IPccccc Final UOG (Repaired)

Laboratory Manual Instrument Process and Control
Experiment No. Objective

EXPERIMENT NO 01 Determine the stroke checking of control valve also record
pneumatic and electrical signals to verify the controlling range
of control valve.
EXPERIMENT NO 02 To calibrate the given pressure gauges by using pneumatic
instrument control calibration apparatus.
EXPERIMENT NO 03 To study the function and operation of bubbler apparatus and
develop relationship between them
 Level and static pressure
 Level and back pressure of air
EXPERIMENT NO 04 To draw the calibration curve of thermocouple by using
mercury filled glass thermometer, also report the temperature
fluid at 2mV, 2.75mV, 8mV
EXPERIMENT NO 05 To study the PLC trainer also determine the securities of the
steam generation system for high and low level
EXPERIMENT NO 06 Record system parameters of level controller apparatus,
standardize the pressure transducer and repeat its accuracy.
EXPERIMENT NO 07 To study the open loop system on level trainer apparatus
control the level of control manually from the outlet at the
constant flow rate of the water. Also report the various
disturbances that can affect the control variable
EXPERIMENT NO 08 Study the behavior of the open loop control system on the
flow controller apparatus and control flow of the fluid manually
and report difficulties which occur during the manual made
operation from characteristics curves, report the type of valve.
EXPERIMENT NO 09 To study the behavior of open loop control system on the
pressure control apparatus maintain the required pressure
manually by operating the control valve
EXPERIMENT NO 10 Study the behavior of closed loop system on level controller
apparatus, control level of measuring tank by the set point.
Also collect the data from response of disturbance on closed
loop system.
EXPERIMENT NO 11 Draw the characteristic curve of control valve on the level
trainer, report type of valve and determine the following.
List of Experiments
EXPERIMENT NO 12 To study the deviation between actions of various type of
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controller (P, PI, and PID). Report which controller gives

offset and which minimizes it; also find which controller is
more efficient.
EXPERIMENT NO 13 Determine the time constant of given mercury thermometer
and thermocouple dipped in an oil bath. Also plot a graph
between Y (t)/A and t/τ. Repeat Y (t) when t = π and t = 2π.
EXPERIMENT NO 14 Determine the effect of step change on level controller
apparatus. Also draw a graph between time and step change.
EXPERIMENT NO 15 Investigate control behavior at temperature control apparatus
by changing the set points.
EXPERIMENT NO 16 To study the split range at temperature controller trainer by a
continuous heating /cooling.
EXPERIMENT NO 17 To study the effect of flow rate on delay time by using
Smallest delay time & Largest delay time.
EXPERIMENT NO 18 To investigate the tuning parameters of P, PI, PID controller
apparatus, also determine optimum tuning parameter using
hit and trial method.
EXPERIMENT NO 19 To study the behavior of closed loop control system on
pressure controller apparatus and control pressure by set
point. Also determine the external disturbances of final
control element.
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Experiment NO. 01
Objective:
Determine the stroke checking of control valve also record pneumatic and
electrical signals to verify the controlling range of control valve.
Apparatus:
Level control trainer
Theory:
Pneumatic valves are valves that control the flow of pressurized air. It is limited
to few hundred fees. He supply of air is completely dry, save to use pneumatic valves
are excellent to use it transmission distance are reasonable. In some cases the air
supply becomes a purge for most instruments. A pressure transducer is that which
converts pressure into a analogue electrical signals from change into pressure and
operates the valve according to the signal
There are mainly two types of control valves based on operations. One is air to
open and air to close, which are also called failure to open and failure to close
respectively. Electrically control valve are partially unlimited 4-20mA DC are partially
universal. They are excellent under usual environmental condition. It is excellent
having no restriction on transmission distance. In this equipment is removed for
maintenance
Procedure:
 First of all turn on the apparatus.
 From the control panel set the opening valve at 0%.
 Note down the value of electrical signals needed to do so with DMM.
 Check the valve of pressure (air inlet) and note down its value.
 Repeat the experiment with different values of valve opening.
 Plot a graph between values of signals and value opening and development
a relationship between them.
Conclusions:
 From the experiment it can be concluded that the value of valve opening is
achieved correctly, if the valve is completely calibrated and the minimum
friction losses there.
 The spring used in the pneumatic control system has particular values of
spring constant.
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Observation and calculations
Sr. no Valve opening Electrical signal Pneumatic signal

