of tank2
q2=outflow of tank2 in LPH
τ1 & τ2 =time constants of tank 1,2 respectively.
VALVE POSITIONS:
1. Input valve of tank1 fully open
2. Valve between tanks 1&2 partially open
3. Output valve of tank2 partially open
4. All other valves closed
PROCEDURE:
1. Switch on the pump
2. Set the flow rate of liquid at desired flow rate(say 50LPH)by adjusting the
rotameter and wait till the level reaches a steady state in both the two tanks.
3. Record the initial flow rate and initial steady state levels in both tanks.
4. Once the level or reaches a steady state give a small step change in flow rate
and note down the heads h1&h2 of tanks1&2 till tanks reach another steady state.
5. Note down the final steady state of head in both the tanks.
6. Find out the overall transfer function by finding τ1,τ2, R1, R2 & A1,A2.
TABULATION AND OBSERVATION:
Diameter of tanks (d1in mm) = 92 mm
Diameter of tanks (d2in mm) = 92 mm
Initial flow rate (LPH) =
Initial steady state level of tank1 (mm) =
Initial steady state level of tank2 (mm) =
Final flow rate (LPH) =
Final steady state level of tank1 (mm) =
Final steady state level of tank2 (mm) =

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S.No Time (t) sec Height of tank1(h1) mm Height of tank1(h2) mm

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MODEL GRAPH:

CALCULATION:
Area of tank (A1) = π/4(d1)2 in m2
Area of tank (A2) = π/4(d2)2 in m2

R1= dH1/dQ = (Final steady state level of tank1) - ( Initial steady state level of
tank1)
(Final flow Rate - Initial flow rate)/3600

R2 = dH2/dQ = (Final steady state level of tank2) - (Initial steady state level of
tank2)
(Final flow Rate - Initial flow rate)/3600
τ1 = A1*R1
τ2 = A2*R2
Transfer function of tank1Q1(s)/Q(s) = 1/τ1s+1

Find out the overall transfer function using the equation

H2(s)/Q(s) =R2/τ1τ2s2+(τ1+τ2+A1R2)s+1

RESULT:
Thus the response of the interacting system was studied and transfer function
was found.

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1907609 PROCESS CONTROL LAB DEPT OF EIE

STUDY OF AC DRIVES

Ex.No:11 (a)
Date:

AIM
To study the closed loop response of AC Motor.
APPARATUS REQUIRED

1. AC Motor Speed Control Trainer

2. Computer with Printer
3. Patch Chords.
BLOCK DIAGRAM

Error Manipulated
variable
S Final control
PI controller element Process
P
(Thyristor actuator (AC Motor)
MV
panel)
Process
variable
IR sensor

EXPERIMENTAL SET UP

AC Motor

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THEORY
PROCEDURE
1. Open 4T double PID MATLAB application Folder.
2. Double click the install batch file.
3. Double click the double PID MATLAB application file.
4.First Click the Connection button .If you click the connection button pop up window will
open which contain the connection succeed dialogue, then press ok button.
5.Then click check box of PID 1 ,after enter the Ti= ,PB= , Kd= ,Td= ,Ts= ,
Sepoint = ,output lower limit=0 ,output upper limit =100 and make sure PID action is
Reverse.
6. Click the configure settings make sure SP from Panel, MV = CH0, DAC = DAC 1
7. Click the Graph Settings Select PID 1 - SP(Black) , MV- CHO(Red) then click the OK
Button
8. Then if you click the Start Button the Response window will open.
9. Observe the response.
10 Change the different set point with the help of Pause and Resume button.
11 Again observe the response.
12. Apply the load disturbance with the help of the loading arrangement.
13. Again observe the response.
MODEL GRAPH

PV SP

Servo Operation Regulatory Operation

(Set point Changes) (Load Disturbance)
SP/PV in %

No of Samples

RESULT
Thus the closed loop response of ac motor using proportional integral
controller was obtained.

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STUDY OF DC DRIVES
Ex.No:11 (b)
Date:

AIM
To study the closed loop response of DC Motor.

