LAB REPORT

2016-CH-405

UNIVERSITY OF ENGINERING AND TECHONOLOGY, LAHORE

 Introduction
Engineering is concerned with understanding and controlling the materials and forces of nature
for the benefit of humankind. Control system engineers are concerned with understanding and controlling
segments of their environment, often called systems, to provide useful economic products for society. The
twin goals of understanding and controlling are complementary because effective systems control requires
that the systems be understood and modeled. Furthermore, control engineering must often consider the
control of poorly understood systems such as chemical process systems.
System:
The number of element and components are connected in a sequence to form a group that group is said to
be a system.
Control System:
The output quantity is controlled by varying the input quantity this system is said to be a control system.
➢Experiment # 1
Objective:
To demonstrate the fundamentals of control engineering using an example of pressure control.

Technical Procedure
This trainer provides a comprehensive experimental introduction to the fundamentals of controls
engineering using an example of pressure control. The air pressure control system is a 2 nd order system. It
comprises two in-line pressure tanks interconnected by a flow control valve. An additional valve on the
second tanks makes air tapping possible and so can used to simulate a disturbance variable. A pressure
sensor measures the pressure in second vessel. The controller used is a state-of-the-art digital industrial
controller. The actuator in the loop is a pneumatically operated control valve with a standardized current
signal input. The controlled variable X and the manipulating variable Y are plotted directly on an integrated
2-channel line recorder. Alternatively, the variables can e tapped as analogue signals at lab jacks on the
switch cabinet. This enables external recording equipment such as an oscilloscope or a flatbed plotter, to
be connected. A process control software (RT 650.50) is optionally available. The software permits the
construction of a complete networked system comprising multiple trainers from the RT 512-RT 552 series.
The key process variables can also be represented and control functions executed. The well-structed
instructional material sets out the fundamentals and provides a step-by-step guide through the experiments.

Line Diagram: Air Receiver Tank

Relief valve

3-way valve

Pneumetic
Controller Globe valve

Air Receiver Tank

Process Description:
Pressure Control Trainer (Model:SE101) has been designed for students experiments on the measurement
and control of air pressure in a vessel. It is on an epoxy coated steel frame with lockable castor wheel. The
air is contained in an air receiver tank before entering the air pressure control tank. A pressure transmitter
is installed to measure the air pressure and is linked to the microprocessor-based controller. The output of
the controller is linked to the pneumatic control valve to manipulate the air flowrate and hence the pressure
in the control tank.
The unit is supplied with a chart recorder. All instrumentation supplied are of industry standard and all
electrical wires are numbered for identification. All electrical wiring is laid in flexible PVC conduit and all
instrument wirings are screened. The Control panel is safely protected against water splashes.

Experimental Capabilities:

• Close loop with Proportional band only control

• Close loop with P Plus Integral time control
• Control loop with P Plus Derivative control
• PID Loop tuning for optimum control
• Self-tuning
• Control valve sizing calculation
• Demonstration of a pressure relief valve for over pressure protection

Components
I. Pressure Controller:
Pressure controllers are electronic controllers which quickly and automatically provide a pressure
based on a supply pressure.
Specifications:
Type: Microprocessor based
Input: 4 to 20 mA
Output: 4 to 20 mA
Controls: P, PI, PD, PID and “Self-Tuning”

II. Pressure Recorder:

Type: Continuous pen

No of pen: 2
Chart: Z-fold
Chart speed: 0 to 3600 mm/hr., Stepped
 III. Control Valve
A control valve is a valve used to control fluid flow by varying the size of the flow passage as directed
by a signal from a controller. This enables the direct control of flow rate and the consequential control
of process quantities such as pressure, temperature, and liquid level.
Specifications:
Type: Globe Actuator:
Diaphragm Input: 3 to 15 psig

IV. I/P Convertor/Positioner:

An I/P Converter is also known as a “current to pressure transducer” as it provides flow/speed
controls and directional control functions in a single valve. Otherwise known as an I/P Transducer,
an I/P Converter eliminates the need for any external power supply by translating electric currents
into pneumatic output.
Specifications:
Input: 4 to 20 mA
Output: 3 to 15 psig

