EXPT.

NAME OF THE EXPERIMENT

NO.

STUDY OF STEP RESPONSE OF FIRST ORDER SYSTEM(THERMOMETER &

1.a
THERMOWELL)

1.b STUDY OF STEP RESPONSE OF SECOND ORDER SYSTEM(MERCURY

MANOMETER & WATER MANOMETER)

2. CASCADE CONTROL TRAINER

3. PRESSURE CONTROLLER TRAINER

4. LEVEL CONTROL TRAINER

STEP RESPONSE OF TWO FIRST ORDER SYSTEMSARRANGED IN NON-

5.a
INTERACTING MODE

5.b STEP RESPONSE OF TWO FIRST ORDER SYSTEMSARRANGED IN

INTERACTING MODE

6 WORKING WITH I TO P AND P TO I CONVERTERS.

7 STUDY OF CHARACTERISTICS OF CONTROL VALVE

8
STUDY OF THE PERFORMANCE OF PID CONTROLLER IN MATLAB / SIMULINK

9
TEMPERATURE CONTROLLER TRAINER
EXPT. NAME OF THE EXPERIMENT
NO.

10 CALIBRATION OF THERMOMETER AND THERMOCOUPLE

11 PROGRAMMABLE LOGIC CONTROL TRAINER

12 FLOW CONTROL TRAINER

13 pH CONTROL TRAINER

14 SHELL AND TUBE HEAT EXCHANGER

Exp. No. :1a
Date:

STUDY OF STEP RESPONSE OF FIRST ORDER SYSTEM

(THERMOMETER)
AIM

To study the step response of the first order system.

THEORY

A thermometer is added with additional resistance (thermo-well) at its bulb to increase its
time constant. The system can generally be considered as first order system.

The dynamic response of first-order type instruments to a step change can be represented

by

Where,

θ =temperature indicated by thermometer, oC

θF =Final steady state temperature,oC

t =time, sec
T = time constant, sec
The linear first order differential has the particular solution for given initial conditions,


 1  e t / T
F

The time constant Τ is the time required to indicate 63.2% of the complete change.

The time constant, T is numerically equal to the product of resistance and capacitance.

PROCEDURE

 Fill the heating bath with clean water by opening the inlet valve of heating bath.
 Switch on beeper and set beep interval to 3 seconds.
 Ensue that cyclic timer is set to 30 seconds on time and 30 seconds off time.
 OBSERVATIONS & CALCULATIONS

1) Initial temperature (0C) =……………

2) Final temperature (0C) =……………

Sl Time (Sec.) Actual temperature (⁰C)

No.

Calculations

Step change = Final temp. – Initial temp.= ………………0C

Value of 63.2% of step =0.632 x (Final temp – Initial temp) + Initial temp
=…………………0C
Plot the graph of Actual temperature Vs. time and note the value of time at63.2% of step
change. This value is observed time constant of the Thermometer. Calculate theoretically
predicted temperature by following equation:
Theoretical temperature = Initial temp. + {Step change x [1-exp (-1xTime/T)]}
=………………….0C
Plot the graph of Theoretical temperature Vs. Time on the same graph plotted above.

Model Graph:
  Switch on Mains to heat the water in heating bath to its boiling point. Switch off the mains.
 The water in heating bath is now near its boiling point. Insert the thermometer in heating bath
suddenly after noting its initial temperature.
 Note the thermometer reading at each beep interval till the temperature reaches
at steady state.

RESULT:
 STUDY OF STEP RESPONSE OF THERMOWELL

PROCEDURE

• Fill the thermo-well with clean water by opening the inlet valve of heating bath.

• Switch on beeper and set beep interval to 3 seconds.

• Ensue that cyclic timer is set to 30 seconds on time and 30 seconds off time. Switch on Mains to

heat the water in thermo-well to its boiling point. Switch off the mains.

• The water in thermo-well is now near its boiling point. Insert the thermometer in thermo-well

suddenly after noting its initial temperature.

• Note the thermometer reading at each beep interval till the temperature reaches at steady state.
• Switch off beeper and fill up the readings observed in “Observations” below.
OBSERVATIONS

1) Initial temperature (0C)

2) Final temperature (0C)

Sr. No. Time (sec) Actual temperature

(0C)

..

Calculations
1. Step change = Final temp. – Initial temp.

2. Value of 63.2% of step =

0.632 x (Final temp. – Initial temp.) + Initial temp.

3. Plot the graph of Actual temperature Vs time and note the value of time at 63.2% of step

change. This value is observed time constant of the thermometer.

4. Calculate theoretically predicated temperature by following equation

Theoretical temp. =-1 x Time

Initial temp +(step change x (1-EXP ( )))
time constant t (from graph)

5. Plot the graph of Theoretical temperature Vs time on the same graph plotted above.
Exp. No. :1b
Date:

STUDY OF STEP RESPONSE OF SECOND ORDER SYSTEM

(MERCURY MANOMETER & WATER MANOMETER)
AIM

To study the step response of the second order system (Mercury manometer& water manometer).

THEORY

The dynamic response of a second order system to a step change can be describedby a second-
order differential equation.The solutions to above equation involve three cases:

1. Under damped condition[ζ<1].

2. Critical damped condition [ ζ=1].
3. Over damped condition [ ζ>1].

The response for under damped system [i.e. ζ<1] can be written as:

   1    1  
 
2 2
y (t )  KM  1  e t /  Cos t  Sin t  
     1 2    
     

In case of manometer:

y(t) = Response at any time ‘t’ after step change (deviation value).

K = Gain factor =1

M = Magnitude of step change

Where,

L = Column length in meter,

µ = Dynamic viscosity in kg/ms.

ρ = Mass density of the manometer fluid in kg/m3.

 OBSERVATIONS

Manometer fluid : water Manometer fluid : Mercury

Dynamic viscosity (µ) = 0.001Kg/m.S Dynamic viscosity (µ) = 0.00157Kg/m.S

Mass density (ρ) = 1000Kg/m3 Mass density (ρ) = 13600Kg/m3

Column length (L) =1.05 m Column length (L) =0.75m

Tube diameter (d) =22 mm Tube diameter (d) =8 mm

Manometer (Water/ Mercury):

Sl. Actual response (mm) Period of oscillation (sec)

No.
 D = Tube diameter in m,

g = Gravitational acceleration in m/sec2

Frequency of damped oscillation (f)= 𝜔𝑛 √(1 − 𝜁 2 )

2𝑔
Natural frequency (𝜔𝑛 ) = √ 𝐿 (rad/sec)

Rise time, (tr) = Time the indicated value takes to first reach the new steady state value.

Time to first peak, (tp) = Time required for the indicated value to reach itsfirst maximum value.

Response/settling time(ts) is defined as the time required for the indicated value to reach and remain
inside a band whose width is equal to +/-5% of the total change in θ. The term 95% response time
sometimes is used to refer to this case. Also, values of +/-1% sometimes are used.

Decay ratio (DR)= c/a (Where c is the height of the second peak).

Overshoot (OS) = a/b

Period of oscillation Pis the time between two successive peaks or twosuccessive valleys of the
response.

PROCEDURE

•Ensure that water level in manometer is set at ‘0’ on the scale.

• Close the vent of water manometer by hand.

 Step change =Final Height – Initial Height = …………….mm
Period of oscillation(T) =……………..S

From graph:
a=…………..; b=…………..; c=……………
Rise time(tr) =……………..S
Decay ratio(DR) = c/a =……………
Overshoot(OS) = a/b =…………….

∴ Ʈ =………..……S

CALCULATIONS
ω = 2π/T

∴ Ʈ =………..……S

𝐿
∴ ƮTheoratical =√2𝑔

=……………S

2𝑔
Damping coefficient =(8𝜇𝐿)/{(𝜌𝑔𝐷²) (√ 𝐿 )}

=…………..S
  Press the rubber bulb to deflect the water to @100mm from ‘0’ level.
 Note the water level reading and quickly open the vent to apply step change.
 Note peak values observed during oscillations.
 Measure the period of oscillations and note average time required for each oscillation.
 Plot the graphs of Actual & Theoretical response Vs Time.
 Note the top peak and bottom peak readings. Also simultaneously note the period of oscillation.
(This can be noted by measuring time required for 4-5 oscillations and then calculating for each
oscillation)
 Repeat process 2-3 times for different step changes.

RESULT
Exp. No. :2

Date:

CASCADE CONTROL TRAINER

AIM

To study the performance of cascade controller.

WORKING PRINCIPLE

Cascade Control Trainer is used to perform cascade control on flow and level process and study the
characteristics of I/P converter industrial standard Rotameter wheel flow meter and orifice with
differential pressure transmitter. DPT is used to measure the flow of fluid in a pipeline. The RF
capacitance level transmitter is used to measure the level of the process.

In cascade control action, pump sucks the water from reservoir and gives it to rotameter and control
valves. While the fluid flows through the orifice plate. A differential pressure developed across is, which
is sensed by differential pressure transmitter corresponding current output (4-20mA) is given to the Data
Acquisition card. Every internal transaction are in voltage.

Here, PC acts s error detector and controller. According to the error signal, corresponding control signal
is given to the I/P converter. It controls the flow of the fluid in pipeline by varying stem position of the
control valve.

The level is a primary control loop and flow is a secondary control loop. For maintaining the level of the
process tank, flow is manipulated level signal is given to the Data Acquisition card. By pass line is
provided to avoid the pump overloading. Rotameter visualize the flow of the fluid in a pipe line.

