National Institute of Technology Raipur: Process Dynamics and Control Lab Manual Subject Code: CH106401CH

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NATIONAL INSTITUTE OF TECHNOLOGY
RAIPUR
PROCESS DYNAMICS AND CONTROL

LAB MANUAL
Subject Code: CH106401CH
Prepared by
Dr. R. Manivannan
Faculty In-charge of PDC Lab
Associate Professor
Chemical Engineering
PDC Lab Manual Chemical Engg. Dept., NIT Raipur

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Experiment Contents Page No.

No.
STUDY OF CONTROL VALVE FLOW COEFFICIENT
1 4
(CV)
STUDY OF INHERENT CHARACTERISTICS OF LINEAR
2 6
CONTROL VALVE
STUDY OF INSTALLED CHARACTERISTICS OF
3 8
CONTROL VALVE
4 STUDY OF HYSTERESIS OF CONTROL VALVE 10
5 STUDY OF RANGEABILITY 12
6 DYNAMICS OF SECOND-ORDER PROCESSES 14
STUDY OF DIFFERENT TYPES OF TEMPERATURE
7 18
SENSORS
8 CHARACTERISTICS OF RTD 20
9 CHARACTERISTICS OF THERMISTOR 22
10 CHARACTERISTICS OF THERMOCOUPLE 24
STUDY AND CALIBRATION OF TEMPERATURE
11 26
TRANSMITTER
12 STUDY AND CALIBRATION OF SEEBECK EFFECT 28
TIME CONSTANT OF MERCURY IN GLASS
13 30
THERMOMETER
14 TIME CONSTANT OF BIMETAL THERMOMETER 32
15 TIME CONSTANT OF RTD SENSOR 34
16 TIME CONSTANT OF THERMISTOR SENSOR 36
17 TIME CONSTANT OF THERMOCOUPLE SENSOR 38
18 STEP RESPONSE OF SINGLE CAPACITY SYSTEM 40
STEP RESPONSE OF FIRST ORDER SYSTEMS
19 43
ARRANGED IN NON-INTERACTING MODE
IMPULSE RESPONSE OF FIRST ORDER SYSTEMS
20 ARRANGED IN NON-INTERACTING MODE 46

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STEP RESPONSE OF FIRST ORDER SYSTEMS

21 49
ARRANGED IN INTERACTING MODE
IMPULSE RESPONSE OF FIRST ORDER SYSTEMS
22 52
ARRANGED IN INTERACTING MODE
23 CHARACTERISTICS OF FLAPPER NOZZLE SYSTEM 54
24 LINEARITY OF I/P CONVERTER 56

25 HYSTERESIS OF I/P CONVERTER 58
26 ACCURACY OF I/P CONVERTER 60
27 REPEATABILITY OF I/P CONVERTER 61
28 LINEARITY OF P/I CONVERTER 63
29 HYSTERESIS OF P/I CONVERTER 64
30 ACCURACY OF P/I CONVERTER 66
31 REPEATABILITY OF P/I CONVERTER 67
32 STUDY OF PROPORTIONAL (P) CONTROLLER 69
33 STUDY OF PROPORTIONAL INTEGRAL (PI) 70

CONTROLLER
STUDY OF PROPORTIONAL DERIVATIVE (PD)
34 71
CONTROLLER
STUDY OF PROPORTIONAL INTEGRAL DERIVATIVE
35 72
(PID) CONTROLLER

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EXPERIMENT NO 1
STUDY OF CONTROL VALVE FLOW COEFFICIENT (CV)
AIM
To determine the flow coefficient CV of the equal percentage control valve / quick opening valve /
linear control valve.
SETUP REQUIRED
Control valve, pump, piping, ball valve, pneumatic compressor
EXPERIMENTAL PROCEDURE
1. Start the setup for Control Valve of equal % characteristics.
2. Open Pneumatic Line for the Control Valve.
3. Open the Control Valve fully. As the Control Valve is Air to close so pressure in diaphragm should
be 0 psig.
4. Adjust the Rotameter for 500 LPH flow by regulating the valve provided at the inlet line of the
Control Valve and wait for 5 minutes to steady the flow.
5. Record the Manometer reading in mm of water.
6. Record the Rotameter reading.
7. Increase the pressure slowly and record the Manometer & Rotameter reading up to 15 Psi.
8. Conduct the experiment for Linear Control Valve. As the Linear Control Valve is Air to Open, so
pressure in diaphragm should be more than 15 psig. Adjust this pressure in diaphragm by operating
the Pressure Regulator. Do not exceed this pressure more than 20 psig.

5
OBSERVATION:
S. No. ΔP, mm of H2O Q, LPH
CALCULATIONS
𝐺
𝐶𝑣 = 1.16𝑄√∆𝑃 = -----------------
Q= Discharge of Fluid in m3/h

∆𝑃 = Pressure Drop in Bar
G= Specific Gravity of Fluid (G = 1)
To convert ∆𝑃 in mm of H2O in Bar = ∆𝑃 in mm of H2O/(10.33×103) Bar.
RESULTS
Flow coefficient CV of the equal percentage control valve was determined to be ……………….
Flow coefficient CV of the linear control valve was determined to be …………………..............
Flow coefficient CV of the quick opening control valve was determined to be ………………….

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EXPERIMENT NO 2
STUDY OF INHERENT CHARACTERISTICS OF CONTROL VALVE
AIM
To study the inherent characteristics of equal percentage control valve / quick opening valve / linear
control valve.
SETUP REQUIRED
1. Start the setup for Linear Control Valve.
3. Open the Control Valve fully. As the Control Valve is air to close so the pressure in the diaphragm
should be 15 psig.
Control Valve.
5. Wait for 5 minutes to steady the flow.
6. Record the manometer reading in mm of water.
8. Now slowly decrease the air pressure by the regulator so that the stem travel towards the closing
position becomes 2mm.
9. The pressure drop across the valve will increase. Throttle the regulatory valve at the inlet of the
control valve to maintain a pressure drop constant
10. Again note down the reading of rotameter and stem travel.
11. Repeat the procedure and take the readings at each 2mm stem travel till the valve is fully closed
(Pressure upto 0 psig).
12. Plot the graph of valve coefficient versus lift to show inherent characteristics of the control valve.

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13. Conduct the same procedure for other to valves too. As the Linear Control Valve is Air to Open,
so Pressure in diaphragm should be 0 psig. Repeat the experimental procedure same as above, but
pressure in the diaphragm will be increased gradually.
OBSERVATION
Stem lift in mm 14 12 10 8 6 4 2 0
Q, LPH
ΔP, mm H2O
CALCULATIONS
𝐺
𝐶𝑣 = 1.16𝑄√∆𝑃 = -----------------
RESULTS
• The inherent characteristics of linear control valve was studied
• The inherent characteristics of equal percentage control valve was studied
• The inherent characteristics of quick opening valve was studied
• Valve coefficient versus lift is plotted to show the inherent characteristic of the control valve.

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EXPERIMENT NO 3
STUDY OF INSTALLED CHARACTERISTIC OF CONTROL VALVE
AIM
To study the installed characteristics of equal percentage control valve, quick opening valve, linear
control valve.
SETUP REQUIRED
1. Start the setup for Equal % Control Valve.
3. Open the Control Valve fully. As the Control Valve is air to close so pressure in diaphragm should
be 0 psig.
Control Valve.
8. Now slowly decrease the air pressure by regulator so that the stem travel towards the closing
position becomes 2mm.
9. Wait for 5 minutes to steady the flow and note down the reading of Rotameter, Manometer and
stem travel
10. Repeat the procedure and take the readings at each 2m stem travel till the valve is fully closed
(Pressure upto 15 psig)
11. Plot the graph of valve coefficient versus lift to show installed characteristic of the control valve.