% mA Psi
Graph:
Graph between valve opening and Pneumatic signal

Valve Opening(%)
Pneumatic Signal
Pneumatic signal=3+ ( % age100

opening
)∗12
Electrical signal=4+ (% age100
opening
)∗16
Experiment NO. 02
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Objective:
To calibrate the given pressure gauges by using pneumatic instrument
control calibration apparatus.
Apparatus:
Electrical and pneumatic instrumental calibration and pressure gauges
Theory:
Calibration is the set of operation that establish under specified conditions the
relationship between the value of quantities indicated by a measuring instrument
and the corresponding values realized by standards. A measuring instrument can
be calibrated by comparing it with standard. In this experiment compare the
pressure gauges with standard electronic and pneumatic instrumentation
calibration bench. A bounden gauge uses a coiled tube, which, as it expands due
to pressure increase causes a rotation of an arm connected to the tube.
Procedure:
 First of all turn the compressor and create some pressure in the tank
 Then turn the air supply on and attach the gauge to the apparatus
 Increase the air pressure and noted all the readings
 Tabulate all the reading using another gauge
 Find the percentage yield error in it and plotted the graphs
Conclusions:
 It can be concluded that value of pressure on standard gauge is different
with that on calibrated gauge.
 Wear and tear in equipment requires calibration after regular intervals.
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Table No 1
Sr. no Standard Calibrated Difference Percentage Percentage

gauge gauge Bar error accuracy
Bar Bar
Graph:
Graph between Standard gauge pressure and calibrated gauge

pressure
Calibrated guage
Standard Guage (Bar)
Table No 2
Sr. no Standard Calibrated Difference Percentage Percentage

gauge gauge error accuracy
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Bar Bar Bar
Graph:
Graph between Standard gauge pressure and calibrated

gauge pressure
EXPERIMENT NO. 03
Objective:
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To study the function and operation of bubbler apparatus and develop

relationship between them
 Level and static pressure

 Level and back pressure of air.
Apparatus:
 Bubbler apparatus
 Meter rod
Theory:
The bubbler of purge method of measurement is probably the oldest and one of
the simplest methods of liquid level determination In this type of system measurement
is based on the fact that the pressure of liquid at an interface point is directly
proportional to the height of liquid above this point
A dip tube is installed vertically so that its open end is placed near the bottom of
the tank being measured. A regulated air supply applied to the dip tube is adjusted so
that it produces air bubble from its open end. The amount of air pressure needed to
produce this action corresponds to the head pressure of the liquid at the bottom of the
tank. This head pressure can be noted with the help of gauge
Procedure:
 First add water in the bubbler tank up to specific height
 Then note the head pressure at the bottom of the tank and air backup pressure
 Then with the help of drain lower the level of tank
 Then with the help of meter rod note the height of water in the tank
 Then note the pressure across the height
 Repeat the same experiment for several readings and draw graphs between
height of water and static pressure and air backup pressure
Conclusions:
 From the experiment it can be concluded that the static & air backup pressure
is decreased as the height of water is decreased
 When the height is more pressure is being applied at the bottom so pressure
will be needed by the air to come out due to which air backup pressure will
increase
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Sr. No Level of Level of column Hydrostatic Back pressure

column Cm pressure
ft Kg/cm2 Kg/cm2
Graph:
Graph betw Level and Hydrostatic Pressure

Hydrostatic Pressure (Bar)
Level (cm)
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EXPERIMENT NO. 04
Objective:
To draw the calibration curve of thermocouple by using mercury filled
glass thermometer, also report the temperature fluid at 2mV, 2.75mV, 8mV
Apparatus:
 Thermometer
 Thermocouple
 Beaker
 Stirrer
 Voltmeter
Theory:
A thermocouple is a sensor for measuring temperature. It consists of tow
dissimilar metals joined together at one end. Calibration is the comparison between
the measurements – one of known magnitude with one device and another
measurement is made in as similar way with the second device. When the junction
of two metal is heated or cooled a voltage is produced that can be correlated back
to the temp
Thermocouples are widely used for temperature measurement for kilns, gas
turbines exhaust, diesel engine & other industrial processes.
Procedure:
 Get the apparatus and note down the reading at room temperature.
 Note the reading of voltmeter at the same time on room temperature.
 Switch on the heater and note the increase temperature on the thermometers
placed in the oil.
 At the same temperature note the reading on voltmeter and continue the
experiment
 Note down the temperature of fluid at 2mV, 2.75mV and 8mV to note the
readings in the table.
 Then draw a graph between temperature and mV.
Conclusions:
 As the temperature of thermocouple increased thermocouple temperature also
increases
 Graph shows a direct relationship between thermocouple and thermometer
readings
 The calibration curve of thermocouple is the calibrated curve achieve by the
calibration of mercury filled thermometer
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Sr.No Temperature (0C) Volts (mV)
Graph:
Graph between Temperature and Voltage