From the analyzer, we can also study the characteristics of level transmitter, DPT, I/P converter, control
valve and justify the various control action on the processes.

APPARATUS REQUIRED

1. VFLPA-501CE
2. Data Acquisition card
3. Cascade control software.
4. Patch chords.
CASCADE CONTROL SCHEME- BLOCK DIAGRAM
PROCEDURE

1. Ensure the availability of Air and Water.

2. Interface the PC with process and check whether all the patching are closed.
3. Maintain Gauge(GI) pressure at 20 PSI by using air regulator knob.
4. Position the hand valve HV1 &HV2 in slightly open position.
5. Switch ON the unit and Data Acquisition card with PC.
6. Invoke cascade control software from PC.
7. Switch on the pump and select desired speed of pump by varying speed control knob.
8. Enter the desired parameters for inner loop(flow) and outer loop(level).
9. Observe the response and save graph.
10. Switch off the pump.
11. Compare the performance of cascade controller with the level process and analyse.

RESULT
EXP. NO:3

DATE :

PRESSURE CONTROLLER TRAINER

List of Experiments
1. Open Loop
2. On/Off Controller
3. Proportional Controller
4. Proportional Integral
5. Proportional Derivative
6. Proportional Integral Derivative

PROCESS CONTROLLER
In automatic controlled process the parameter to be controlled is measured and compared with the set
point by process controller. The difference between the measured signal and the set point is error. The
controller performs on-line calculations based on error and other setting parameters and generates an
output signal. The output signal drives the final control elements like control valve or a damper to
control the process to the set point.
1.STUDY OF OPEN LOOP RESPONSE (MANUAL CONTROL)

AIM: To study the response of Open Loop control system

PROCEDURE:

• Start the set up, adjust the vent valve.

• Select open loop Experiment (click on “Change Expt.” Button, click on “Change”, Click on “Open
Loop” button.)

• Close the control valve by increasing the controller output to 100%. Note down steady state process
value.

• Apply the step change by 10% to controller output and wait for the process value to reach the steady
state value. Note down the process value.

• Repeat the above step until the controller output reaches to minimum 0%.
OBSERVATIONS

Tabulate the observations as follows

Controller output in % Process Value in %

100

90

80

• From the above data , note the output required for maintaining the process at desired set points. (for
particular vent valve opening).

• Set the output of the controller to the noted value and at steady state apply the load change to the
process. Load change can be given by slightly varying the vent valve. Observe new steady state
process value.
2. STUDY OF ON/OFF CONTROLLER

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

DESCRIPTION

A special case of proportional control is On-Off control. If the proportional band of the controller is
made very low (=0) the controller out put will move from one extreme position to other for slight
deviation of process value from the set point. This very sensitive action is called On-Off control because
final control element is either open (On) or close (Off) i.e. operates like a switch. These are the simplest
controllers.
These controllers incorporate a dead band to keep the output from cycling rapidly between on and off.
The controller will not turn on or off until the error signal moves out of the dead band. The process
variable controlled by an on/off controller always
cycles back and forth about the set point as shown in the fig. Dark line and dotted line shows process
parameter and reference values respectively.
Hysteresis is a value set in the vicinity of on-off operating point. Upper hysteresis is value or band in
which process value is allowed to operate above the set point and lower hysteresis is value or band in
which process value is allowed to operate below the set point.
PROCEDURE

• Start the set up, adjust the vent valve.

• Select “On-Off mode” option for the control from software. (click on “Change Expt.” Button, click
on “Change”, Click on “On-Off mode” button.)
• Change Hysteresis value to 1%.(Range 0.1-10%)

• Change the values of the set point and observe the On-Off control operation.
OBSERVATIONS
Observe that if process value exceeds the set point and increases above the value of (0.5x Hysteresis),
control valve is full open and if process value decreases below the set point by (0.5 x Hysteresis), the
control valve closes fully i.e. controller operates like On/Off switch.
3. STUDY OF PROPORTIONAL (P) CONTROLLER

AIM: To study the performance of Proportional controller for step change in set point for the Pressure
control system

DESCRIPTION

In proportional controller the control algorithm generates a linear control output proportional to
deviation. In proportional action the amount of change in the measured value (or deviation) is expressed
in percent of span that is required to cause the control output to change from 0 to 100 % is called the
proportional band. The controller output is given by:

Where, OP is the output, PB is proportional band in %, b is the bias value, and e is the error signal. If
there is no biasing, output OP will become zero when error is zero. Hence bias value decides the value
of output when error is zero.

The proportional controllers usually show some difference between the set point and process variable
called offset. The offset can be reduced by decreasing proportional band or by readjusting the bias. With
decrease in proportional band the process becomes oscillatory.

There are two types of controller actions:

1) Increase-increase in which output increases as measurement increases. (error e =

measurement – set point)

2) Increase-decrease in which output decreases as measurement increases. (error e = set point

–measurement)
OBSERVATIONS

• Observe steady state error decreases as proportional band decreases.

• Observe the effect of very low proportional band values (system works in oscillatory mode).

• Observe the response of the system at load change. Load change can be given by slightly
manipulating the vent valve of the tank.
PROCEDURE

 Start the set up, adjust the vent valve.

• Select P Mode option for control from software. (click on “Change Expt.” Button, click on
“Change”, Click on “P Mode” button.)

• Keep the set point to 50%. Change output mode to Manual. Adjust output value so as to match the
process value with set point and apply this output value as bias value to the controller. Adjust the
proportional band to 50%.

• Switch the controller to Auto mode.

• Apply step change of 10% to set point and observe the response.

• Switch the controller to Manual mode. Decrease proportional band to half of the previous value &
then shift controller to Auto mode. With each decrease, obtain a new response of the step change.
Ensure that the set point changes are around the same operating point (@ 5-10% only).

• 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.

• Set the controller to the settings obtained in the above step and wait for the system to reach at steady
state.
4. STUDY OF PROPORTIONAL INTEGRAL (PI) CONTROLLER

AIM: To study the performance of Proportional Integral controller for step change in set point for the
Pressure control system

DESCRIPTION

The offset in proportional controller can be overcome by adding integral action. The control algorithm
that applies changes in output as long as deviation exits, so as to bring the deviation to zero, is called
integral action. Output of proportional-Integral controllers is given by:

Where OP is the output, b is the bias, PB is the proportional band in %, e is the error signal, Ti is
integral time; this is the time required to repeat proportional action.

PROCEDURE

• Start the set up, adjust the vent valve.

• Select PI Mode option for control from software. (click on “Change Expt.” Button, click on
“Change”, Click on “PI Mode” button.)

• Adjust the process value by changing the output of controller in manual mode to a particular
temperature (set point =40%).

• Set the proportional band estimated from Proportional control (from previous experiment). Start
with derivative time=0 and integral time=1000 sec., which will cut off the derivative action and
widen the effect of integral action.
 OBSERVATION

•
Observe the effect of reducing integral time on offset and on the response of the process.
• Set the set point to desired temperature (@40%). Allow the process to reach at steady state. Record
the steady state error.

• Switch on the controller to manual mode. Reduce the integral time to half of the previous value.
Switch to Auto mode and apply step change to the set point by 2 to 3%. Note the response of the
system.

• Using trial and error, find out an integral time, which gives satisfactory response to the step change
in set point.
5. STUDY OF PROPORTIONAL DERIVATIVE CONTROLLER

AIM : To study the performance of Proportional Derivative controller for step change in set point for
the Pressure control system

DESCRIPTION

This mode of control is described by the relationship

Where OP is the output, b is the bias, PB is the proportional band in %, e is the error signal, Td is
derivative time.

Larger the derivative time larger is the action. Smaller is the proportional band the larger is the
derivative action.

In order to achieve faster response and more stable operation in slow processes derivative action is
added to apply an output component proportional to the rate of change of input (error). Derivative action
is used with P action or PI action.

PROCEDURE

• Start the set up, adjust the vent valve.

• Select PD Mode option for control from software. (Click on “Change Expt.” Button, click on
“Change”, Click on “PD Mode” button.)

• Select PD controller. Set the proportional band estimated from Proportional control (P only). Start
with derivative time=0 and integral time=6000 sec., which will cut off the derivative action and
widen the effect of integral action.

• Set the set point to desired temperature (@40%). Allow the process to reach at steady state. Note the
response of the system.

• Switch on 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 2 to 3%. Note the response of the system.

• Increase the derivative time gradually and observe the process response for step change.
OBSERVATION

Observe the effect of increasing derivative time. Also note that the process may show offset as effect
of integral action is cut off.
6. STUDY OF PROPORTIONAL INTEGRAL DERIVATIVE CONTROLLER

AIM: To study the performance of Proportional Integral Derivative controllers for step change in set
point for the Pressure control system

DESCRIPTION

PID controllers are used for controlling almost all process variables like temperature, flow, level,
pressure etc. in a continuous or batch process.

The output of a PID controller is given by:

Where OP is the output, b is the bias, PB is the proportional band in %, e is the error signal, Ti is the
integral time and Td is derivative time .

Selection of proportional band, integral time and derivative time to achieve desired process response to
load changes is called tuning of controller.

PROCEDURE

• Start the set up, adjust the vent valve.

• Select PID Mode option for control from software. (click on “Change Expt.” Button, click on
“Change”, Click on “PID Mode” button.)

• Switch the controller to manual mode.

• 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.

• Change the controller to Auto mode. Apply step change by 2 to 3% to the set point and observe the
response of the process.