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12. Plot the graph of the flow versus lift.
13. Conduct the experiment for other two valves. As the Linear Control Valve is Air to Open, so
Pressure in diaphragm should be 0 psig. Repeat the experimental procedure same as above, but
pressure in the diaphragm will be increased gradually.
OBSERVATION
Stem lift in mm 14 12 10 8 6 4 2 0
Q, LPH
ΔP, mm H2O
CALCULATIONS
𝐺
𝐶𝑣 = 1.16𝑄√∆𝑃 = -----------------
RESULTS
• The installed characteristics of linear control valve was studied
• The installed characteristics of equal percentage control valve was studied
• The installed characteristics of quick opening valve was studied
• Flow versus lift was plotted to show the inherent characteristic of the control valve.
EXPERIMENT NO 4

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STUDY OF HYSTERESIS OF CONTROL VALVE

AIM
To study the hysteresis of Control Valve
SETUP REQUIRED
1. Start the setup for equal % Control Valve.
3. Open the Control Valve fully. As the Control Valve is air to close so pressure in diaphragm should
be 0 psig.
Control Valve.
8. Now slowly increase the air pressure by regulator up to 3 psig.
9. Wait for 5 minutes to steady the flow and note down the reading of Rotameter, Manometer and
pressure in psig.
10. Repeat the procedure and take the readings at +3 psig till the valve is fully closed (Pressure upto
15 psig).
11. Now increase the pressure upto 20 psig and start decreasing the pressure gradually upto 15 psig.
13. Record the manometer reading in mm of water and rotameter reading
14. Repeat the procedure and take the readings at -3 psig till the valve is fully opened (Pressure upto
0 psig).

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15. Calculate valve flow coefficient for actuator pressure for every reading.
16. Plot the graph of actuator pressure versus flow coefficient. The ratio of maximum difference
between flow coefficients at same actuator pressure to that of maximum flow coefficient is termed
as hysteresis.
Repeat the experiment for other two valves. As the Control Valve is air to open so keep in mind
this parameter during conducting the experiment.
OBSERVATION
Pressure Increasing Pressure Decreasing Pressure

psig mm of H2O Q, LPH mm of H2O Q, LPH
3
6
9
12
15
CALCULATIONS
𝐺
𝐶𝑣 = 1.16𝑄√∆𝑃 = -----------------
𝐶𝑣 𝑎𝑡 𝑑𝑒𝑐𝑟𝑒𝑎𝑠𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒− 𝐶𝑣 𝑎𝑡 𝑖𝑛𝑐𝑟𝑒𝑎𝑠𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑟𝑒

Hysteresis %= × 100=----------------
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐶𝑣
RESULTS
Percentage hysteresis of linear control valve is found to be………………………….
Percentage hysteresis of equal percentage control valve is found to be………………………….
Percentage hysteresis of quick opening control valve is found to be………………………….
Actuator pressure versus flow coefficient is plotted for all the three valves.

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EXPERIMENT NO 5
STUDY OF RANGEABILITY
AIM
To study the rangeability of equal % valve
SETUP REQUIRED
1. Start the setup for equal % Control Valve.
2. Adjust the Rotameter valve and set 500 LPH flow.
3. Set actuator air pressure to 3 psig.
4. Note down the flow rate and pressure at inlet of control valve.
5. Set actuator air pressure to 15 psig.
6. Note down the flow rate and pressure at inlet of control valve.
7. Repeat the experiment by keeping constant pressure drop across the control valve and note the
flow rates.
OBSERVATION
Pressure ΔP F Cv Remarks
(psig) mm of H2O LPH
Nearly 3 max
Nearly 15 min
CALCULATIONS
𝐶𝑣 𝑚𝑎𝑥
𝑅=
𝐶𝑣 𝑚𝑖𝑛

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𝐹𝑚𝑎𝑥
𝑅=
𝐹𝑚𝑖𝑛
For equal % valve flow has an exponential characteristics of rangeability, F = Rm-1. R is the rangeability
of the valve and m is its fractional stem position.
RESULTS
Rangeability of the linear control valve was found to be……………………………
Rangeability of the equal percentage control valve was found to be……………………………
Rangeability of the quick opening control valve was found to be……………………………

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EXPERIMENT NO 6
DYNAMICS OF SECOND ORDER PROCESSES
AIM
To study the step response of mercury manometer and water manometer
SETUP REQUIRED
Needle valve, U-tube manometer, Compressor
1) Mercury Manometer:
1. Ensure that mercury level in manometer is set at zero on the scale.

2. Close vent connection by putting finger on it.
3. Adjust the needle valve and vent to raise the mercury level to 200mm from zero level.
4. Note the mercury level reading and quickly open the vent to apply the step change and record
the videograph. Note the top peak and bottom peak readings and also simultaneously note the
period of oscillation from the videograph.
2) Water Manometer:
1. Ensure that water level in manometer is set at zero on the scale.
2. Close the vent of water manometer by putting hand on it.
3. Adjust the needle valve and vent to deflect the water column to 450mm from zero level.
4. Note the mercury level reading and quickly open the vent to apply the step change and record
the videograph. Note the top peak and bottom peak readings and also simultaneously note the
period of oscillation from the videograph.

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TABULATION OF OBSERVATION
Mercury Manometer:
ConstantS
Manometer fluid = Mercury
Dynamic viscosity 𝜇 = 0.0016 kg/ms
Mass density 𝜌 = 13550 kg/m3
Column length L = 0.760 m
Tube diameter D = 0.005 m
Step change (mm):
Period of oscillation (sec):
SN Actual response* Period of oscillation (sec)
(mm)
1
2
3
*: Note peak values observed during oscillations.
Water Manometer:
ConstantS
Manometer fluid = water
Dynamic viscosity 𝜇 = 0.001 kg/ms
Mass density 𝜌 = 998 kg/m3
Column length L = 1.050 m
Tube diameter D = 0.022 m
Step change (mm):
Period of oscillation (sec):
SN Actual response* Period of oscillation (sec)
(mm)
1
2
3
*: Note peak values observed during oscillations.

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CALCULATIONS
1. Damping coefficient is calculated using the below equation.

