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21CH58P
PROCESS CONTROL LABORATORY
Lab Manual
2024-25

(2021 Regulation)
 Course code 21CH58P Semester IV
Category PROFESSIONAL CORE COURSE (PCC) L T P C
Course Title PROCESS CONTROL LABORATORY 0 0 4 2

COURSE OBJECTIVES:

 To determine experimentally the methods of controlling the processes includingmeasurements

using process simulation techniques..
.
PRE REQUISITE:

 Process Instrumentation, Dynamics and Control

LIST OF EXPERIMENTS:

1. Response of first order system

2. Response of second order system
3. Response of Non-Interacting level system
4. Response of Interacting level system
5. Open loop study on a thermal system
6. Closed loop study on a level system
7. Closed loop study on a flow system
8. Closed loop study on a thermal system
9. Tuning of a level system
10. Tuning of a pressure system
11. Tuning of a thermal system
12. Flow co-efficient of control valves
13. Characteristics of different types of control valves
14. Closed loop study on a pressure system
15. Closed loop response of cascade control system
16. Optimum Controller Tuning using Ziegler Nichols method

Total: 60 Periods

OUTCOME:

Students would gain knowledge to develop and use of right type of control dynamics for process
control under different operative conditions. They also learn to determine experimentally various
controlling process measurements using process simulation techniques.
 LIST OF EQUIPMENTS:

Quantity
Sl.No Description of Equipment
required
.
1 U tube manometer with controller 1
2 Interacting Tank 1
3 Non Interacting Tank 1
4 Open loop control system 1
5 Closed loop control system 1
6 ON/OFF controller 1
7 Control valve characteristics 1
8 Pressure Tuner 1
9 Temperature Tuner 1
10 Proportional Controller 1
11 Flow Transmitter 1
12 Level Transmitter 1
13 Cascade control system 1

COURSE OUTCOMES:

At the end of the course, the student will be able to:

CO Knowledge
Course Outcomes
No Level
Develop and use of right type of control dynamics for process control
CO1 K3
under different operative conditions.
Understand the response of open loop and closed loop systems with
CO2 K3
different control configurations.

COURSE OUTCOMES MAPPING WITH PROGRAM OUTCOMES AND PROGRAM

SPECIFIC OUTCOMES:

CO. P P P P P P P P P P P P PS PS PS
No. O O O O O O O O O O O O O O O
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
C508.1 3 2 - - 2 - - - - - - - 2 2 2
C508.2 3 2 - - 2 - - - - - - - 2 2 2

Note: 3 – Substantial (Highly relevant)

2 – Moderate (Medium)
1 – Slight (Low)

KI - Understand; K2 - Remember; K3 – Analyse; K4 – Apply; K5 – Evaluate; K6 – Create

 21CH58P-PROCESS CONTROL LABORATORY

S.
Name of the Experiment Page No
No
1

10

11

12

13

14
15
16

17
Expt:

Date:

CHARACTERISTICS OF CONTROL VALVES

AIM

1. To Study the characteristics of ON/OFF, Linear and Equal Percentage control valves

2. To calculate the Gain and valve coefficients for above valves

3. To calculate the sensitivity and rangeability for above valves

CONTROL VALVE AND ITS COMPONENTS

The control valve consists of two major components

A. Actuator.
B. Valve.

The actuator is made of the following components

1. Flexible diaphragm.
2. Spring [usually] and spring tension element [range location element].
3. Plate, Stem and locknut.
4. Housing.

Control Valve Trainer

The valve is made of the following components

1. Body.

2. Plug.
3. Stem.

4. Pressure tight connection.

THEORY

A control valve is the usual mechanism for adjusting the input of the process control system. In most
industrial process control system, control valve is the final control element. It is used to control flow of
fluid viz. air, water, gas, steam, coolant water, vacuum, contaminated or viscous fluid, mild acids, alkalis
[non injurious to body, stem, seating and gland packing. The control valve is essentially a variable
resistance to the flow of a fluid, in which the resistance and therefore the flow can be changed by a signal
from a process controller.
The control valve consists of an actuator and a valve. The valve itself is divided into the body and the
trim. The body consists of housing for mounting the actuator and connections for attachment of the valve
to a supply line and a delivery line. The trim, which is enclosed within the body, consists of a plug, a
valve seat, and a valve stem.

The actuator moves the valve stem as the pressure on a spring-loaded diaphragm change. The stem
moves a plug in a valve seat in order to change the resistance to flow through the valve. When a valve
is supplied by the manufacturer, the actuator and the valve are attached to each other to form one unit.
For most actuators, the motion of the stem is proportional to the pressure applied on the diaphragm. In
general, this type of actuator can be used for functions other than moving a valve stem. For example, it
can be used-to adjust dampers, variable speed drives, rheostats, and other devices. As the pressure to the
valve varies over its normal range of operation (3 to 15 psig) the range of motion of the stem varies from
a fraction of an inch to several inches depending on the size of the actuator. Manufacturers provide a
range of actuators for various valve sizes.

The valves available vary over a wide range of sizes. The size is usually referred to by the size of the
end connectors. For example, a one-inch valve would have connectors (threaded or flanged) to fit into a
one-inch pipe line. In general, the larger the valve size the larger the flow capacity of the valve. For the
control valve shown in Fig. 1, an increase in signal pressure above the diaphragm exerts a force on the
diaphragm and back plate, which causes the stem to move down; this causes the cross-sectional area for
flow between the plug and the seat to decrease, thereby reducing or throttling the flow. Such valve action
as shown in Fig.1 is called pressure-to-close action. The reverse action shown in Fig.2 is pressure-to-
open, can be accomplished by designing the actuator so that pressure is applied to the underside of the
diaphragm, for which case an increase in pressure to the valve raises the stem. An alternate method to
reverse the valve action is to leave the actuator as shown in Fig.1 and to invert the plug on the stem and
place it under the valve seat.

The valve shown in Fig.1 is single-seated, meaning the valve contains one plug with one seating surface.
For a single-seated valve, the plug must open against the full pressure drop across the valve. If the
pressure drop is large, this means that a larger, more expensive actuator will be needed. To overcome
this problem, valves are also constructed with doubleseating as shown in Fig. 3. In this type valve, two
plugs are attached to the valve stem and each one has a seat. The flow pattern through the valve is
designed so that the pressure drop across the seat at A tends to open the plug and the pressure drop across
the seat at B tends to close the plug. This counterbalancing of forces on the plugs reduces the effort
needed to open the valve with the result that a smaller, less expensive actuator is needed. In a double-
seated valve, it is difficult to have tight shut-off. If one plug has tight closure, there is usually a small
gap between the other plug and its seat. For this reason, single-seated valves are recommended if the
valve is requited to be shut tight. In many processes, the valve is used for throttling flow and is never
expected to operate near its shut-off position. For these conditions, the fact that the valve has a small
leakage at shut-off position does not create a problem.

CONTROL VALVE CHARACTERISTICS

LINEAR CHARACTERISTICS

For studying the linear characteristics, a globe valve with sliding stem is used. A bevelled disc or poppet
valve consists of a globe valve with the sliding stem. Full flow is achieved with relatively short
movement of the stem. In short linear flow is the flow which is directly proportional to valve lift.

EQUAL PERCENTAGE CHARACTERISTICS

The flow area increases more rapidly with lift as valve opens in equal percentage valve for an ideal equal
percentage valve the flow characteristics would be straight line on a semi log graph. In equal percentage
flow, the flow changes by a constant percentage of its instantaneous value for each value of valve lift.
Whereas in quick opening, flow increases rapidly with initial travel reaching near its maximum at a low
lift.

QUICK OPENING FLOW CHARACTERISTICS

A valve with quick opening flow characteristic provides a maximum change in flow rate at low travels.
The curve is basically linear through the first 40 percent of valve plug travel, and then flattens out
noticeably to indicate little increase in flow rate as travel approaches the wide-open position. Control
valves with quick –opening flow characteristics are often used for ON /OFF applications. Flow rate must
be established quickly as the valves begin to open. Consequently, they are often used in relief valve
applications. (Quick- opening valves can also be selected for the many of the same applications for
which linear flow characteristics are recommended, since the quick opening characteristic is linear up to
about 70 percent of maximum flow rate. Linearity decreases sharply after flow area generated by valve
plug travel equals flow area of port. For a typical quick opening valve, such as that shown in figure, this
occurs when valve plug travel equals one fourth of port diameter.

