LAB REPORT PROCESS AND

DYNAMIC CONTROL
SUBMITTED TO: SIR HASEEB JATOI


SUBMITTED BY:
ARSLAN ALI (2011-CH-63)
UNIVERSITY OF ENGINEERING & TECHNOLOGY
LAHORE

LAB#01 1
TH
SEPTEMBER, 2014 LAB LAYOUT



LAB#02 8
TH
SEPTEMBER, 2014 DEAD WEIGHT CALIBRATOR
OBJECTIVE
Calibration of Pressure Gauge using Dead Weight Calibrator
EQUIPMENT
1. The Dead Weight Calibrator
2. Standard Weights
3. Precision Gauge (if possible)


PROCEDURE
1. We closed the Needle Valves #2, #3, #4 while keeping the valve #1 open, so that the oil
can be added to the system
2. We checked the level of hydraulic oil in the Oil Cup; it was fill up to the mark. (in case
oil is less, add more oil to fill the cup unless the hydraulics may not develop).
3. Rotate the piston handle outwards completely to suck the oil in it.
4. We closed Needle Valve #1 now and opened Valve #2 (Pan for Weights) and Valve #3
(Pressure Gauge) after mounting the gauge to be tested on the nipple provided above
Needle Valve #3. (In case a precision gauge is also mounted, then open the valve #4 as
well, we didnt had any such gauge) Hence Oil flows to these points now and hydraulics
developed.
5. After this, we in ascending order put the standard weights on the Pan
6. Turn the handle of the cylinder piston to transmit the pressure toward the weight and
pressure gauge/s
7. When the fluid pressure is equal to the pan, it is lifted as well as the gauge indicates the
corresponding pressure. Note that the weight should be lifted to red line only. Beyond
white line it would be in effective.
8. We noted the reading and increased the weights in ascending order and then noted the
readings in descending order as well.
PRECAUTIONS
1. The relevant valves should be promptly closed and opened as mentioned in the
procedure; otherwise the hydraulic oil might spill outside or on the face of the users.
2. The standard weights should be placed, with care.
3. The hand wheel should be turned back before removing any heavy weights.

Weight Pressure (Kg/cm
2
) Inverse
0 0.7 0.5
1 1.0 1.0
2 1.1 1.8
3 2.0 2.2
4 3.5 4
5 4.2 4.2
6 5.0 5.8
11 10.0 10.3
16 16.0 16
21 22.0 22
26 26.0 26.3
36 38.0 36.2
46 46 46
56 55.5 56
62 62.0 62

0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70
Weight v/s Rev.Pressure

`

0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70
Weight v/s Pressur

LAB#03 15
TH
SEPTEMBER, 2014 THERMOCOUPLE
OBJECTIVE
To determine the time constant of a typical Iron-Constantan Thermocouple

EQUIPMENT
1. Thermocouple (J Type: Iron Constantan)
2. Heater
3. Digital Voltmeter
4. Stopwatch
5. Hookup Wires

PROCEDURE
Note the readings on the digital voltmeter. Switch on heater. As thermocouple receives heat,
digital voltmeter reading changes, record the reading every minute. After some time the
measured voltage shall settle on a particular time constant from the plot.
Draw graph of EMF V/S Time. Establish the time constant from the plot.
Establish the temperature at all measured EMF using the thermocouple table for
appropriate metals.



OBSERVATIONS
EMF VS TIME
Graph:



TIME CONSTANT CALCULATIONS
Max Reading on digital voltmeter = 9.4
63.2% of Max = 5.9408 mV
Time Constant = 12.85 min


0.1
0.3
0.6
1
1.5
2.1
2.7
3.3
3.9
4.5
5.1
5.6
6.2
6.6
7
7.4
7.7
8
8.3
8.5
8.7
8.9
9
9.1
9.3
9.4 9.4 9.4
0
1
2
3
4
5
6
7
8
9
10
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
E
M
F

TIME
EMF(MV) VS TIME (MIN)

TEMP VS TIME
Graph:


TIME CONSTANT CALCULATIONS
Max Reading of Temperature = 175.14
o
C
63.2% of Max = 110.6885
o
C
Time Constant = 12.2 min

QUESTIONS/ANSWERS FOR BETTER UNDERSTANDING
I. What are different types of thermocouple and which type of thermocouple used here?
Thermocouples are identified by a single letter type and grouped according to their
temperature range
0
15
30
45
60
75
90
105
120
135
150
165
180
195
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
T
e
m
p

(
D
e
g

C
)

Time (min)
Temp( Deg C) Vs Time (min)

1. Base Metals up to 1000 C Type J, Type E, Type T, Type K
2. Noble Metals up to 2000 C Type R, Type S, Type B
3. Refractory Metals up to 2600 C Type C, Type D, Type G

J-Type thermocouple was used in this experiment.

II. What do you know about SeeBeck Effect?
In 1821, Thomas Seebeck discovered if metals of two different materials were joined at both
ends and one end was at a different temperature than the other, a current was created. This
phenomenon is known as the Seebeck effect and is the basis for all thermocouples.