• Change the proportional band, integral time, derivative time and observe the response of the process
for step change for each change in setting.
OBSERVATION

Compare the steady state response of the PID controller with P, PI and PD controller obtained in the
previous experiments.
Exp. No. :4

Date:

LEVEL CONTROL TRAINER

AIM

To study the performance of different controller (Proportional controller)

APPARATUS REQUIRED

1. Process station
2. Data acquisition card
3. Process control software with PC
4. Path chords
5. compressor

THEORY

Two position control applied in a process station results in a continuous oscillation in the
quantity to be controlled. This drawback was overcome by a continuous action which could be
maintained by a continuous balance of the input and output. The continuous control modes include
proportional, derivative or integral control modes or a combination of these modes.

PROPORTIONAL CONTROLLER

In this control mode, the actuating signal for the control action is proportional to the error
signal. The error signal being the difference between the set point and the feedback signal. The output of
this control mode can be represented as:

u(t)=Kp e(t) + u0

u(t)=controller output at any time

e(t)=actuating error signal

Kp= proportional gain between error and controller output

The range of errors to cover the 0% to 100% controller output is called the proportional band.
PROCEDURE

1. Ensure the availability of air and water.

2. Interface the PC with process station and check whether all the patching is closed.
3. Switch on process station, water pump ( by adjusting round knob), air input, and PC and data
acquisition card.
4. Maintain G pressure at 20 psi by adjusting air regulator knob.
5. Position HV1 valve in a partially opened mode and HV2 valve in a slightly opened mode
6. Open process control software in PC and select ‘Trainer>>Level’.
7. Then select ‘control >>ONN-OFF
8. Then check the performance of P with different controller selection in ‘control’ menu.
9. Select Kp,Ki and Kd values by tuning process or trial and error method.
10. Save the optimum parameter values and process curves.

RESULT
EXP. NO:5a

DATE :

STEP RESPONSE OF TWO FIRST ORDER SYSTEMS

ARRANGED IN NON-INTERACTING MODE
AIM
To study the step response of two first order systems arranged in non-interacting mode.

THEORY
Here the outlet flow from tank 1 discharges directly into the atmosphere before spilling into the
tank 2 and the flow through R1 depends only on H1. The variation in H2 in tank 2 does not affect the
transient response occurring in tank 1. So we can here consider the overall system as two individual
systems cascaded.The overall transfer function can be written as,

H 2 ( s ) / Q( s )  R2 /(( 1 2 s 2  ( 1   2  A1 R2 ) * s  1))
where  1  A1 R1 and  2  A2 R2

PROCEDURE

• Start the setup.

• A flexible pipe is provided at the Rota meter 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.
• Switch on the pump and adjust the flow to @40 LPH. Allow the level of both th etanks (Tank-1
& Tank-2) to reach at steady state and record the initial flow and steady state levels of both
tanks.
• Apply the step change with increasing the Rota meter flow by @ 10 LPH.
• Record the level of Tank-2 at the interval of 30 sec, until the level reaches at steady state.
• Record final flow and steady state level of Tank1
• Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level.
• Repeat the experiment by throttling outlet valve (R1) to change resistance.
OBSERVATIONS

Diameter of tanks ( ID) = 92mm

Initial flow rate (Q1) =…………LPH
Initial steady state level of Tank-1 =………...mm

Initial steady state level of Tank-2 = …………mm

Final flow rate (Q2) =………….LPH
Final steady state level Tank-1 = …………mm
Final steady state level Tank-2 = …………mm

Level of Tank-
Sl no. Time (S) H(t) Observed(mm) H(t) Predicted(mm)
2(mm)

*Take readings till the steady state reached in level of Tank-2.

CALCULATIONS

H2(t)Observed = (Level at time ‘t’ ̶ level at time ‘0’ second)×10-3

  t  t 
 (   )  1  1   
H2(t)Predicted = AR2 1  1 2  e 1  e 2  ……………………. (1)
  1   2  2 1 
 
 


Where,

H (t)Predictedis level in Tank-2 predicted at time‘t’ in min.

A = magnitude of step change = Flow after step input - Initial flow rate in m3/sec.

τ1= A1 x R1

τ2= A2 x R2 Where,

τ1 is time constant of Tank-1 andτ2 is time constant of Tank-2.

A1is area of Tank-1andA2is area of Tank-2.

R1 is resistance of outletvalve of Tank-1andR2is resistance of outlet valve of Tank-2.

Area of Tank-1 = ( π/4) (d12) =…………. m2

Area of Tank-2 = ( π /4) (d22) =…………. m2

Considering non-linear resistance at outlet valve of both tanks, it can be calculatedas

R1 = dH1 /dQ

R2 = dH2 /dQ

Where,

dH1 is change in level of Tank-1.

dQ is change flow of from initial to finalstate.

dH2 is change in level of Tank-2 at initial and final state.

Put the values in equation (1) to find out H (t) Predictedand plot the graph of H(t)

Predicted and H (t) Observed v/s time.

RESULT
Exp. No. :5 b

Date:

STEP RESPONSE OF TWO FIRST ORDER SYSTEMS ARRANGED IN

INTERACTING MODE

AIM

To study the step response of two first order systems arranged in interacting mode.

THEORY

Here the flow through R1 depends upon the level difference (H 1-H2) between the two tanks.
Such a system is said to be interacting since any change in the level of Tank-2,

H2 will affect the flow rate Q1. The overall transfer function can be written as

H 2 ( s ) / Q( s )  R2 /(( 1 2 s 2  ( 1   2  A1 R2 ) * s  1))
where  1  A1 R1 and  2  A2 R2

PROCEDURE

• Start the setup.

• 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.

• Switch on the pump and adjust the flow @40 LPH. Allow the level of both Tank-2 and Tank-3, to
reach the steady state and record the initial flow (Q1) and steady state levels of both tanks (H1& H2).

• Apply the step change with increasing the rotameter flow by @ 10 LPH.

• Record the level of the Tank-2 at the interval of 30 sec, until the level reaches at steady state.

• Record final steady state flow and level of Tank 3

• Carry out the calculations as mentioned in calculation part and compare the predicted and observed

values of the tank level.

• Repeat the experiment by throttling outlet valve (R2) to change resistance.

OBSERVATIONS

Diameter of tanks ( ID) = 92mm

Initial flow rate (LPH) =

Initial steady state level of Tank-1 =………..mm

Initial steady state level of Tank-2 = …………mm

Final flow rate (LPH) =

Final steady state level Tank-1 = ………….mm

Final steady state level Tank-2 = ………….mm

Level of Tank 2 H(t) Observed H(t) Predicted

Sl no. Time (Sec)
(mm) (mm) (mm)

*Note: Take readings till the steady state reached in level of Tank-2
CALCULATIONS

H2(t)Observed = (Level at time ‘t’ seconds-level at time ‘0’ second)×10 -3

   
 1/  e t  1 /  e  t 
H2(t)Predicted = AR2 1            1
 1/   1/   

Where,

A = Magnitude of step change

= Flow after step input - Initial flow rate in m3/sec

τ1 = A1 x R1

τ2= A2 x R2

Where,

τ1 is time constant of Tank-1 andτ2is time constant of Tank-2.

A1is area of Tank -1andA2is area of Tank-2.

R1is resistance of outletvalve of Tank-1andR2 is resistance of outlet valve of Tank-2.

Considering non linear resistance at outlet valve of both tanks, it can calculated as

dH 1 dH 2
R1  , R2 
dQ dQ

Where,

dH is change in tank height for change in flow dQ.

Calculate values of b, αand β from equations given in theory part.Put the values in equation (1) to find
out H (t) Predictedand plot the graph of H (t) Predictedand H (t) Observed Vs time

RESULT:
 Exp. No. :6

Date:

WORKING WITH I TO P AND P TO I CONVERTERS.

AIM

On completion of this unit you will able to understand experimental working of I to P and P to I
converters..

In this unit you will perform following experiments.

Working with I to P converter.

Working with P to I converter.

6.1 WORKING WITH I TO P CONVERTER

PROCEDURE

1) Make the connection as per wiring sequence as given above.

2) Keep AFR knob fully CCW (OFF) position.
3) Connect air supply at the input of FRL unit. Switch ON compressor
4) Keep manual valves V1 = OFF, V2 = ON, V3 = OFF position.
5) Set current meter range at 20mA range.
6) Keep SW3 on CIP panel at down position, S1 at right side (4-20mA) and pot P1 at fully CCW position.
7) Make switch ON supply on EMT8 panel by pressing SW1 switch.
8) Now set the knob on AFR unit such that you will get 1 bar pressure at the output gauge of AFR.
9) Now increase the pot P1 on CIP panel observing on DPM & set it to 0.5V.
10) Now take the readings as per following observation table for voltage, current, pressure. .

EQUIPMENTS REQUIRED

MIT16 setup.
Current meter (DMM)
 BLOCK DIAGRAM FOR I TO P CONVERTER

20 pin FRC
P out
1 phase EMT8 panel CIP panel I to P converter
I out 3 to 15 psi
supply Silencer
Power supply
4 to
20mA
20 psi air
Compressor FRL AFR unit Pressure gauge (PG3)
supply
unit
3 to 15 psi
Pressure gauge (PG1) 2 bars
WIRING SEQUENCE

Panel connections
Sr. no. From To Sr. no. From To

1 CIP (14) CIP (9) 2 CIP (10) Current meter (+ve)

3 Current meter (-ve) I to P (+ve) 4 CIP (20) I to P (-ve)

5 EMT8 (6) CIP (14) 6 EMT8 (7) CIP (20)

OBSERVATION TABLE FOR I TO P

Sr. no Voltage on EMT8 Current on current Pressure on PG3 (psi)

DPM (V) meter (mA)

1 0

2 0.5

3 1.00

4 1.5

5 2.0

6 2.5
RESULT
6.2 WORKING WITH P TO I CONVERTER

PROCEDURE

1) Make the connection as per wiring sequence as given above.