Fig. 1
 Fig. 2

Fig. 3

APPARATUS REQUIRED

1. On /Off, Linear and Equal Percentage Control valve

2. Motor Pump
3. Rota meter
4. Air regulator
5. Pressure Gauge
PROCEDURE FOR ON/ OFF CONTROL VALVE

1. Switch ON the compressor and motor.

2. Close the hand valve HV1.

3. The pressure was fixed at certain value between 3 – 15 psi and flow rate of exit stream was
measured using rotameter.
 4. ON/Off valve was opened, it was ensured that the other two valves are in closed condition.

5. Flow rate and lift observedare tabulated for the corresponding pressure value.

6. Steps 3 – 5 were repeated for the various values of pressure.

7. Steps 3 – 6 were repeated for linear valve and equal percentage valve, while keeping the
corresponding other two valve in closed condition.

8. Fraction of lift and Fraction of flow were calculated and graph was drawn.

9. Sensitivity and Rangeability were calculated.

EXPERIMENTAL SETUP

MODEL GRAPH
TABULAR COLUMN

Initial Stem position:

Control Stem Flow Rate Fractio Fraction Valve Rangeability

Control Gain
pressure Position n of lift of flow coefficients Cv Max / Cv
valve type (Q)
( G) Cv
(P) (psi) (S) (mm) (LPH) S / Smax Q / Qmax Min

On / Off

Linear
opening

Equal
percentage
Formulae and Calculation:

Specific gravity of water = 1

∆P = (∆Ppsi x 1.0132) / 14.7 = bars

Q = Q LPH / 1000 = m3 / hr

𝑄/𝑄𝑚𝑎𝑥
Gain = 𝑆/𝑆𝑚𝑎𝑥

Cv = 1.16 Q (Sp.Gravity/ ∆P)1/2 =

Sensitivity = dx/dy (slope from the graph)

Rangeability = Cv Max / Cv Min

Perform the calculation for the valves On / Off, Linear opening, Equal percentage

RESULT

1) The characteristics of ON/OFF, Linear and Equal Percentage control valves were studied and
plotted in the graph.
2) The gain values and valve coefficients are calculated
3) Rangeability for different valves were calculated
VIVA VOCE:
1. What is the purpose of a control valve in a process control system?
2. What are the key characteristics of a control valve?
3. What is the effect of changes in process conditions (such as pressure and temperature) on the control
valve's characteristics?
4. Differentiate between linear and equal percentage flow characteristics in control valves.
5. How can you minimize the effects of cavitation and flashing in control valve?
6. What is meant by the term "rangeability"
7. How does rangebility and sensitivity affect the valve characteristics?
8. List out the scenarios that would make you choose an equal percentage control valve over a linear
control valve or ON/OFF valve?
9. What are fraction of lift and fraction of flow in control valve characteristics?
10. Can you provide an example from a real-world industrial application where the choice of control valve
characteristic significantly impacted the process control performance?

REFERENCES:

1. https://youtu.be/Hck-0yRRGSQ
2. https://youtu.be/cLstR1lzI_0
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

CLOSED LOOP STUDY ON A LEVEL CONTROLLER

AIM:

To study the performance of ON/OFF and PID controllers for step change in set point for the Level
control system

REQUIREMENTS:

Level Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

The role of the level controller is to determine the desired control action by sensing the level of water column
in the process tank with the help of a level transmitter by producing current in the range of 4 to 20 mA. As
per the desired level to be attained in the process tank, a pneumatic control valve is opened or closed
(manipulated) by an I/P controller to minimize any error to maintain a steady level in the process tank with
the help of supervisory control and data acquisition (SCADA) system. The process setup consists of supply
water tank fitted with centrifugal pump for water circulation. The rate of flow is regulated by the pneumatic
control valve. A level transmitter used for level sensing produces current in the range of 4 to 20 mA
proportional to the height of water column in the water tank. The difference in desired level and current water
level is computed. Based on this information the controller determines the desired water level. The process
parameter (level) is controlled by microprocessor based digital indicating controller which manipulates
pneumatic control valve through I/P converter.
Specifications:
Level Transmitter: Type electronic, two wire, range 0-250 mm, output 4-20 mA
▪ I/P converter: Input 4-20 mA, output 3-15 psig
▪ Control valve: Pneumatic(Air to close); Size: ¼ inch; Input: 3-15 psig
▪ Valve Characteristics:Linear
▪ Rotameter: 10-100 LPH
▪ Pump: Type submersible
▪ Process tank: Transparent
▪ Air filter regulator: Range 0-2.5 kg/cm2
EXPERIMENTAL SETUP

PV-Test point for 2 wire level transmitter input (4-20mA).

CO-Test point for the I/P converter input (4-20mA).

G1-It is used to indicating the output pressure of air regulator.

G2 - To indicate the I/P converter output.

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the level process control.
6. Switch ON the compressor. Air pressure regulator output pressure should maintained at 20 psi.
7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the level process.
12. Setpoint (Sv) shall be given in the SCADA software and tune the PID values for attaining setpoint.
13. Apply the setpoint of level from 10 – 90 cm.
14. Select the control parameters option to open the PID parameters.
15. Select and set the ON/OFF controller.
16. Check if the setpoint is attained in the graph. If not attained then tune the PID values (change the
kp, ki, kd values)
17. Stop logging when the setpoint is stabilized and export the logging table values to MsExcel and the
graph.
18. Repeat the procedure steps 9 - 17 for the PID controller.
19. Switch off the compressor and pump.
TABLUATION

ON-OFF Controller

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (mm)
(mm) (%)
PID Controller

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (mm)
(mm) (%)
MODEL GRAPH

RESULT

The performance of ON/OFF AND PID controllers for step change in set point for the Level control
system was studied and the performance was shown in graphs.
VIVA VOCE:

1. What is a closed-loop control system, and how does it differ from an open-loop control system?
2. What are the basic components of a closed-loop control system?
3. Define the terms "set point," "process variable," "controller output," and "error" in the context of a
closed-loop control system.
4. Define the term "error".
5. What is servo problem in control system?
6. How can the choice of controller tuning parameters impact the performance of a closed-loop level
control system?
7. Discuss the importance of alarm and safety systems in a closed-loop level control setup.
8. Define the term dead time in relation to level control and how it can affect control system
performance.
9. Compare proportional, integral, and derivative control actions. How are they combined in a PID
controller?
10. Provide an example of a real-world application where a closed-loop level control system is used.

REFERENCES:

1. https://youtu.be/l3eHCa4PaOQ
2. https://youtu.be/DtV0ASunhqU
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

OPEN LOOP STUDY ON A LEVEL CONTROLLER

AIM:

To study the open loop response for the Level control system.

REQUIREMENTS:

Level Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

An open-loop study on a level controller involves analyzing the behavior and response of a control system
without incorporating any feedback from the output to adjust the control action. This type of study helps in
understanding the basic characteristics, limitations, and dynamics of the system under consideration. Unlike
closed-loop control systems, where the output is measured and used to adjust the control action, an open-
loop system does not have any feedback mechanism. The control action is determined solely based on the
predetermined input signal. It predicts how the system will respond to specific input signals without any
corrective actions. This allows you to analyze the inherent behavior of the system and observe its transient
and steady-state responses.

a mathematical model that describes how the liquid level changes over time based on the inflow and outflow
rates. Let:

h(t) = Liquid level at time t

Q_in = Inflow rate of liquid into the tank

Q_out = Outflow rate of liquid from the tank

A = Cross-sectional area of the tank

Using principles of fluid dynamics, we can derive a differential equation that relates the rate of change of
liquid level to the inflow and outflow rates:

dh(t)/dt=A1⋅(Qin−Qout)

Open-loop control has several limitations. It doesn't account for disturbances: If there are unexpected changes
in the system, such as variations in the outflow rate or sudden changes in the process conditions, the control
action will not adapt. It lacks robustness: Open-loop control is sensitive to parameter variations and
uncertainties in the system. It’s not suitable for dynamic systems: Systems with changing characteristics over
time cannot be effectively controlled using open-loop strategies. An open-loop level controller analysis helps
us understand the basic response of a system to input changes but falls short when it comes to achieving
accurate and reliable control. Closed-loop control systems, which incorporate feedback, are necessary for
real-world applications where stability, accuracy, and adaptability are crucial.