Voltage (mv)
Temp(oC)
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EXPERIMENT NO. 05
Objective:
To study the PLC trainer also determine the securities of the steam generation
system for high and low level.
Apparatus:
PLC trainer
Theory:
The whole system of PLC trainer works like a boiler system. The first tank, tank
1 is the main storage tank of the system from where raw water is obtained. The
second tank, tank 2 act as de-aerator where water is purified i.e. conductivity is
decreased. Then after passing from de-aerator water enters the stream tank the main
boiler. Also a gas stream is injected from which fire is fixed.
Procedure:
 The pump 1 pumps the raw water from storage tank to the de-aerator.
 The level switch L1 is calibrated with valve S2 to S3.the level switch purpose
is to fully open or close valve S 2 to S3 valve as per the level of tank 2 e.g. is
level is fully/exceeding limit, then the valve S 2 is closed and S3 becomes
open resulting in the circulation of water in tank 1.
 After that pump 2 pumps the water having low conductivity to the steam
tank. Here level switch L2 is installed inn steam tank.
 The L2 is calibrated with valve S 4 and S5. When the level of tank is filled S 5
valve opens and S4 closed, resulting in circulation in tank 2.
 The gas stream enabled and fire is fire in seam tank & steam is generated.
 The valve S7 is only for the purpose of maintenance
Conclusions:
 When level in steam drum was low S1 and S3 valves were fulfill
requirements.
 When level in steam down was high then S 4 and S1 were open which
showed the recirculation of H2O to de-aerator.
 When level of de-aerator was low S1 S4 valves were open to continue water
supply, S1 & S3 valves open level of de-aerator was high
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Steam drum
Low level High level
Open Close Open Close
De-aerator
Low level High level
Open Close Open Close
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Experiment NO. 06
Objective:
Record system parameters of level controller apparatus, standardize
the pressure transducer and repeat its accuracy.
Apparatus:
Trainer level controller
Theory:
A pressure transducer is a transducer that converts pressure into analogue
electrical signal. Although there are various types of pressure transducers, one of the
most common is the strain-gauge base transducer. The conversion of pressure into an
electrical signal is achieved by the physical deformation of strain gauges which are
bounded into the diaphragm of the pressure transducer and wired into a wheat stone
bridge configuration.
Pressure applied to the pressure transducer produces a deflection of the

diaphragm which introduces strain to the gauges. The strain will produce will an
electrical resistance change proportional to the pressure.
Pressure transducer is generally available with 3 types of electrical output, mill

volt, amplified voltage and 4-20mA
Procedure:
 First of all start the trainer level control.
 When the apparatus comes in running condition, maintain the level in the level
glass.
 When tank is gull of water its level is seen in the level glass.
 A sensor is attached with the level glass, it sense the level in level glass.
 The level glass id filled by opening the valves.
 At end decreases the level by closing the valve and note its calibrated value on
the meter.
 Make a table and note the actual and calibrated values in it and find the
accuracy of the system.
Conclusions:
 A pressure transducer is installed which converts the pneumatic signal to the
electrical signal.
 The percentage error may be due to the random or systematic error of the
transducer.
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Observations and calculations
Standard level in tank Calibrated Percentage

Cm (sensor level) accuracy
System parameters
Manipulated variable is water flow rate
 Control valve, Pneumatic valve, Pump, Storage tank, Level tank, Inlet control,
Outlet control
total accuracy
overall accuracy = ∗100=99.203 %
no . of samples
Graph:
Graph b/w Tank level and Sensor level

Sensor level(cm)
Tank level (cm)
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Experiment No. 07
Objective:
To study the open loop system on level trainer apparatus control the level
of control manually from the outlet at the constant flow rate of the water. Also
report the various disturbances that can affect the control variable .
Apparatus:
Level controller apparatus
Theory:
An open loop controller also called a non-feedback controller is a type of
controller which computes its input to a system using only the current state and its
model of the system.
A characteristics of an open loop control system is that it does not feed back to
determine if its input has achieved desired goal or not. It is often use in a simple
process.
Procedure:
 First of all level in the storage tank was checked
 Then switch on the apparatus
 Then by pass valve was made at a certain position and was switched on.
 The level was maintained in the transparent column by opening the valve to a
desired position.
 The percentage opening of valve was also checked.
 The experiment was repeated by maintaining water level at different heights
Conclusions
 The actual level maintained is slightly less than the required level.
 At the level in the transparent tank increases the percentage opening of the
outlet valve of water decreases
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Required level Actual level Valve opening