APPARATUS REQUIRED
1. DC Motor Speed Control Trainer
2. Computer with Printer
3. Patch Chords.
BLOCK DIAGRAM
Manipulated variable

SP Final control
PI controller element Process
(Thyristor actuator
PV panel) (DC Motor)

IR sensor

EXPERIMENTAL SET UP

AC 230 V ,50Hz

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THEORY

PROCEDURE

1. Open 4T double PID MATLAB application Folder.

2. Double click the install batch file.
3. Double click the double PID MATLAB application file.
4.First Click the Connection button .If you click the connection button pop up
window will open which contain the connection succeed dialogue, then press ok
button.
5.Then click check box of PID 1 ,after enter the Ti= ,PB= , Kd=
,Td= ,Ts= , Setpoint = , output lower limit=0 ,output upper limit
=100 and make sure PID action is Reverse.
6. Click the configure settings make sure SP from Panel, MV = CH0, DAC =
DAC 1
7. Click the Graph Settings Select PID 1 - SP(Black) , MV- CHO(Red) then
click the OK Button
8. Then if you click the Start Button the Response window will open.
9. Observe the response.
10 Change the different set point with the help of Pause and Resume button.
11 Again observe the response.
12. Apply the load disturbance with the help of the loading arrangement.
13. Again observe the response

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MODEL GRAPH

PV SP

Servo Operation Regulatory Operation

(Set point Changes) (Load Disturbance)
SP/PV in %

No of Samples

RESULT
Thus the closed loop response of AC Motor using proportional integral
controller was obtained.

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DESIGN AND IMPLEMENTATION OF MULTILOOP PID CONTROLLER ON

THE SIMULATED MODEL OF A TYPICAL INDUSTRIAL PROCESS
Ex.No: 12
Date:
AIM

To design and implemented MIMO system using MATLAB software.

APPARATUS REQUIRED

1. Matlab software

2. Printer
THEORY
The Quadruple tank is a laboratory process with four interconnected tanks
and two pumps and two three port control valves as shown in figure. . The
process inputs are u1 and u2 (input voltages to pumps, 0-180V) and the outputs
are y1 and y2 (voltages from level measurement devices 0-2.5V). The target is
to control the level of the lower two tanks with inlet flow rates.
The quadruple tank system is a multi input multi output system that could
be used to analyze different control strategies. It is considered as a two double
tank process. The setup consists of four interacting tanks, two pumps and two
valves. Tank1 and tank4 are placed below tank 2 and tank3 to receive water
flow by action of gravity when manual valves are kept open.
To accumulate the outgoing water from tank1 and tank4 a reservoir is
present in the bottom. Every tank has a manual valve fitted to outlet. The action
of pumps (centrifugal) 1 and 2 is to suck water from the reservoir and deliver it
to tanks based on the control valve opening. The output of each pump is split
into two using a three way control valve. Pump 1 is shared by tank1 and tank3,
while pump 2 is shared by tank2 and tank 4. Thus each pump output goes to two
tanks, one lower and another upper diagonal tank and the flow to these tanks are
controlled by the position of the valve represented as γ. Due to gravitational
force the lower tanks receive water from their corresponding upper tanks. The
system aims at controlling the liquid levels in the lower tanks. The control valve
positions give the ratio in which the output from the pump is divided between
the upper and lower tanks.

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QUADRUPLE TANK PROCESS

Block diagram

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Output response

Procedure:

1. Write a Simulink program for a given transfer function of MIMO system.

2. Tune the process for tank 1 and tank 2 using IMC tuning techniques to find
PID values.

3.Change the setpoint and load disturbance for servo and regulator operation.

4.Observe the responses for tank 1 &2.

RESULT

Thus the MIMO system was implemented using MATLAB software.

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ADDITIONAL EXPERIMENTS

SIMULATION OF LUMPED /DISTRIBUTED PARAMETER SYSTEM

Ex.No :13
Date:
AIM:
To simulate Lumped and Distributed Parameter system using
MATLABsoftware.

APPARATUS REQUIRED:
1.MATLAB software
2.Printer
THEORY

Lumped Parameter System

Consider a perfectly insulated, well-stirred tank where a hot liquid stream

at 60ºC is mixed with a cold liquid stream at 10ºC (Shown Figure below). The
well mixed assumption means that the fluid temperature in the tank is uniform
and equal to the temperature at the exit from the tank. This is an example of a
lumped parameter system, since the temperature docs not vary with spatial
position.