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the temperature process control.
6. Switch ON the compressor. Air pressure regulator output pressure should be maintained at 20 psi.
7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the level process.
12. Select the control parameters option to open the PID controllers.
13. Select and set the OPEN controller.
14. Controlled variable (Cv) shall be given in the SCADA software and change in process variable (Pv)
is noted down.
15. Apply the Cv from 0 – 100% and check whether the system pressure is maintained from 3 – 15 psi.
16. Note down the pressure value.
 17. Stop logging when the process variable is stabilized and export the logging table values to Ms Excel
and the graph.
18. Switch off the compressor and pump.

TABLUATION

OPEN Controller

Controlled Variable (Cv) =

Pressure (psi) =

Process Variable Controlled

Sl. Time Set point (Sv)
(Pv) Variable (Cv)
No. (Seconds) (mm)
(mm) (%)
RESULT

The open loop response for the Level control system was studied and the performance was shown
in graph.

VIVA VOCE:

1. What is a open-loop control system, and how does it differ from an closed-loop control system?
2. What are the basic components of a open-loop control system?
3. Define the terms "set point," "process variable," "controller output," and "error" in the context of an
 open-loop control system.
4. What is the significance of not having feedback in an open-loop control system?
5. In what situations would you recommend using an open-loop control system over a closed-loop
system?
6. Discuss a scenario where an open-loop level control system might not be suitable, and a closed-loop
system would be preferred.
7. How can you analyze the overshoot and settling time of the system based on the data obtained in an
open-loop study?
8. How can you tune or optimize the level controller's parameters based on the findings of the open-
loop study.
9. Discuss a real-world example where an open-loop study on a level controller led to significant
improvements in system operation.
10. How can the results of an open-loop study guide the design and implementation of a closed-loop
control system for level control?

REFERENCES:

1. https://youtu.be/pp03-vmaWRg
2. https://youtu.be/U8_KNgoY5LM
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

CLOSED LOOP STUDY ON A FLOW CONTROLLER

AIM:

To study the performance of ON/OFF and PID controllers for step change in set point for the Flow
control system

REQUIREMENTS:

Flow Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

The measurement and control of flow can be said to be the very heart of process industries.
Continuously operating manufacturing processes involve the movement of raw materials, products, and
waste throughout the process.

Flow process controller is used to perform the control action on Flow process. In this unit flow is the
process variable and is sensed and given to controller. A Differential Pressure Transmitters used to measure
the Flow of the fluid through orifice plate. In this unit, pump sucks the water from reservoir tank and gives
it to control valve. Every internal transaction is in voltage. Here, PC acts as error detector and controller.
According to the error signal, computer develops a control signal. This control signal is given to I/P Converter
which operates the control valve. Control valve acts here as final control element which controls the flow of
the fluid in pipeline by varying stem position of the control valve. Flow is the manipulated level signal here
and is given to the Data acquisition card. By pass liens provided to avoid the pump overloading. Data
Acquisition card has ADC and DAC, so that it acts an effective link between the process and the controller.

EXPERIMENTAL SETUP:
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).

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the flow process control.
6. Switch ON the compressor. Air pressure regulator output pressure should be maintained at 20 psi.
7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the flow process.
12. Setpoint (Sv) shall be given in the SCADA software and tune the PID values for attaining setpoint.
13. Apply the setpoint of level from 30 – 250 LPH.
14. Select the control parameters option to open the PID parameters.
15. Select and set the ON/OFF controller.
 16. Check if the setpoint is attained in the graph. If not attained then tune the PID values (change the
kp, ki, kd values)
17. Stop logging when the setpoint is stabilized and export the logging table values to Ms Excel and the
graph.
18. Repeat the procedure steps 9 - 17 for the PID controller.
19. Switch off the compressor and pump.
TABLUATION

ON-OFF Controller

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (LPH)
(LPH) (%)

PID Controller

Set point (Sv) Process Variable Controlled Variable

Sl. Time
TEMP (Pv) (Cv)
No. (Seconds)
(LPH) (LPH) (%)
MODEL GRAPH

RESULT

The performance of ON/OFF AND PID controllers for step change in set point for the flow control system
was studied and the performance was shown in graphs.
VIVA VOCE:

1. State the principle of flow controller.

2. What is the main objective of conducting a closed-loop study on a flow controller?
3. What are the key components required for setting up a closed-loop study on a flow controller?
4. What types of sensors or instruments are typically used to measure flow rates in a closed-loop study
on a flow controller?
5. How does the choice of control parameters, such as proportional, integral, and derivative gains,
impact the behavior of the flow controller in a closed-loop study?
6. How does the process of tuning a PID controller affect the results obtained from a closed-loop study
on a flow controller?
7. Why is it important to select an appropriate set point or reference value for the flow controller
during the closed-loop study?
8. How do you confirm the attainment of steady state in flow controller system?
9. List out the industrial application of closed-loop study on a flow controller.
10. What challenges might you encounter while conducting a closed-loop study on a flow controller,
and how would you address them?

REFERENCES:

1. https://youtu.be/5KvUCrIOcqA
2. https://youtu.be/HgUbEB157TI
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

OPEN LOOP STUDY ON A FLOW CONTROLLER

AIM:

To study the open loop response for the flow control system.

REQUIREMENTS:

Flow Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

The role of the flow controller is to determine the desired control action by sensing the flow of water column
in the process tank with the help of a flow transmitter by producing current in the range of 4 to 20 mA. As
per the desired flow rate to be attained in the process tank, a pneumatic control valve is opened or closed
(manipulated) by an I/P controller to minimize any error to maintain a steady flow in the process tank with
the help of supervisory control and data acquisition (SCADA) system. The process setup consists of supply
water tank fitted with centrifugal pump for water circulation. The rate of flow is regulated by the pneumatic
control valve. A level transmitter used for level sensing produces current in the range of 4 to 20 mA
proportional to the height of water column in the water tank. The difference in desired level and current water
level is computed. Based on this information the controller determines the desired water level. The process
parameter (level) is controlled by microprocessor based digital indicating controller which manipulates
pneumatic control valve through I/P converter.

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquisition.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the flow process control.
6. Switch ON the compressor. Air pressure regulator output pressure should be maintained at 20 psi.
7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the flow process.
12. Select the control parameters option to open the PID controllers.
13. Select and set the OPEN controller.
14. Controlled variable (Cv) shall be given in the SCADA software and change in process variable (Pv)
is noted down.
15. Apply the Cv from 0 – 100% and check whether the system pressure is maintained from 3 – 15 psi.
16. Note down the pressure value.
17. Stop logging when the process variable is stabilized and export the logging table values to Ms Excel
and the graph.
18. Switch off the compressor and pump.

TABLUATION

OPEN Controller

Controlled Variable (Cv) =

Pressure (psi) =

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (LPH)
(LPH) (%)
RESULT

The open loop response for the flow control system was studied and the performance was shown in graph.
VIVA VOCE:

1. What factors should be considered when designing an open-loop flow control system?
2. What are the main components of an open-loop control flow system?
3. What steps can be taken to mitigate the impact of disturbances on an open-loop flow controller?
4. What is the fundamental principle of an open-loop flow controller?
5. Discuss a scenario where open-loop control might not be suitable for maintaining flow rate in a
tank.
6. How the lack of feedback does affects the ability of an open-loop flow controller to adapt to
changing conditions?
7. What is the primary difference between the "sensor" and the "actuator" in an open-loop control flow
system?
8. Why is the "open-loop control signal" predetermined and not adjusted during operation?
9. Why an open-loop control level system is not suitable for processes with changing dynamics?
10. Can you provide an example of a real-world application that utilizes an open-loop control flow
system?