2) Keep AFR knob fully CCW (OFF) position.
3) Connect air supply at the input of FRL unit. Switch ON compressor
4) Keep manual valves V1 = ON, V2 = OFF, V3 = OFF position.
5) Set current meter range at 20mA range.
6) Switch ON supply on EMT8 panel by pressing SW1 switch.
7) Now slowly increase the pressure by moving knob on AFR unit such that you will get 2.5 psi
pressure at the output gauge of AFR.
8) Now take the readings as per following observation table for pressure, voltage, current.

EQUIPMENTS REQUIRED

MIT16 setup.
Current meter (DMM)
Block diagram for P to I converter

20 pin FRC
1 phase
EMT 8 panel Pressure sensor Sensor o/p EMT9 Signal
supply
power supply conditioning
CIP panel V to I block circuit

0-1 bar
Com FRL AFR Current o/p to
press unit unit current meter
or Pressure gauge PG2 0-
15 psi

WIRING SEQUENCE

Panel connections
Sr. no. From To Sr. no. From To

1 EMT8 (6) EMT9 (16) 2 EMT8 (7) EMT9 (15)

3 EMT9 (16) CIP (9) 4 CIP (10) Current meter (+ve)

5 Current meter (-Ve) CIP (20)

OBSERVATION TABLE FOR P TO I CONVERTER.

Sr. no Pressure at PG1 on Voltage on EMT9 tag no. Current on CIP tag no.
AFR (psi) 16 measured on EMT8 10 measured on DMM
DPM (V)

1 0

2 2.5

3 5

4 7.5

5 10
RESULT
Exp. No. :7
Date:

STUDY OF CHARACTERISTICS OF CONTROL VALVE

AIM
To Study the characteristics of control valve

THEORY
Valve is essentially a variable orifice. Control valve is a valve with a pneumatic, hydraulic, electric
(excluding solenoids) or other externally powered actuator that automatically, fully or partially opens or
closes the valve to a position dictated by signals transmitted from controlling instruments. Control
valves are used primarily to throttle energy in a fluid system and not for shutoff purpose. The figure
shows basic elements and internal parts of typical pneumatic control valve.
Depending upon the valve plug design the control valves can be classified as quick opening, linear and
equal percent type.

Linear: Flow is directly proportional to valve lift.

Q = ky
Where,
Q = flow at constant pressure drop.
y = valve opening
k = constant

Equal%:Flow changes by a constant percentage of its instantaneous value for each unit of valve lift.

Q  b  e ay

Where,
Q = flow at constant pressure drop
y = valve opening.
e = base of natural logarithms.
Constants a and bcan be evaluated to give more convenient form

Q  Q0  e log R / y max  y

Where,

Qo = Flow at constant drop at zero stroke

R = Flow range of valve, maximum to minimum at constant drop.
ymax = maximum rated valve opening.
 Top Casing

Area Plate
Diaphragm

Air Connection

Bottom Casing

Spring

Actuator Stem

Yoke

Spring Adjustor

O
Travel Plate

Travel Indicator

Coupling

Plug Stem

Gland Pusher

Gland Packing

Bonnet

Plug

Seat Guide

Body

Control Valve (Air to Open)

Quick opening: Flow increases rapidly with initial travel reaching near its maximum at a low lift. It is
generally not defined mathematically.

Valve actions and actuator mechanism

Different types of actuators are used to control the stem travel of the valve, like electrical actuators,
pneumatic actuator, Hydraulic actuators etc. In this product pneumatic actuators are used for control
valves.Spring opposed diaphragm actuator positions the valve plug in response to the controller signals.
Mostly the controller signals are in the range of 3 - 15 psig.

Direct acting actuator (air to close):

Direct acting actuators basically consist of a pressure tight housing sealed by a flexible fabric
reinforced elastomer diaphragm. A diaphragm plate is held against the diaphragm by a heavy compression
spring. Signal air pressure is applied to upper diaphragm case that exerts force on the diaphragm and the
actuator assembly. By selecting proper spring rate or stiffness, load carrying capacity, and initial
compression, desired stem displacement can be obtained for any given input signal.

Reverse acting actuator (air to open):

In case of reverse acting actuators the stem gets retracted with increase in pressure.

Control valve flow coefficient

A control valve regulates the flow rate in a fluid delivery system. In general a close relation exists
between the pressure along the pipe and the flow rate so that if pressure is changed, then the flow rate is also
changed. A control valve changes the flow rate by changing the pressure in the flow system because it
introduces the constriction in the delivery system so we can say that the flow rate through the constriction is
given by

Q  K P -------------------(1)

The correction factor K in above equation allows selection of proper size of valve to accommodate the rate of
flow that the system must support. This correction factor is called as valve coefficient and is used in valve
sizing.
Valve coefficient

G
Cv  1.16  Q  (In S I Units)
P
Where,
G is specific gravity of liquid.
Q flow in m3/h, ∆P pressure drop in bar.

Valve Characteristics

The amount of fluid passing through a valve at any time depends upon the opening between the plug
and seat. Hence there is relationship between stem position, plug position and the rate of flow, which is
described in terms of flow characteristics of a valve. Inherent and Installed are two types of valve
characteristics.

Inherent characteristics:

The inherent flow characteristic of control valve is the relation between the flow and the valve travel
at constant pressure drop across the valve. Following are the inherent characteristics for different types of
valves.

100

90

80
FLOW % OF MAXIMUM

70

60

50

40

30

20

10

0
0 10 20 30 40 50 60 70 80 90 100

VALVE LIFT % OF FULL LIFT

Installed characteristics: The Inherent characteristics of the valves described are subject to distortion due to
variations in pressure drop with flow. Line resistance distorts linear characteristics towards that of quick
opening valve and equal% to that of linear.

Hysteresis of control valve

Hysteresis is a predictable error resulting from the differences in the transfer functions when a reading
is taken from above and below the value to be measured. In case of control valves for same actuator signal
different stem travel (hence valve coefficients) are obtained depending upon the direction of change in the
signal. The maximum error in stem travel (or valve coefficient) expressed in % for same actuator pressure
while opening and closing the valve is indicated as hysteresis.

Rangeability of equal % valve

Equal% valve has characteristics such that given percent change in stem position produces an
equivalent change in flow. Generally this type of valve does not shut off the flow completely in its limit of
stem travel. The Rangeability (R)is defined as the ratio of maximum to minimum controllable flow.

Fmax
R
Fmin
Where,
Fmax is the flow when the valve stem is at extreme open position.
Fmin is the flow when valve stem is at extreme closed position.
(Fmax, Fmin represents flow rates measured at constant pressure drop across control valve. Hence rangeability
R also can be defined as ratio of Cv max to Cv min.)

For equal percent valve flow has exponential characteristics of rangeability,

F  R m1

Where ,
R is the rangeability of the valve.
m is its fractional stem position.
OBSERVATIONS
Type of control valve: Linear / Equal% / Quick opening

(Fill up the column "valve coefficient" after calculations)

Sr. Pressure drop Flow Stem position Valve coefficient Cv

No
∆P (mm of H2O) (LPH) (in %)

CALCULATIONS
Specific gravity (G) = 1 (for water)

Pressure drop across valve (bar), ∆P= ∆P in mm of H2O×1.013/(10.33×103)

=
Cv= 1.16 Q x √ (G/∆P)
Where,
Flow (Q) =……….. LPH =………10-3 m3/h
 Valve positioner

Valve positioner is a device used with actuator. The actuator stem motion is accurately compared with the
signal from controller. Any deviation from the desired position results in an error signal which activates
pneumatic relay having an independent air supply. Some of the advantages of positioner are as follows:

 Helps in overcoming valve stem friction

 Matches input signal with valve stroke

 Increases speed of response of control valve

 Possibility of split ranging, alteration in valve characteristics and action reversal

PROCEDURE

 Clean the “Tank supply”. Fill with distilled water.

 Close the hose cocks provided to the pressure indication tube.

 Open the regulating (gate) valves provided at the inlet of linear control valve. Also open the hose cock in

the respective line.

 Switch on the pump and wait for 2-3 mins and ensure that water overflows to supply tank.Adjust the top air

regulator to provide 20-25 psi air supply to valve positioner and adjust bottom air regulator to 15-18 psi to

fully open the linear control valve.

 Ensure that rotameter lifts to its maximum range.

 Vary the bottom air regulator pressure from 3-15 psi and ensure smooth working of control valve.

 Close the hose cock of liner valve. Remove the air connection connected at IN of valve positioner and

connect it to the actuator of equal % control valve.

 Open the inlet valve (gate valve) at the inlet of equal % control valve. Ensure water circulation.

 Vary the bottom air regulator pressure from 3-15 psi and ensure smooth working of control valve.
 Open the inlet valve of the Linear control valve. Open the respective hose cock for pressure indication.

(Close the inlet valves and hose cocks of other control valves.)

 Ensure that pressure regulator outlet is connected to the valve actuator of the linear control valve under

study. Keep the control valve fully open by adjusting air regulator. (In case of control valve with valve

positioner: Ensure that the bottom pressure regulator outlet is connected to “IN” port at the valve

positioner. Adjust the top pressure regulator to 20-25 psi for air supply to valve positioner).