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Example Problem

A tank contains 3m3of a solution consisting of 300 kg of sugar dissolved

in water. Pure water is pumped into the tank at the rate of 15 L/s, and
the mixture(kept uniform by stirring) is pumped out at the exact same
rate. How long willit take for only 30 kg of sugar to remain in the tank?

Sugar concentration tank.

Solution

Assume an isothermal process and a perfect mixing tankAfter dividing

both sides of the equation by ρ, the material balance equationis reduced
to

The inlet and exit volumetric flow rates are equal; hence:

accordingly,

The concentration of sugar in the tank is determined by component

massbalance. The initial concentration of sugar in the tank is c(0):

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The final concentration is cf :

Component Balance

The component balance of sugar (A) equation:

Since the feed stream contains fresh water, the feed concentration
ofsugar (A) is zero; cf = 0:

Differentiation of the left side of the equation can be done via

productrule:

Since volume of the tank from the total mass balance is constant,
theequation is reduced to:

Divide both sides of the equation by V:

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Rearranging and integrating both sides of the equation, we have:

Which leads to:

Substitute the values of known parameters in the integrated equation:

Solve for time (the time required to achieve the final concentration):
t = 460.517 s
The MATLAB/Simulink solution of the ODE is shown in Figure

SIMULINK BLOCK DIAGRAM:

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OUTPUT RESPONSE

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PROCEDURE
1. Develop a Simulink program for a lumped &distributer parametersystem.
2. Observe the response for the same.

RESULT

Thus the lumped and distributed parameter system was implemented using
MATLAB software.
MATHEMATICAL MODEL OF A TYPICAL INDUSTRIAL PROCESS USING
NONPARAMETRIC IDENTIFICATION METHODS

Ex.No 14
Date:

AIM:
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To simulate any industrial process using non parametric identification

method using MATLAB software.

APPARATUS REQUIRED:
1.MATLAB software
2.Printer

THEORY
System Identification is the study of Modeling dynamic Systems from
experimental data.

The System Identification Procedure

1. Collect Data. If possible choose the input signal such that the data has
maximally informative.

2. Choose Model Structure. Use application knowledge and engineering

intuition. Most important and most difficult step (don’t estimate what you know
already)

3. Choose Identification Approach. How would a good model look like?

4. Do. Choose best model in model structure (Optimization or estimation)

5. Model Validation. Is the model good enough for our purpose?

System Identification Methods

• Non-parametric Methods (SI).

The results are (only) curves, tables, etc. These methods are simple to apply.
They give basic information about e.g. time delay, and time constants of the
system.

• Parametric Methods (SI)

The results are values of the parameters in the model. These may provide better
accuracy (more information), but are often computationally more demanding.

PROCEDURE

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PROCEDURE

1. Draw a tangent line in the graph.

2. Find k,τ,td from a graph.from the values we get transfer function model.
3. After that find the controller values using k,τ,td in cohen coon tuning
method.
4. Then we write a coding for a close loop system.
5. Observe the close loop response of P, PI and PID controllers.

K=B/A
𝜏 = B/Slope
Slope= opposite / adjacent
td=Delay Time

RESULT

Thus the non parametric identification method used for hair dryer
process was implemented in MATLAB software.

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VIVA VOCE - Questions &answers

1. List any four objectives of process control.

Suppressing the influence of external disturbances, optimizing the performance
and stability of the process, increasing the productivity, Cost effective.

2. Define process
Any system comprised of dynamic variables usually involved in manufacturing
and production operations. Process is defined as an operation or series of
operations performed on the material during which some materials are placed in
more useful state.

3. What is manipulated variable?

It is a variable, which is altered by the automatic control equipment so as to
keep the variable under control and make it conform to the desired value.

4. Define Controlled variable

It is the variable, which is to be maintained precisely at set value

5. What do you mean by self-regulation?

It is the tendency of the process to adopt a specific value of controlled variable
for nominal load with no control operations.

6. Why do we need mathematical modeling of process?

To analyze the behavior of the process. The physical equipment of the chemical
process we want to control has not been constructed. Consequently we cannot
experiment to determine how the process reacts to various inputs and therefore
we cannot design the appropriate control system. If the process equipment needs
to be available for experimentation the procedure is costly. Therefore we need a
simple description of how the process reacts to various inputs, and this is what
the mathematical models can provide to the control designer.