8𝐿𝜇 2𝑔
Damping coefficient (𝜁) = 𝜌𝑔𝐷2 √ 𝐿
(Where L = column length in meter,

𝜇=Dynamic viscosity in kg/ms
𝜌 = Mass density of manometer fluid in kg/m3,
D = tube diameter in m,
g = Gravitational acceleration in m/sec2)
2. Natural frequency of oscillations is calculated using the following equation.
2𝑔
Natural frequency (𝜔𝑛 ) = 2𝜋√ 𝐿 in rad/sec)
3. Period of oscillations is calculated using the following equation

2𝜋
𝑃=
𝜔𝑛 √1 − 𝜁 2
4. Frequency of damped oscillations using the following equation
𝜔𝑛 × √1−𝜁 2
Frequency of damped oscillation (𝑓) = 2𝜋
5. Decay ratio is calculated using the following equation

−2𝜋𝜁
𝐷𝑅 = exp ( )
√1 − 𝜁 2
6. Overshoot is calculated using the below equation
Overshoot (𝑂𝑆) = a/b = √𝐷𝑒𝑐𝑎𝑦 𝑟𝑎𝑡𝑖𝑜
7. Characteristic time is calculated using the following equation
2𝜋
Characteristic time (𝜏) = 𝜔 in sec.
𝑛
8. Theoretical response for different time values is calculated using the below equation
√1−𝜁 2 𝜁 √1−𝜁 2
𝑦(𝑡) = 𝐾𝑀 × {𝑒 −𝜁𝑡/𝜏 [cos ( 𝑡) + sin ( 𝑡)]}
𝜏 √1−𝜁 2 𝜏
Note: Make sure that Radian mode is used in the calculator

In case of manometer:
𝑦(𝑡) = response at any time t after step change (deviation value).
𝐾= Gain factor = 1

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𝑀 = magnitude of step change

9. Plot the graphs of actual and theoretical response vs time.
RESULTS
1. The dynamics of a second order system were studied

2. Certain deviations were observed between the observed and theoretical values.

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EXPERIMENT NO. 7
STUDY OF DIFFERENT TYPES OF TEMPERATURE SENSORS
AIM
To study the different types of temperature sensors
SETUP REQUIRED
Temperature measurement setup
Visual study of sensors

Observe the following different sensors provided with setup
a) Thermometer
b) Bimetal dial thermometer
c) RTD probe
d) Thermistor probe
e) Thermocouple probes
f) Bare elements of RTD, thermocouple and thermistors.
Measurement of output of Sensors by multimeter

1. Fill the ice pot with ice.
2. Check the output of RTD, Thermistor and Thermocouple by multimeter at ambient
temperature of tap water taken in the heater (OFF) and note in following table.
3. Turn on the heater and maintain the temperature at 90oC
4. Check the output of RTD, Thermistor and Thermocouple by multimeter and note in following
table.
5. Shift the probe to the icepot.

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OBSERVATION
Output Output
observed observed
Sr.
Type of sensor at at
No
Ambient 90°C
Temperature temperature
1 RTD Ω Ω
2 Thermistor KΩ KΩ
3 Thermocouple mV mV
RESULTS
• The RTD type temperature sensor shows resistance in................. Ω, which increases
with rise in temperature.
• The Thermistor type sensor shows resistance in .....................KΩ, which decreases with
rise in temperature.
• The thermocouple type sensor gives out put in ....................millivolts, which increases
with rise in temperature.

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EXPERIMENT NO. 8
CHARACTERISTICS OF RTD
AIM
To study the characteristics of RTD
SETUP REQUIRED
1. Keep the RTD probe and thermometer in the ice bath.

2. Connect the RTD output to Multimeter to measure resistance in ohms
3. Note the reading of Thermometer and corresponding output of RTD in Ohms in the following
observation table.
4. Increase temperature of Ice bath to @10°C by removing some ice and adding water. Note the
readings of thermometer and multimeter.
5. Repeat above step to note reading @20°C.
6. Shift the RTD and thermometer from ice bath to hot water bath filled with water of ambient
temperature and note the reading.
7. Switch on the heater of hot water Bath for @30-40 sec to raise the bath temperature to @40°C.
Wait for @ 20 seconds and note the reading.
8. Repeat above step to get readings at the interval of @10°C.
OBSERVATION
Approx. Temp at readings Thermometer reading Resistance of RTD

to be taken (°C) (°C) (Ω)
0
10
20
30

21
40
50
60
70
80
90
100
GRAPHS
• Plot the graphs of resistance of RTD in Ω versus Temperature °C of the sensor.
RESULTS
• Resistance of RTD in Ω increases linearly with the temperature °C of the sensor.

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EXPERIMENT NO. 9
CHARACTERISTICS OF THERMISTOR
AIM
To study the characteristics of thermistor.
SETUP REQUIRED
1. Keep the Thermistor probe and thermometer in the Ice bath.

2. Connect the Thermistor output to Multimeter to measure resistance in KΩ
3. Note the reading of Thermometer and corresponding output of Thermistor in KΩ in the following
observation table.
4. Increase temperature of Ice bath to 10°C by removing some ice and adding water. Note the readings
of thermometer and multimeter.
5. Repeat above step to note reading @ 20°C.
6. Shift the Thermistor and thermometer from ice bath to hot water bath filled with water of ambient
temperature and note the reading.
7. Switch on the heater of hot water bath for @30-40 sec to raise the bath temperature to 40°C. Wait
for 20 seconds and note the reading.
8. Repeat above step to get readings at the interval of @10°C.
OBSERVATION
Approx. temp. at readings Thermometer Reading Resistance of Thermistor

to be taken (°C) (°C) (KΩ)
0
10

23
20
30
40
50
60
70
80
90
100
GRAPHS
Plot the graphs of resistance of thermistor in KΩ versus Temperature °C of the sensor.
RESULTS
The resistance of thermistor in KΩ decreases gradually with the Temperature °C of the sensor.

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EXPERIMENT NO. 10
CHARACTERISTICS OF THERMOCOUPLE
AIM
To study the characteristics of thermocouple
SETUP REQUIRED
1. Two thermocouples (junctions) are connected and one of the thermocouples (Junctions) is kept in
ice bath to maintain constant reference junction. (Note: The connection/joint of two positive arms
of the thermocouples does not form a junction as the metals are same)
2. Arrange the experiment and keep both thermocouples
(junctions) and mercury thermometer in ice bath. Note the output voltage with digital multimeter.
Record the observations in following table.
3. Transfer one of the thermocouples (junctions) and mercury thermometer to hot water bath filled
with ice-cold water. Gradually increase the temperature of the hot water bath. Record the
observations at the interval of 10°C in the observation table. (Note: Wait for steady state for each
observation).
OBSERVATION
Approx. temp. at readings Thermometer Reading Output of thermocouple

to be taken (°C) (°C) (mV)
0
10
20
30
40
50
60
70
80

25
90
100
GRAPHS
Plot the graphs of thermocouple output in mV versus Temperature °C.
RESULTS
The thermocouple output in mV increases linearly with the temperature.

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EXPERIMENT NO. 11
STUDY AND CALIBRATION OF TEMPERATURE TRANSMITTER
AIM
To study and calibrate the temperature transmitter
SETUP REQUIRED
Calibration of Transmitter using Boiling water and Ice
1. Connect the RTD probe to temperature transmitter.

2. Connect the transmitter output to multimeter for measuring output DC current in milliamps. Ensure
that power supply to the transmitter is ON.
3. Keep the RTD probe and mercury thermometer in ice bath. Adjust Zero potentiometer
“Z” till the output current is 4.0 mA (at 0oC)
4. Shift the RTD probe and mercury thermometer in boiling water. Now adjust Span potentiometer
“S” till the output current is corresponds to mercury thermometer reading. (100°C = 20.0 mA.)
5. Repeat above two steps till both readings are correct
6. Now the transmitter is calibrated for temperature range from 0 to 100°C.
Calibration of Transmitter using fixed value resistances

1. Connect the multimeter to the socket marked as “100 Ω” adjust the respective potentiometer
provided at the backside of the panel till multimeter shows 100Ω resistance. (This value
corresponds to resistance of RTD PT-100 probe at 0oC).
2. Repeat above step for socket marked as “138.5Ω”. (this value corresponds to resistance of RTD
PT-100 probe at 100°C)
3. Connect the transmitter output to multimeter for measuring output DC current in
milliamps. Ensure that power supply to the transmitter is ON.
4. Connect the multimeter to output of the transmitter (adjust the multimeter to

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measure DC mA) and ensure the power supply is ON to the transmitter.

