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LAB MANUAL
Process Dynamics and Control Lab
(Undergraduate Level)
1
CHN 303: CHEMICAL ENGINEERING LABORATORY
PROCESS DYNAMICS AND CONTROL (UNDERGRADUATE LEVEL)
AUTUMN 2017
List of Experiments
Instructions
Students have to enter in the laboratory in LABORATORY COAT and SHOES. LOOSE
DRESS is not allowed in the laboratory.
An Index sheet will be provided from the lab on the first day of the experiment. Students
have to fill all experiments in sequence according to their turn. The dates of experiment
and report submission, and page numbers will be filled by the TA.
Students should bring a stapled report in A4 sheet (with the original observation data
sheet) of the experiment performed in the last turn.
Students must show a sample calculation for one data set (different for each team
member) and draw graphs manually on graph sheet.
Students should write the observations in the provided data sheets and get it signed by the
TA at the end of the experiment.
There will be a penalty for late submissions (75% and 50% of marks of the experiment
for late by one and two weeks, respectively) and students coming late would not be
permitted to enter in the laboratory.
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CHN 303: CHEMICAL ENGINEERING LABORATORY
PROCESS DYNAMICS AND CONTROL (UNDERGRADUATE LEVEL)
TABLE OF CONTENTS
Experiment Page
Experiment topics
No No
Dynamics of stirred tank with proportional ON/OFF temperature
1 1
controller
2 Dynamics of evacuated tank 7
3 Dynamics of thermometer 9
4 Control valve characteristics (three valves) 13
(A) Study of control valve flow coefficient (Cv) 16
(B) Study of inherent characteristics of linear control valve 19
(C) Study of installed characteristics of control valve 22
(D) Study of Hysteresis of control valve 24
(E) Study of Rangeability 27
5 Interacting and Non-Interacting System 29
(A) Step response of single capacity system 30
Step response of first order systems arranged in non-interacting
(B) 35
mode
Impulse response of first order systems arranged in non-interacting
(C) 40
mode
(D) Step response of first order systems arranged in interacting mode 44
Impulse response of first order systems arranged in interacting
(E) 48
mode
6 Dead weight tester for pressure gauge calibration 52
7 Dynamics of pressurized tank 55
EXPERIMENT NO. 1
DYNAMICS OF STIRRED TANK TEMPERATURE CONTROLLER
OBJECTIVE
1. To study the dynamics of a stirred tank system fitted with electric heating assembly.
2. To study the response of an ON/OFF temperature controller thermostat fitted to the tank.
3. To estimate temperature band within which it controls the temperature of the tank.
THEORY
When a step input in terms of heat (by switching the electrical heater ON) is applied to the stirrer tank
vessel its temperature gradually increases and finally attains a constant value depending upon the
magnitude of step input and flow rate of water through the stirred tank. By recording the temperature
history of the vessel, the time constant ( ) of the system can be computed.
f, To Thermocouple Controller
T
V
Q f, T
Figure 1.1: Sketch of the stirred tank system for mass balance
Let,
C Specific heat capacity of the fluid entering the tank (J/kg.K)
f Volumetric flow rate of the fluid (in m 3 /s)
To Initial temperature (in K)
T Final temperature (in K)
T Reference temperature (in K)
Density of the fluid (kg/m 3 )
Q in Rate of heat input (J/s)
Making an energy balance on the tank as shown in the Figure 1.1 above we get,
f C (To T ) f C (T T ) Qin
d
dt
CV (T T ) ….(1)
dT
f C (To ) f C (T ) Qin CV ….(2)
dt
Qin dT
(To T ) ….(3)
Cf dt
V
….(4)
f
dT
At steady state, 0
dt
Q s in
(To T s ) 0
s
….(5)
C f
From equation (3) and equation (5) we get
Qin Q s in d
(To To ) (T T ) (T Ts )
s s
….(6)
fC dt
Let’s we define the deviation variables,
To To o ….(7)
s
T T s ….(8)
d
o H
….(10)
fC dt
Suppose we assume there is no variation in temperature of input stream then o 0 then
H d
….(11)
fC dt
Now taking Laplace operator both sides we get,
H ( s)
( s) s ( s) ….(12)
fC
( s) (1 / fC )
….(13)
H ( s) (s 1)
A
For a step input to heat H ( s) ….(14)
s
A(1 / fC )
( s) ….(15)
s (s 1)
A 1
( s) s( s 1 / ) ….(16)
fC
A 1 1
( s) s (s 1 / ) ....(17)
fC
Taking inverse Laplace we get,
(t )
A
fC
1 e t / ….(18)
A
Hence from eq.(8) and eq.(18) T Ts (1 e t / ) ….(19)
fC
When the thermostat is used to control the temperature of the stirrer tank vessel heated by electric heater
it controls the temperature within the band. By studying the temperature-time history of the stirrer tank
vessel when controller pressed into action this temperature band can be estimated.