REFERENCES:

1. https://youtu.be/xjaphhTUYNA
2. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York, 2008.
3. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

CLOSED LOOP STUDY ON A PRESSURE CONTROLLER

AIM:

To study the performance of ON/OFF and PID controllers for step change in set point for the Pressure
control system

REQUIREMENTS:

Pressure Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

Pressure process controller is used to perform the control action on pressure process. In this unit pressure is
the process variable and is sensed and given to controller. A Piezo electric pressure transmitter is used to
measure and transmit the pressure developed in the process tank. In this unit, pressure is developed from a
compressor and is given to the unit. Every internal transaction is in voltage. Here, PC acts as error detector
and controller. According to the error signal, computer develops a control signal. This control signal is given
to I/P Converter which operates the control valve. Control valve acts here as final control element which
controls the pressure inside the process tank by varying its plug opening according to the controller output.
Data Acquisition card has ADC and DAC, so that it acts an effective link between the process and the
controller. Relief valve is being used for safety purpose by which excess pressure developed in the process
tank can be removed.

A pneumatic amplifier, also called a booster or relay, raises the pressure and/or air flow volume by some
linearly proportional amount from the input signal. Thus, if the booster has a pressure gain of 10, the output
would be 30-150 psi for an input of 3-15psi.This is accomplished via a regulator that is activated by the
control signal. A schematic diagram of one type of pressure booster is shown in above figure. As the signal
pressure varies, the diaphragm motion will move the plug in the body block of the booster. If motion is down,
the gas leak is reduced and pressure in the output line is increased. The devices shown in reverse acting
because a high-signal pressure will cause output pressure to decrease.
Nozzle / Flapper System

A very important signal conversion is from pressure to mechanical motion and vice versa. This conversion
can be provided by a nozzle/flapper system (sometimes called a nozzle/baffle system). A regulated supply
of pressure, usually over 20psig, provides a source of air through the restriction. The nozzle is open at the
end where the gap exists between the nozzle and flapper and air escapes in this region. If the flapper moves
down and closes off the nozzle opening so that no air leaks, if the signal pressure will rise to the supply
pressure.

As the flapper moves away, the signal pressure will drop because of the leaking gas. Finally when the flapper
moves away, the pressure will stabilize at some value determined by the maximum leak through the nozzle
.Figure shows the relationship between signal pressure and gap distance. Note the great sensitivity in the
central region. A nozzle /flapper is the designed to operate in the central region where the slope of the line is
greatest. In this region, the response will be such that a very small motion of the flapper can change the
pressure by an order of magnitude.

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the pressure process control.
6. Switch ON the compressor. Air pressure regulator output pressure should be maintained at 20 psi.
 7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the flow process.
12. Setpoint (Sv) shall be given in the SCADA software and tune the PID values for attaining setpoint.
13. Apply the setpoint of pressure from 0 – 20 psi.
14. Select the control parameters option to open the PID parameters.
15. Select and set the ON/OFF controller.
16. Check if the setpoint is attained in the graph. If not attained then tune the PID values (change the
kp, ki, kd values)
17. Stop logging when the setpoint is stabilized and export the logging table values to Ms Excel and the
graph.
18. Repeat the procedure steps 9 - 17 for the PID controller.
19. Switch off the compressor and pump.

TABLUATION

ON-OFF Controller

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (psi)
(psi) (%)
PID Controller

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (psi)
(psi) (%)

MODEL GRAPH
RESULT

The performance of ON/OFF AND PID controllers for step change in set point for the Pressure control
system was studied and the performance was shown in graphs.
VIVA VOCE:

1. What is the primary function of a pressure controller?

2. List the role of "proportional," "integral," and "derivative" in the context of PID control for pressure
regulation.
3. What is hysteresis in the context of pressure control, and how is it managed?
4. State the importance of tuning a closed-loop pressure controller for optimal performance.
5. Define the terms "overshoot" and "undershoot" in the context of closed-loop control and their
relation to pressure control.
6. What safety measures should be taken into consideration when implementing a closed-loop
pressure control system?
7. What is meant by the term "flapper nozzle gap," and how does it affect the control system's
performance?
8. Discuss the concept of air entrainment in a flapper system and its consequences.
9. What safety precautions should be taken when dealing with high-pressure systems and controllers?
10. How does a pressure controller handle varying loads or demand changes in an industrial process?
11. How do variations in the sensor's accuracy impact the overall performance of the closed-loop
pressure control system?
12. Can you provide an example of an industrial application where a closed-loop pressure control
system is crucial?

REFERENCES:

1. https://youtu.be/NaH5G576bz8
2. https://youtu.be/IKtO9drWvWw
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

OPEN LOOP STUDY ON A PRESSURE CONTROLLER

AIM:

To study the open loop response for thePressure control system.

REQUIREMENTS:

Pressure Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

-Pressure control trainer is designed for understanding the basic principles of pressure control. The process
set up consists of pressure vessel fitted with pneumatic control valve. Pressure transmitter is used for pressure
sensing. The process parameter (Pressure) is controlled by microprocessor based digital indicating controller
which manipulates pneumatic control valve fitted at Outlet of pressure tank outlet through I/P converter.
These units along with necessary piping are fitted on support housing designed for tabletop mounting. The
controller can be connected to computer through Ethernet /USB port for monitoring the processing SCADA
mode

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the flow process control.
6. Switch ON the compressor. Air pressure regulator output pressure should be maintained at 20 psi.
7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the pressure process.
12. Select the control parameters option to open the PID controllers.
13. Select and set the OPEN controller.
14. Controlled variable (Cv) shall be given in the SCADA software and change in process variable (Pv)
is noted down.
15. Apply the Cv from 0 – 100% and check whether the system pressure is maintained from 3 – 15 psi.
16. Note down the pressure value.
17. Stop logging when the process variable is stabilized and export the logging table values to Ms Excel
and the graph.
18. Switch off the compressor and pump.

TABLUATION

OPEN Controller

Controlled Variable (Cv) =

Pressure (psi) =

Process Variable Controlled Variable

Sl. Time Set point (Sv)
(Pv) (Cv)
No. (Seconds) (psi)
(psi) (%)
RESULT

The open loop response for the Pressure control system was studied and the performance was shown in
graph.
VIVA VOCE:

1. How is the set point determined and implemented in an open-loop pressure control study?
2. What safety considerations should be taken into account when conducting an open-loop study on a
pressure system?
3. How is the performance of an open-loop pressure control system evaluated or measured?
4. Describe the process of calibration and setup for an open-loop pressure control experiment.
5. What are the potential implications of using an open-loop pressure control system in critical or
sensitive processes?
6. How does the absence of feedback affect the stability of an open-loop pressure control system?
7. Can you propose scenarios where an open-loop pressure control system would be more suitable than
a closed-loop system?
8. What measures can be taken to enhance the accuracy and reliability of an open-loop pressure control
system?
9. What is dead time?
10. What are the potential consequences of a failure or malfunction in an open-loop pressure control
system?

REFERENCES:

1. https://youtu.be/IKtO9drWvWw
2. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York, 2008.
3. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

CLOSED LOOP RESPONSE OF CASCADE CONTROL SYSTEM

AIM:

To study the closed loop performance of cascade controller system.

REQUIREMENTS:

Cascade Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY

Cascade Control Trainer is used to perform cascade control on flow and level process and study the
characteristics of I/P converter, industrial standard Rotameter, wheel flow meter and orifice with differential
pressure transmitter. DPT is used to measure the flow of fluid in a pipeline. The RF capacitance level
transmitter is used to measure the level of the process tank. In cascade control action, pump discharges the
water from reservoir and give it to rot meter and control valve. While the fluid flows through the orifice plate.
A differential pressure developed across it, which is sensed by differential pressure transmitter corresponding
current output (4-20mA), is given to the Data Acquisition card.

Every internal transaction is in voltage. Here, PC acts as error detector and controller. According to the error
signal, corresponding control signal is given to the I/P converter. It controls the flow of the fluid in pipeline
by varying stem position of the control valve. The level is a primary control loop and flow is a secondary
control loop. For maintaining the level of the process tank, flow is manipulated level signal is given to the
Data Acquisition card. By pass line is provided to avoid the pump overloading. Rotameter visualize the flow
of the fluid in a pipe line.From this analyzer, we can also study the characteristics of level transmitter, DPT,
I/P converter, control valve and justify the various control action on the processes.