 Adjust the regulating valve and set the flow rate. (Set 400 LPH flow for linear/equal% valve or 600 LPH

for quick opening valve). Note for measuring lower flow rates below rotameter minimum range use

measuring jar.

 For studying other valve (equal %/ Quick opening) remove the air connection connected to the actuator

and connect it to actuator of other valve. (In case of set up with valve positioner remove connection at the

“IN” port of the valve positioner and connect to the actuator of the other control valves). Repeat the steps

above.

RESULT
Exp. No. :8

Date:

STUDY OF THE PERFORMANCE OF PID CONTROLLER IN MATLAB /

SIMULINK

AIM

To study the effect of gain, integral time and derivative time of PID Controller on the closed loop performance.

THEORY

The most commonly used controller in industry is PID controller. Here three tuning parameters are available in
hand. The controller gain kc which will increase the closed loop response, τi, which will eliminates the offset and
τd which will makes the performance robust.

The controller representation is:

Gc(s) = kc + (1/ τi)s + τd

TRANSFER FUNCTION:

Case-1: Design and performance of PID controller using Z-N settings:

Ziegler-Nichols Method:

1. First, note whether the required proportional control gain is positive or negative. To do so, step the input u up
(increased) a little, under manual control, to see if the resulting steady state value of the process output has
also moved up (increased). If so, then the steady-state process gain is positive and the required Proportional
control gain, Kc, has to be positive as well.
2. Turn the controller to P-only mode, i.e. turn both the Integral and Derivative modes off.
3. Turn the controller gain, Kc, up slowly (more positive if Kc was decided to be so in step 1, otherwise more
negative if Kc was found to be negative in step 1) and observe the output response. Note that this requires
changing Kc in step increments and waiting for a steady state in the output, before another change in Kc is
implemented.
4.When a value of Kc results in a sustained periodic oscillation in the output (or close to it), mark this critical
value of Kc as Ku, the ultimate gain. Also, measure the period of oscillation, Pu, referred to as the ultimate
period. ( Hint: for the system A in the PID simulator, Ku should be around 0.7 and 0.8 )

If M is the amplitude ratio of the system response at the cross over frequency ω co,

Ultimate gain = Ku=1/M

Ultimate period of sustained cycling Tu= 2 Π / ωco

5. Using the values of the ultimate gain, Ku, and the ultimate period, Pu, Ziegler and Nichols prescribes the
following values for Kc, tI and tD, depending on which type of controller is desired:

Ziegler-Nichols Method (Closed-loop P-Control Test)

Step 0: Develop a Simulink model as below

Step 1: Determine the sign of process gain.

Step 2: Implement a proportional control and introducing a new set-point.
Step 3: Increase proportional gain until sustained periodic oscillation.
Step 4: Record ultimate gain and ultimate period Ku and Pu.
Step 5: Evaluate control parameters as prescribed by Ziegler and Nichols (Using Table 1).
Step 6: Evaluate the performance of P, PI and PID controllers and compare the closed loop responses (Servo
regulatory).
As an alternative to the table above, another set of tuning values have been determined by Tyreus and
Luyblen for PI and PID, often called the TLC tuning rules. These values tend to reduce oscillatory effects
and improves robustness.

Tyreus-Luyben Method (Closed-loop P-Control test)

Step 1-4: Same as steps 1 to 4 of Ziegler-Nichols method above.

Step 5: Evaluate control parameters as prescribed by Tyreus and Luyben (Table 2).

Step 6: Evaluate the performance of P, PI and PID controllers and compare the closed loop responses (Servo
regulatory).

Case-2: Design and performance of PID controller using Cohen-Coon settings:

Cohen Coon Tuning Method

1. Under Manual mode, wait until the process is at steady state.

2. Next, introduce a step change in the input.
3. Based on the output, obtain an approximate first order process with a time constant t delayed by t DEL
units from when the input step was introduced.

The values of t and tDEL can be obtained by first recording the following time instances:

t0 = time when input step was initiated

t2 = time when half point occurs

t3 = time when 63.2% point occurs

4. From the measurements based on the step test: t0, t2, t3, A and B, evaluate the following process
parameters:

5. Based on the parameters K, t and tDEL, the controller parameters Kc, tI and tD can be calculated.
Table 1: Ziegler Nichols Tuning Rules

Table 2. Tyreus-Luyben Tuning Rules for PI and P

Table 3. Cohen-Coon Tuning Rules.

 Cohen-Coon Method (Open-loop Test)
Step 1: Perform a step test to obtain the parameters of a FOPTD (first order plus time delay) model

i. Make sure the process is at an initial steady state

ii. Introduce a step change in the manipulated variable
iii. Wait until the process settles at a new steady state

Step 2: Calculate process parameters: t 1, τ, τdel, K, r.

Step 3: Using the process parameters, use the prescribed values given by Cohen and Coon (Table 3).

Step 4: Evaluate the performance of P, PI and PID controllers and compare the closed loop responses.

RESULT
Exp. No. :9

Date:

TEMPERATURE CONTROL TRAINER

LIST OF EXPERIMENTS

1.Conduct a step test on temperature control trainer and find the transfer function of system using System
Identification tool box (In Matlab).
2.Study the performance of different controllers On/Off Control and PID Control on temperature control trainer.

EXPERIMENT: 01

AIM
Conduct a step test on temperature control trainer and find the transfer function of system using System
Identification tool box

APPARATUS REQUIRED:
1. Arduino Uno R3.
2. Temperature control shield.
3. Adaptor(12V,2 amp).
4. Communication cable(A/B standard USB 2.0)
5. A computer with Matlab Software.

THEORY:
The temperature control trainer is an application of feedback control with an Arduino, an LED, two heaters, and
two temperature sensors. The heater power output is adjusted to maintain a desired temperature set point.
Thermal energy from the heater is transferred by conduction, convection, and radiation to the temperature sensor.
Heat is also transferred away from the device to the surroundings.
Figure: Controller output step with measured process variable response
System Identification Toolbox™ provides MATLAB functions, SIMULINK blocks, and an app for constructing
mathematical models of dynamic systems from measured input-output data. It lets you create and use models of
dynamic systems not easily modelled from first principles or specifications. You can use time-domain and
frequency-domain input-output data to identify continuous-time and discrete-time transfer functions, process
models, and state-space models.
PROCEDURE

 Plug in power supply to electrical outlet and USB connection Temperature control trainer to computer.
 Open Temperature control trainer folder in PC, choose step test folder and double click the file
“step_Test.slx”
 Give the step change in the heater and run Simulink and observe the system response. Collect the data
(With and without disturbance)
 Open system identification tool box GUI.
 Import the data in system identification GUI, choose time domain and give the input and output
variables.
 Choose time plot in system identification GUI and estimate transfer function (Choose: Transfer function)
by adjusting the poles and zeros obtain the best fitting model for the collected data.

RESULT
EXPERIMENT 02

AIM:

Study the performance of different controllers On/Off Control and PID Control on temperature control trainer.

APPARATUS REQUIRED:
1. Arduino Uno R3
2. Temperature control shield
3. Adaptor(12V,2 amp)
4. Communication cable(A/B standard USB 2.0)
5. Matlab Software.

THEORY:
The temperature control lab is an application of feedback control with an Arduino, an LED, two heaters, and
two temperature sensors. The heater power output is adjusted to maintain a desired temperature set point.
Thermal energy from the heater is transferred by conduction, convection, and radiation to the temperature
sensor. Heat is also transferred away from the device to the surroundings.
ON/OFF CONTROL:
One of the most widely used type of control is the On/Off control. On/Off control is also referred as two
position control. Two position controls is a position the of controller action in which the manipulated variable is
quickly changed to either a maximum or minimum value depending upon the controlled variable is greater or
lesser than the set point.
If the controlled variable is below the set point, the controller output is 100% the controlled variable is above the
set point, the controller output is 0% when the differential gap is zero. The tuning parameter for ON/OFF control
are differential gap and time delay.
Figure: Process under on/off control with dead band

Figure: Response Of PV To Step Change Of SP Vs Time for P,PI and PID control
 Differential Gap:
Differential gap is the region in which the control causes the manipulated variable to maintain its previous until
the controlled variable has moved slightly beyond the set point. Small differential gap is not preferred. Because
it introduces oscillations and reduces the life of final control element.

PROPORTIONAL INTEGRAL DERIVATIVE CONTROL:

Proportional Integral Derivative (PID) control automatically adjusts a control output based on the difference
between a set point (SP) and a measured process variable (PV). The value of the controller output u(t) is
transferred as the system input.
𝑒(𝑡) = 𝑆𝑃 − 𝑃𝑉
𝐾𝑐 𝑡 𝑑(𝑃𝑉)
𝑢(𝑡) = 𝑢𝑏𝑎𝑖𝑠 + 𝐾𝑐 𝑒(𝑡) + ∫ 𝑒(𝑡)𝑑𝑡 − 𝐾𝑐 𝜏𝐷
𝜏𝐼 0 𝑑𝑡
The 𝑢𝑏𝑎𝑖𝑠 term is a constant that is typically set to the value of u(t) when the controller is first switched from
manual to automatic mode. This gives "bumpless" transfer if the error is zero when the controller is turned on.
The three tuning values for a PID controller are the controller gain, 𝐾𝑐 , the integral time constant τI, and the
derivative time constant τD. The value of𝐾𝑐 is a multiplier on the proportional error and integral term and a
higher value makes the controller more aggressive at responding to errors away from the set point. The integral
time constant τI (also known as integral reset time) must be positive and has units of time. As τI gets smaller, the
integral term is larger because τI is in the denominator. Derivative time constant τD also has units of time and
must be positive. The set point (SP) is the target value and process variable (PV) is the measured value that may
deviate from the desired value. The error from the set point is the difference between the SP and PV and is
defined as e(t)=SP−PV
PROCEDURE:

1. ON/OFF CONTROL.

Plug in power supply to electrical outlet and USB Connection to PC, switch on the PC.