V. Pressure Transmitter:
A pressure transmitter or pressure sensor is a device that measures pressure in a liquid, fluid, or
gas. Pressure transmitters are commonly used to measure pressure inside of industrial machinery
in order to alert the user before a catastrophe occurs.
Specifications:
Range: 0 to 30 psig
Output: 4 to 20 mA

VI. Air Regulator:

Manifold regulators help provide multiple pressures from a common inlet. They can be controlled
remotely via a small pilot regulator. They are ideal for use in applications requiring a constant
pressure with variable flow rate.
Specifications:
Air supply: 100 psig
Output: a) 0 to 60 psig
b) 0 to 30 psig
VII. Air Receiver Tank:
Specifications:
Capacity: 50 litters
Material: Mild Steel

VIII. Pressure Gauge:

Pressure measurement is the analysis of an applied force by a fluid on a surface. Pressure is
typically measured in units of force per unit of surface area. Many techniques have been
developed for the measurement of pressure and vacuum.
Specifications:
Type: Bourdon Tube
Dial size: 100 mm
Range: 2 to 100 psig
References:
http://www.vvitengineering.com
Inshall Traders
www.wikipedia .com
➢Experiment # 2
 Flow Instrumentation Bench
Objective:
Calibration of different flow meters, position dependency of flow meters, Investigation of
properties of open and controlled loop system and plotting and comparison of pressure
loss curves.

Flow Instrumentation Bench:

Description:
This trainer provides the comprehensive experimental introduction to fundamental of control
engineering using an example of Pressure Control. The air pressure control is a 2nd order system.
It comprises two in-line Pressure tanks interconnected by a flow valve. An additional valve on the
second tanks makes air tapping possible and so can be used to simulate a disturbance variable. A
pressure sensor measures the Pressure in the second vessel. The actuator used in the loop is
pneumatically controlled valve with a standardized current signal input unit. The controlled signal
X and manipulated variables Y are plotted directly on 2-channel line recorder. Alternatively, the
variables can be tapped as analogue signals at lab jacks on the switch cabinet.
Components of Trainer:
The flow instrumentation trainer contains following components:

1. Submerged Pump:
Submersible Pump is a device with hermitically sealed motor close-coupled to the pump body.
The whole body submerged in the fluid is to be pumped. It is represented by cavitation.

2. Rotameter:
Rotameter is device which measures the volumetric flowrate of fluid in a closed tube. It is a
variable area flowmeter which measures flow by allowing cross sectional area of fluid to vary.

3. Sensor:
Sensor is a device that measures a physical quantity and converts it into signals.

4. Controller:
Controller receives the signals from sensor and match with the standard value assigned to it and if
there is a fluctuation, then it decides which variables (Temperature, Pressure, and Flowrate) should
be controlled.

5. Electromagnetic Sensor:
The device to measure physical quantity such as pressure and convert it into signals.
Procedure:
• .Firstly, switch on the system and fill the tank with water.
• Flow will be measured using Rotameter and controlled by Controller.
• When the flowmeter is calibrated, the software will show X variation against Y.

Applications:
Flow Instrumentation Trainer can be used for:
• Controlling flow of Natural Gas
• Measurement of Compressed Air Flow
• Controlling Burner
• Measuring Steam Flow
➢Experiment # 3
Objectives:
➢ Studying the operation, configuration and parameterization of the local industrial controller
manually and by using the process control software
➢ Studying the fundamentals of control engineering
➢ Processing of process variables using external equipment such as computer plotter.