EXPERIMENTAL SETUP:
BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:

1. First fill the water in the reservoir tank.

2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the USB convertor port is enabled.
5. Open the SCADA software for the cascade process control.
6. Switch ON the compressor. Air pressure regulator output pressure should be maintained at 20 psi.
7. Switch ON the pump.
8. Hand valve should be partially opened.
9. Check whether the pressure of system maintained in the range of 3-15 psi.
10. Set the minimum flow rate in rotameter and note down the value.
11. Click start logging to start the cascade process.
12. Setpoint (Sv) shall be given in the SCADA software and tune the PID values for attaining setpoint.
13. Apply the setpoint of flow from 30 – 250 LPH and level from 10 – 90 cm.
14. Select the control parameters option to open the PID parameters.
15. Select and set the ON/OFF controller.
16. Check if the setpoint is attained in the graph. If not attained then tune the PID values (change the
kp, ki, kd values)
17. Stop logging when the setpoint is stabilized and export the logging table values to Ms Excel and the
graph.
 18. Repeat the procedure steps 9 - 17 for the PID controller.
19. Switch off the compressor and pump.

TABLUATION

ON-OFF Controller

Controlled
Process Controlled
Set point Variable Process
Sl. Time Variable Set point (Sv) Variable (Cv)
(Sv) (Cv) Variable (Pv)
No. (Seconds) (Pv) (mm) Level
(LPH) Flow (mm)
(LPH) (%)
(%)

PID Controller:

Controlled
Process Controlled
Set point Variable Process
Sl. Time Variable Set point (Sv) Variable (Cv)
(Sv) (Cv) Variable (Pv)
No. (Seconds) (Pv) (mm) Level
(LPH) Flow (mm)
(LPH) (%)
(%)
RESULT

Thus, the performance of Cascade controller was studied and the performance was shown in graphs.
VIVA VOCE:

1. How does a cascade control system differ from a single-loop control system?
2. What is the role of the primary controller and the secondary controller in a cascade control setup?
3. What is set point tracking and disturbance rejection in cascade control?
4. What is load regulation? Mention its significance in cascade control systems.
5. How does a disturbance in the inner loop affect the performance of a cascade control system?
6. Discuss the importance of tuning parameters in a cascade control system. How are these parameters
determined?
7. Define Decoupling.
8. List the primary components and their interactions in a closed-loop cascade control system.
9. Mention the potential drawbacks or limitations of closed-loop cascade control systems.
10. Compare the performance of a closed-loop cascade control system with that of other control
strategies, such as proportional-integral-derivative (PID) control.

REFERENCES:

1. https://youtu.be/hXD3h6uz0VY
2. https://youtu.be/jD8MFtm0WAQ
3. https://youtu.be/FHk4C9hUkXU
4. . Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New
York, 2008.
Expt:
Date:
CLOSED LOOP STUDY ON A TEMPERATURE CONTROLLER
AIM:
To study the performance of ON/OFF and PID controllers for step change in set point for the
Temperature control system

REQUIREMENTS:
Temperature Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY
Temperature process controller is used to perform the control action on temperature process. In this
unit, temperature is the process variable. A Resistance Temperature Detectors (RTD) sensor is being used to
measure the temperature of the process and is transmitted by RTD transmitter. In this unit, water is stored up
in the over head tank by pumping water from reservoir tank through pump. Water from over head tank is
allowed to heater through a rotameter. Rotameter is being provided for giving disturbance to the process and
for operational safety of the heater. For conducting experiment flow rate in minimum value (say 30Lph). In
the outlet of heater, an RTD is provided for sensing the temperature and is transmitted by RTD transmitter.
Every internal transaction is in voltage. Here PC acts as error detector and controller. According to the error
signal, computer develops a control signal. This control signal is given to the Silicon control rectifier (SCR)
power driver circuit by which firing angle varies. Accordingly, the supply delivered to heater varies and thus
the process gets controlled. Data acquisition card has the ADC and DAC so that it acts as an effective link
between the process and controller.

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:
1. First fill the water in the reservoir tank.
2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the port is enabled using RS485 to USB converter.
5. Open the SCADA software for the temperature process control.
6. Switch ON the pump.
7. Switch ON the heater.
8. Hand valve should be partially opened.
9. Set the minimum flow rate in rotameter and note down the value.
10. Click start logging to start the temperature process.
11. Setpoint (Sv) shall be given in the SCADA software and tune the PID values for attaining setpoint.
12. Apply the setpoint of temperature from 40 – 70 °C.
13. Select the control parameters option to open the PID parameters.
14. Select and set the ON/OFF controller.
15. Check if the setpoint is attained in the graph. If not attained then tune the PID values (change the
kp, ki, kd values)
16. Stop logging when the setpoint is stabilized and export the logging table values to MsExcel and the
graph.
17. Repeat the procedure steps 10 - 17 for the PID controller.
18. Switch off the heater and pump.

TABLUATION

ON-OFF Controller

Set point (Sv) Process Variable Controlled Variable

Sl. Time
TEMP (Pv) (Cv)
No. (Seconds)
(°C) (°C) (%)
 PID Controller

Set point (Sv) Process Variable Controlled Variable

Sl. Time
TEMP (Pv) (Cv)
No. (Seconds)
(°C) (°C) (%)

MODEL GRAPH

20
TEMP IN DEGREE CENTIGRDE

15

10 0 50 100

RESULT
The performance of ON/OFF AND PID controllers for step change in set point for the Temperature
control system was studied and the performance was shown in graphs.
VIVA VOCE:
1. What are the basic components of a closed-loop temperature control system?
2. What is the significance of feedback in closed-loop control systems?
3. How is an error signal calculated in closed-loop temperature control?
4. How do PID parameters (proportional, integral, and derivative gains) affect the performance of a
temperature control system?
5. What are the common challenges or issues encountered in closed-loop temperature control systems?
6. How does the Ziegler-Nichols tuning method help in setting up PID parameters?
7. What is the anti-windup mechanism and its purpose in closed-loop temperature control?
8. Discuss the importance of tuning and optimizing a closed-loop temperature control system.
9. What are some alternative control strategies to PID for closed-loop temperature control?
10. How does adaptive control contribute to the efficiency of closed-loop temperature control systems?
11. Provide examples of industries or applications where closed-loop temperature control is critical.
12. Discuss the trade-offs between accuracy, responsiveness, and stability in closed-loop temperature
control.
REFERENCES:
1. https://youtu.be/CBF0CRzy6Bo
2. https://youtu.be/BmvNwXSq8CQ
3. https://youtu.be/BW8FxORQZ30
4. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
Expt:
Date:

OPEN LOOP STUDY ON A TEMPERATURE CONTROLLER

AIM:
To study the open loop response for the Temperature control system.

REQUIREMENTS:
Temperature Control System Unit, PC with SCADA software, RS485 to USB converter cable.

THEORY
The system consists of heater, blower, and thermistor arrangement. Thermistor is used to sense the
temperature of the air flow. It is made of semiconductor material having a negative temperature co-efficient
ie. If temperature increases, resistance decreases, vice versa. The variation in the resistance is inserted into
the wheat stone bridge. The bridge is balanced at room temperature. It is designed to measure the temperature
of (0 - 100°C). The bridge voltage is amplified and signal conditioned to give (0-5V). Desired temperature
(35°C - 95°C) is given by the set value POT. User can study the set value disturbance by giving step input to
the controller by internal mode or external mode. Blower is placed adjacent to the heater. It is used to load
the process thereby user can study the load disturbance on the process. In the controller section, it compares
the desired temperature and actual temperature in terms of voltage and produces control voltage. This voltage
is compared with in built ramp signal and creates a pulse waveform with varying duty cycle. Power isolation
is provided to isolate the high voltage from low voltage sources.