Cm Cm
Graph:
Graph between required level and actual level

Actual level (cm)
Required level (cm)
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EXPERIMENT NO. 08
Objective:
Study the behavior of the open loop control system on the flow controller
apparatus and control flow of the fluid manually and report difficulties which
occur during the manual made operation from characteristics curves, report the
type of valve.
Apparatus:
Flow controller apparatus
Theory:
Following are types of valves
 Air to open valve

 Air to close valve
Air to open valve

When air supply is given to them the valve opens. It is also called failure to close
valve.
Air to close valve
When air supply is given to them the valve closes. It is also called failure to open
valve.
Pneumatic controlled valves are most commonly used in industry due to their long life
and easy maintenance.
These valves can be operated via single control system under a single person. They
can be used over variety of control parameters. And easy to install.
Procedure:
 First of all check the apparatus.
 Switch on level flow controller.
 Set the control valve to manual mode and switch on the pump.
 Adjust the rotameter readings with the help of valve..
 When steady state is achieved, note down the rotameter and the control valve
reading.
 Note down percentage opening of valves
 Repeat the experiment by changing the flow rates of rotameter.
Conclusions
 In open loop control system the fluctuation are more and chances of loses are
more.
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 As the percentage opening of valve increases the controller reading increases,

with increase of percentage opening of valve rotameter reading increases.
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Observations and calculations
Rota meter Rota meter Controlling Magnetic percentage

readings readings reading L/hr inductive reading opening valve
L L/hr L/hr
Graph:
Graph between rotameter reading and controller reading
Controlling Reading
Rotameter Reading
EXPERIMENT NO. 09
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Objective:
To study the behavior of open loop control system on the pressure
control apparatus maintain the required pressure manually by operating the
control valve.
Apparatus:
Pressure controller apparatus
Theory:
An open loop controller also called as non-feed controller is a type of controller
which computes its input into a system using only the current sate and its model of the
system. A characteristic of open loop control system does not observe the output of
the process that it is controlling. It may not compensate for the disturbance in the
system.
An open loop control system is controlled directly and only by one input signal without
the benefit of feedback
Procedure:
 Check and run the apparatus also see the display on the screen.
 Set the operation to manual mode, open and close the valve.
 When desired pressure is achieved open the outlet valve.
 Measure the percentage opening of valve.
 Repeat the experiment by changing pressure in the tank.
 Draw graph b/w required pressure and actual pressure.
Conclusions:
 As the percentage opening of valve increases the pressure in the tank also
increases.
 Higher the pressure in the system the move it is difficult to control the system.
 The manual control of pressure system is tough, it requires vast experience
and practice
 The actual pressure maintained was slightly higher than the required level.
Observations and Calculations
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Sr.No Required pressure Reading from controller percentage

(bar) (bar) valve opening
Graph:
Graph between percentage valve opening and required pressure
Required pressure (Bar)
percentage valve opening
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Experiment No. 10
Objective:
Study the behavior of closed loop system on level controller apparatus,
control level of measuring tank by the set point. Also collect the data from
response of disturbance on closed loop system.
Apparatus:
Level controller apparatus
Theory:
Closed-loop liquid level control apparatus is a practice-oriented experiment set
in applied control technology designed especially for didactic purposes. The controlled
system or liquid level basin is characterized by the fact that it has a medium response
time. Thus experiments can be performed rapidly and can be simultaneously monitor
how the experiment is proceeding. The experiments focus on determining the most
important parameters of controlled systems with compensation and the set-up and
optimization of control loops with continuous and discontinuous controllers. The liquid
level basin has a plain form on which the foils can be attached to facilitate the marking
of the liquid level as a function of time.
Procedure:
 First of all set the automatic mode of process on level trainer.
 Then enter the set point from 10 to 60 and note the output value.
 Then for collection of data from response of disturbance on the closed loop
system.
 Enter the set point 20, 30, and 40 and note the reading against set point, when
the steady state is achieved.
 Find the percentage opening of value at each set point from the controller.
Conclusion:
 In a closed loop control system, information regarding to disturbance which
occurs in the system is directly set to the controller, which takes a decision
automatically for the elimination of disturbance and shows correct set point
value.
 Control of closed loop system is better than open loop or manual control
system.
 Also graph shows that closed loop has greater efficiency
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Sr. No Set Point (cm) Indicated S.P Control (cm) Percentage Valve Opening
Graph:
Set Point
%age Valve Opening
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Experiment No. 11
Objective:
Draw the characteristic curve of control valve on the level trainer, report type
of valve and determine the following.
 Turn down ratio