7. Name different test inputs.

Step, Ramp, Impulse, Sinusoidal, Parabolic inputs

8. Name a process giving inverse response.

Drum boiler system, in which the flow rate of the cold feed water is increased
by a step the total volume of the boiling water and consequently the liquid level
will decrease for a short period and then it will start increasing.
9. Define interacting system and give an example.
When two level tanks are connected in series, the dynamic behaviour of one
tank affects the other tank and vise versa.

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10. A tank operating at 10ft head, 51pm outflow through a valve and has a cross
section area of 10 sq ft. calculate the time constant.
T=RA, R=H/Q=10/(5X5.885X10-4)

11. Write any two characteristics of first order process modeling.

Smaller the value of time constant, the steeper the initial response of the
system.
A first order lag process is self-regulating the ultimate value of the response
equal to Kp (steady state gain of the process) for a unit step change in the input.

13. Distinguish between continuous process and batch process.

A process in which the materials or work flows more or less continuously
through a plant apparatus while being treated is termed as continuous process.
The problem of continuous process is due to load changes. (e.g.) storage vessel
control.
A process in which the materials or work are stationary at one physical location
while being treated is termed as batch process. (e.g.) furnace.

14. Explain the function of controller.

Determines the value of the controlled variable, compares the actual value to the
desired value, determines the deviation and produces the counteraction
necessary to maintain the smallest possible deviation between desired value and
actual value.

15. What is the operation of the final control element?

Final control element is the mechanism, which alters the value of the
manipulated variable in response to the output signal from the automatic control
device.

16. Define Process control.

Controlling the process by measuring a variable representing the desired state of
the product and automatically adjusting one of other variables of the process.

17. List the two types of process control.

Direct process control – Controlled variable directly indicates the performance
of the process. Eg. Water heater system
Indirect Process control – Controlled variable indirectly indicates the
performance of the process. Eg. Annealing

18. What is Servo operation and Regulator operation?

If the purpose of the control system is to make the process follow the changes in
set point as quick as possible, then it is servo operation.

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In many of the process control applications, the purpose of control system is to

keep the output (controlled variable) almost constant in spite of changes in load.
Mostly in continuous processes the set point remains constant for longer time.
Such an operation is called regulator operation.

19. What is mathematical modeling?

Set of equations that characterize the process is termed as Mathematical Model.
The activities leading to the construction of the model is called mathematical
modeling.

20. Define a non-interacting system.

If the dynamic behaviour of one tank is affected by the other tank, and the
reverse is not true, then it is called as non-interacting system. Eg. Two level
tanks connected in parallel. Here the liquid heads are independent of each other.

22. Mention two drawbacks of derivative action.

(i) The output of controller is zero at constant error condition.
(ii) It will amplify the noise present in the error signal.

23. What are the steps involved to design a best controller?

Define appropriate performance criterion (ISE, IAE, ITATE).
Compute the value of the performance criterion using a P, PI, or PID controller
with the best setting for the adjusted parameters Kp, Ti, Td.
Select controller, which gives the best value for the performance criterion.

24. Define proportional control mode

A controller mode in which the controller output is directly proportional to the
error signal. P=Kpep+P0 where, P-controller output, Kp - Proportional gain, ep -
Error in percent of variable range, P0 – Controller output with no error (%).

25. Define proportional band.

The range of error to cover the 0% to 100% controller output is called the
proportional band (PB) because the one-to-one correspondence exists only for
errors in this range.

26. Write the relation ship between proportional band and proportional gain.
The reciprocal of gain expressed, as a percentage is called proportional band.
PB=100/Kp.

27. Define offset.

It is the steady state deviation (error) resulting from a change in value of load
variable.

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28. Define error (deviation)?

It is the difference at any instant between the values of controlled variable and
the set point. E = S.P - P.V

30. Why is the electronic controller preferred to pneumatic controller?

Electronic signals operate over great distance without time lags. Electronic
signals can be made compatible with digital controllers. Electronic devices can
be designed to be essentially maintenance free. Intrinsic safety techniques
eliminate electrical hazards. Less expensive to install. More energy efficient.
Due to the above said properties electronic controllers are preferred to
pneumatic controller.

32. Write any two limitations of single speed floating control.

The present output depends on the time history of errors and such history is not
known, the actual value of controller output floats at an undetermined value. If
the deviation persists controller saturates at either 100% or 0% and remain there
until an error drives it towards opposite extreme.