APPARATUS
Electric Heater
To over head
VB
To Drain
PROCEDURE
1. Open valve (VC) so as to fill the overhead tank. Once the water level in the overhead tank attains
a constant level, water from the overflow line starts flowing in the bottom reservoir from where it
is pumped back to the overhead tank.
2. Open the valve (VA) to allow the flow of water from overhead tank to stirred tank. Slowly the
water level in the tank rises and through valve (VB) it drains out.
3. Switch ON the stirrer and switch ON the electric heater. Fix the value of set point temperature in
the controller at 90 °C. This will ensure the heater to remain on as due to the low capacity of the
heater the final temperature will never reach 90 °C with time.
4. Monitor the rise in temperature in the stirrer tank. Continue monitoring the temperature and time
till the temperature in the tank stabilizes.
5. Switch OFF the heater and note the fall in the temperature with time till it attains a constant
value.
6. Fix the set point temperature between (40-50) °C in the controller and start recording the
temperature of the stirred tank with time. After a few minutes the electric bulb attached to the
controller will stop glowing indicating that electric heater has been switched OFF by the
thermostat. Keep on noting the temperature-time history of the tank. After a few minutes the bulb
will again glow indicating that the heater has been switched ON. Keep on noting the temperature-
time history till the electric bulb stops glowing for the second time.
Draw a plot between temperature and time for the case and from this plot compute the time
constant of the stirred tank.
B) When the electric heater was switched OFF (without controller operating)
Time, in s
Temperature, in °C
Draw a plot between temperature and time for the case and from this plot compute the time
constant of the stirred tank.
C) When the controller was pressed into service to control tank temperature
Time, in s
Temperature, in °C
Draw a plot between temperature and time for the case and compute the temperature control band
from the plot, i.e., the temperature drop in tank observed between the ON and OFF states of the
controller.
DISCUSSIONS
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg.168-172.
EXPERIMENT NO. 2
DYNAMICS OF EVACUATED TANK
OBJECTIVE
1. To study the dynamics of evacuated tank
THEORY
The following figure shows a sketch of the major parts of the instruments.
Manometer
Vacuum
Tank
Vacuum pump
Mercury
reservoir
Figure 2.1: Schematic of the evacuated tank assembly
APPARATUS
1. Mercury Reservoir and U-tube
2. Vacuum Pressure Gauge (0 to -760 mmHg)
3. Vacuum tank with vent cock
4. Vacuum pump
PROCEDURE
1. Start the vacuum pump and observe the rise of mercury in the tube. The vent cock on the vacuum
tank should remain closed while vacuum is being created. Note the levels at some proper time
intervals till the maximum vacuum has been achieved (Condition-1).
2. After steady state is attained, note the level of the mercury in the u-tube attached to the reservoir
and also the vacuum pressure indicated by the pressure gauge.
3. Crack open the vent cock approximately half-way suddenly, so that the vacuum starts falling very
slowly. Note the fall in vacuum in the vessel (pressure gauge) and inlet line (U-tube manometer),
as a function of time, till a new steady state is reached i.e. the pressure ceases to vary (Condition-
2).
4. Give the next step input by suddenly closing the vent cock and observe the change in pressure
with time P(t) (Condition-3).
5. Plot the pressure as a function of time (i.e P(t) vs time(t)) and discuss the results with
mathematical analysis.
6. Report the time constants at three different conditions and compare them.
Repeat the tables for condition – 2 and condition – 3 with varied openings of vent cock.
DISCUSSIONS
REFERENCES
EXPERIMENT NO. 3
DYNAMICS OF THERMOMETER
OBJECTIVE
1. To study the dynamics of a thermometer with and without thermowell.
THEORY
A simple mercury thermometer is a first order system under the following assumption.
1. All the resistance to heat transfer resides in the film surrounding the bulb.
2. All the thermal capacity is in the mercury.
3. The glass wall containing the mercury does not expand or contract during the transient response.
Y (s) 1
X (s) s 1
where, τ is the time constant given by (mC/hA), m is the mass of mercury, C is the specific heat capacity,
h is heat transfer coefficient and A is the area of heat transfer. The introduction of thermowell leads to a
second order system due to additional resistance and capacitance of the oil. The transfer function is of the
form:
Y ( s) 1
2 2
X ( s) ( s 2 s 1)
The system is over damped with the values of and 𝜁calculated using methods such as slope and
intercept method, method of moments, method of Harriot, etc.