BLOCK DIAGRAM OF THE EXPERIMENTAL SETUP

PROCEDURE:
1. First fill the water in the reservoir tank.
2. Check the interface of PC with the unit and Data Acquistion.
3. Check if the necessary connections are in proper setup.
4. Check if the port is enabled using RS485 to USB converter.
5. Open the SCADA software for the temperature process control.
6. Switch ON the pump.
7. Switch ON the heater.
8. Hand valve should be partially opened.
9. Set the minimum flow rate in rotameter and note down the value.
10. Click start logging to start the temperature process.
11. Select the control parameters option to open the PID controllers.
12. Select and set the OPEN controller.
13. Controlled variable (Cv) shall be given in the SCADA software and change in process variable (Pv)
is noted down.
14. Apply the Cv from 0 – 100%.
15. Stop logging when the process variable is stabilized and export the logging table values to Ms Excel
and the graph.
16. Switch off the heater and pump.

TABLUATION

OPEN Controller
Controlled Variable (Cv) =

Set point (Sv) Process Variable Controlled Variable

Sl. Time
TEMP (Pv) (Cv)
No. (Seconds)
(°C) (°C) (%)
MODEL GRAPH

20
TEMP IN DEGREE CENTIGRDE

15

10 0 50 100

RESULT
The open loop response for the Temperature control system was studied and the performance was shown in
graph.
VIVA VOCE
1. What is the role of the set point in an open-loop temperature control system?
2. How is the control signal determined in an open-loop temperature control system?
3. What is the function of the heater or actuator in an open-loop system?
4. Why is an open-loop temperature control system less adaptable to changes in the process?
5. Give an example of a situation where an open-loop temperature control system might be suitable.
6. What challenges can arise in maintaining accuracy in an open-loop temperature control system?
7. Discuss the implications of disturbances or variations in the process on an open-loop control
system.
8. In what types of processes or applications might an open-loop control system be inadequate?
9. Discuss a scenario where manual intervention might be required in an open-loop temperature
control system.
10. What considerations should be taken into account when designing an open-loop control system for
temperature regulation?
11. Why might an open-loop system be more suitable for processes that are well-defined and stable?
12. Explain why adaptive control strategies are generally not used in open-loop temperature control
systems.

REFERENCES:
1. https://youtu.be/DE0hWLdkckg
2. https://youtu.be/-KXagooLmpI
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

RESPONSE OF NON-INTERACTING LEVEL SYSTEM

AIM

To find the response from the Transfer Function that relates H/Q for a given step input in the non-
interacting tank System.

APPARATUS REQUIRED

Non-Interacting level system setup, stop watch.

THEORY

The overall transfer function of non-interacting system is the product of two first-order transfer functions,
each one of which is the transfer function of a single tank operating independently of the other.

In the above figure the level in tank 2 depends on the level on tank 1 whereas the level in tank 1 in
independent on the level on tank 2 this condition is termed as non-interacting. In general considering two
systems if the output of first system is not affected by the conditions in second system then the system is
said to be Non - Interacting.

The flow resistance, for the liquid of constant density and the tanks to have uniform cross- sectional area is
linear. The flow-head relationships for the two linear resistances of the tanks in the Non Interacting System
are given by the expressions.

Consider the two tank system shown in experimental setup. The outlet flow from tank1 discharges directly
into the atmosphere before spilling into tank 2 and it flows through R1, depends only on h1. The variation
in h2 in tank 2 does not affect the transient response occurring in tank 1. This type of system is referred as
non-interacting system. Assume the liquid to be of constant density, the tanks to have uniform cross
sectional area and the flow resistances to be linear.

The mass balance equation of tank 1 is

q1 – q2 = A1 (dh1 / dt) --- (1)

The mass balance equation of tank 2 is

q2– q3 = A2 (dh2 / dt ) --- (2)

The flow head relationships for the two linear resistances are given by the expressions

q2 = h1 / R1, q3 = h2 / R2 --- (3)

Combining the equations (1) and (3) we get the transfer function for tank 1 is

Q2(s) / Q1(s) = 1 / (1s+1) --- (4)

Where Q2 = q2 – q2s, Q1= q1 – q1s, 1 = R1A1

Combining the equations (2) and (4) we get the transfer function for tank 1 is

H2(s) / Q2(s) = R2 / (2s+1)

Where H2 = h2 – h2s, 2 = R2A2

The overall transfer function of non interacting system is

H2(s) / Q1(s) = R2 / ( 2s+1) ( 1s+1)

Where, q1 = Inflow to tank 1 in lph.

A1, A2= the area of tank 1 & 2.

h1, h2= Output variable head of tank1 & 2.

R1, R2 = Resistance of valve in the outlet tank1 & 2.

q2 = Inflow to tank 2 in lph.

q3 - Outflow of tank 2 in lph

1, 2 – time constants of tank 1, 2 respectively

FORMULA & CALCULATIONS:

CALCULATION OF RESISTANCE
TRANSFER FUNCTION

The response is

PROCEDURE

1. The unit is switched ON,

2. An inflow of X LPH is set in the Rota meter by adjusting the Valve HV1
3. Wait for some time, so that the level in process tank 1 and tank 2 reaches steady state value.
4. The steady state level in process tank 1 and tank 2 are noted (h1)mm (Now the inflow is equal to
outflow)
5. Now the inflow rate to process tank 1 is suddenly increased to Y LPH by adjusting HV1.
6. Variation in level of process tank 1 and tank 2 are tabulated with respect to time (say for every 10
seconds) unit it reaches the new steady state h2mm.
7. Level Vs time graph is drawn.
8. Time constant of the process tank 1 and tank 2 are calculated. (Time constant is defined as the time
taken for the output to reach 63.2% of its final output).
9. Time constant can also be defined as the product of resistance and capacitance of the tank.
τ = RC
Where R - Resistance to flow (out flow), C – Capacitance(Area).
10. From the above relation the resistance of the valve is calculated.
11. From the Resistance and the Time Constant, the response curve was drawn for the given step input.

GRAPH

Calculation of Time Constant

By substituting the values of Time Constants of the two tanks and the valve resistance, the response curve
was drawn.

EXPERIMENTAL SETUP

TABULATION

Rise in Liquid Rise in Liquid Predicted rise in

SI.No Time (sec) Level of tank 1 Level of tank 2 liquid level

(cm) (cm) of tank 2 (cm)

RESULT

The response curve was drawn from the Transfer Function that relates H/Q for a given step input in the
non-interacting tank System.
VIVAVOCE

1. How did you ensure the non-interaction between the energy levels in your system theoretically?
2. What is the significance of ensuring non-interaction between the levels in your system?
3. How does the non-interacting nature of the system affect the overall behavior or dynamics?
4. What measurements did you take to verify that the levels in your system were non-interacting?
5. What were the main results or observations from your experiment with the non-interacting level
system?
6. What are the potential advantages or limitations of studying non-interacting level systems?
7. What are the key theoretical concepts or principles that are relevant to the non-interacting system
experiment?
8. State the relationship between time constant and system’s behavior.
9. What are the key characteristics that define a non-interacting system?
10. How can you identify the system's rise time, settling time, and steady-state behavior from the step
response?

REFERENCES

1. https://www.youtube.com/watch?v=OygfyVMcQzE
2. https://www.youtube.com/watch?v=URcL7dIxIdY
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
4. Stephanopoulos, G., “Chemical Process Control “, Prentice Hall of India, 2003.
Expt:

Date:

RESPONSE OF INTERACTING LEVEL SYSTEM

AIM

To find the response from the Transfer Function that relates H/Q for a given step input in the interacting
tank System.

APPARATUS REQUIRED

Interacting level system setup, stop watch.

THEORY

The overall transfer function cannot be found by simply multiplying together the separate transfer function.
The term interacting is often referred to as loading. We see that the effect of interaction has been to change
the effective time constants of the interacting system. One time constant has become considerably larger
and the other smaller than the time constant τ of either tank in the non interacting system.

In the above fig the level in tank 3 depends on the level on tank 1 where as the level in tank 1 in
dependent on the level on tank 3 this condition is termed as interacting. In general considering two system
if the output of first system is affected by the conditions in second system then the systems are said to be
Interacting.