Line Diagram:

Description:
This temperature control trainer provides a comprehensive experimental introduction to the fundamentals
of instrumentation and control engineering using an example of temperature control.
First of all, a circulating pump delivers water within a closed circuit. The flow rate of water can be adjusted
by a hand-operated valve. The loop also contains a screw-in heater, a heat exchanger with fan, and three
integrated thermocouples for temperature measurement. Dead times can be represented by the use of
different lengths of process delay. A thyristor power controller is used as the actuator. The controller used
is a state-of-the-art digital industrial controller. It can be configured as a continuous or a switching device,
and can activate the heater via the actuator and/or the fan. The controlled variable X and the manipulating
variable Y are plotted directly on an integrated 2-channel line recorder. Alternatively, the variables can be
tapped as analogue signals at lab jacks on the switch cabinet. This enables external recording equipment
such as an oscilloscope or a flatbed plotter, to be connected.
Components of Equipment and their Function:
Their function is described below:

Pump:
The pump is used to transfer water from the storage to the trainer in order to study the behavior of
temperature on it.

PID Controller:
A proportional integral derivative (PID) controller can be used as a means of controlling temperature,
pressure, flow and other process variables. As its name implies, a PID controller combines proportional
control with additional integral and derivative adjustments which help the unit automatically compensate
for changes in the system.

Heat Exchanger:
Use to transfer heat from high temperature source to surrounding using air that comes from the blower/fan.

Switch Cabinets:
Switch cabinets/switchgear contain sensitive electrical, electronic and mechanical components to perform
control, drive, power supply and safety functions.

Thermocouple:
A Thermocouple is a sensor used to measure temperature. Thermocouples consist of two wire legs made
from different metals. The wires legs are welded together at one end, creating a junction. This junction is
where the temperature is measured. When the junction experiences a change in temperature, a voltage is
created.

Fan:
The purpose of the fan to provide the air to exchanger for exchanging heat.

Ball Valve:
Ball valve is the most used fluid shutoff valve in upstream oil and gas production facilities, both onshore
and offshore.

Screw-in Heater:
It is used for précised heat control for the equipment as it supplies heat to small quantity of liquid but in a
controlled manner.

Procedure:
1. Turn on the equipment carefully.
2. First of all calibrate the equipment and note the value if there is any for calibration.
3. Now, set a value of temperature which want to attain for the liquid.
4. Turn On the pump and then heater and wait for the temperature to rise.
5. During this, carefully watch the temperature gauge.
 6. When the temperature increases beyond the set point then the heater will be switched off
automatically by the controller.
7. Now, the controller is said to be in the off condition.
8. The reading is noted down for this condition.
9. The reading is noted down after every 10-15 min in increase or decrease in temperature.
10. A graph is drawn between time and temperature.
11. The same procedure is repeated for different set points.

Calculations:
Set Point=

Sr No. Time (sec) Temperature (OC) Controller Position

Result:
The characteristics of the controller for given set point are obtained.
➢Experiment # 4
➢
Level Control Trainer

Description of Equipment:

This trainer provides a comprehensive experimental introduction to the fundamentals of control

engineering using an example of level control.
A pump delivers water from a storage tank to the transparent level-controlled tank. The liquid level is
measured by a pressure transducer installed at the base of the level-controlled tank.

The controller used is a state-of-the-art digital industrial controller. The actuator in the control loop
is a pneumatically operated control valve with an electro-pneumatic positioner. A valve in the outlet line
enables defined disturbance variables to be generated. Alternatively, the variables can be tapped as analogue
signals at lab jacks on the switch cabinet. This enables external recording equipment, such as an
oscilloscope or a flatbed plotter, to be connected.

Components

Pressure transducer:
A pressure transducer, often called a pressure transmitter, is a transducer that converts
pressure into an analog electrical signal. Although there are various types of pressure transducers, one of
the most common is the strain-gage base transducer.

The conversion of pressure into an electrical signal is achieved by the physical deformation of strain
gages which are bonded into the diaphragm of the pressure transducer and wired into a wheatstone bridge
configuration. Pressure applied to the pressure transducer produces a deflection of the diaphragm which
introduces strain to the gages.
The strain will produce an electrical resistance change proportional to the pressure.