The time response of the first order system to a step input is given by
A
X ( s) is given by
s
0 when t 0
Y (t ) t
A(1 e ) when t 0
A t 1 t
Y (t ) A 1e 2e 2
( 2 1 )
where 1 - 2 1 and 2 2 1
APPARATUS
1. Thermowell
2. Glass bulb thermometer
3. Hot air blower
PROCEDURE
CALCULATIONS
Time, in s
Temperature, in °C
A = (Tf - Ti ) = _________ °C
-t
Y( t ) A (1 - e
),
2 3
Therefore, ________ s
6
During Cooling:
Similarly, the cooling curve is obtained with a forcing function of step input of negative magnitude.
Time, in s
Temperature, in °C
A = (Ti - Tf ) = _________ °C
A
Y ( s )
s (s 1)
-t
Y (t ) - A (1 - e
)
where, Y(t) is deviation temperature.
________ s
2 _______ s
3 _ _____ s
2 3
Therefore, _________ s
6
Time, in s
Temperature, in °C
A t 1 t
Y (t ) A 1e 2e 2
( 2 1 )
where 1 - 2 1 and 2 2 1
The value of Y(t) at different time (t) can be obtained from the plot of experimental data. Follow the
procedure given on page 297 in Process Systems Analysis and Control by D. R. Coughanowr, 2 nd Edition
to identify the process transfer function.
DISCUSSIONS
REFERENCES
Donald R. Coughanowr, “Process systems analysis and control”, 2nd Ed., McGraw Hill, NY,
1991, pg.297-299.
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg.71-75.
EXPERIMENT NO. 4
CONTROL VALVE CHARACTERISTICS (THREE VALVES)
OBJECTIVE
INTRODUCTION
If the control valve is used to control fluid flow, some mechanism must physically open or close
the valve. Different types of actuators are used to control the stem travel of the valve, like
electrical actuator, pneumatic actuator, hydraulic actuator etc. In present set-up, 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.
There are two types of actuators described below.
Direct acting actuators basically consists 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
rates or stiffness, load carrying capacity and initial compression, desired stem
displacement can be obtained for any given input signal.
DESCRIPTION
The present set-up consists of three control valves with pneumatic actuators. One control valve is
with equal percentage characteristics (air to close type), second is with On/Off characteristics (air
to open type) and third is with linear characteristics (air to open type). Apparatus is self-
contained water re-circulating unit. Compressed air supply is to be provided from user end.
Water from sump tank is sucked and delivered to a constant level overhead tank by means of a
centrifugal pump. Water flows back from overhead tank to sump tank through the control valve.
Each control valve is provided with a ball valve at the inlet. Flow rate of water passing through
the control valve is measured with the help of rotameter. A common water manometer is
provided for the measurement of water pressure head at the inlet of control valve. As outlet of
control valve is open to the atmosphere, the pressure at inlet of control valve is considered as
pressure drop across the valve. Change in the stem travel/ position of control valve results in the
change in flow through the control valve. This adjustment is done by regulating the air pressure
inside the diaphragm of control valve (3 to 15 psig). For this purpose a pressure regulator with
pressure gauge is provided in pneumatic line. Pressure gauge facilitates to get direct reading of
pressure inside the diaphragm of control valve. Individual ball valves are provided to actuate the
pneumatic line for individual control valve. For detecting the stem travel/position, scale is
provided on each control valve.
UTILITIES REQUIRED
1. Electricity supply: Single phase, 220V AC, 50Hz, 5-15 A. Socket with earth connection.
2. Compressed air supply: 1 CMH at 2 bar
3. Water supply
4. Drain
1. Never run the apparatus if power supply is less than 180 volts & greater than 230 volts.
2. If the apparatus will not be in use for more than one month, drain the apparatus
completely and fill pump with cutting oil.
3. To prevent clogging of moving parts, run pump at least once in a fortnight.
4. Always use clean water.
5. Always keep apparatus free from dust.
TROUBLESHOOTING
1. If pump gets choked, open the back cover of pump and rotate the shaft manually.
OBJECTIVE
THEORY
A control valve is used to control the flow rate in a fluid delivery system to control the process.
There is a close relation between pressure and the flow rate in fluid stream passing through the
pipe so that if the pressure is changed, the flow rate will also be 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 can
be given as:
K
Q …….(1)
P
The most important factor associated with control valve is correction factor K of the above
equation. This correction factor allows selection of proper size of valve to accommodate the flow
that the system must support. This correction factor is called the valve coefficient and is used in
valve sizing.