 Cv of the valve
 Pressure drop across the valve
Apparatus:
Level control trainer, flow control trainer
Theory:
Level Control Trainer:
The Level Control Trainer is designed for demonstration on open and closed
tank level measurement as well as to provide a hands on experience on how a level
loop can be controlled using microprocessor based controller. The equipment consists
of industrial grade instrumentation to exhibit a realistic working environment of a
standard industrial level process control loop.
Flow Control System Trainer:
The Flow Control System Trainer is the system, which outlines the basics of
Closed Loop Flow Control and various aspects related to it.
Procedure:
 First of all set the valve trainer apparatus in the operating condition.
 Connect the apparatus with rotameter to find the value of flow rate against the
opening of the valve.
 Set the opening of the valve 10 % at start and find the flow rate from rotameter
 Similarly by changing the opening of control valve from 10 to 100 %. I find the
V.F.R from the rotameter.
 Turn down ratio:
 TDR = Max Flow / Min flow
 Cv of the valve from the value Kv = Cv
 Pressure drop across the valve
o qv = Cv F(x) √ (ΔP/G)
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Conclusion:
 As the percentage opening increases the flow through the valve also increases,
because stem position and flow are directly related.
 As the flow rate increases the pressure drop through the valve was also high.
 Cv is the capacity coefficient of the valve, when Cv is high it means flow
capacity of the valve is high and size of the valve is small.
 Characteristic curve of the control valve is the relation between the flow rate
and stem position or the lift.
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Sr. No Rotameter Reading (gpm) Percentage Valve Opening ΔPv
Turn Down Ratio = Max Flow/Min Flow

T.D.R = Flow at 100% opening / Flow at 10% opening
Cv of the Valve:
Cv = 4
ΔPv across the Valve: at 100%, and then at 10 %
As
qv = Cv F(x) √ (ΔPv / G)
So
ΔPv /G = qv2 / (Cv F(x)) 2
ΔPv = G qv2 / (Cv F(x)) 2
Graph:
Flowrate (gpm)
%age Valve Opening
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ΔPv
Percentage Valve Opening
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Experiment No. 12
Objective:
To study the deviation between actions of various type of controller (P, PI,
and PID). Report which controller gives offset and which minimizes it; also find
which controller is more efficient.
Apparatus:
Level controller trainer, stop watch
Theory:
Proportional controller:
A proportional control system is a type of linear feedback control system. Two

classic mechanical examples are the toilet bowl float proportioning valve and the fly-
ball governor. This controller sets the manipulated variable in proportion to the
difference between the set point and the measured variable. The bigger the
difference, the greater the change in the manipulated variable.
Proportional-Integral Controller:
To remove the offset integral action is required and so PI control is normally

used. It works by summing the current controller error and the integral of all previous
errors. Proper tuning of the integral part of a PI controller can improve its performance.
Proportional-Integral-Derivative Controller:
A proportional-integral-derivative controller (PID controller) is a generic control

loop feedback mechanism (controller) widely used in industrial control systems. A PID
controller calculates an "error" value as the difference between a measured process
variable and a desired set point. The controller attempts to minimize the error by
adjusting the process control inputs. The PID control scheme is named after its three
correcting terms, whose sum constitutes the manipulated variable (MV). The
proportional, integral, and derivative terms are summed to calculate the output of the
PID controller.
Procedure:
 First of all set the required controller in parameters from the controller.
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 Give the set point at 10 cm and noted the value when it reach at steady
state point.
 Take more reading by changing the set point at 20, 30, 40 cm etc.
 Take more reading and change the type of controller PID and repeat the
experiment.
 Then find the offset for the controller
 Offset = (Set point) – (Steady state value)
Conclusion:
 Study the various type of controller it can be concluded that,
 Integral controller minimizes the offset, it is only found in the proportional
and differential controller.
 Proportional integral differential controller is more efficient and good as
compared to other controller. 45 % controllers used in industry are the PID
controller.
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PID Controller:
Sr. No Set Point (cm) Process Variable Percentage Valve

