Manipal University Jaipur

Department of Biotechnology & Chemical Engineering

CE 3231 – PROCESS DYNAMICS & CONTROL LAB

III YEAR, 6TH SEMESTER, 2024-25

EXPERIMENT #1
EXPERIMENT TITLE – SINGLE TANK SYSTEM

INSTRUCTOR:
Instructor Name – Prof. (Dr.) Anees Y. Khan
Made By – Mragank Rastogi (229101003)

Experiment Carried On: - January 16, 2025

Report Submitted On: - January 23, 2025

PRELAB REPORT (10) ______

EXECUTIVE SUMMARY (10) ______
OBJECTIVES/INTRODUCTION/SCOPE/PROCEDURE (30) ______
RESULTS & DISCUSSION (30) ______
CONCLUSIONS (5) ______
REFERENCES (5) ______
APPENDIX
a) Original data, sample calculations, other information (5) ______
GENERAL COMPLETENESS
a) Conciseness and neatness (5) ______
TOTAL (100) ______
 Table of Contents

EXECUTIVE SUMMARY …………………………………………………… 3

1. OBJECTIVE ………………………………………………………………... 4
2. INTRODUCTION ………………………………………………………….. 4
3. THEORY AND EXPERIMENTAL SETUP ……………………………... 4
APPENDIX AND RESULT …………………………………………………... 8
4. DISCUSSION ……………………………………………………………… 11
5. PRECAUTION ……………………………………………………………. 13
6. CONCLUSION ……………………………………………………………. 13
7. REFERENCES ……………………………………………………………. 14
EXECUTIVE SUMMARY
This experiment studied how a single tank system responds to changes in water flow. We tested
two types of changes: step change (gradually increasing flow) and impulse change (sudden water
addition).
For the step change, we increased the flow from 40 LPH to 64 LPH and observed that the water
level rose quickly at first and then slowed down, finally stabilizing at 184 mm after about 5
minutes.
For the impulse change, we added 200 mL of water suddenly, causing the water level to jump to
97 mm. Over time, the level gradually returned to its original state as the extra water drained out.
The results followed the expected behavior of a first-order system, meaning the system adjusted
smoothly without sudden jumps or oscillations. Small differences in readings may have been
caused by minor errors in measurement, flow variations, or environmental factors.
Overall, this experiment helped us understand how tanks respond to changes in water flow,
which is important for controlling water levels in real-world applications like water treatment
and industrial processes.
1. OBJECTIVE
To study the dynamic response of a single tank system subjected to a step and impulse change.

2. INTRODUCTION
We are carrying out this experiment to gain knowledge about single tank system would react
when subjected to a step and impulse change respectively.
A single liquid tank is basically a first order process in which the inlet flow from a source of
liquid (q) enters in the liquid tank from the top and exits from a small opening at the bottom
whose flow is controlled via a valve that acts as a resistance ‘R’. Where A is the area of the tank
and q o is the volumetric outlet flow rate of liquid from the bottom of the tank.
The system’s response to changes in inlet flow (step change) and sudden disturbances (impulse
change) provides valuable insights into system dynamics, process control strategies, and the
determination of key parameters such as the time constant and system resistance.
Assumption: -
1. Liquid of constant density.
2. Uniform cross-sectional area of tank.
3. Linear flow resistance.
This setup allows for controlled experimentation, making it useful for understanding first-order
system dynamics and process control principles.

3. THEORY AND EXPERIMENTAL SETUP

FIG 1: - SINGLE TANK SYSTEM (FOR MATERIAL BALANCE)

Balance on Tank gives:
dh
q ( t )−qo ( t )= A1 ….. ….. (1)
dt
The flow-head relationship for linear resistance is given by:
h
q o= ….. ….. (2)
R
Upon Combining the two equations, it yields:
h dh
q− =A 1 ….. ….. (3)
R dt
At steady state, dh/dt = 0.
hs
q s− =0 ….. ….. (4)
R
Subtracting equation 4 from 3;

1 d (h−hs )
q−q s=
R
( h−hs ) + A1
dt
….. ….. (5)

Deviation Variables:
q−q s=Q

h−hs =H

Rewriting equation 5 as:

1 dh
Q= H + A1 ….. ….. (6)
R dt
Using Laplace Transform yields:
1
Q ( s )= H ( s ) + A1 H ( s) ….. ….. (7)
R
Rearranging gives:
H (s ) R
= ….. ….. (8)
Q(s ) (τs+1)
Where, τ = A1R;
Now, for a step change of magnitude A,
Q ( t ) =A∗u ( t ) ….. ….. (9)
Therefore, the overall transfer function for a step change from equation (8) becomes:
 A R
H 2 ( s )= ….. ….. (10)
s (τs+1)

Now; Taking R = 1: -
A 1
H 2 ( s )= ….. ….. (11)
s (τs+1)

Taking Laplace Transform of equation 11:

−t
H ( t ) =A (1−e τ )
Now,
For an impulse change of magnitude V (volume added to the system):
Q ( t ) =V∗δ(t ) ….. ….. (12)
Similarly, the overall transfer function for an impulse change is given as:
V ∗R
H 2 ( s )= ….. ….. (13)
(τs+1)
Now; Taking R = 1: -
V ∗1
H 2 ( s )= ….. ….. (14)
( τs+1 )
Taking Laplace Transform of equation 14:
−t
V
H ( t ) = (e τ )
τ

EXPERIMENTAL SETUP: -
The experimental setup consists of a single tank system with a controlled inlet and outlet,
designed to study the system’s dynamic response to step and impulse changes. The key
components of the setup are:
1. Tank 1 (Primary Tank) – The main system where water level variations are observed. It
receives inflow from the pump and discharges through a controlled valve (R1).
2. Tank 2 & Tank 3 – These additional tanks are part of the setup but are not actively used
in the experiment. They may serve as reservoirs or for system modifications in other
configurations.
3. Rotameter – A flow-measuring device that ensures precise control of the inlet flow rate.
It helps in maintaining steady-state conditions before applying disturbances.
 4. Pump – Circulates water through the system by drawing from the sump tank and
delivering it to Tank 1.
5. Valves (R1, R2, R3) –
o R1 (Primary Outlet Valve) – Controls the outflow from Tank 1, regulating the
resistance in the system.
o R2 and R3 (Additional Valves) – These control flows in Tank 2 and Tank 3 but
are not involved in this experiment (remained closed).
6. Sump Tank – A collection reservoir for water that drains from the system, ensuring
continuous circulation.

FIG 2: - PROCESS FLOW DIAGRAM FOR SINGLE TANK SYSTEM

Procedure: -
Starting: -

1. Turn on the main power supply.

2. Ensure proper pipe fittings and connections between Tank 1 and the rotameter.

3. Partially close the outlet valve R1, fully open R2, and keep R3 completely closed.

4. Start the pump and set the flow rate to the desired level.

5. Allow the liquid level in Tank 1 to stabilize at a steady state.

For a Step Change: -

1. Once the steady state is achieved, apply step change by increasing the inlet flowrate to the
tank.

2. Record the water level after every fixed interval of time till steady state is reached.

3. Once the steady state is achieved, record the final level of the tank.

4. Repeat for another set of readings.

For an Impulse Change: -

1. Once the system reaches steady state apply impulse change by adding 200 ml of water directly
to the tank.

2. Record the water level immediately.

3. Record the water level in the tank after every fixed interval of time till steady state is reached.

4. Once the steady state is achieved, record the final level of tank.

5. Repeat for another set of readings.

Closing: -

1. Once all the readings are taken, switch off the pump and the main power supply.

2. Drain out the tank and clean the apparatus.

APPENDIX AND RESULT

For Step Change: -

Initial Flow Rate = 40 LPH

Final Flow Rate = 64 LPH

TABLE 1: STEP UP
S.No. Time (sec) h (mm) H (mm)
1 0 87 0
2 10 91 4
3 20 101 14
4 30 109 22
5 40 118 31
 6 50 125 38
7 60 131 44
8 70 136 49
9 80 142 55
10 90 147 60
11 100 151 64
12 110 155 68
13 120 159 72
14 130 162 75
15 140 164 77
16 150 167 80
17 160 169 82
18 170 172 85
19 180 174 87
20 190 175 88
21 200 177 90
22 210 178 91
23 220 179 92
24 230 180 93
25 240 182 95
26 250 183 96
27 260 184 97
28 270 184 97
29 280 184 97
30 290 184 97
31 300 184 97
32 310 184 97
33 320 184 97
34 330 184 97

For Impulse Change: -

Volume of water added = 200 mL

Flow Rate = 43 LPH

TABLE 2: FOR IMPLUSE

S.No. Time (sec) h (mm) H (mm)
1 0 68 0
2 10 97 29
3 20 95 27
4 30 91 23
5 40 88 20
6 50 86 18
 7 60 84 16
8 70 82 14
9 80 80 12
10 90 78 10
11 100 77 9
12 110 76 8
13 120 75 7
14 130 74 6
15 140 73 5
16 150 72 4
17 160 72.5 4.5
18 170 71 3
19 180 70.3 2.3
20 190 70 2
21 200 69.8 1.8
22 210 69 1
23 220 68.4 0.4
24 230 68.1 0.1
25 240 68 0
26 250 68 0
27 260 68 0
28 270 68 0
29 280 68 0
30 290 68 0

SAMPLE CALCULATION: - (FOR STEP CHANGE)

Initial Height of Tank 1 = 87mm

Final Height of Tank 1 = 184mm

Value of 63.2% of step (t = τ ¿ = 0.632 * (184 – 87) = 61.304

At 61.304, from the graph we got the value of τ =93 sec

From experimental data: -

Area of Tank 1 = 68.22 cm2=6822 mm 2

H = 184 – 87 = 97mm

Q = 64 – 40 = 24 LPH = 6666.67 mm3 /sec

H 97 mm 2
R= = =0.0145 sec /mm
Q 6666.67 mm / sec
3
τ =A∗R=¿ 6822 * 0.0145 = 98.92 sec

∴ τ =98.92 sec

From experimental data we got the value of time constant ( τ ) to be 98.92 seconds, but we get the
value of (τ) from graph to be 93 seconds.