The flow-head relationships for the two linear resistances of the tanks in the Interacting System are given
by the expressions.

Consider a two tank system shown relationship for tank 1 is q2 = (h1 - h2) / R1
in experimental setup. The second tank is The mass balance equation of tank 1 is q1 – q2 = A1 (dh1 / dt ) ---
said to load the first tank. The flow through (1)
R1 depends on the difference between h1
and h2. The analysis is started by writing The mass balance equation of tank 2 is q2 – q3 = A2 (dh2 / dt ) ---
mass balance on the tank. The balances on (2)
tank 1 and 2 are the same. The flow head
The flow head relationships for the two h1 = Output variable head of tank1.
linear resistances are given by the
expressions R1 = Resistance of valve in the outlet tank1.

q2 = h1 / R1 , q3 = h2 / R2 --- (3) q2 = Inflow to tank 2 in lph.

at steady state, the flow equation is q1s – A2 = the area of tank 2.

q2s = 0, q2s – q3s = 0 h2 = Output variable head of tank2.
By solving all the above equations using R2 = Resistance of valve in the outlet tank2.
laplace transform, we get the transfer
function q3 - Outflow of tank 2 in lph

H2(s) / Q1(s) = R2 / (12s2 +1(1 + 2 + A1 τ1, τ2 – time constants of tank 1, 2 respectively

R2)s +1 )

Where q1 = Inflow to tank 1 in lph.

A1 = the area of tank 1.

Calculation of Resistance

TRANSFER FUNCTION

PROCEDURE

1. The unit is switched ON,

2. An inflow of X LPH is set in the Rota meter by adjusting the Valve HV1
3. Wait for some time, so that the level in process tank 1 reaches steady state value.
4. The steady state level in process tank 1 is noted (h1)mm (Now the inflow is equal to outflow)
 5. Now the inflow rate to process tank 1 is suddenly increased to Y LPH by adjusting HV1.
6. Variation in level of process tank 1 and tank 2 tabulated with respect to time (say for every 10
seconds) unit it reaches the new steady state h2mm.
7. Level Vs time graph is drawn.
8. Time constant of the process tank 1 and tank 2 are calculated. (Time constant is defined as the time
taken for the output to reach 63.2% of its final output).
9. Time constant can also be defined as the product of resistance and capacitance of the tank.
τ = RC
Where R - Resistance to flow (out flow), C - Capacitance (Area).
10. From the above relation the resistance of the valve is calculated.
11. From the Resistance and the Time Constant, the response curve was drawn for the given step input.

GRAPH

Calculation of Time Constant

By substituting the values of Time Constants of the two tanks and the valve resistance, the response curve
was drawn.

EXPERIMENTAL SETUP
TABULATION

Sl. Time Rise in Rise in Liquid Predicted

No (sec) Liquid Level Level of tank 2 rise in liquid

of tank 1 (cm) level of tank

(cm) 2 ( cm)

RESULT

The response curve was drawn from the Transfer Function that relates H/Q for a given step input in the
interacting tank System.
VIVA VOCE:

1. What was the objective of this experiment?

2. What were the components or elements involved in the interacting system?
3. How did the components in your experiment interact with each other?
4. How did you ensure the controlled environment necessary for the experiment?
5. What type of data did you collect during the experiment?
6. How did you measure and record the interactions between the components?
7. What analytical methods did you use to interpret the collected data?
8. What were the independent and dependent variables in your experiment?
9. Did you implement any controls to ensure the validity of your results?
10. How did you manage or account for any potential confounding variables?
11. What were the main results or findings of your experiment?

REFERENCES:

1. https://youtu.be/b7Klg28kdF8
2. https://youtu.be/AJF2HJLGAPc
3. Coughnowr, D., “Process Systems Analysis and Control “, 3rd Edn., McGraw Hill, New York,
2008.
Expt:

Date:

RESPONSE OF SECOND ORDER SYSTEM (U- TUBE MANOMETER)

AIM

1. To study the dynamic response of a U-Tube manometer following a step change

2. To study the characteristics of an under-damped second order response like overshoot, rise time,
decay ratio, response time etc.
3. To determine the transfer function of second order system.

APPRATUS REQUIRED

U – Tube Manometer Experimental setup, stop watch

THEORY

The dynamic behavior of the U-tube liquid manometer with equal diameter columns corresponds to an under-
damped dynamic system. Improving the dynamic response (decreasing the overshoot and the settling time,
increasing the phase and delay margins) can be achieved by increasing the connection tube length, by
decreasing the columns diameter and by using a high density liquid manometer

A system which can be represented by a linear second order differential equation is called as a second order
system. A U-Tube Manometer is a second order system. In many applications the pressure difference to be
measured may vary with time. The response time of the measuring instrument and the connecting tubes
decide the response time.

On applying force balance and solving the obtained equation, we get the transfer function for this second
order system as

Where

k = Gain

τ = Characteristic time

ε = Damping Factor or Damping Coefficient

G(s) is the transfer function of the system under consideration

The dynamic behavior of the U-tube liquid manometer with equal diameter columns corresponds to an under-
damped dynamic system. Improving the dynamic response (decreasing the overshoot and the settling time,
increasing the phase and delay margins) can be achieved by increasing the connection tube length, by
decreasing the columns diameter and by using a high density liquid manometer.

When the pressure at the top of the two legs are equal, the two-mercury level are at rest at the same horizontal
plane. Let us assume that there is suddenly a pressure difference P = P1 - P2 is imposed on the two legs of
the manometer. To know the dynamic response of the level in the two legs. We have to proceed as below.

Let us apply Newton’s law on the plane ‘C’ of the manometer. Balance of forces on the system = mass ×
acceleration

F = m.a

{(Force . due to pressure p1 on leg1) - (Force due to pressure P2 on leg2) - (Force due to liquid level
difference in the two legs) - (Force due to fluid friction)}

= (Mass of liquid in the tube) × (Acceleration) (or)

 BLOCK DIAGRAM OF U TUBE MANAOMETER

PROCEDURE

1. Install the equipment is good manner.

2. Fully close the hand valve and release all the release valve.
3. Now, fully close the release valve.
4. Apply the pressure by Foot pump to the manometer.
5. Switch ON the unit and the computer.
6. Observe the dynamic response of the manometer.
7. Again, release the pressure.
8. Check the U-tube manometer for atmospheric pressure acts on both limbs or nor.
9. Observe the steady state height of U-tube manometer where no atmospheric pressure acts on both
either limbs.
10. Apply the pressure inputs to one of the limbs for a certain amount of time.
11. Note the displacement of manometric fluid from the steady state height and time of oscillation.

Observations:

1. steady state height

H(s) = cm.

2. Initial Height, H (i) = cm.

Observation Table:

Sr.
Height H(t) (cm) Time t in (sec) Y(t) = ( H(t) – H(i)/ H(s)- H(i)
No.

Calculations:

f = cyclical frequency

From the graph,

T=
f= s-1

Rise time from the graph = s

Response time from the graph = s

GRAPH:

RESULT:

a. The dynamic response of a U-Tube manometer following a step change was studied.
b. To study the characteristics of an under-damped second order response like overshoot, rise time,
decay ratio, response time etc., was studied and
c. The transfer function of second order system was determined.
VIVA VOCE:

1. What is the basic principle behind a U-tube manometer?

2. How does the height difference between the two columns of liquid in the U-tube relate to the
pressure difference in the system?
3. What type of liquid did you use in the manometer, and why was this specific liquid chosen?
4. How did you measure pressure using the U-tube manometer?
5. What are the units of pressure that you obtained from the height difference of the liquid columns?
6. how the behavior of the liquid in the U-tube manometer is affected by changes in pressure?
7. How do you ensure accurate readings from the U-tube manometer?
8. Are there any factors or errors that might affect the readings?
9. In what practical situations or industries is a U-tube manometer commonly used?
10. What are some limitations of using a U-tube manometer for pressure measurement?