(cm) Opening
PI Controller:
Sr. No Set Point (cm) Process Variable (cm) Percentage Valve Opening
PD Controller:
P Controller:
Graph:
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Actual Value
PID Controller
PI Controller
PD Controller
P Controller
Set point
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Experiment No. 13
Objective:
Determine the time constant of given mercury thermometer and
thermocouple dipped in an oil bath. Also plot a graph between Y (t)/A and t/τ.
Repeat Y (t) when t = π and t = 2π
Apparatus:
Thermometer, thermocouple, beaker, heater
Theory:
Thermometer:
It consists of a bulb containing mercury attached to a glass tube of narrow
diameter; the volume of mercury in the tube is much less than the volume in the bulb.
The volume of mercury changes slightly with temperature; the small change in volume
drives the narrow mercury column a relatively long way up the tube. The space above
the mercury may be filled with nitrogen or it may be at less than atmospheric pressure,
a partial vacuum.
Thermocouple:
A thermocouple consists of two dissimilar conductors in contact, which
produces a voltage when heated. The size of the voltage is dependent on the
difference of temperature of the junction to other parts of the circuit. Thermocouples
are a widely used type of temperature sensor for measurement and control and can
also be used to convert a temperature gradient into electricity. Commercial
thermocouples are inexpensive, interchangeable, are supplied with standard
connectors, and can measure a wide range of temperatures. In contrast to most other
methods of temperature measurement, thermocouples are self powered and require
no external form of excitation. The main limitation with thermocouples is accuracy;
system errors of less than one degree Celsius (°C) can be difficult to achieve.
Procedure:
 First of all pour the 150 ml of lube oil in the beaker and placed the beaker on
heating bath.
 Then insert the thermocouple into the beakers and started to heat the lube oil
up to 120oC.
 Insert another thermometer and a thermocouple into beaker and started to note
readings after an interval of 2 sec.
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 Then tabulate the readings and plot the graph.
Conclusion:
 Electrical signals travel faster than other signals
 EMF produced is directly proportional to the temperature difference
 The mean time for thermocouple is 0.36 min and for thermometer is 0.532 min
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For Thermometer:
y= 100 oC Room Temp = 36 oC Amplitude = A = 64 oC
Sr. Temperature Y(t)=Y-Ys Y(t)/A τ=t / (ln(1-τt t/ τ = ln 1/1- (τ t

No (°C) (°C) /A) /A)
For Thermocouple:
y= 100 oC Room Temp = 36 oC Amplitude = A = 64 oC
Sr. E.M.F (V) Temp (oC) yt=y-y3 (yt /A) t = 1/ln (1- τt t/ τ = ln(1-yt
No /A) /A)
Graph:
Thermometer:
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Thermometer
(yt /A)
t/ τ
Thermocouple:
Thermocouple
(yt /A)
t/ τ
Experiment No. 14
Objective:
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Determine the effect of step change on level controller apparatus. Also

draw a graph between time and step change.
Apparatus:
Level controller apparatus, stop watch
Theory:
Closed-loop liquid level control" is a practice-oriented experiment set in applied
control technology designed especially for didactic purposes. The controlled system or
liquid level basin is characterized by the fact that it has a medium response time. Thus
experiments can be performed rapidly and can be simultaneously monitor how the
experiment is proceeding. The experiments focus on determining the most important
parameters of controlled systems with compensation and the set-up and optimization
of control loops with continuous and discontinuous controllers. The liquid level basin
has a plain form on which the foils can be attached to facilitate the marking of the
liquid level as a function of time. The character of the controlled system can be
modified by using various sliding partitions (delays of the 1 st and 2nd order).
Procedure:
 First of all set the apparatus in operating condition.
 Then turn on the air supply, set the set point.
 After that note the reading at the interval of 2 seconds up to 2 minutes.
 Then change the set point and repeat the experiment.
 Then tabulate the readings and draw a graph between time and step change.
Conclusion:
 From the experiment I concluded that it can be predicted from the graph that
the effect of step change is in the form of sinusoidal.
 As the set point is increased the readings obtained are also increased up to a
certain point, at this point the step change occurs as a sinusoidal.
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Sr. No Time (Sec) Set Point (10 cm) Set Point (20 cm) Set Point (30 cm)
Graph:
10 cm
Step Change
Linear (10 cm)