5. Connect the sockets marked “100 Ω” to the transmitter input and adjust Zero
potentiometer “Z” of the transmitter for output signal of 4.0 mA.
6. Connect the sockets marked “138.5 Ω” to the transmitter input and adjust Span
potentiometer “S” of the transmitter for output signal of 20.0 mA.
7. Repeat above two steps till both readings are correct.
Now the transmitter is calibrated for temperature range from 0 to 100 °C.
OBSERVATION
• Connect the RTD PT-100 probe to the transmitter and ensure that transmitter output is correct
in the calibration range.
RESULTS
• The temperature transmitter is studied and calibrated.

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EXPERIMENT NO. 12
STUDY OF SEEBECK EFFECT
AIM
To study the Seebeck effect
SETUP REQUIRED
1. Two thermocouples (junctions) are connected and one of the thermocouples (Junctions) is kept in
air to maintain constant reference junction. (Note: The connection/joint of two positive arms of the
thermocouples does not form a junction as the metals are same)
2. Connect the output of thermocouples given for study of Seebeck effect to digital milliVoltmeter.
Switch on digital milliVoltmeter.
3. Keep one of the thermocouple probes in air (at ambient temperature) and other in hot water bath
with thermometer.
4. Adjust the temperature of hot water bath to different temperatures shown in observation table by
switching the heater On and Off. Note the thermometer reading and corresponding milliVolts
generated for each temperature.
OBSERVATION
Aprx. Temp. at Actual Current Air Output Difference in

readings to be thermometer temperature milivolts temp. (T2-T1)
taken (°C) reading (T2) °C (T1) °C
ε ∆T °C
30
40
50
60

29
70
80
90
100
CALCULATIONS & GRAPH:

The emf produced is proportional to the difference in temperature and further, to the
difference in the metallic thermal transport constants.
emf produced in Volts ε = α (T2 - T1)

where α = constant in volts /°C
T1, T2 = junction Temperatures in °C
To get the value of α plot a graph of ε(milliVolt) versus ∆Τ.
The slope of this graph is the α for the particular sensor.
α = 41.14 µV/°C for sensor supplied with this setup.
RESULTS
• The actual measured values are verified.

30
EXPERIMENT NO. 13
TIME CONSTANT OF MERCURY IN GLASS THERMOMETER
AIM
To determine the time constant of mercury in glass thermometer
SETUP REQUIRED
1. Heat the water in hot water bath to @70-80°C.

2. Set the beeper for beep interval of @2sec. (Count number of beeps in 1min. for adjustment of
beeper).
3. Note the reading of mercury in glass thermometer.
4. Insert the thermometer in hot bath at any beeping instant.
5. The thermometer reading suddenly starts rising due to step change. Note the
readings at every beep till temperature goes to steady state.
6. Repeat the procedure for different bath temperature.
OBSERVATION
Reading No. (beep) Time in seconds Observed Temp.

(Thermometer reading) °C
0(Initial) 0
1 TX1
2 TX2
3
4
Up to steady state

31
Beep interval in seconds (T):
GRAPH:
Plot the graph of observed temperature versus Time in seconds.
CALCULATIONS
• Mark the temperature of 63.2% of step change value on the graph.
• Note the time required for 63.2% step change. This is the time constant of thermometer. (63.2%
of step change value = 0.632 x (final temp – initial temp) + initial temp.)
RESULTS
Time constant of mercury in glass thermometer is ...........................

32
EXPERIMENT NO.14
TIME CONSTANT OF BIMETAL THERMOMETER
AIM
To determine the time constant of bimetal thermometer
SETUP REQUIRED

2. Set the beeper for beep interval of @2sec. (Count number of beeps in 1min. for adjustment of
beeper).
3. Note the reading of bimetal thermometer.
4. Insert the bimetal thermometer in hot bath at any beeping instant.
5. The thermometer reading suddenly starts rising due to step change. Note the
readings at every beep till temperature goes to steady state.
OBSERVATION
Reading No. (beep) Time in seconds Observed Temp.

(Thermometer reading °C)
0(Initial) 0
1 TX1
2 TX2
3
4
Up to steady state
GRAPH

33
CALCULATIONS
• Note the time required for 63.2% step change. This is the time constant of bimetal
thermometer. (63.2% of step change value = 0.632 x (final temp – initial temp) + initial temp.)
RESULTS
Time constant of bimetal thermometer is ...........................

34
EXPERIMENT NO. 15
TIME CONSTANT OF RTD SENSOR
AIM
To determine the time constant of RTD sensor
SETUP REQUIRED
1. Heat the water in hot water bath to @70-80 C.

2. Set the beeper for beep interval of @2.5sec. (Count number of beeps in 1min. for adjustment of
beeper).
3. Connect the RTD output to multimeter for measuring element resistance in Ohms.
4. Note the initial reading of multimeter
5. Insert the RTD probe in hot water bath at any beeping instant.
6. The multimeter reading suddenly starts rising due to step change. Note the readings at
every beep till reading goes to steady state.
Reading No. (beep) Time in seconds Observed Resistance (Ω)

0(Initial) 0
1 TX1
2 TX2
3
4
Up to steady state

35

GRAPH:
Plot the graph of observed output versus Time in seconds.
CALCULATIONS
• Note the time required for 63.2% step change. This is the time constant of RTD. (63.2% of
step change value = 0.632 x (final resistance – initial resistance) + initial resistance)
RESULTS
Time constant of RTD sensor is ...........................

36
EXPERIMENT NO. 16
TIME CONSTANT OF THERMISTOR SENSOR
AIM
To determine the time constant of thermistor sensor
SETUP REQUIRED
1. Heat the water in hot water bath to @70-80 C.

2. Set the beeper for beep interval of @2.5sec. (Count number of beeps in 1min. for adjustment of
beeper).
3. Connect the thermistor output to multimeter for measuring element resistance in KΩ.
4. Note the initial reading of multimeter
5. Insert the thermistor probe in hot water bath at any beeping instant.
6. The multimeter reading suddenly starts rising due to step change. Note the readings at
every beep till reading goes to steady state.
Reading No. (beep) Time in seconds Observed Thermistor

reading (KΩ)
0(Initial) 0
1 TX1
2 TX2
3
4
Up to steady state

37
CALCULATIONS
• Note the time required for 63.2% step change is the time constant of thermistor.
• 63.2% of step change value = 0.632 x (final thermistor reading – initial thermistor reading) +
initial thermistor reading)
GRAPHS
Plot the graph of observed output versus Time in seconds.
RESULTS
Time constant of thermistor is ...........................

38
EXPERIMENT NO. 17
TIME CONSTANT OF THERMOCOUPLE SENSOR
AIM
To determine the time constant of thermocouple sensor
SETUP REQUIRED

2. Set the beeper for beep interval of @2sec. (Count number of beeps in 1min. for
adjustment of beeper).
3. Connect the Thermocouple to temperature Indicator and note the reading of
temperature indicator as initial temperature.
4. Insert the thermocouple probe in hot water bath at any beeping instant.
5. The temperature indicator reading suddenly starts rising due to step change.
6. Note the readings at every beep till reading goes to steady state.
OBSERVATION
Reading No. (beep) Time in seconds Observed Temperature

reading (⸰C)
0(Initial) 0
1 TX1
2 TX2
3
4
Up to steady state

39
GRAPHS
CALCULATIONS
• Note the time required for 63.2% step change is the time constant of thermocouple
• 63.2% of step change value = 0.632 x (final temperature reading – initial temperature reading)
+ initial temperature reading
RESULTS
Time constant of thermocouple sensor is ...........................