The valve coefficient is measured as the number of USGPM (US Gallon per minute) that flows
through a fully open valve with a pressure drop of 1 psig. (1 US gallon = 3.785 Liters)
Pv
Q KV …….(2)
G
where, Q is flow rate, m3/hr and ΔPv is pressure drop across valve, kgf/cm2
KV 0.856 CV …….(3)
G
CV 11.6 Q …….(4)
P
where, Q is discharge rate of fluid in m3/h, ΔP= Pressure drop across the wide-open valve, kPa,
G = Specific gravity relative to water. G=1 for water
PROCEDURE
OBSERVATION TABLE:
2. Linear Valve 2
CALCULATION
Make the calculation for Cv as per equation (4) and tabulate in observation table above.
When conducting the experiment for the linear control valve keeping in mind that it is “air to
open” which means pressure in diaphragm should be more than 15 psig. Adjust this pressure in
diaphragm by opening the pressure regulator. Do not increase this pressure to more than 20 psig.
NOMENCLATURE
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg. 423-440.
OBJECTIVE
The amount of flow passing through a valve at any time depends upon the opening between the
plug and the seat. Hence there is a relationship between stem position, plug position, and the rate
of flow, which is described in terms of the flow characteristics of a valve. Inherent and installed
are two types of flow characteristics of a control valve.
INHERENT CHARACTERISTIC
The inherent 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.
10 20 30 40 50 60 70 80 90 100
Quick opening
Flow % of maximum
Lnear
Equal
0
0 10 20 30 40 50 60 70 80 90 100
PROCEDURE
OBSERVATION TABLE:
S.No. 1 2 3 4 5 6 7 8
Pressure Regulator
Reading, in psig
Stem lift in mm
Q, LPH
The constant pressure drop across the control valve ΔP, in cm H2O = ___________
CALCULATION
Perform the experiment for the other two valves. As the equal percentage control valve is “air to
close” pressure in diaphragm should be 0 psig for fully open condition. Repeat the experimental
procedure same as above, but pressure in the diaphragm will be increased gradually.
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg. 423-440.
OBJECTIVE
The amount of flow passing through a valve at any time depends upon the opening between the
plug and the seat. Hence there is a 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 flow characteristics of a control valve.
INSTALLED CHARACTERISTIC
The installed characteristic of control valves described is subjected to distortion due to variations
in pressure drop with flow. Line resistance distorts linear characteristics towards that quick
opening valve and equal percentage to that of linear control valve.
PROCEDURE
OBSERVATION TABLE:
S.No. 1 2 3 4 5 6 7 8
Pressure Regulator
Reading, in psig
Stem lift in mm
Q, LPH
ΔP, in cm H2O
DISCUSSION:
Installed characteristics of the linear valve slightly approaches to the characteristics of quick
opening valve and that of equal percentage valve approaches to the linear characteristic because
of the pipe friction and other resistance to the flow.
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg. 423-440.
OBJECTIVE
THEORY
Hysteresis is the difference in reading while opening and closing the valve. In case of control
valves for same actuator signal different stem level (hence valve coefficients) are obtained
depending upon the direction of change. The maximum error in stem travel (or valve coefficient)
expressed in percent for same actuator pressure while opening and closing the valve is indicated
as hysteresis.
EXPERIMENTAL PROCEDURE
14. Repeat the procedure and take the reading at each at -3 psig till the valve is fully opened
(Pressure down to 0 psig).
15. Calculate the valve flow coefficient for actuator pressure for every reading.
16. Plot the graph of actuator pressure vs. flow coefficient. The ratio of maximum difference
between flow coefficients at same actuator pressure to that of maximum flow coefficient
is termed as hysteresis.
17. Repeat the experiment for the other valves.
OBSERVATION TABLE:
12
15
CALCULATION
G
CV 11.6Q ….(1)
P
Repeat the experiment for the linear control valve. As the control valve is “air to open” so
pressure in diaphragm should be 15 psig.
NOMENCLATURE
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg.423-440.
OBJECTIVE
THEORY
Equal percentage valve has characteristics such that flow changes by a constant percentage of its
instantaneous value for a given percentage change in stem position. 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 …….(1)
Fmin
where, Fmax is the flow when the valve stem is at nearly extreme open position foe maximum
controllable flow and Fmin is the flow when valve stem is at nearly extreme closed position for
minimum controllable flow. Fmax and Fmin represent 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.
PROCEDURE
OBSERVATION TABLE:
Nearly 3
Nearly 15
CALCULATION
Cv max
R ........ …….(3)
Cv min
Fmax
R ........ …….(4)
Fmin
Repeat the experiment by keeping constant pressure drop across the control valve and note the
flow rates.
NOMENCLATURE
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg. 423-440.