Open Temperature control trainer folder in PC.

Open On/Off control-Simulink folder and double click On_Off_Control.slx.

Observe the response of the system by giving the step change. Collect the data and draw graph.

2. PID CONTROL.

Open the Temperature control trainer folder in PC.

Open PID control- Simulink and double click on arduino_pid_R2014a.slx file.

Put the PID Parameters in PID Control box and click on run button.

Observe the temperature control trainer response and save the graphs.

RESULT:
EXP. NO:10

DATE :

CALIBRATION OF THERMOMETER AND THERMOCOUPLE

AIM

To study the characteristics of thermocouple RTD and thermisters.

THEORY

When two dissimilar materials are brought into contact , a potential difference develops as a result of an effect
known as the “seeback effect”. A thermocouple is a very simple temperature sensor operates based on the
seeback effect, which results in the generation of a thermoelectric potential when two dissimilar metals are
joined together at a junction.The electric potential of the material accepting electrons becomes negative at the
interface, while the potential of the material providing the electrons become positive. Thus an electric field is
established by the flow of electrons across the interface. When this electric field become sufficient to balance the
diffusion forces, a state of equilibrium with respect to electron migration is established. Since the magnitude of
the diffusion force is controlled by the temperature of the diffusion forces is controlled by the temperature of
the thermocouple junction, the electric potential developed at the junction provides a measure of the
temperature.

The electric potential is usually measured by introducing a special junction in an electric circuit. The voltage
across terminals M-N can be represented approximately by an empirical equation having the form,

Eo = C1 (T1-T2) + (C2 (T12 – T22)

metal A

T1 T2

metal B metal B
TABULAR COLUMN

Sl no Actual RTD Thermocouple Reading

temperature temperature J-Type K-Type T-Type
emf temp emf temp emf temp
o o o o o
- C C mV C mV C mV C
When C1 and C2 are thermoelectric constants that depends on the material used to form the junctions. T 1 and T2
are junction temperatures.

PROCEDURE

 Check connection made and switch ON the instrument by INSTRUMENT ON switch at the front panel The
display glows to indicate the instrument is ON.
 Allow the instrument is ON position for 10 minutes for initial warm up.
 Pore around 3/4th full of water to the kettle and place sensors and thermometer inside the kettle.
 Digital temperature controller used is of RTD type.
 Set the temperature in the temperature controller to the required temperature with the keys provided in the
front panel. Press the menu button and the increment or decrement keys.
 Connect the sensor to be measure the temperature by connecting to the terminals marked thermocouple.
 Note down he initial water temperature from the thermometer and the mV for the room temperature from
the milli-volt meter.
 Switch on the power supply to the kettle and note down the actual temperature from the thermometer to the
required temperature. The heater will be off at the set temperature. Tabulate the reading in the tabular
column.
 Experiment can be repeated for the other two sensors. Temperature in the thermometer and the indicator
reading in steps of 10 o C can be tabulated.
 Fuse provided at the front panel for over current protection

EXPERIMENTS TO STUDY THE CHARACTERISTICS OF THERMOCOUPLE RTD AND

THERMISTOR:

 Connect SENSOR O/P terminals to Ammeter.

 Repeat the experiment 1 but measure the thermocouple output through milli-voltmeter.
 Tabulate the reading in the tabular column given below. Plot the graph for temperature change in the
thermometer v/s change in the milli-volt/resistance.

RESULT
EXP. NO:11

DATE :

PROGRAMMABLE LOGIC CONTROL TRAINER

AIM

To study the digital input/output operation of Programmable Logic Controller (PLC) using ladder logic
diagram.

WORKING PRINCIPLE

A programmable logic controller, which is usually called a PLC is a programmable controller, is a solid-state
digital industrial computer. The top three units are PLCs of different sizes within the Allen-Bradley
MicroLogix 1000 family. A handled programming terminal is pictured in the figure.

It can be classified as a solid-state member of the computer family. A programmable computer is an

industrial computer in which control devices such as limit switches, push buttons, proximity or photoelectric
sensors, float switches or pressure switches, to name a few, provide incoming control signals into the unit.
An incoming control signal is called an input.

Input interact with instructions specified in the user ladder program which tells the PLC how to react to the
incoming signals. The user program also directs the PLC on how to control field devices like motor starters,
pilot lights and solenoids. A signal going out of the PLC to control a field device is called an output.

A PLC simply follows the instructions stored in memory. Each instruction that is entered will be placed in
the memory of the PLC for future use and reference. Further, each instruction that is entered will be placed
in memory in ascending order.

VersaPro Software

The VersaPro application is installed in the GE Software Program group. The application can be started by
selecting Start->Programs->GE Software->VersaPro. It is possible to create a shortcut to the VersaPro
application and place the shortcut on the desktop or to click on a file created by VersaPro (the file in the
VersaPro folder with a .fld extension) and start the application in the context of the selected folder. VersaPro
may also be started using CTRL-ALT-V.
 Fig. Simple block diagram of PLC

TRUTH Tables

OR GATE
A B OUTPUT
0 0 0
1 0 1
0 1 1
1 1 1

AND GATE
A B OUTPUT
0 0 0
1 0 0
0 1 0
1 1 1
VersaPro allows you to customize editor and window options. It is important to confirm the default language
and hardware configuration before creating a new folder. Other options may be customized before opening a
folder, or after the folder is opened. General Options VersaPro’s default hardware configuration is the
VersaMax PLC. The default block language is Ladder Diagram. To change the default configuration so that
you can create programs and hardware configuration for the target devices, or to customize display and
editing options, select the Tools menu and choose Options. The Options dialog box will appear.

VersaPro provides several options when creating a new folder. You can create an empty folder or create a
new folder based on an existing VersaPro folder. VersaPro also provides an option for you to create a folder
by importing content from Logicmaster 90 (series 90-30 or series 90 micro folders) or Control (Series 90-30
or VersaMax folders).

GE Fanue Series Kit

GE Fanue Series One Integrator’s Kit Selection Guide Integrator’s Kits are designed for users who required
the capability to view, edit and monitor the execution of Series One and Series One Junior PLC programs.
There are many ways in which these tasks can be accomplished, and choosing the right method for your
hardware can often be confusing. To make things easier, they have developed kits that include all of the
hardware, firmware, and software necessary to get started.

QIC610INTKIT

Our most versatile Integrator’s Kit, this package is built around the LogicMaster 1 Programming software. It
includes a licensed copy of LogicMaster 1 (IC64IPBE324), one Data Communications Unit
(IC610CCM105), one universal cable kit with RS-232/RS-422 converter, and a CD containing a complete
set of manuals for the Series One product family. The QIC610INTKIT is compatible with all Series One and
Series One Junior PLCs with the exception of systems having an IC610CPU101 CPU module.

QS1PORTABLEKIT

This kit consists of a Portable Programmer unit (IC610PRG110), a Hand-held Programmer (IC610PRG105),
a Series One Program Pack (IC610PRG116), and a CD containing a complete set of manuals for the Series
One Product family. Printer and audio cables are not included. QS1PORTABLEKIT is designed for use with
Series One PLCs: another version of this kit called the QS1JRKIT, is available for use with Series One
Junior Products.
NOR GATE
A B OUTPUT
0 0 1
1 0 0
0 1 0
1 1 0

NOT GATE
A OUTPUT
0 1
1 0

NAND GATE
A B OUTPUT
0 0 1
1 0 1
0 1 1
1 1 0

NOR GATE
A B OUTPUT
0 0 0
1 0 1
0 1 1
1 1 0

XNOR GATE
A B OUTPUT
0 0 1
1 0 0
0 1 0
1 1 1
 QS1JRKIT

The QS1JRKIT is intended for use solely with Series One Junior PLCs. It is functionally identical to the
QS1PORTABLEKIT described above, but substitutes a Series One Junior Program Pack (IC610PRG115) in
place of the Series One Program Pack.

PROCEDURE

1. Open the Versapro software.

2. Go to file and select ‘New folder’ option.
3. In the ‘New folder’ window, give any folder name and select finish.
4. Programming window will be open, here we can create the program.
5. Select normally Open Contact and place in the first row.
6. Select Open Coil and place in senses to the input.
7. Select I/P contact type sense and press Enter.
8. Select O/P coil type IQ and press Enter.
9. Select ‘View’ hardware configuration.
10. In PLC diagram, right click and select replace module.
11. Select the PLC module number and click OK.
12. In parameters window, set password value to disable.
13. Ensure PLC is switched ON.
14. Select PLC and click Connect option.
15. Select PLC option, select Clear, Select Yes, then OK.
16. Select PLC option, store hardware, select OK.
17. Click Run.