40
EXPERIMENT NO 18
STEP RESPONSE OF SINGLE CAPACITY SYSTEM
AIM
To obtain experimentally the step response of single capacity system
SETUP REQUIRED
Interacting and Non-Interacting systems, electrical supply: 230 +/- 10 VAC, 50 Hz, single phase
electric supply with proper earthing. (Neutral-Earth voltage less than 5 VAC) 5A with three pin socket
with switch, water supply (Initial Fill)
1. Start up the set up
2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the top Tank
1. Keep the outlet valves (R1 & R2) of the Tank 1 & Tank 2 slightly closed
3. Switch on the pump. Adjust Rotameter flow rates in steps of 10 LPH from 50 to 100 LPH and note
steady state levels for Tank 1 against each flow rate
4. From the data obtained select a suitable band for experimentation. (Say 90-100 LPH in which we
are getting more readings of tank level)
5. Adjust the flow rate at lower value of the band selected (say 90 LPH) and allow the level of the
Tank 1 to reach the steady state and record the flow and level at steady state
6. Apply the step change by increasing the Rotameter flow by @ 10 LPH
7. Immediately start recording the level of the Tank 1 at the interval of 15 sec, until the level reaches
at steady state
8. Carry out the calculations as mentioned in calculation part and compare the predicted and observed
values of the tank level
TABULATION OF OBSERVATIONS
Diameter of tank mm ID 92 mm

41
Initial flow rate (LPH):
Initial steady state tank level (mm):
Final flow rate (LPH):
Final steady state tank level (mm):
(Fill up columns H(t)Observed and H(t)Predicted after calculations)
Sr. No. Time Level H(t)Observed H(t)Predicted
(sec) (mm) (mm) (mm)
1 0
2 15
3 30
4 --
CALCULATIONS
H (t) observed = (Level at time t - level at time 0) x 10 –3 m
H(t) Predicted = AR { (1- e -t/) }
Where
H (t)Predicted is level predicted at time t
A = magnitude of step change
= Flow after step input - Initial flow rate in m3/sec
R = Outlet valve resistance in sec/m2
Considering non-linear resistance at outlet, it can be calculated as R = dH /dQ

42
Where dH is change in level (Final steady state level - Initial steady state level) and dQ is change
flow (Final flow rate after step change - Initial flow rate)
 = Time constant in sec
=A1 x R Where A1 is area of tank in m2 and R is resistance of outlet valve in sec/m2
A1 = Area of tank = (Π/4) (Diameter of tank in m) 2
t = Time in sec from initial steady state
Plot the graph of H(t) Vs time for observed and predicted levels
RESULTS
1 The step response of single capacity system was studied and a graph was plotted between time
vs. H (both observed and predicted).
2 It was observed that the theoretical value (predicted) of height matches with the experimental
values (observed).

43
EXPERIMENT NO 19
STEP RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN NON-INTERACTING

MODE
AIM
To obtain experimentally the step response of first order systems in non-interacting mode
SETUP REQUIRED
1. Start up the set up.
2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the top Tank
1. Keep the outlet valves (R1 & R2) of both Tank 1 & Tank 2 slightly closed. Ensure that the
valve (R3) between Tank 2 and Tank 3 is fully closed
3. Switch on the pump and adjust the flow to @ 90 LPH. Allow the level of both the tanks (Tank 1
& tank 2) to reach at steady state and record the initial flow and steady state levels of both tanks
4. Apply the step change with increasing the Rotameter flow by @ 10 LPH
5. Record the level of Tank 2 at the interval of 30 sec, until the level reaches at steady state
6. Record final flow and steady state level of Tank 1
7. Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level
8. Repeat the experiment by throttling outlet valve (R1) to change resistance

44
OBSERVATIONS
Diameter of tanks ID 92mm
Initial steady state level of Tank 1 (mm):
Final steady state level of Tank 1 (mm):
Final steady state level of Tank 2 (mm):
(Fill up columns H2(t)Observed and H2(t)Predicted after calculations)
Sr. No. Time Level of tank 2 H2(t)Observed H2(t)Predicted
1 0
2 30
3 60
CALCULATIONS
H2(t)observed = (Level at time t - level at time 0) x 10 -3 m
   1  −t   1   −t   
H 2 ( t )Pr edicted = A R 2 1 − 1 2   e 1  −    e 2    .................(1)

1 −  2   2    1  
 

  
Where
H2(t)predicted is level in tank 2 predicted at time t in m.

45
= Flow after step input - Initial flow rate in m3/sec.
1 = A1 x R1
2 = A2 x R2
where 1 is time constant of tank 1, A1 is area of tank 1 and R1 is resistance of outlet valve of tank 1.
2 is time constant of tank 2, A2 is area of tank 2 and R2 is resistance of outlet valve of tank 2
Area of tank 1 = π d12/4 in m2
Area of tank 2 = πd22/4 in m2
Considering non-linear resistance at outlet valve of both tanks, it can be calculated as
R1 = dH1 /dQ
R2 = dH2 /dQ
where dH1 is change in level of tank 1 and dQ is change flow of from initial to final state and dH2 is
change in level of tank 2 at initial and final state.
Put the values in equation (1) to find out H2(t)Predicted and plot the graph of H2(t)Predicted and H2(t)Observed
vs time.
RESULTS
1 The step response of two first order systems arranged in non-interacting mode is studied and a
graph is plotted between time vs. H (both observed and predicted).
2 It is observed that the theoretical value (predicted) of height matches with the experimental
values (observed).

46
EXPERIMENT NO 20
IMPULSE RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN NON-

INTERACTING MODE
AIM
To obtain experimentally the impulse response of first order systems in non-interacting mode
SETUP REQUIRED
2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the top tank
(T1). Keep the outlet valves (R1 & R2) of both Tank 1 & Tank 2 slightly closed. Ensure that the
valve (R3) between two bottom tanks T2 and T3 is fully closed
3. Switch on the pump and adjust the flow to @ 90 LPH. Allow the level of both Tank 1 and Tank 2,
to reach the steady state and record the initial flow and steady state levels of both tanks.
4. Apply impulse input by adding 0.5 lit of water in Tank 1
5. Record the level of the Tank 2 at the interval of 30 sec, until the level reaches to steady state
6. Record final steady state level of Tank 1
OBSERVATIONS
Diameter of tanks ID 92mm
Initial steady state tank 1 level (mm):

47
Volume added (lit.):
Final steady state tank 1 level (mm):
1 0
2 30
3 60
4 --
CALCULATIONS
H2(t)Observed = (Level at time t - level at time 0) x 10-3 m
  −t   −t 
 e  −  e 2
1

   
H 2 ( t )Pr edicted = VR2      ..................(1)

  1 −  2 
 
 
V = volume of liquid added as an impulse input (in m3)
(For 1, 2 and R2 refer values obtained in the step response experiment)
Put the values in above equation to find out H2(t)Predicted and plot the graph of H2(t)Predicted and
H2(t)Observed vs time.