EXPERIMENT NO. 5
INTERACTING AND NON-INTERACTING SYSTEMS
INTRODUCTION
The setup is design to study dynamic response of single and multi-capacity process when
connected in interacting and non-interacting mode. It is combined to study
1. Single capacity process
2. Non-interacting process and
3. Interacting process.
The observed step response of the tank level in different mode can be compared with
mathematically predicted response.
Tank 1
R1
Rotameter
Tank 2
Tank 3
R2 R3
Figure 5.1: Overall schematic of the interacting and non-interacting tank system
APPARATUS
1. Supply tank
2. Pump for water circulation.
3. Rotameter for flow measurement.
4. Valves for controlling fluid flow.
5. Transparent tanks with graduated scales, which can be connected in interacting and non-
interacting mode.
OBJECTIVE
THEORY
Step function: Mathematically, the step function of magnitude A can be expressed as
where,
A 0 when t 0 A
X (t ) and X ( s)
A when t 0 s
X(t)
0 t
To study the transient response for step function, consider the system consisting of a tank of
uniform cross sectional area A1 and flow resistance R1 such as for a valve. Qo, volumetric flow
rate through the resistance, is related to head h1 by a linear relationship.
A1
R1 h1
qo
(Mass flow in) – (Mass flow out) = Rate of accumulation of mass in the tank
dh1
q(t ) qo (t ) A1
dt ……………(2)
Combining equation (1) and (2) to eliminate qo(t) gives the following linear differential equation:
h1 dh
q A1 …………..…(3)
R1 dt
dh1
Initially the process is operating at steady state, which means that 0
dt
h1s
qs 0 ……………(4)
R
where, the subscript‘s’ indicates the steady state value of the variable.
Defining deviation variable: q qs Q and h1 h1s H1 equation (5) can be written as:
H1 dH 1
Q A1 ……………(6)
R dt
H 1 ( s)
Q( s ) A1 sH1 ( s) ..…………(7)
R
Equation (7) can be rearranged into standard form of first order system as:
H 1 ( s) R1
where 1 A1 R1 . …………..(8)
Q( s ) (s 1)
A
Q(t ) Au (t ) or Q( s) …………(9)
s
A R1
H 1 (s) ………….(10)
s ( 1 s 1)
H 1 (t ) AR1 1 e
t
………….(11)
According to above equation (11) we can find the nature of curve as shown in Figure 5(A).3
below.
H1(t) in m
Single tank
t in s
2. Switch on the pump. Adjust rotameter flow rates in steps of 10 LPH from 40 to 70 LPH
and note steady state levels for tank 1 against each flow rate.
3. From the data obtained select a suitable band for experimentation, say 50-60 LPH in
which we will be getting more readings of tank level.
4. Adjust the flow rate at lower value of the band selected, say 50 LPH and allow the level
of the tank 1 to reach steady state and record the flow and level at steady state.
5. Apply the step change by increasing the rotameter flow by 10 LPH.
6. Immediately start recording the level of the tank 1 at the interval of 15 sec, until the level
reaches at steady state.
7. Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level.
8. Repeat the experiment by throttling outlet valve (R1) to change resistance.
OBSERVATIONS
CALCULATIONS
time constant in s
1 2 2
A1 R1 where A1 is the area of the tank in m and R 1 is resistance of outlet valve in s/m
where, dH1 = change in level (Final steady state level – Initial steady state level)
dQ = change in flow (Final flow rate after step change – Initial flow rate).
t
H 1 (t ) predicted AR1 1 e 1
Plot the graph of H1(t) vs. time(t) for observed and predicted levels.
DISCUSSIONS
Observed response fairly tallies with theoretical calculated response. Deviations observed may
be due to following factors:
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg.99-104.
OBJECTIVE
1. To study the step response of two first order systems arranged in non-interacting mode
THEORY
In non-interacting systems we assume the tanks have uniform cross sectional area and the flow resistance
is linear. To find out the transfer function of the system that relates h 2 to q, writing a mass balance around
the tank, we proceed as follows.
q(t)
A1
R1 h1
q1
A2
R2 h2
q2
Non interacting system
dh1
q q1 A1 …..(1)
dt
A mass balance at tank 2 is given as
dh2
q1 q 2 A2 …..(2)
dt
The flow head relationships for the two linear resistances in non-interacting system are given by the
expressions.
h1
q1 .…(3)
R1
h2
q2 …..(4)
R2
Q1 ( s) 1
…..(5)
Q( s ) 1 s 1
Q1 q1 q1s
where Q q q s …..(6)
A R
1 1 1
H 2 h2 h2 s
where …..(8)
2 A2 R2
Overall transfer function can be calculated as follows
H 2 ( s) R2
…..(9)
Q( s ) ( 2 s 1) ( 1 s 1)
1 t 1 t
H 2 (t ) AR2 1 1 2 e1 e2 …..(13)
1 2 2 1
According to above equation we can find the nature of curve as shown below.