RESULT

Working of PLC of AND, OR, NOT, NAND, NOR, XOR and XNOR was studied and formed respectively
in the given figure
EXP. NO:12

DATE :

FLOW CONTROL TRAINER

LIST OF EXPERIMENTS

1.Open Loop
2.On/Off Controller
3.Proportional Controller
4.Proportional Integral
5.Proportional Derivative
6.Proportional Integral Derivative

WORKING PRINCIPLE

Flow control trainer is designed for understanding the basic principles of flow control. The process setup
consists of supply water tank fitted with pump for water circulation. A DP transmitter is used for flow
sensing which measures differential pressure across orifice meter. The process parameter (flow) is
controlled by microprocessor based digital indicating controller which manipulates pneumatic control valve
through I/P converter. The control valve is fitted in water flow line. These units along with necessary piping
are fitted on support housing designed for tabletop mounting. The controller can be connected to computer
through Ethernet / USB port for monitoring the process in SCADA mode.

GENERAL INSTRUCTIONS

1.The experiment Nos 1 the 6 are to get feel of the process and PID settings.
2.Startup Setup
3.Switch on electric supply.
4.Switch on Mains.
5.Switch on electric supply.
6.Switch on Mains.
7.Switch on the pump and adjust the bypass valve to set rotameter flow at 100 LPH.
8.Switch on the compressed air source and adjust the air regulator to set supply air pressure at @ 2 kg/cm^2
9.Double click on Apex_Process_Trainers icon on the desktop

1.STUDY OF OPEN LOOP RESPONSE (MANUAL CONTROL)

AIM

To study the response of Open Loop control system

PROCEDURE

1.Start up set up as explained in general instructions.

2.Click Select Experiment, select Open Loop and click Start
3.Close the control valve by increasing the controller output to 100%.
4.Apply the step change by 10% to controller output and wait for process value to reach the steady state
value.
5.Repeat the above step until the controller output reaches to minimum 0%.
Fig. Schematic representation of Flow Control Trainer

OBSERVATIONS

Tabulate the observations as follows

Controller output in % Process Value in %

100
90
80
….
0

 From the above data, note the output required for maintaining the flow at desired set points.
2.STUDY OF ON/OFF CONTROLLER

AIM

To study the performance of ON/OFF Controllers for a step change in set point

PROCEDURE

1.Start up set up as explained in general instructions.

2.Click Select Experiment, select On-Off Mode and click Start
3.Change Hystresis value to 5%.(Range 0.1-10%)
4.Change the values of the set point and observe the On-Off control operation.
OBSERVATIONS

 Observe that if process value exceeds the set point and increases above the value of (0.5x Hysteresis),
control valve is fully closed and if process value decreases below the set point by (0.5 x Hysteresis), the
control valve opens fully i.e. controller operates like On/Off switch.
3.STUDY OF PROPORTIONAL CONTROLLER

AIM

To study the performance of Proportional Controllers for a step change in set point

PROCEDURE

 Start up set up as explained in general instructions.

 Click Select Experiment, select P Mode and click Start
 Adjust the process value by switching the controller to manual mode to a particular flow (say 50 %) on the
screen and apply output of the controller as bias value. Change the proportional band to 100%.
 Switch the controller to auto mode.
 Apply step change of 10% to set point.
 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%).
 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.
 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.

 Observe the effect of very low proportional band values (system works as on-off control).
 Observe the response of the system at load change. Load change can be given by slightly varying the flow
rate with the help of rotameter manually.
4.STUDY OF PROPORTIONAL INTEGRAL CONTROLLER

AIM

To study the performance of Proportional Integral Controllers for a step change in set point

PROCEDURE

 Start up set up as explained in general instructions.

 Click Select Experiment, select PI Mode and click Start
 Set the proportional band estimated in Proportional control. Set derivative time to 0 sec and integral time
6000 sec, which will cut off the derivative action and widen the effect of integral action.
 Set the set point to desired flow value (@70%). Allow the process to reach at steady state.
 Record the steady state error.
 Switch the controller to manual mode. Reduce the integral time to half of the previous value. Switch to
Auto mode and apply step change (+/- 10%) to the set point. Note the response of the system.
 Repeat above step to observe the effect of changes in Integral setting.
OBSERVATIONS

 Observe the effect of reducing integral time on offset and on the response of the process.
5.STUDY OF PROPORTIONAL DERIVATIVE CONTROLLER

AIM

To study the performance of Proportional Derivative Controllers for a step change in set point

PROCEDURE

 Start up set up as explained in general instructions.

 Click Select Experiment, select PD Mode and click Start
 Set the proportional band estimated from Proportional control (P only) Set derivative time to 0 and integral
time=6000 sec.
 Set the set point to desired value (@70%). Allow the process to reach at steady state. Note the response of
the system.
 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 to 10%. Note the response of the system.
 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.

6.STUDY OF PROPORTIONAL INTEGRAL DERIVATIVE CONTROLLER

AIM

To study the performance of Proportional Integral Derivative Controllers for a step change in set point

PROCEDURE

 Start up set up as explained in general instructions.

 Click Select Experiment, select PID mode and click Start
 Switch the controller to manual mode.
 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.
 Adjust the set point to @ 50 %. Switch the controller to auto mode. Apply step change of 10%. Observe the
process response.
 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.
EXP. NO:13

DATE :

pH CONTROL TRAINER

AIM

To study the performance of Proportional Integral Derivative control with change in set point for pH
process

WORKING PRINCIPLE

pH process has two dosing pumps one for acid solution and other for base solution. If you wish to increase
pH towards 14 then base solution needs to be added and if you want to decrease towards 0 pH then acid
needs to be added. The upward movement of
pH needs forward acting PID controller while downward movement of pH needs reverse acting PID
control. Inactive (error) band is sometimes needed to prevent continuous shifting between the two PID
outputs which appears as oscillatory behavior on MV graph. Once MV is within error band of SP then both
outputs are kept off / to default values, thus stability.

FIG. SETUP DIAGRAM OF PH CONTROL LOOP

 Proportional Integral Derivative control with manual change in set point

Fig: Block diagram of PID controller

PROCEDURE

1. Connect the test set up as per the wiring sequence.

2. Double click on PID controller 11.0 icon on the desktop.
3. Now Click on PID controller menu, now PID control main window will open.
4. Now in main PID window set PB 20%, Ti = 10, Td = 2.5, Ts=2, Kd=10, set value=30, Set o/p lower =0%
& upper =100, reverse action.
5. In PID setting windows select channel 0 from IO for MV & source for set value from SP of PID controller
1, ratio factor=1, Output on DAC 1. Now in this setting window click on Gain scheduler, now click on
‘active’ button, click on ‘MV’ button. Enter values in ‘MV’ row and in ‘Ki’ row as shown below.
 Now click on ‘split control’, click on ‘Error’ and enter following values in this window.

Rest of the setting are deselected. Press ‘OK’ button.

6. Set valves position as V1 slightely open, V2, V3 and V4 closed. Switch ON all the pumps supply.
7. Start PID controller and Open the graph window. In setting of graph window select XT graph & process
monitoring mode. Add new graph of SP & MV. Select sample on ‘Pid controller 1’ & press save settings
button.
8. Now press ‘start graph’ button on the graph window & observe the graph of SP & MV on screen with 2
Sec sampling time with 40Samples/Div.
9. Observe the system response of the process for set point change. Vary the set point on the panel from 30 to
50 % manually. But while changing the set point always let the sensor o/p to settle. Observe the graph of
measured variable Vs set point.
10. After performing experiment stop the PID controller.

CONCLUSION

From the graph it is observed that the process settles within the error band of ±1.
Exp. No. :14

Date:

SHELL AND TUBE HEAT EXCHANGER

14.a CO-CURRENT CONTROL

AIM

To calculate heat transfer rate and effectiveness of shell & tube heat exchanger in co-current mode.

THEORY

Modes of Heat Transfer

There are three modes of heat transfer:

1. Conduction
2. Convection
3. Radiation

Conduction

Conduction is the flow of heat, which occurs either due to the exchange of energy from one molecule
to another without appreciable motion of the molecules or due to the motion of free electrons if they
are present. It occurs in all media-solids, liquids and gases - in which temperature differences exist.
A simple experiment to observe the phenomenon is to heat one end of a metal bar over a flame.
Gradually the other end of metal bar also heats up and we say that this is due to heat being conducted
along the bar.

The equation for the heat transfer by conduction may be written as:
dQ/dq = (k. A. dt)/dL,

Q= Heat transfer in time q, t= temperature difference

L= distance across which t is measured,

A= area at right angles to the flow of heat,

K= thermal conductivity of the medium

Convection

Unlike solids, molecules in liquids and gases have freedom of motion, and in moving they carryover
their energy. The transfer of heat from one region to another, due to such macroscopic motion in a
liquid or gas, added on to the energy transfer by conduction is called heat transfer by convection. It is
usual to classify heat transfer by convection as either forced or free. When the fluid motion is caused
by an external agency such as pump or a blower, the situation is said to be one of forced convection.
On the other hand, when there is no such external agency and the fluid motion occurs due to density
variations caused by temperature differences, the situation is said to be one of free or natural
convection.

Radiation

All bodies at all temperature levels emit thermal radiation. Unlike conduction and convection, this
mode of heat transfer does not require any material medium. The propagation of energy in this mode
is carried out by electromagnetic waves emitted from the surface of another body, a part of the
energy is reflected, a part transmitted through the body and the remainder absorbed by the body.

The net transfer of heat between two bodies is expressed by the Stefan-Boltzmann law, which is
ordinarily written as:

qr =0.173pA[(T1/100)4-(T2/100)4], qr= net heat transferred, p=permissivity,

A-area of the radiating or receiving surface

T1, T2 Temperatures of the hotter and colder bodies resp.