34. Why derivative mode of control is not recommended for a noisy process?
The series capacitor in the derivative controller will amplify the noise in the
error signal.

35. Define integral windup?

The integral term of a P+I controller causes its output to continue changing as
long as there is a non-zero error. Often the errors cannot be eliminated quickly,
and given enough time this P+I mode produces larger and larger values for
integral term, which in tern keeps increasing control action until it is saturated.
This condition is called integral windup and occurs during manual operational
changes like shutdown, changeover etc.

36. What are the two modes of controller?

Discontinuous and continuous modes are the two modes of controller.

37. Define Discontinuous mode of controller.

In discontinuous mode, the controller command initiates a discontinuous change
in the controller parameter. Eg. Two position mode controller (ON-OFF), Multi
position mode controller, single speed and multiple speed controller

38. Define Continuous mode of controller.

In continuous mode, smooth variation of the control parameter is possible.
Eg. Proportional, integral, Derivative and composite control modes

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40. Define cycling.

Oscillations of error about zero is called cycling. This means the variable is
cycling above and below the set point value.

41. Write Ziegler- Nicolas turning formulae.

Mode Kp Ti (Min) Td (Min)
Proportional Ku / 2 - -
Proportional – Integral Ku / 2.2 Pu / 1.2 -
Proportional – Integral – Derivative Ku / 1.7 Pu / 2 Pu / 8
Where,
Ku – Ultimate gain, Pu – Ultimate period of sustained cycling.

42. Define controller turning.

Deciding what values to be used for the adjusted parameters of the controller is
called controller turning.

43. What is reaction curve?

Controller is disconnected from the final control element. The process reaction
curve is obtained by applying a step change, which actuates the final control
element, and plotting the response of the output with respect to time.

44. What performance criterion should be used for the selection and turning of
Controller?
1. Keep the maximum error as small as possible.
2. Achieve short settling time.
3. Minimize the integral of the errors until the process has settled to its
desired set Point.

45. Define ultimate gain.

The maximum gain of the proportional controller at which the sustained
oscillations occur is called ultimate gain (Ku).

46. What is ITAE and when to go for it?

ITAE means Integral Time Absolute Error. To suppress the errors that persist
for long time, the ITAE critertion will tune the controllers better because the
presence of large t amplifies the effect of even small errors in the value of the
integral.

47. What are the parameters required to design a best controller?

Process Parameters (K, t), Controller parameters (Kp, Ti, Td), and
performance creation (ISE, IAE, IATE)
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48. Write the practical significance of the gain margin.

1. It constitutes a measure of how far the system is the brink of instability.
2. Higher the gain margin (above the value of one), the higher the safety
factor we use for the controller turning.
3. Typically, a control designer synthesizes a feedback system with gain
margin larger than 1.7. This means that amplitude ratio can increase 1.7
times above the design value before the system becomes unstable.
.
49. Why is it necessary to choose controller settings that satisfy both gain
margin and phase margin?
The gain margin and Phase margin are the safety factors, which is used for the
design of a feedback system. Beyond the phase margin and gain margin the
system goes to unstable position.

51. Name the time integral performance criteria measures.

1. Integral of the Square Error (ISE),
2. Integral of the Absolute value of Error (IAE),
3. Integral of Time weighted Absolute Error.

52. Define Integral Square Errors (ISE).

ISE = ∫ e2 (t) dt. Limit 0 to ∞
If we want to strongly suppress large errors, ISE is better than IAE because
errors are squared and contribute more to the value of integral.
53. Define Integral Absolute Errors (IAE)
IAE = ∫ |e2 (t) | dt. Limit 0 to ∞.
If we want to suppress small errors, IAE is better than ISE because when we
square small numbers, they even become smaller.
54. Define Integral of Time weighted Absolute Error (ITAE)
ITAE = ∫t e2 (t) dt. Limit 0 to ∞
To suppress errors that persist for long times, ITAE criterion will tune the
controllers better because the presence of large t amplifies the effect of even
small errors in value of integral.

55. Define One-quarter decay ratio.

It is a reasonable trade off between fast rise time and reasonable settling time.

56. Give the satisfactory control for gas liquid level process.
Proportional Control is the satisfactory control for liquid level process.