H2(t) in m
Non interacting
tanks
t in s
OBSERVATIONS
CALCULATIONS
Magnitude of step change.
Let A
Flow after step input Initial flow rate in m /s
3
1 t 1 t
H 2 (t ) Pr edicted AR2 1 1 2 e1 e2
1 2 2 1
= Level in tank 2 predicted at time t in meter.
Plot the graph of
DISCUSSIONS
Observed response fairly tallies with theoretical calculated response. Deviations observed may
be due to following factors:
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg. 123-130.
OBJECTIVE
1. To study the impulse response of two first order systems arranged in non-interacting mode
THEORY
X (t ) A (t ) …..(1)
Where,
A/b 0 when t 0 Lim X (t ) A (t )
b 0
A and
L[ A (t )] A
X (t ) when 0 t b
X(t)
b
0 when t b
0 b t
H 2 ( s) R2
Q( s ) ( 2 s 1) ( 1 s 1)
Q(t ) V (t ) …..(2)
Q(s) V …..(3)
VR2
Hence we find H 2 ( s) …..(4)
( 2 s 1) ( 1 s 1)
t t
2
e e
1
For impulse change H2 at time t is given by H 2 (t ) VR 2 …..(5)
2
1
Considering linear resistance at outlet valve of the tank 2, the value of R2 can be calculated as:
H 2, s
R2 …..(6)
Q
where H2,s is the steady state level of tank 2 and Q is the steady flow through the system from the pump.
Before and after the impulse the tank levels and flow rates will return to this steady state value and hence
these are used for calculating resistance of the valve.
Put the values in equation (3) to find out H(t) predicted and plot the graph of
PROCEDURE
1. Start the setup by inserting the flexible pipe provided at the rotameter outlet in to the
cover of the top tank 1. Ensure that the valve (R3) between tank 2 and tank 3 is fully
closed.
2. Switch on the pump and adjust the flow rate to 35 LPH. Allow the level of both the tanks
(tank 1 and tank 2) to reach at steady state and record the initial flow and steady state
levels of both tanks.
3. Apply impulse input by adding 0.5 liters of water in tank 1.
4. Record the level of tank 2 at an interval of 15 s, until the level reaches steady state (same
as before impulse is added).
5. Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level.
6. Repeat the experiment by throttling outlet valve (R1) to change resistance.
OBSERVATIONS
CALCULATIONS
Let
Outlet valve resistance in s/m 2 of tank 1
R1 H 1,s
Q (When considerin g non linear resistance at outlet).
Outlet valve resistance in s/m 2 of tank 2
R2 H 2 , s
Q (When considerin g non linear resistance at outlet)
time constant (in s) of tank 1.
1 A1 R1 where A1 (d1 2 ) is the area of the tank 1 in m 2 and R 1 is resistance of
4
2
outlet valve (in s/m ) of tank 1
time constant (in s) of tank 2.
2 A 2 R2 where A2 (d 2 2 ) is the area of the tank 2 in m 2 and R 2 is resistance of
4
2
outlet valve (in s/m ) of tank 2
Where, H1,s , H2,s = steady state level of tanks 1 and 2
Q = steady state flow through the system.
H 2 (t ) observed = (Level at time t – Level at time t = 0) x 10-3
t t
2
e 1
e
H 2 (t ) Pr edicted VR 2
2
1
V= Volume of liquid added as an impulse input (in m3).
DISCUSSIONS
Observed response fairly tallies with theoretical calculated response. Deviations observed may
be due to following factors:
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, 123-130.
OBJECTIVE
1. To study the step response of two first order systems arranged in interacting mode
THEORY
Assuming the tanks of uniform cross sectional area and valves with linear flow resistance the transfer
function of interacting system can be written as:
q(t)
A2 A3
R2 h2 R3 h3
q2
q3
H 2 ( s) R2
…..(1)
Q( s) 3 2 s ( 3 2 A3 R2 ) s 1
2
Let,
1 1 A3 R2
b …..(2)
3 2 3 2
b b 2 1
…..(3)
2 2
3 2
b b 2 1
…..(4)
2 2 3 2
In terms of transient response the interacting system is more sluggish than the non-interacting system.
According to above equation we can find the nature of curve as shown below.
Non interacting
tanks
H2(t) in m
Interacting
tanks
t in s
OBSERVATIONS
CALCULATIONS
Magnitude of step change.