20 cm
Linear (20 cm)
30 cm
Linear (30 cm)
Time (Sec)
Experiment No. 15
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Objective:
Investigate control behavior at temperature control apparatus by
changing the set points.
Apparatus:
Thermometer, thermocouple, temperature controller
Theory:
The Temperature control system trainer is the system, which outlines the
basics of Temperature Control loop and other aspects related to it. The unit provides
the opportunity of investigating the effects of a change of controller parameters
(proportional band, integral and derivative times) on the control capability of the
system. Of particular benefit to the student is the fact that the unit is made up of typical
items of control equipment currently used in industrial applications, thereby providing
an excellent opportunity for familiarization.
Procedure:
 First of all, switch on the apparatus and after that turn on pump.
 Then select the control mode where only heater operated.
 Then enter the set point to apparatus.
 Note the heater condition where only heater process values oscillated between
set points.
 Same experiment was repeated for different set points.
Conclusion:
 The difference between set point and the actual value is less then controller is
efficient.
 The offset in the temperature controller is not so high.
 As the set point increases the percentage value opening also increased.
Page
Observations and Calculations:

Sr. No Set Point (oC) Actual Value (P.V) (oC) Percentage Valve Opening (%)
Graph:
Temperature Controller Behavior

Indicated Value (oC)
Set Point (oC)
Experiment NO. 16
Page
Objective:
To study the split range at temperature control trainer by a continuous
heating/cooling
Apparatus:
Temperature controller apparatus
Theory:
A common application for split range control is when a temperature control loop
must at times apply heat to a process and at other time apply cooling. This is normally
accomplished by two valves, one called the “heating valve”, the other the “cooling
valve”. In the usual installation, each valve operates through one-half of the
controller’s output range, applying the maximum heating or cooling at the extremes of
the controller’s output range. At the midpoint of the range, neither heating nor cooling
is applied.
Procedure:
 First of all switch on the apparatus and give the controller set point values.
 Then note the starting temperature, at the start of fan temperature was noted
and when fan was turned off, then again note the temperature.
 After that change the set points and repeat the same experiment.
Conclusion:
 As the process value increases from the set point (+1 oC) the fan starts. The fan
shut of as the process value equals the set point value.
 The deviation from the set point value will be controlled by split range controller.
Page
Sr. Set Point Process Value, Heater off, Process Value, Mean Actual
No (oC) Fan Start Fan off Temperature
(oC) (oC) (oC)
Graph:
Split range control

Actual Mean Temp (0C)
Setpoint (0C)
Page
Experiment No. 17
Objectives:
To study the effect of flow rate on delay time by using,
 Smallest delay time

 Largest delay time
Theory:
Delay time is defined as the time required by a system to reach the steady state
position for larger path at flow rate delay time is less.
Procedure:
 First of all closed all delay element path and open short path.
 Switch on the apparatus and select the set point 40 oC for T2. When all system
acquires 40oC, then open the longer path valve and close short path.
 Then note Ts and time to reach Ts.
 Similarly at 50oC, repeat the same procedure at this temperature.
Conclusion:
 For higher flow rate delay time is less because fluid reaches the steady state
soon, and for smaller flow rate delay time is more.
 Delay time is inversely related with delay element.
Page

Longer Delay time:
Sr. Pump Speed Set Point Delay Time

No (oC) (Sec)
Shorter Delay Time:
Sr. Pump Speed Set Point Delay Time

No (oC) (Sec)
Graph:
Delay Time
Longer delay time

Shorter delay time
Set Point (0 C)
Experiment No. 18
Objective:
Page
To investigate the tuning parameters of P, PI, PID controller apparatus,

also determine optimum tuning parameter using hit and trial method.
Apparatus:
Level Control Trainer
Theory:
Proportional controller:
A proportional control system is a type of linear feedback control system. Two

classic mechanical examples are the toilet bowl float proportioning valve and the fly-
ball governor. This controller sets the manipulated variable in proportion to the
difference between the set point and the measured variable. The bigger the
difference, the greater the change in the manipulated variable.
Proportional-Integral Controller:
To remove the offset integral action is required and so PI control is normally

used. It works by summing the current controller error and the integral of all previous
errors. Proper tuning of the integral part of a PI controller can improve its performance.
Proportional-Integral-Derivative Controller:
A proportional-integral-derivative controller (PID controller) is a generic control