Centrifugal pump:
Positive displacement pump makes a fluid move by trapping a fixed amount and forcing
(displacing) that trapped volume into the discharge pipe.
Some positive displacement pumps use an expanding cavity on the suction side and a decreasing cavity on
the discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows
out of the discharge as the cavity decreases. The volume is constant through each cycle of operation.
A positive displacement pump must not operate against a closed valve on the discharge side of the pump,
because it has no shutoff head like centrifugal pumps. A positive displacement pump operating against a
closed discharge valve continues to produce flow and the pressure in the discharge line increases until the
line bursts, the pump is severely damaged, or both.
A pressure relief or safety valve on the discharge side of the positive displacement pump is therefore
necessary. The relief valve can be internal or external.

Pneumatic actuator:
A Pneumatic actuator mainly consists of a piston which develops the motive power. It keeps the
air in the upper portion of the cylinder, allowing air pressure to force the diaphragm or piston to move the
valve stem or rotate the valve control element.
Valves require little pressure to operate and usually double or triple the input force. The larger the
size of the piston, the larger the output pressure can be. Having a larger piston can also be good if air supply
is low, allowing the same forces with less input. These pressures are large enough to crush objects in the
pipe.
The valves input is the "control signal." This can come from a variety of measuring devices, and each
different pressure is a different set point for a valve.

Rotameter:
Rotameter is variable area flow meter used to measure fluid flow. It works on the principle of up
thrust force exerted by fluid and force of gravity. The buoyant force exerted on an immersed object is equal
to the weight of liquid displaced by the object. Under this principle, the rotameter works with float-tapered
tube system.

A rotameter is made up of a tapered tube and a float inside it. The glass tapered tube has a scale on the
surface or a scale is placed adjacent to it, according to purpose.

Tapered tube:
The tapered tube is placed vertically in the flow channel with a conical shape inside. The quantity
measured is defined by the height of float going up. Glass tubes are used for both liquid and gas
measurement. Metallic tubes are used where the process fluid with high temperature and pressure.

Float:

Stainless steal floats are commonly used, there are different types of metals from lead to
aluminium used as floats. A float material, shapes are also varied according to applications
considering density.

Spherical shape floats are used for small flows.

Advantages:
✓ No external power needed
✓ Simple Reliable Design
✓ Can Measure Liquid or Gas Flows
✓ Scale is approximately linear
✓ It can measure flow rates of corrosive fluid
✓ Better rangeability
✓ Low cost and low pressure drop

Disadvantages:
• It should be mounted vertically
• And requires lining mounting
• Uncertainty of measurement
• Difficult to handle the glass type

Flow control valve:

A flow control valve regulates the flow or pressure of a fluid. Control valves normally respond
to signals generated by independent devices such as flow meters or temperature gauges. Control valves are
normally fitted with actuators and positioners. Pneumatically-actuated globe valves and diaphragm
valves are widely used for control purposes in many industries, although quarter-turn types such as
ball and butterfly valves are also used.
Automatic control valves do not require an external power source, meaning that the fluid pressure is enough
to open and close them.
Automatic control valves include pressure reducing valves, flow control valves, back-pressure sustaining
valves, altitude valves, and relief valves.

Applications:
➢ Study of PID control

➢ Optimization of level control

➢ Operation and calibration of transmitter, converter and valve

➢ Study of stability of single loop level control system

➢ Study of cascade control

➢ Configuration of microcontroller based controllers

➢ Demonstrate the proportional control of level

Specifications:
Level/Flow controller:
Type: Microprocessor based
Input: 4 to 20mA
Output: 4 to 20mA
Controls: P, PI, PD, PID and ‘Self-Tunlng’
System dimensions:
4.5 Ft. (L) x 1.5 Ft. (W) x 4.5 Ft. (H)
Electric supply:
AC 230, 50 Hz
Clean, Dry & Dust Free Compressed Air Supply:
2.1 Kg/cm3
Level Control Tank:
Capacity: 60-L
Material: Stainless Steel
Sump Tank:
Capacity: 120-L
Material: Stainless Steel

Line tracing:

ICA
01