Flow arrangements

Transfer types of heat exchangers have three basic flow arrangements:

a. Co-current flow (parallel flow) type, in which fluid flow in the same direction.
b. Counter-current flow type, in which fluid flow in the opposite direction.
c. Cross flow type, in which fluid flow at right angle one another.
Co-current flow
In this type of heat exchanger both hot and cold fluids enter the exchanger at same end and flow
through the exchanger in the same direction. At the entrance of the exchanger, a large driving force
prevails, giving a relatively large heat transfer rate. As the fluid progress through the exchanger, the
temperature driving force becomes less and less so that the rate drops off asymptotically as the steam
approach some limiting temperature. The net result of this type of variation in T is that the
exchanger is much more effective for a unit area of heat transfer surface at the entrance than it is near
the exit.

Temperature δ TR

δ TL

Length

Temperature in co-current flow heat exchanger

Counter-current flow
In this type of heat exchanger, the two fluids exchanging heat pass each other in opposite directions.
Here, the driving force is much more nearly constant throughout the length of the exchanger. The net
result is that a unit surface gives about the same rate of exchange throughthe entire exchanger.
Temperature

δTR

δ TL

Length

Temperature in counter flow heat exchanger

TYPES OF TRANSFER TYPE HEAT EXCHANGER

Shell & tube heat exchanger

A shell & tube heat exchanger of transfer type can be in the form of a tube arrangement. When the
required heat transfer surface is large, the recommended exchanger is the shell and tube type. In this
type of heater or cooler, large heat transfer surface can be achieved economically and practically by
placing tubes in the bundle. The ends of the tubes are mounted in a tube sheet. This is very
commonly accomplished by expanding the ends of tube into a close-fitting hole in the tube sheet by a
process called by rolling. The resultant tube bundle is then enclosed by a cylindrical casing (shell),
through which the second fluid flows around and through the tubebundle.

One fluid flow through the inner tubes and the other through the shell surrounding it. The fluid
flowing through the tubes enters a header or channel where it is distributed through the tubes in co-
current flow and leaves the unit through another header. Either the hot or the cold fluid may flow in
the shell of the exchanger surrounding the tubes. The heat transfer takes place across the walls of the
inner tubes.
 Fluid Bin

Fluid Aout
Fluid Ain

Fluid Bout

Shell & tube co-current flow heat exchanger

Fluid Bout

t
Fluid Aout
Fluid Ain

Fluid Bin

Shell and tube counter flow heat exchanger

Double pipe heat exchanger:

This heat exchanger is constructed by placing pipe inside a pipe. One fluid passes through the inner
pipe and the other through annular area between the pipes. The heat transfer takes place across the
walls of the inner tubes. This is the simplest and cheapest type of heat exchanger. These can be made
from standard fittings, and are useful where only a small heat transfer area is required. Several units
can be connected in series to extend their capacity.

Performance parameters of heat exchanger

Effectiveness
The term effectiveness is defined as follows:

Effectiveness = Rate of heat transfer in heat exchanger/ Maximum possible heat transfer rate

It is a dimensionless measure of how well the heat exchanger is performing.

Logarithmic mean temperature difference

The mean temperature difference (∆Tm) between the hot and cold sides in a heat exchanger isdefined
by the expression

∆Tm = 1/A ∫ ∆T dA

where ∆Tm = Mean temperature difference

dA = Elementary area across which heat is being transferred

∆T = Temperature difference between the two fluids at the area dA

Because of logarithm in denominator, the mean temperature difference is often called the
logarithmic mean temperature difference and the symbol LMTD is used.

LMTD = [(Δ TL) - (Δ TR)] / loge (Δ TL/ Δ TR) 0K

Δ TL = T3 - T1 and Δ TR = T4 - T2
where

T1 = Cold water inlet temperature

T2 = Cold water outlet temperature

T3 = Hot water inlet temperature

T2 = Hot water outlet temperature

Overall heat transfer coefficient

The overall heat transfer coefficient can be most easily measured by experimentally. The overall
temperature difference and the total heat transfer can usually be measured directly for a heat
exchanger of known area.

Overall Heat transfer coefficient

Ud = Q/ (Hs x LMTD) KJ/hrm2 0 K

Ud = Q x 1000
W m2 0K

(Hs x LMTD) x 3600

Where

Ud = Overall Heat transfer coefficient

Q =Average heat transfer

LMTD = Logarithmic mean temperature

difference Hs = Effective heating surface in m2
Procedure:

 Start up the set up.

 Ensure that Shell & tube heat exchanger is connected for water inlet and outlet
connections in co-current mode as per piping schematic.
 Open both rotameter (F1 & F2) valves to circulate water and adjust water flow @ 50
LPH.
 Adjust air regulator (R) to set supply air pressure (S) at 20 psig.
 Confirm water flow through rotameters and switch on mains of heater. Now switch
on heater 1 and heater 2. Heater 2 (Dimmer) is adjusted so that hot water outlet
temperature (T3) is maintained @ 700C.
 Switch on the computer. Execute ACE.exe
 Note the observations and log data after steady state i.e. after all the temperatures
remain stable and process value (PV) matches set point (SP). Now enter current flow
rates (F1 & F2). Repeat experiment with different flow rates to get more readings.
 Proceed further to next experiment otherwise shut down the set up as mentioned in
commissioning part above.
OBSERVATIONS:

Technical data of heat exchanger:

A) Type: Shell and tube, single pass.

Shell side fluid: Cold water

Tube side fluid: Hot water

Tube diameter: OD 0.006 m × ID 0.004 m

No. of tubes: 4

Length of tubes: 0.910 m

Material of tubes: SS304

Shell diameter: OD 0.0334 m × ID 0.0278 m

Material of shell: SS 304

𝜋∗(𝑇𝑢𝑏𝑒 𝑂𝐷+𝑇𝑢𝑏𝑒 𝐼𝐷)∗𝑁𝑜.𝑜𝑓 𝑡𝑢𝑏𝑒𝑠

Effective heating surface HS= 2

3.142∗(0.006+0.004)∗4
Hs= ( )
2

Hs=0.06283 m2 ~ 0.06 m2
 Nomenclature:

Parameter Description Units

T1 Cold water inlet Deg. C
T2 Cold water outlet Deg. C
T3 Hot water inlet Deg. C
T4 Hot water outlet Deg. C
F1 Cold water flow LPH
F2 Hot water flow LPH

Observation table:
Obs. No. Temp. Temp. Temp. Temp. F1 F2
T1+273 T2+273 T3+273 T4+273
0K 0K 0K 0K For water For water
LPH=Kg/hr LPH=Kg/hr

Calculations

 Heat given by hot water

H1 =m Cp Δ T KJ/hr.

m=Mass of hot water Kg/hr

Cp= Specific heat of water KJ/Kg 0K = 4.183 KJ/Kg 0K

 Heat taken by cold water

H2 =m Cp ΔT. KJ/hr.

m =Mass of cold-water Kg/hr

Cp =Specific heat of water KJ/Kg 0K = 4.183 KJ/Kg K

Δ T = T2 - T1 Temperature difference of cold-water K

 Average heat
transfer
𝐻1+𝐻2
Q= 2

KJ/hr

 Overall Heat transfer coefficient

Ud = Q/ (Hs x LMTD) KJ/hr m2 0

K

𝑄𝑋1000
 Ud =(𝐻𝑠 𝑥 𝐿𝑀𝑇𝐷)3600 W m2 0 K

 Hs = Effective heating surface in m2

 LMTD = (ΔTL)- (ΔTR)/ loge ( ΔTL/ ΔTR) 0K

 ΔTL = T3- T1 , ΔTR= T4- T2

 Effectiveness of heat exchanger = Heat gained by cold water/ Heat gained by hot water

=(H2/ H1) X 100

RESULTS
14.b. COUNTER CURRENT CONTROL

AIM

To calculate heat transfer rate and effectiveness of shell and tube heat exchanger.

PROCEDURE
 Repeat the experiment no.1 in counter current mode by changing the piping and
valve positions as per piping schematic and observe the performance.
 Proceed further to next experiment or shut down the set up.

Type Shell and tube

Material SS304 - SS304
Shell ID mm 27.80
Tube OD mm 6.0
Tube ID mm 4.00
No tubes 4
Tube length 0.910

HS m2 0.06
Observation table:
Obs. Temp. Temp. Temp. Temp. F1 F2
No. T1+273 T2+273 T3+273 T4+273
0K 0K 0K 0K For water For water
LPH=Kg/hr LPH=Kg/hr

Calculations

 Heat given by hot water

H1 =m Cp Δ T KJ/hr.

m=Mass of hot water Kg/hr

Cp= Specific heat of water KJ/Kg 0K = 4.183KJ/Kg 0K

 Heat taken by cold water

H2 =m Cp ΔT. KJ/hr.

m =Mass of cold-water Kg/hr

Cp =Specific heat of water KJ/Kg 0K = 4.183 KJ/Kg K

Δ T = T2 - T1 Temperature difference of cold-water K

 Average heat
transfer
Q=
𝐻1+𝐻2
KJ/hr
2

 Overall Heat transfer coefficient

Ud = Q/ (Hs x LMTD) KJ/hr m2 0

K

𝑄𝑋1000
 Ud =(𝐻𝑠 𝑥 𝐿𝑀𝑇𝐷)3600 W m2 0 K

 Hs = Effective heating surface in m2

 LMTD = (ΔTL)- (ΔTR)/ loge ( ΔTL/ ΔTR) 0K

 ΔTL = T3- T1 , ΔTR= T4- T2

 Effectiveness of heat exchanger = Heat gained by cold water/ Heat gained by hot water

=(H2/ H1) X 100

RESULTS