REFERENCES:

1. https://youtu.be/_8bkJQo06io
2. https://youtu.be/BKlVn6D9uxE
3. https://www.youtube.com/live/ohCFTGBdiWA?feature=share
Expt:
Date:
TUNING OF CONTROLLERS

AIM:

To tune the controllers using Ziegler Nichols controller settings

THEORY:

The process of experimentation for obtaining the optimum values of the controller parameters with respect
to a particular process is known as controller tuning. A response that gives minimum overshoot and $ decay
ratio is often considered as a satisfactory response. In many cases, tuning is done by trial and error until such
a response is obtained. In order to compare different responses that use different sets of controller parameters,
a criterion that reduces the entire response to a single number, or a figure of merit, is desirable.It is needless
to say, that controller tuning is very much process dependent and any improper selection of the controller
settings may lead to instability, or deterioration of the performance of the closed loop system. In 1942 two
practicing engineers, J.G. Ziegler and N.B. Nichols, after carrying out extensive experiments with different
types of processes proposed certain tuning rules, there were readily accepted and till now are used as basic
guidelines for tuning of PID controllers. Subsequently, G.H. Cohen and G.A. Coon in 1953 proposed further
modifications of the above techniques. Still then, the methods are commonly known as Ziegler-Nichols
method.

PROCEDURE:

Ziegler and Nichols did not suggest that the ultimate gain (Ku) and ultimate period (Pu) be computed from
frequency response calculations based on the model of the process. They intended that Ku and Pu be obtained
from a closed-loop test of the actual process. When the rules were first proposed, frequency response methods
and process models were not generally available to the control engineers. The rules are presented below, and
are in the form that one would use for actual application to a-real process.

After the process reaches steady state at the normal level of operation, remove the integral and derivative
modes of the controller, leaving only proportional control. On some PID controllers, this requires that the
integral time (τI) be set to its maximum value and the derivative time (τD) to its minimum value. On modern
controllers (microprocessor-based), the integral and derivative modes can be removed completely from the
controller.
Select a value of proportional gain (Kc), disturb the system, and observe the transient response. If the
response decays, select a higher value of Kc and again observe the response of the system. Continue
increasing the gain in small steps until the response first exhibits a sustained oscillation. The value of gain
and the period of oscillation that correspond to the sustained oscillation are the ultimate gain (Ku,) and the
ultimate period (Pu).

From the values of Ku, and Pu found in the previous step, use the Ziegler-Nichols rules given in Table to
determine controller settings (Kc,τI,τD).

The ultimate period Pu is defined as the period of the sustained cycling that would occur if a proportional
controller with gain Ku were used.
GRAPH:

RESULT:

The tuning of controllers was done using Zeigler- Nichols Settings.

VIVA VOCE:

1. What is the Ziegler-Nichols tuning method, and what is its primary purpose in control systems?
2. How does the Ziegler-Nichols method determine the ultimate gain and ultimate period?
3. Explain the significance of the ultimate gain and ultimate period in the context of controller tuning.
4. What are the three types of controllers that can be tuned using the Ziegler-Nichols method?
5. What is the "Ziegler-Nichols Closed-Loop" tuning method, and how does it differ from the open-loop
method?
6. How does the Ziegler-Nichols method help in setting the proportional, integral, and derivative gains of
a PID controller?
7. Why is it important to observe the system's response during the "overshoot" phase when using the
Ziegler-Nichols method?
8. What criteria are used to determine the ultimate gain and ultimate period in the Ziegler-Nichols
method?
9. Explain the concepts of "critical gain" and "critical period" in the Ziegler-Nichols tuning method.
10. Discuss the effect of increasing the proportional gain in the Ziegler-Nichols method on system stability
and response.
11. How might the Ziegler-Nichols tuning method be adapted for systems with nonlinear dynamics or
complex behaviors?
12. Discuss the trade-offs between performance, stability, and robustness when using the Ziegler-Nichols
method for controller tuning.
13. Why is it recommended to fine-tune the initial Ziegler-Nichols settings based on the specific
requirements of a control application?
14. Why the Ziegler-Nichols method is may not be suitable for all types of control systems or processes?

REFERENCES:

1. https://youtu.be/nvAQHSe-Ax4
2. https://youtu.be/IB1Ir4oCP5k
3. https://youtu.be/1ImhKwpSmuc
Expt:

Date:

RESPONSE OF FIRST ORDER SYSTEM USING MATLAB

AIM:

To obtain the response of first order system for step, impulse and sinusoidal function for the transfer
function 10/(0.1s+1) using MATLAB

STEPS:

Step Input:

%Y(s)= 10/s(0.1s + 1)
num=10; %num=>numerator
den=[0.11]; %den=>denominator
step(num,den) %step=>MATLAB function for step input
sys=tf(num,den) %tf=>numerical values of plot
[temp,t]=step(sys); %Assigns variables temp and t to the
response data=[t,temp] %Concatenation of matrix anddisplay

Impulse Input:

num=1
;
den=[1
1];
sys=tf(num,den)
[y,x]=impulse(sys);
data=[xy]
plot(x,y)

Sinusoidal Input:

%x=sin(4t)
num=1
;
den=[1
1];
sys=tf(num,den)
t=0:0.1:10; % Sets up a time vector to be used for the sine wave
input. u=sin(4*t); % Defines the sine wave inputfunction.
z=lsim(sys,u,t); % Invokes the linear simulator within MATLAB and assigns the output to
z. plot(t,z,t,u) % Plots the input and output on the sameaxes.
 holdon % Holds the axes for furthergraphs.
w=0.2353*exp(-t)+0.2425; % Transient
envelope. plot(t,w) % Plots the
transientenvelope.
q=0.2425; % Peak height for the ultimate periodic
response. plot(t,q) % Plots the steady-state peak height

Model Graph:

Step Input:

Impulse Input:

Sinusoidal Input:
RESULT:

The response of first order system for step, impulse and sinusoidal function using MATLAB was obtained.
VIVA VOCE:

1. What is the key characteristic that distinguishes a first-order system from higher-order systems?
2. Could you write down the general form of a first-order linear differential equation that represents the
behavior of a first-order system?
3. How did you implement the first-order system in MATLAB?
4. What MATLAB functions or commands did you use to simulate the system's response?
5. What is the significance of the time constant in the context of a first-order system?
6. How does changing the value of the time constant affect the system's behavior?
7. What is a step response, and why is it important to study in the context of a first-order system?
8. How can you derive the transfer function of a first-order system from its differential equation?
9. Why is the transfer function representation useful in control system analysis?
10. How can you identify the system's rise time, settling time, and steady-state behavior from the step
response?

REFERENCES:

1. https://youtu.be/vhwwro2Pg8Y
2. https://youtu.be/Ho4Y7FvZ_Fw
3. https://youtu.be/dkM1DZK1hCQ
Expt:

Date:

RESPONSE OF NON- INTERACTING FIRST ORDER SYSTEM USING SIMULINK

AIM:

To obtain the response of four tanks in series using Simulink.

PROCEDURE:

MODEL GRAPH:

RESULT:
The response of four tanks in series using Simulink was obtained.

VIVA VOCE:

1. What a non-interacting first-order system is in the context of control systems?

2. What are the key characteristics that define a non-interacting system?
3. What was the main objective of the lab experiment involving a non-interacting first-order system in
Simulink?
4. What are the steps you took to set up the Simulink model for the non-interacting first-order system.
5. What Simulink blocks did you use to represent the system's components and behavior?
6. How did you translate the system's transfer function into a Simulink model?
7. What parameters did you need to input into the Simulink blocks to accurately represent the system?
8. Did you consider any initial conditions for the system's response? If so, how did you incorporate
them into the Simulink model?
9. How do initial conditions affect the transient response of a first-order system?
10. How did you simulate and analyze the step response of the non-interacting first-order system in
Simulink?
11. What information can you extract from the step response graph in Simulink?
12. How did you determine the time constant of the first-order system using the Simulink model and
simulation results?
13. Can you explain the relationship between the time constant and the system's behavior?
14. From the Simulink simulation, how did you determine the rise time and settling time of the system's
response?
15. What do these time parameters indicate about the system's transient and steady-state behavior?

REFERENCES:

1. https://youtu.be/OygfyVMcQzE
2. https://youtu.be/HwylU4E2060
3. https://youtu.be/dthue61IoKI