III. Why Thermocouples are preferred?
Thermocouples can be used to temperatures as high as 3100F, generally cost less than
RTDs and they can be made smaller in size (down to approximately .020 dia) to allow for
faster response to temperature. Thermocouples are also more durable than RTDs and can
therefore be used in high vibration and shock applications. Thermocouples are generally less
expensive than RTDs.

IV. Why results are not reliable?
Time of Response of thermocouple is very slow.
V. Show Thermocouple measuring circuit?


VI. Can Thermocouple measure gas, liquid and solid temperature?
Yes, it can measure gas, liquid and solid surface temperature.

VII. Why is thermocouple inclined above the heater?
There is no such restriction of inclination angle, but it is done only as a precaution. Has the
Thermocouple been placed straightly above the heater, it would have heated up the wires
connected to its other end, which we dont want.

VIII. Which characteristics of thermocouple can be determined?

1. Response Time:
It is defined as the time required to reach 63.2% of an instantaneous temperature change.

2. Speed of Response:
The speed of response of a sensor mainly depends on his mass and thermocouples can be
very thin so fast response

3. Sensitivity:
Sensitivity of thermocouple refers to how much sensitive thermocouple is to any
change.

IX. What is Hot Junction and Cold Junction?
A thermocouple is a type of temperature sensor, which is made by joining two dissimilar
metals at one end. The joined end is referred to as the HOT JUNCTION. The other end of
these dissimilar metals is referred to as the COLD END or COLD JUNCTION.




X. What is Cold Junction Compensation?
Simulate the potential effects that would result for a thermocouple wire pair between the
terminals, at their measured temperature, and another junction at a reference temperature of 0
degrees. Measure the potential across the thermocouple wire pair in series with the simulated
potential. Apply the linearizing curve to the sum, thus obtaining an estimated absolute
temperature directly. This is known as cold junction compensation. Usually, the simulation is
done electronically with specialized integrated circuit devices.


Electronic cold junction compensation

XI. Write on Thermocouple Installation?

Vertical installation is preferred in very high temperatures to avoid protection tube or
element sagging. Install thermocouples away from AC power lines to prevent electrical
noise. Do not run thermocouple wires in the same conduit with electrical wires.

Do not run a single thermocouple to two different instruments. This will result in instrument
imbalance.

A dual thermocouple should be used instead.

Electrical: Connect the positive thermocouple extension wire to the positive thermocouple
wire and the negative extension wire to the negative thermocouple wire.

TYPE J - The positive element is magnetic. It has a lower resistance in ohms per foot than
the negative element in the same wire gauge.

TYPE K - The negative element is slightly magnetic. It has a lower resistance in ohms per
foot than the positive element in the same wire gauge.

TYPE E - The negative element has a lower resistance in ohms per foot than the positive
element for the same wire gauge.

TYPE T -The positive element is copper in appearance. It has a lower resistance per foot in
ohms than the negative element of the same wire gauge.

TYPE R or S -The negative element is softer. The positive element has a lower resistance in
ohms per foot than the negative element of the same wire gauge.

TYPE N -The positive element has a higher resistance in ohms per foot than the negative
element of the same wire gauge.

OPERATION:
The temperature of the connection head should be kept at ambient temperature if possible to
avoid errors due to temperature gradient. The maximum recommended temperature at the
terminal block is 400F.

XII. Explain Measuring sensor mechanism of thermocouple?

One particular advantage of thermocouples is that the sensing elements themselves are very
small, allowing thermocouples to be inserted into very small spaces and to respond to rapidly
changing temperatures. The electrical nature of the process means that the circuitry for
reading the thermocouple output can be remote from the sensor itself. Note that
thermocouple effects will be encountered wherever one metallic conductor meets another, so
that temperature differences along circuit boards can also give rise to voltages which are
comparable with the output from thermocouples. The resistance to the flow of electricity in
metallic materials varies with temperature. This can be used to good effect in platinum
resistance detectors. Platinum is particularly stable both electrically and mechanically and is
also stable with respect to time, producing a relatively linear change in resistance versus
temperature.
Because the output resistance change to temperature is relatively small, it follows that lead
lengths and resistances are therefore important features. In general when lead lengths are
short, or can be considered as an acceptable additive content, two wire configuration is
sufficient.
Three wire is the most commonly used and unless otherwise specified is supplied as
standard, the third wire is the compensator for lead length and providing that all three wire
have equal resistance, compensates for any ZERO or SPAN errors. (Not true for all bridges).
Four wire provides for high precision and is recommended for use with Zener Barriers.

XIII. What are the precautions while using thermocouple?

If operating at high temperatures, check the specifications of the probe insulation.
It takes up to 5 s for the outputs to turn ON after the power supply is turned ON. Take this
time into consideration.
Connection: Many measurement errors are caused by unintentional junctions. Remember that
any junction of two different metals will cause a junction. If you need to increase the length
of the leads from your thermocouple, you must use the correct type of thermocouple
extension wire.
To minimize thermal loading and improve response times, thermocouples are often made of
thin wire. It is always a good precaution to measure the resistance of your thermocouple
before use.