4. DISCUSSION

For Step Change (Step Up): -

120 Time vs Deviation

100
Deviation H (mm)

80

60

40

20

0
0 50 100 150 200 250 300 350
Time (sec)

FIG 3: - STEP CHANGE RESPONSE CURVE OF H (DEVIATION) VS TIME

When we increased the water flow from 40 LPH to 64 LPH, the water level in the tank started
rising. At first, the increase was fast, but over time, it slowed down and eventually reached a new
steady level of around 184 mm. This follows the expected behavior of a first-order system,
where changes happen quickly at the start and then gradually settle. From figure 3, at t = τ , we
get τ =93 sec

From the data, we can see that it took about 4-5 minutes for the system to stabilize. This matches
the theoretical model, confirming that the system reacts in a predictable way when there is a
sudden change in inflow.
 TIME VS DEVIATION
1.2
1

Deviation H (mm)
0.8
0.6
0.4
0.2
0
0 50 100 150 200 250 300 350
Time (sec)

FIG 4: - STEP CHANGE RESPONSE CURVE OF H (DEVIATION) VS TIME

A comparison of Figure 4 (theoretical) and Figure 3 (experimental) shows that both follow a
first-order system response, with a rapid initial rise and gradual stabilization within 4-5 minutes.
The theoretical curve is smooth, with a time constant (τ) of 98.9 seconds, while the experimental
data shows slight deviations due to noise, disturbances, or sensor inaccuracies with a time
constant (τ) of 93 seconds. Despite minor differences, both responses align well, confirming the
model’s validity in predicting the system’s behavior under a step change.

For Impulse Change: -

Time vs Deviation
35

30

25
Deviation H (mm)

20

15

10

0
0 50 100 150 200 250 300 350
Time (sec)

FIG 5: - IMPULSE CHANGE RESPONSE CURVE OF H (DEVIATION) VS TIME

For the impulse test, we added 200 mL of water to the tank all at once. This caused a sudden rise
in water level to 97 mm. After that, the level started to slowly decrease as the extra water drained
out. The decrease was fast at first and then slowed down over time, following the expected
pattern of a first-order system.

By looking at the figure 4, the water level returned to its original state, we can estimate how the
system naturally stabilizes. The results showed that the system does not oscillate or overshoot,
meaning it behaves smoothly without sudden jumps.

Comparison with Theory: -

The experiment results match well with what we expected based on theory. The way the water
level changed in both tests was similar to the predicted behavior of a first-order system.
However, small differences may have occurred due to practical factors like slight variations in
flow, minor measurement errors, or small disturbances in the environment.

Possible Errors: -

There might be some errors which have affected the results, including:

 Measurement errors: Manually recording water levels could lead to small mistakes.
 Flow variations: The pump might not always supply exactly the same flow.
 Environmental effects: Things like small vibrations or temperature changes might have
slightly affected the results.

5. PRECAUTION

1. Check Equipment Setup – Ensure all pipes, valves, and connections are properly fitted before
starting the experiment to avoid leaks.

2. Maintain a Steady Flow – Adjust the rotameter carefully to ensure a constant inlet flow rate
before applying step or impulse changes.

3. Avoid Air Bubbles – Ensure there are no air bubbles in the system as they might affect the
accuracy of the readings.

4. Record Readings Accurately – Measure water levels carefully at the correct time intervals to
ensure precise results.

5. Prevent Overflow – Do not exceed the tank’s capacity to avoid water spillage and inaccurate
measurements.

6. CONCLUSION
This experiment helped us understand how a single tank system reacts to changes in water flow.
When we increased the flow (step change), the water level rose quickly at first and then slowly
reached a stable level. When we suddenly added water (impulse change), the level increased
instantly but then gradually returned to normal.

Both results matched what we expected based on theory, showing that the system behaves like a
first-order process. This experiment also showed how important factors like time constant affect
the system’s response.

Overall, the experiment gave us a clear understanding of how tanks respond to changes.

7. REFERENCES

1. Coughanowr, D. R., & LeBlanc, S. (2017). Process Systems Analysis and Control (3rd ed.).
McGraw-Hill.

2. Seborg, D. E., Edgar, T. F., & Mellichamp, D. A. (2016). Process Dynamics and Control
(4th ed.). Wiley.

3. Lab Manual, Process Dynamics & Control Lab.