loop feedback mechanism (controller) widely used in industrial control systems. A PID
controller calculates an "error" value as the difference between a measured process
variable and a desired set point. The controller attempts to minimize the error by
adjusting the process control inputs. The PID control scheme is named after its three
correcting terms, whose sum constitutes the manipulated variable (MV). The
proportional, integral, and derivative terms are summed to calculate the output of the
PID controller.
Procedure:
 First of all set the apparatus in operating conditions.
 Select the set point and keep it constant.
 Select the proportional controller and note the values of process variables by
varying (xpi) tuning factor.
 Take 10 readings by changing (xpi).
 Same experiment is repeated with other controllers.
Page
Conclusion:
 From the reading we concluded that in P controller by keeping set point
constant and increasing value of xp, the offset increases.
 And also concluded that offset in PI controller is less as compared to P
controller.
Page

xpi Set Point 40 cm Set Point 40 cm Set Point 60 cm Set Point 60 cm
Process Variable Offset Process Variable Offset
Graph:
Set Point 40 cm
Set Point 60 cm
xpi
Offset
Page
Experiment No. 19
Objectives:
To study the behavior of closed loop control system on pressure
controller apparatus and control pressure by set point. Also determine the
external disturbances of final control element.
Apparatus:
Pressure level trainer
Theory:
This teaching and training system provides a comprehensive experimental
introduction to the fundamentals of process control using an example of pressure
control. The air pressure control system is a 2nd order system. It comprises two in-line
pressure vessels interconnected by a restrictor valve. An additional valve on the
second tank makes air tapping possible and so can be used to simulate a disturbance
variable. A pressure transducer measures the pressure in the 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.
Procedure:
 Firstly set the apparatus in operating condition and checked that all the values
and necessary parts in working condition.
 After that supply the instrument air. Then in control panel enter the operating
mode give set point.
 Note %age opening of valve.
 Repeat experiment by changing set points
Conclusions:
 Indicated pressure and % age valve opening are directly related.
 3 way valve used in pressure controller with which we control of air in 3
different directions by using single value.
Page

Sr. No Set Point Percentage opening Indicated Pressure
(bar)
Graph:
Actual Pressure (bar)
Percentage Valve Opening (%)
The End
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Laboratory Manual Instrument Process and Control

Experiment No. Objective

controller (P, PI, and PID). Report which controller gives

Observation and calculations

Sr. no Valve opening Electrical signal Pneumatic signal

Graph between valve opening and Pneumatic signal

Pneumatic signal=3+ ( % age100

Observation and calculations

Sr. no Standard Calibrated Difference Percentage Percentage

Graph between Standard gauge pressure and calibrated gauge

Standard Guage (Bar)

Sr. no Standard Calibrated Difference Percentage Percentage

Bar Bar Bar

Graph between Standard gauge pressure and calibrated

To study the function and operation of bubbler apparatus and develop

 Level and static pressure

Observation and calculations

Sr. No Level of Level of column Hydrostatic Back pressure

Graph betw Level and Hydrostatic Pressure

Observation and calculations

Sr.No Temperature (0C) Volts (mV)

Graph between Temperature and Voltage

Observation and calculations

Low level High level

Open Close Open Close

Low level High level

Open Close Open Close

Pressure applied to the pressure transducer produces a deflection of the

Pressure transducer is generally available with 3 types of electrical output, mill

Observations and calculations

Standard level in tank Calibrated Percentage

Graph b/w Tank level and Sensor level

Tank level (cm)

Observation and calculations

Required level Actual level Valve opening

Graph between required level and actual level

Required level (cm)

 Air to open valve

Air to open valve

 As the percentage opening of valve increases the controller reading increases,

Observations and calculations

Rota meter Rota meter Controlling Magnetic percentage

Observations and Calculations

Sr.No Required pressure Reading from controller percentage

percentage valve opening

Observations and Calculations

%age Valve Opening

 Turn down ratio

Flow Control System Trainer:

Observations and Calculations

Turn Down Ratio = Max Flow/Min Flow

ΔPv = G qv2 / (Cv F(x)) 2

%age Valve Opening

Percentage Valve Opening

A proportional control system is a type of linear feedback control system. Two

To remove the offset integral action is required and so PI control is normally

A proportional-integral-derivative controller (PID controller) is a generic control

Observations and Calculations

Sr. No Set Point (cm) Process Variable Percentage Valve

 Then tabulate the readings and plot the graph.

Observations and Calculations

y= 100 oC Room Temp = 36 oC Amplitude = A = 64 oC

Sr. Temperature Y(t)=Y-Ys Y(t)/A τ=t / (ln(1-τt t/ τ = ln 1/1- (τ t