48
RESULTS
1 The impulse response of two first order systems arranged in non-interacting mode was studied
and a graph was plotted between time vs. H (both observed and predicted).
values (observed).

49
EXPERIMENT NO 21
STEP RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN INTERACTING MODE
AIM
To obtain experimentally step response of first order systems in interacting mode
SETUP REQUIRED
2. A flexible pipe is provided at the rotameter outlet. Insert the pipe in to the cover of the Tank 3.
Keep the outlet valve (R2) of Tank 2 slightly closed. Ensure that the valve (R3) between Tank 2
and Tank 3 is also slightly closed.
3. Switch on the pump and adjust the flow to @ 90 LPH. Allow the level of both Tank 2 and Tank
3, to reach the steady state and record the initial flow and steady state levels of both tanks
4. Apply the step change with increasing the Rotameter flow by @ 10 LPH
5. Record the level of the Tank 2 at the interval of 30 sec, until the level reaches at steady state
6. Record final steady state flow and level of Tank 3
7. Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level

50
OBSERVATIONS
Diameter of tanks ID 92 mm
Final steady state level Tank 2 (mm):
Final steady state level Tank 3 (mm):
(Fill up columns H2(t)observed and H2(t)predicted after calculations)
1 0
2 30
3 60
4 --
CALCULATIONS
H2 (t) Observed = (Level at time t - level at time 0) x 10 -3 m
 1  1 
  exp( t )  −  exp(  t )  
      ..............(1)
H 2 (t ) Predicted = AR2 1 − 
 1 1 
  −   
 
Where

51
= Flow after step input - Initial flow rate in m3/sec
Where 2 is time constant of tank 2, A2 is area of tank 2 and R2 is resistance of outlet valve of tank 2
3 is time constant of tank 3, A3 is area of tank 3 and R3 is resistance of outlet valve of tank 3.
1 1 A3 R2
b= + + .................................................(2)
2 3  2 3
−b  b  2  1  
= +   −    ...................................(3)
2  2    2 3  
−b  b  2  1  
= −   −    ...................................(4)
2  2    2 3  
Considering non linear resistance at outlet valve of both tanks, it can calculated as
R2 = dH2 /dQ and R3 = dH3 /dQ
Where dH is change in tank height for change in flow dQ. Calculate the values of b,  and  from
equations 2-4.
Substitute the values in equation (1) to find out H2(t)Predicted and plot the graph of H2(t)Predicted and
H2(t)Observed vs time
RESULTS
1 The step response of two first order systems arranged in interacting mode is studied and a graph
is plotted between time vs. H (both observed and predicted).
2 It is observed that the theoretical value (predicted) of height matches with the experimental
values (observed).

52
EXPERIMENT NO 22
IMPULSE RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN INTERACTING

MODE
AIM
To obtain experimentally impulse response of first order systems in interacting mode
SETUP REQUIRED
2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of Tank 3. Keep
the outlet valve (R2) of Tank 2 slightly closed. Ensure that the valve (R3) between both Tank 2 and
Tank 3 is slightly closed
3. Switch on the pump and adjust the flow to @ 90 LPH. Allow the level of both the tanks to reach
at steady state and record the initial flow and steady state levels.
4. Apply impulse input by adding 0.5 lit of water in Tank 3
5. Record the level of the Tank 2 at the interval of 30 sec, until the level reaches to steady state
6. Record final steady state level of Tank 3
OBSERVATIONS
Diameter of tankS ID 92mm
Volume added (lit.):

53
1 0
2 30
3 60
4 --
CALCULATIONS
H2(t)observed = (Level at time t - level at time 0) x 10 -3
H 2 ( t )Predicted =
VR2
 2 3 ( −  )
( e( t ) − e(  t ) ) ...............................................(7)
V = volume of liquid added as an impulse input (in m3)
(For calculating 2,3, ,  and R2 refer to the step response experiment)
Put the values in above equation to find out H2(t)Predicted and plot the graph of H2(t)Predicted and H2(t)
Observed vs time.
RESULTS
1 The impulse response of two first order systems arranged in interacting mode was studied and
a graph was plotted between time vs. H (both observed and predicted).
values (observed).

54
EXPERIMENT NO 23
CHARACTERISTICS OF FLAPPER NOZZLE SYSTEM
AIM
To study the characteristics of flapper nozzle system and to determine the gain of flapper nozzle
system.
SETUP REQUIRED
Flapper nozzle system with suitable compressor
1. Adjust the air supply to 20 psig by air regulator.
2. Increase the gap between flapper and nozzle to get 3 psi signal pressure and note the dial reading.
3. Decrease the gap between flapper and nozzle by gap adjusting screw. Note the dial gauge reading
for each psi change in signal pressure. Ensure that supply pressure is maintained at 20 psi.
4. Repeat the set of observation by increasing the gap.
OBSERVATIONS
Increasing:
Nozzle Gap Signal

S.No
(μm) Pressure (psi)
1 0
2 10
3 20
4 30
5 40
6 50
7 60
8 70
9 80

55
10 90
11 100
Decreasing:
Nozzle Gap Signal

S.No
(μm) Pressure (psi)
1 100
2 90
3 80
4 70
5 60
6 50
7 40
8 30
9 20
10 10
11 0
CALCULATIONS
𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑠𝑖𝑔𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝐺𝑎𝑖𝑛 𝑜𝑓 𝑓𝑙𝑎𝑝𝑝𝑒𝑟 𝑛𝑜𝑧𝑧𝑙𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 = 𝑝𝑠𝑖/𝑚𝑚
𝑐𝑜𝑟𝑟𝑒𝑠𝑝𝑜𝑛𝑑𝑖𝑛𝑔 𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑛𝑜𝑧𝑧𝑙𝑒 𝑔𝑎𝑝
(Note: Plot the graph of signal pressure (y) verses nozzle gap (x) and calculate the slope)
RESULTS
• The characteristics of flapper nozzle system was studied.

• Gain of flapper nozzle system was found to be …………………. psi/mm for increasing gap
and ………………….. psi/mm for decreasing gap.

56
EXPERIMENT NO 24
LINEARITY OF I/P CONVERTER
AIM
To study the linearity of I/P converter.
SETUP REQUIRED
I/P converter setup
2. Put digital calibrator in source mode.
3. Give current input in the step of 4 mA from 4 to 20 mA by slowly rotating the knob of digital
calibrator.
4. Note down corresponding pressure on output pressure gauge in psig.
5. Tabulate above readings in the observation table given below.
OBSERVATIONS
S. No. Input current Standard Output Pressure Actual Output Pressure
(mA) (psig) (psig)
1 4 3
2 8 6
3 12 9
4 16 12
5 20 15
CALCULATIONS
• Linearity: Linearity of I/P converter is 5% maximum of output span between 3 to 15 psig (as stated
by manufacturer). Therefore 5/100 * (15-3) = 0.6 psig. This is the maximum deviation in the
output.

57
• Plot graph of Input current (mA) on X axis and output pressure (psig) on Y-axis. Draw a straight
line that best fits all the points.
• The graph shows the straight line.
• Observe the maximum deviation in output and compare with specified by manufacturer.
RESULTS
• Some deviation in actual linearity of I/P converter from manufacturer’s specification was observed,
as it depends upon accuracy of pressure gauges used, accuracy of digital calibrator and visual error
in recording the readings.