Let A
Flow after step input Initial flow rate in m /s
3
DISCUSSIONS
Observed response fairly tallies with theoretical calculated response. Deviations observed may
be due to following factors:
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg.123-130.
OBJECTIVE
1. To study the impulse response of two first order systems arranged in interacting mode
THEORY
Mathematically, the impulse function of magnitude A is defined as
X (t ) A (t ) …..(1)
Where,
A/b 0 when t 0 Lim X (t ) A (t )
b 0
A and
L[ A (t )] A
X (t ) when 0 t b
X(t)
b
0 when t b
0 b t
H 2 ( s) R2
…..(2)
Q( s) 3 2 s ( 3 2 A3 R2 ) s 1
2
Q(t ) V (t ) …..(3)
Q(s) V …..(4)
VR2
H 2 ( s) …..(5)
3 2 s ( 3 2 A3 R2 ) s 1
2
VR2
H 2 (t ) [et e t ] …..(6)
3 2 ( )
where,
1 1 A3 R2
b …..(7)
3 2 3 2
b b 2 1
…..(8)
2 2 3 2
b b 2 1
…..(9)
2 2 3 2
PROCEDURE
1. Start the setup by inserting the flexible pipe provided at the rotameter outlet in to the
cover of the top 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.
2. Switch on the pump and adjust the flow rate to 35 LPH. Allow the level of both the tanks
(tank 2 and tank 3) to reach steady state and record the initial flow and steady state levels
of both tanks.
3. Apply impulse input by adding 0.5 liters of water in tank 3.
4. Record the level of tank 2 at an interval of 15 s, until the level reaches steady state (same
as before impulse is added).
5. Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level.
6. Repeat the experiment by throttling outlet valve (R3) to change resistance.
OBSERVATIONS
CALCULATIONS
Let
Outlet valve resistance in s/m 2 of tank 2
R2 H 2 , s
Q (When considerin g non linear resistance at outlet )
Outlet valve resistance in s/m 2 of tank 3
R3 H 3, s
Q (When considerin g non linear resistance at outlet).
time constant (in s) of tank 2.
2 A 2 R2 where A2 (d 2 2 ) is the area of the tank 2 in m 2 and R 2 is resistance of
4
2
outlet valve (in s/m ) of tank 2
time constant (in s) of tank 3.
3 A 3 R3 where A3 (d 3 2 ) is the area of the tank 3 in m 2 and R 3 is resistance of
4
2
outlet valve (in s/m ) of tank 3
where, H3,s , H2,s = steady state levels of tank 3 and 2
Q = steady flow through the system.
H 2 (t ) observed = (Level at time t – level at time t = 0) x 10-3
VR2
H 2 (t ) Pr edicted [et e t ]
3 2 ( )
V= Volume of liquid added as an impulse input (in m3).
Plot the graph of
DISCUSSIONS
Observed response fairly tallies with theoretical calculated response. Deviations observed may
be due to following factors:
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, “Process systems analysis and control”, 3rd Ed.,
McGraw Hill, NY, 2009, pg. 123-130.
EXPERIMENT NO. 6
DEAD WEIGHT TESTER FOR PRESSURE GAUGE CALIBRATION
OBJECTIVE
1. Calibration of pressure gauge by Dead weight tester
THEORY
C
I E
K
F
APPARATUS
1. Weights
2. Pressure gauge for calibration
3. Testing apparatus
PROCEDURE
1. Set level by placing a spirit level on the weight table (A) and adjusting the leveling
screws (H).
2. Wind capstan handle of screw press (G) fully in, i.e., clockwise.
3. Remove reservoir cap (D) and pour oil (only castor oil technical grade free from acids
and water traces, not Castrol until nearly full and open valve (?).
4. Screw capstan (G) in and out until bubbles stop appearing in the reservoir.
5. Screw capstan (G) fully out.
6. Close the valve (F).
7. Select correct adopter and fit gauge/instrument (under test) at gauge post (K) using a
proper copper washer or bonded seal. Gauge should never be mounted until the priming
operation (step – 4) is done.
8. Ensure that the gauge /instruments to be tested are internally clean, if water, dirt or
chemicals are sucked into the system from contaminated instruments, the ram system will
be seriously damaged.
9. Load the weight table (A) with the weights. The equivalent of the weight table must also
be taken into account.
10. Apply the pressure with the screw press (?) until the weights begin to rise. Spin weight
table by hand and adjust the capstan until weight table skirt floats within the indicator red
band. The red band is easily visible on the piston cylinder from a seated position.
11. It is essential that the weights should be spinning freely whilst taking readings.
12. Never take off weights without removing all pressure in the system by unscrewing the
press (?).