57. Give the satisfactory control for gas pressure process.

Proportional Control is the satisfactory control for liquid level process.

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58. Give the satisfactory control for vapour pressure process.

PI Control is the satisfactory control for vapour pressure process having fast
response.

59. Give the satisfactory control for temperature process.

PID Control is the satisfactory control for temperature process.

60. Give the satisfactory control for composition process.

PID Control is the satisfactory control for composition process.

61. Define ratio control.

Ratio control is a special type of feed forward control where two disturbances
are measured and held in a constant ratio to each other.

62. Define cascade control.

In the scheme there will be two controllers namely primary controller and
secondary controller. The output of the primary controller is used to adjust the
set point of a secondary controller, which in turn sends a signal to the final
control element. The process output is fed back to the primary controller and a
signal from an intermediate stage of the process is fed back to the secondary
controller.

63. When cascade control will give improved performance than conventional
feedback control?
In conventional feedback control, variations in flow not dictated by the
controller are caused by changes in pressure differential at the valve, which in
turn result from changes in pressure of supply, changes in downstream pressure
and so on. These changes are difficult to counteract since they must carry
through the process before they are detected in the controller. Supply changes
sometimes occur suddenly or over a wide range and deviation may become
excessive before a new balance of conditions can be established. Such
conditions are overcome by cascade control.

64. Explain the purpose of cascade control for heat exchangers?

In heat exchangers, the control objective is to keep the exit temperature of
stream at a desired value. But the flow rate of the inlet stream creates the low
disturbance throughout the process. The secondary loop is used to compensate
the flow rate of the inlet stream.

65. What is mean by auctioneering control?

Auctioneering control configurations select among several similar
measurements the one with the highest or lowest value and feed it to the

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controller. Thus it is a selective controller, which possesses several measured

outputs and one manipulated input.

66. Give any two types of selective control system.

1. Override control. 2. Auctioneering control.

67. What is limit switch?

In some cases it is necessary to change from the normal control action and
attempt to prevent a process variable from exceeding an allowable upper or
lower limit. This can be achieved by the use of special types of switches called
limit switches.

68. Mention the types of limit switches.

1. High Selector Switch (HSS), 2. Low Selector Switch (LSS).

69. What is HSS?

High Selector Switch (HSS) is a limit switch, which is used whenever a process
variable should not exceed an upper limit.

70. What is LSS?

Low Selector Switch (LSS) is a limit switch, employed to prevent a process
variable from exceeding a lower limit.

71. What is override control?

During the normal operation of the plant or during its startup or shutdown it is
possible that dangerous situations may arise which may lead to destruction of
equipment and operating personnel. In such cases it is necessary to change from
the normal control action and attempt to prevent a process variable from
exceeding an allowable upper or lower limit. This can be achieved by the use of
special type switches called limit switches (HSS and LSS). This type of
protective control is called override control.

72. What is split-range control?

A single process output can be controlled by co-coordinating the actions of
several manipulated variables all of which have same effect on the
controlled output. Such systems are called split-range control systems.

73. Differentiate split-range control and selective control.

Split-range control system involves one measurement and more than one
manipulated variables but selective control system involves one manipulated
variables and several controlled outputs.

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74. Why are fuel and air sent at a specified ratio into a combustion chamber?
To obtain the most efficient combustion.

75. What are decouplers?

The special element introduced in a system to cancel the interaction effects
between the two loops and thus render two non-interacting control loops is
called decouplers

76. When is inferential control used?

It is used in some cases where the controlled variable cannot be measured
directly and the influence of the disturbance cannot be measured.

77. What are the advantages of feed forward controller?

1. Acts before the effect of disturbance has been felt by the process.
2. It is good for slow systems. (Multi capacity or with significant dead time)
3. It does not introduce instability in the closed loop response.

78. What are the disadvantages of feed forward controller?

1. Requires identification of all possible disturbances and their direct
measurement
2. Cannot cope with unmeasured disturbances.
3. Sensitive to process parameter.
.
79. What are the advantages of feedback controller?
1. It does not require identification and measurement of disturbance.
2. It is insensitive to modeling errors.
3. It is insensitive to parameter changes.

80. What are the disadvantages of feedback controller?

1. It is unsatisfactory for slow processes with significant dead time.
2. It may create instability in the closed loop response
3. It waits until the effect of the disturbances has been felt by the process
before control action is taken.