58
EXPERIMENT NO 25
HYSTERESIS OF I/P CONVERTER
AIM
To study the hysteresis of I/P converter.
SETUP REQUIRED
I/P converter setup
2. Put digital calibrator in source mode.
3. Give current input in the step 4 mA from 4 to 20 mA by slowly rotating the adjust knob on digital
calibrator.
4. Note down corresponding output pressure on output pressure gauge in psig.
5. Now note the output pressure in psig by applying input current in decreasing mode from 20 mA to
4 mA.
OBSERVATIONS
S. No. Input Output S. No. Input Output Hysteresis
current pressure current pressure (psig)
(mA) (psig) (X) (mA) (psig) (Y) (Y) – (X)
1 4 1 4
2 8 2 8
3 12 3 12
4 16 4 16
5 20 5 20

59
CALCULATIONS
• Hysteresis of I/P converter is 0.5 psig typical (as stated by manufacturer). Calculate hysteresis by
using formula:
• Hysteresis =Output at decreasing Input – Output at increasing input.
• Plot the graph showing hysteresis as input (increasing and decreasing) on X axis and corresponding
output on Y-axis.
RESULTS
• Some deviation in hysteresis of I/P converter was observed as it depends upon accuracy of pressure
gauges used accuracy of digital calibrator and visual error in recording the readings.

60
EXPERIMENT NO 26
ACCURACY OF I/P CONVERTER
AIM
To study the accuracy of I/P converter.
SETUP REQUIRED
I/P converter setup
1. Start up the set up as mentioned in commissioning part above.
2. Now put digital calibrator in source mode.
3. Give current input in the step of 4 mA from 4 to 20 mA by slowly rotating the knob of digital
calibrator.
4. Note down corresponding pressure on output pressure gauge in psig.
OBSERVATIONS
S. No. Input current Standard Output Actual Output Deviation (psig)
(mA) Pressure (psig) (X) Pressure (psig) (Y) (Y) – (X)
1 4 3
2 8 6
3 12 9
4 16 12
5 20 15
CALCULATIONS
Uncertainty error (%) = ((Y-X)/X) ͯ 100
Calculate average uncertainty error
Accuracy (%) = 100 – average uncertainty error (%)
RESULTS
• Accuracy of I/P converter was found to be ……………………………

61
EXPERIMENT NO 27
REPEATABILITY OF I/P CONVERTER
AIM
To study the repeatability of I/P converter.
SETUP REQUIRED
I/P converter setup
2. Now put digital calibrator on source mode.
3. Give current input in the step 4 mA from 4 to 20 mA by slowly rotating the adjust knob on digital
calibrator.
4. Note down corresponding output pressure on output pressure gauge in psig.
5. Now repeat the above steps for more trials.
OBSERVATIONS
S. No Input current Output pressure S. No. Input current Output pressure
(mA) (psig) (X) (mA) (psig) (Y)
Trial 1 Trial 2
1 4 1 4
2 8 2 8
3 12 3 12
4 16 4 16
5 20 5 20

62
S. No Input current Output pressure S. No. Input current Output pressure

(mA) (psig) (X) (mA) (psig) (Y)
Trial 3 Trial 4
1 4 1 4
2 8 2 8
3 12 3 12
4 16 4 16
5 20 5 20
CALCULATIONS
Repeatability: Note down the values of output for same input in repeated trials. Repeatability can be
found out in % of each reading.
• Calculate the average output for a given input.

• Calculate the deviation (D) between average output and standard output.
• Full scale deflection (FSD) is 15 psig.
• Repeatability (%) = (D / FSD) * 100
RESULTS
Repeatability of I/P converter was found to be ……………………………

63
EXPERIMENT NO 28
LINEARITY OF P/I CONVERTER
AIM
To study the linearity of P/I converter.
SETUP REQUIRED
P/I converter setup
2. Put digital calibrator in measure mode.
3. Give pressure input in the step of 3 psig from 3 to 15 psig by slowly rotating the air regulator.
4. Note down corresponding current output on digital calibrator in mA.
OBSERVATIONS
S. No. Input Pressure (psig) Standard Output current Actual Output current
(mA) (mA)
1 3 4
2 6 8
3 9 12
4 12 16
5 15 20
CALCULATIONS
• Plot graph of Input pressure (psig) on X axis and output current (mA) on Y-axis. Draw a straight
line that best fits all the points. The graph shows the straight line.
• Observe the maximum deviation in output and compare with specified by manufacturer.
RESULTS
• Some deviation in actual linearity of P/I converter from manufacturer’s specification was observed,
as it depends upon accuracy of pressure gauges used, accuracy of digital calibrator and visual error
in recording the readings.

64
EXPERIMENT NO 29
HYSTERESIS OF P/I CONVERTER
AIM
To study the hysteresis of P/I converter.
SETUP REQUIRED
P/I converter setup
2. Put digital calibrator on measure mode.
5. Now note the output current in mA by applying input pressure in decreasing mode from 15 psig to
3 psig.
OBSERVATIONS
S. No. Input Output S. No. Input Output Hysteresis
pressure current pressure current (psig)
(psig) (mA) (X) (psig) (mA) (Y) (Y) – (X)
Increasing input current Decreasing input current
1 3 1 15
2 6 2 12
3 9 3 9
4 12 4 6
5 15 5 3
CALCULATIONS
• Calculate hysteresis by using formula:
• Hysteresis =Output at decreasing Input – Output at increasing input.

65
• Plot the graph showing hysteresis as input (increasing and decreasing) on X axis and corresponding
output on Y-axis.
RESULTS
• Some deviation in hysteresis of P/I converter was observed as it depends upon accuracy of pressure
gauges used accuracy of digital calibrator and visual error in recording the readings.

66
EXPERIMENT NO 30
ACCURACY OF P/I CONVERTER
AIM
To study the accuracy of P/I converter.
SETUP REQUIRED
P/I converter setup
2. Now put digital calibrator in measure mode.
OBSERVATIONS
S. No. Input pressure Standard Output Actual Output Deviation (mA)
(psig) Current (mA) (X) Current (mA) (Y) (Y) – (X)
1 3 4
2 6 8
3 9 12
4 12 16
5 15 20
CALCULATIONS
Uncertainty error (%) = ((Y-X)/X) ͯ 100
Calculate average uncertainty error
Accuracy (%) = 100 – average uncertainty error (%)
RESULTS
• Accuracy of P/I converter was found to be ……………………………

67
EXPERIMENT NO 31
REPEATABILITY OF P/I CONVERTER
AIM
To study the repeatability of P/I converter.
SETUP REQUIRED
P/I converter setup
2. Now put digital calibrator on measure mode.
4. Note down corresponding current output on digital calibrator in psig.
5. Now repeat the above steps for more trials.
OBSERVATIONS
S. No Input pressure Output current S. No. Input pressure Output current
(psig) (mA) (psig) (mA)
(X) (Y)
Trial 1 Trial 2
1 3 1 3
2 6 2 6
3 9 3 9
4 12 4 12
5 15 5 15
S. No Input pressure Output current S. No. Input pressure Output current

(psig) (mA) (psig) (mA)
(X) (Y)
Trial 3 Trial 4
1 3 1 3
2 6 2 6
3 9 3 9
4 12 4 12
5 15 5 15

68
CALCULATIONS
Repeatability: Note down the values of output for same input in repeated trials. Repeatability can be
found out in % of each reading.
• Calculate the average output for a given input.