13. After the test is finished stop the weights spinning, wind back the screw press (?) fully
and open the valve (?). The tester is now ready for another test.
14. In high pressure testers, a slight leakage through the cylinder vent hole on the side of the
ram cylinder is normal.
DISCUSSIONS
REFERENCES
EXPERIMENT NO - 7
DYNAMICS OF PRESSURIZED TANK
OBJECTIVE
THEORY
The following figure shows the schematic of the experimental set-up. The objective is to study the
changing pressure dynamics of the tank under varied flow conditions and determine its time constant.
Relief Valve
PG2
V5
V4
V1 PG1
Tank
V2 V3 V6
Air compressor
Figure 7.1: Schematic diagram for the study of dynamics of pressurized tank system
The compressed air to the tank is provided through the valves V 1, V2 and V3 and pressure in the inlet line
can be measured by the pressure gauge (PG1). The main instrument is the tank which is provided with a
pressure gauge (PG2), a relief valve (V4), outlet valves (V5 and V6). For pressurizing the tank, first the
pressure is built in the inlet line. The valve (V3) is closed and using valves (V1 and V2), bring the pressure
in the inlet line to say 20 psig. Then keeping both outlet valves (V 5 and V6) closed, slightly open valve V3
to let air into the tank, thus pressurizing it. Caution: while letting air into the tank, the inlet line pressure
might fall. In order to maintain the constant pressure inlet condition, you may adjust valves V 1 and V2.
Readings are taken until the pressure in the tank reaches the line pressure of say 20 psig.
The process can be continued with valve V5 slightly opened and until a new steady state is reached.
Experiment with different openings of V5 to get different steady states and determine the time constant for
the tank.
The transfer function for the system can be derived from the mass balance of air for the general flow
system where we will assume certain flow through valve V5. Consider the following simplified system for
purpose of mass balance of air
P2
P1
V3 V5 Pa
P2, V
fin fout
Let the volume of the tank be V and gauge pressure inside the tank be P2. The inlet line gauge pressure be
P1. The inlet valve V3 has a valve coefficient of Kv3 and outlet valve V5 has a valve coefficient of Kv5.
Then the flow rate of air through these valves are related to pressure drops across them as follows
𝐾
𝑖 = √𝑃 − 𝑃
√
𝐾 5
= √𝑃
√
Assuming density of air is constant at 𝜌 = 𝑃 + 𝑃𝑎 𝑉⁄𝑅𝑇. The mass balance then gives,
𝐾 𝐾 5 𝑃
√𝑃 − 𝑃 − √𝑃 =
√ √ 𝑃 + 𝑃𝑎
Multiply by (P2 +Pa) and linearize this equation to get a first order system.
𝐾 (𝑃 , + 𝑃𝑎 )
[(√𝑃 − 𝑃 , )(𝑃 , + 𝑃𝑎 ) + {(√𝑃 − 𝑃 , ) − } (𝑃 − 𝑃 , )]
√ (√𝑃 − 𝑃 , )
𝐾 5 (𝑃 , + 𝑃𝑎 ) (𝑃 − 𝑃 , )
− [√𝑃 , (𝑃 , + 𝑃𝑎 ) + { + √𝑃 , } (𝑃 − 𝑃 , )] =
√ √𝑃 ,
As the experimenter will hold P1 constant and steady state values are constant we can simplify the
equation as follows with deviation variables for pressure in the tank as 𝑃′
𝐾 𝐾 5 𝑃′
[ + 𝑃′ ] − [ + 𝑃′ ] =
√ √
𝑃 =
𝜏 +
where,
𝐾 −𝐾 5 √
= and 𝜏 =
𝐾 5 −𝐾 𝐾 5 −𝐾
− ⁄𝜏
𝑃 =𝑃 , +
𝜏
Using various experiments as detailed above we can experimentally find the time constant 𝜏 and compare
with the simplified first order approximation derived.
APPARATUS
1. Air Compressor
2. Tank to hold pressurized air
3. System of valves to regulate air
PROCEDURE
Condition – 3: the valve V5 is closed and again tank pressure is brought back up to P2,s. After attaining
steady state value, the valve is cracked open one more time by half turn.
Take readings of tank pressure P2(t) with time (t) and obtain new steady state value (P2,sh).
Time, t in s
Pressure, P2, in Pa
The change in outlet valve flow rate caused a pressure magnitude change of (P2,s - P2,sh).
Plot vessel pressure (P2) vs. time for all the cases of valve openings you experiment with.
Compute time constant of the system using different methods for rising and decreasing pressures
separately for all the cases.
DISCUSSIONS
REFERENCES