81. What is flashing in control valve?

When the valve outlet pressure P2 is less than or equal to the vapour pressure of
the process liquid, some of the liquid flashes into vapour and stays in vapour
phase as it enters the downstream piping. The specific volume increases as
liquid changes to vapour.
The resulting high velocities can erode material.

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82. When do you use a valve positioner?

If the diaphragm actuator does not supply sufficient force to position the valve
accurately and overcome any opposition that flowing conditions create a
positioner may be required.

83. Give two examples for electric actuators.

Motor, Solenoids.

84. What is the need of I/P converter in a control system?

In some process loop the controller is electronic and the final control element is
pneumatic one. To interconnect these two we need a device that should linearly
converts electric current in to gas pressure (4 – 20mA to 3 - 15psi). Such device
is called I/P converter.

85.Why installed characteristics of a control valve are different from inherent

characteristics?
Inherent characteristics are which the valve exhibits in the laboratory condition
where the pressure drop is held constant. Installed or resultant characteristics
are the relationship between flow and stroke when the valve is subjected to
pressure conditions of the process.

86. Explain the function of pneumatic transmission lines.

Used to transmit the input signals into standard instrumentation pneumatic
output signals (3 to 15 psi or 20 to 100 KPa).

88. What is meant by cavitation in control valve?

When a liquid enters a valve and the static pressure at the vena contracta drops
to less than the fluid vapor pressure and the recovering to above fluid vapour
pressure, this pressure recovery causes an implosion or collapse of the vapour
bubbles formed at the vena contracta. This condition is called cavitation

89. What is “equal percentage” in the equal percentage valve?

A given percentage change in stem position produces an equivalent change in
flow that is an equal percentage.

90. What are the types of control valve characteristics?

1. Inherent characteristics,
2. Installed characteristics.

92. What is “quick opening”( decreasing sensitivity type valve) control valve?
Small movement of the valve stem results in maximum possible flow rate
through the valve.

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93. What is “Linear” control valve?

This type of valve has a flow rate that varies linearly with the stem position.

94. Define Control Valve sizing.

The proper sizing of the control valve is important because of the effect on the
operation of the automatic controller.
Q = Cv.√ (Δp/Sg)
Q-Flow rate
Cv-Valve coefficient
Δp - pressure difference across valve.
Sg - Specific gravity of liquid.

95. Name any one final control element.

Control Valve.

96. What is the function of control valve in a flow control system?

The function of control valve in flow control system is to regulate the flow.

97. Name one application of electrical actuators.

Solenoid coil used to change gears.

98. Name the two types of plugs.

Single-seated and double-seated plug type control valves.

99. Define Range ability.

It is the ratio of maximum controllable flow to minimum controllable flow.
R = Qmax / Qmin

100. What is rotating shaft type control valves?

Control valves in which the restriction is accomplished by the rotation of a plug
or vane may be called rotating shaft type.
1. Rotating-plug valves
2. Butterfly valves
3. Louvers.
101. What is time – domain analysis?
If the response of a dynamic system to an input is expressed as a function of
time it is time-domain analysis. It is possible to compute the time response of a
system if the nature of input and the mathematical model of the system are
known.

102. What are the components of time response in any system?

The time response of any system has two components: transient response and
the steady-state response. Transient response is dependent upon the system
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poles only and not on the type of input. It is therefore sufficient to analyze the
transient response using a step input. The steady-state response depends on
system dynamics and the input quantity. It is then examined using different test
signals by final value theorem.

103. What are standard test signals? Give examples.

Usually, the input signals to control systems are not known fully ahead of time.
For example, In a radar tracking system, the position and the speed of the target
to be tracked may vary in a random fashion. It is therefore difficult to express
the actual input signals mathematically by simple equations. The characteristics
of actual input signals are a sudden shock, a sudden change, a constant velocity,
and constant acceleration. The dynamic behavior of a system is therefore judged
and compared under application of standard test signals – an impulse, a step, a
constant velocity, and constant acceleration. Another standard signal of great
importance is a sinusoidal signal.
Standard test signals

a) Step signal: r (t ) = Au (t ).
b) Ramp signal: r (t ) = At ; t  0.
c) Parabolicsignal:
r (t ) = At 2 / 2; t  0.
d) Impulse signal: r (t ) =  (t ).