• Calculate the deviation between average output and standard output.
• Full scale deflection (FSD) is 20 mA
• Repeatability (%) = (D / FSD) * 100
RESULTS
Repeatability of P/I converter was found to be ……………………………

69
EXPERIMENT NO 32
STUDY OF PROPORTIONAL (P) CONTROLLER
AIM
To study the operation of P controller.
SETUP REQUIRED
Universal process control trainer with workstation
1. Click Select Experiment |Select P mode |Click Start.
2. Adjust the process value by switching the controller to manual mode to a particular flow (say 50
%) on the screen and set this output as bias (MR) value. Change the proportional band to 100%.
3. Switch the controller to auto mode.
4. Apply step change of 5% to set point.
5. Switch the controller to manual mode. Decrease proportional band to half of the previous value.
With each decrease, obtain a new response of the step change. Ensure that the set point changes
are around the same operating point (Say 50%).
6. Using trial and error approach, find a value of proportional band so that the response to a step
change has at most one overshoot and one undershoot.
7. Set the controller to the settings obtained in the above step and wait for the system to reach at
steady state.
OBSERVATIONS
• Observe steady state error decreases as proportional band decreases.

• For Level control there is no steady state error as the process is self-integrating.
• Observe the effect of very low proportional band values (system works as on-off control).
• Observe the response of the system at load change.
• For Flow control loop (Pump outlet) Load change can be given by slightly varying the flow
rate with the help of valve V10 manually.
RESULTS
• The operation of proportional controller was studied.

70
EXPERIMENT NO 33
STUDY OF PROPORTIONAL INTEGRAL (PI) CONTROLLER
AIM
To study the operation of PI controller.
SETUP REQUIRED
1. Click Select Experiment |Select PI Mode |Click Start.
2. Select PI Mode. Set the proportional band estimated in Proportional control. And integral time
500 sec, which will cut off the derivative action and widen the effect of integral action.
3. Set the set point to desired flow value (@50%). Allow the process to reach at steady state.
Record the steady state error.
4. Switch the controller to manual mode. Reduce the integral time to half of the previous value.
Switch to Auto mode and apply step change (+/- 5%) to the set point. Note the response of the
system.
5. Repeat above step to observe the effect of changes in Integral setting.
OBSERVATION
• Observe the effect of reducing integral time on offset and on the response of the process.
RESULTS
• The study of proportional integral (PI) controller was carried out.

• The effect of reducing integral time on offset and on the response of the process was
observed.

71
EXPERIMENT NO 34
STUDY OF PROPORTIONAL DERIVATIVE (PD) CONTROLLER
AIM
To study the operation of PD controller.
SETUP REQUIRED
1. Click Select Experiment |Select PD Mode |Click Start.
2. Select PD controller. Set the proportional band estimated from Proportional control (P only) set
derivative time to 0 sec.
3. Set the set point to desired value (@50%). Allow the process to reach at steady state. Note the
response of the system.
4. Switch the controller to manual mode Increase the derivative time by 1 sec. Switch to Auto mode
and apply step change to the set point by 5%. Note the response of the system.
5. Increase the derivative time gradually and observe the process response for step change.
OBSERVATIONS
• Compare the steady state response of the PD controller with PI controller obtained in the
previous experiment.
• Note the effect of noisy flow measurement on the derivative action
RESULTS
• The study of proportional derivative (PD) controller was carried out.

• Steady state response of PD controller with PI controller was compared.

72
EXPERIMENT NO 35
STUDY OF PROPORTIONAL INTEGRAL DERIVATIVE (PID) CONTROLLER
AIM
To study the operation of PID controller.
SETUP REQUIRED
Universal Process Control Trainer with Workstation
1. Click Select Experiment |Select PID Mode |Click Start
2. Switch the controller to manual mode.
3. Change the proportional band to the value that estimated in proportional controller. Set integral
time and derivative time based on the responses in previous experiments.
4. Adjust the set point to @ 50 %. Switch the controller to auto mode. Apply step change of 5%.
Observe the process response.
5. Change the proportional band, integral time, derivative time and observe the response of the
process for step change for each change in setting.
OBSERVATIONS
• Compare the steady state response of the PID controller with P. PI and PD controller
obtained in the above experiment.
RESULTS
• The operation of proportional integral derivative controller was studied.

• The effect of reducing integral time on offset and on the response of the process was observed.

National Institute of Technology Raipur: Process Dynamics and Control Lab Manual Subject Code: CH106401CH

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1

NATIONAL INSTITUTE OF TECHNOLOGY

PROCESS DYNAMICS AND CONTROL

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

Experiment Contents Page No.

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

STEP RESPONSE OF FIRST ORDER SYSTEMS

23 CHARACTERISTICS OF FLAPPER NOZZLE SYSTEM 54

24 LINEARITY OF I/P CONVERTER 56

33 STUDY OF PROPORTIONAL INTEGRAL (PI) 70

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

STUDY OF CONTROL VALVE FLOW COEFFICIENT (CV)

1. Start the setup for Control Valve of equal % characteristics.

2. Open Pneumatic Line for the Control Valve.

5. Record the Manometer reading in mm of water.

6. Record the Rotameter reading.

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

S. No. ΔP, mm of H2O Q, LPH

Q= Discharge of Fluid in m3/h

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

STUDY OF INHERENT CHARACTERISTICS OF CONTROL VALVE

2. Open Pneumatic Line for the Control Valve.

5. Wait for 5 minutes to steady the flow.

6. Record the manometer reading in mm of water.

7. Record the Rotameter reading.

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

STUDY OF INSTALLED CHARACTERISTIC OF CONTROL VALVE

1. Start the setup for Equal % Control Valve.

2. Open Pneumatic Line for the Control Valve.

5. Wait for 5 minutes to steady the flow.

6. Record the manometer reading in mm of water.

7. Record the Rotameter reading.

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

12. Plot the graph of the flow versus lift.

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

STUDY OF HYSTERESIS OF CONTROL VALVE

To study the hysteresis of Control Valve

1. Start the setup for equal % Control Valve.

2. Open Pneumatic Line for the Control Valve.

5. Wait for 5 minutes to steady the flow.

6. Record the manometer reading in mm of water.

7. Record the Rotameter reading.

8. Now slowly increase the air pressure by regulator up to 3 psig.

12. Wait for 5 minutes to steady the flow.

13. Record the manometer reading in mm of water and rotameter reading

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

Pressure Increasing Pressure Decreasing Pressure

𝐶𝑣 𝑎𝑡 𝑑𝑒𝑐𝑟𝑒𝑎𝑠𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒− 𝐶𝑣 𝑎𝑡 𝑖𝑛𝑐𝑟𝑒𝑎𝑠𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑟𝑒

Percentage hysteresis of linear control valve is found to be………………………….

Percentage hysteresis of equal percentage control valve is found to be………………………….

Percentage hysteresis of quick opening control valve is found to be………………………….

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

To study the rangeability of equal % valve

1. Start the setup for equal % Control Valve.

2. Adjust the Rotameter valve and set 500 LPH flow.

3. Set actuator air pressure to 3 psig.

5. Set actuator air pressure to 15 psig.

PDC Lab Manual Chemical Engg. Dept., NIT Raipur

Rangeability of the linear control valve was found to be……………………………

Rangeability of the equal percentage control valve was found to be……………………………

Rangeability of the quick opening control valve was found to be……………………………

PDC Lab Manual Chemical Engg. Dept., NIT Raipur