104. What are the transient-response characteristics of a control system?

The transient-response characteristics of a control system to a unit step input,
includes the following:
t
1. Delay time, d
t
2. Rise time, r
t
3. Peak time, p
M
4. Peak overshoot, p
t
5. Settling time, s
e
6. Steady-state error, ss

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t
1. Delay time, d : It is the time required for the response to reach 50% of the
final value in first attempt.
t
2. Rise time, r : It is the time required for the response to rise from 0 to 100%
of the final value for the underdamped system.
t
3. Peak time, p : It is the time required for the response to reach the peak of
time response or the peak overshoot.
t
4. Settling time, s : It is the time required for the response to reach and stay
within a specified tolerance band ( 2% or 5%) of its final value.
Mp
5. Peak overshoot, : It is the normalized difference between the time
response peak and the steady output and is defined as,
c(t p ) − c()
%M p = 100%
c ( )
e
6. Steady-state error, ss : It indicates the error between the actual output and
desired output as ‘t’ tends to infinity.
ess = lim[r (t ) − c(t )]
t → .
105. What is the advantage of state – space analysis?
1) It can be used on systems having more than one feedback loop,
2) It can be used on systems having multiple inputs and outputs,
3) It helps in finding out a set of feedback parameters that place the system
poles at any desired location, if all the state variables are available for
measurement (observable state variables).

106. What is a feed back control system?

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A basic feedback control system block diagram is shown in Figure below. The
Laplace operator s is a complex variable equal to σ + jω, which provides
information about damping and oscillatory characteristics of a system. The
reason for operating in the Laplace domain is that many complicated dynamic
operations in the time domain become much simpler mathematical operations in
the Laplace domain. For example, when a signal is input to a block, the time
domain operation consists of a convolution (i.e. a mathematical operation
involving integration of time-shifted functions) between the input and the
impulse response of the block. On the other hand, when the signal and the block
are transformed to the Laplace domain, the transformed signal and the transfer
function of the block are simply multiplied together to provide the output. To
simplify this process, one can use transform pairs available in Laplace transform
tables as well as a number of stability theories that have been developed. It turns
out that it is easier to analyze and interpret a control system’s dynamic
characteristics in the Laplace than the time domain. When the analysis of the
system’s characteristics has been completed, the final response can be obtained
simply by inverse transformation.

In Figure shown above, E(s) or the difference between the input X(s) and the
product of the output and feedback gain, Y(s) * H(s), serve as the driving signal
for the forward-loop gain G(s). It can be shown that the overall transfer function
is given by

For H(s) = 1, which is usually the case, F(s) becomes,

The above equation is the basis for much of control systems theory. It can be
seen that if G(s)*H(s) equals −1, F(s) would go to infinity and the system would
become unstable. This can occur if the gain and latency values embedded in
G(s), H(s) are too large. Indeed, much of control systems theory involves the

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determination of the conditions for instability and the system modifications

needed to avoid arriving at these unstable conditions.

107. State final value theorem.

Final value theorem is another useful control system property, where the steady-
state time domain response is given by:

The theorem states that the steady-state time domain step response can be
obtained directly from the transfer function. For example, for a unit step input
X(s) = 1/s, and transfer function
F(s) = 2/(s + 3), the steady-state time domain output value is,

The final value theorem forms the basis for static analysis of feedback control
systems.

108. Why is Control needed in any process?

Chemical plants are intended to be operated under known and specified
conditions. There are several reasons why this is so:
a) Safety:
Formal safety and environmental constraints must not be violated.
b) Operability:
Certain conditions are required by chemistry and physics for the desired
reactions or other operations to take place. It must be possible for the plant to be
arranged to achieve them.
c) Economic:
Plants are expensive and intended to make money. Final products must meet
market requirements of purity, otherwise they will be un-saleable. Conversely
the manufacture of an excessively pure product will involve unnecessary cost. A
chemical plant might be thought of as a collection of tanks in which materials
are heated, cooled and reacted, and of pipes through which they flow. Such a
system will not, in general, naturally maintain itself in a state such that precisely
the temperature required by a reaction is achieved, a pressure in excess of the
safe limits of all vessels be avoided, or a flow rate just sufficient to achieve the
economically optimum product composition arise.

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