IPC LAB Manual Exp 1-10 DS - 2020

PCE Lab
B. M. S. College of Engineering
Bengaluru-19
Department of Chemical Engineering

(Accredited by Washington accord Tier 1)
Process Control Engineering (16CH6DCPCE)
Laboratory Manual
6th Semester
Dr. D. Sreelakshmi Page 1

PCE Lab
Department of Chemical Engineering

Process Control Engineering
Laboratory Manual
Name of the Student:
USN:
Faculty In-charge:

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List of Experiments
Sl. No. Title of the Experiment Date Page No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

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Experiment 1 Single Tank System

Aim:
(i) To determine the time constant of a single tank system by evaluating the resistance
and capacitance of the system.
(ii) To determine the time constant of a single tank system from response study for a step
change in the input flow rate.
(iii) To compare the theoretical and experimental response of the tank to a step change in
the inlet flow rate
Apparatus:
Stop watch, Experimental setup, measuring jar, bucket.
Theory:
A single tank system is one which consists of a tank of constant cross sectional area with a
linear resistance attached at the outlet. This system behaves as a first order system. Consider
a single tank system as shown below in the figure. The tank has a uniform cross sectional
area ‘A’. Liquid is flowing into the tank at volumetric flow rate q(t) and flowing out at
volumetric flow rate qo(t) through a resistance R (weir). The density of the liquid flowing
through the tank is assumed to be constant.
q(t)
h1(t) R1
q1(t)
A first order system is characterized by a capacity to store material, energy or momentum and
the resistance associated with the flow of mass, energy or momentum reaching the capacity.

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If a step input is applied to a capacity-dominated process such as a single tank, the output
begins to change instantaneously but does not reach its steady state value for a period of time.
The time required to reach 63.2 % of its steady-state value is defined as the time constant.
For a single tank, the product of the resistance and capacitance gives the time constant τ1.
 1= A1  R 1
The transfer function of the given system can be written as
𝑌(𝑆) 𝑅1
=
𝑋(𝑆) 𝜏1 𝑆 + 1
The response of this first order system for a step change of magnitude m in the input is given
𝑡
−
by 𝐻(𝑡) = 𝑚 𝑅1 (1 − 𝑒 𝜏1 )
Procedure:
Part A: Determination of time constant of the system
1. Measure the dimensions of the tank. The cross-sectional area, A1 of the tank is the
capacitance C1.
2. Keep the inlet valve fully open and the bypass valve partially open.
3. Switch on the pump.
4. Set the inlet flow rate using the rotameter and wait for the tank level to reach steady
state.
5. Note down the level in the tank and also the corresponding steady state outlet flow
rate by collecting water for a known duration of time. This is the initial steady state
condition at time t = 0.
6. Repeat the above procedure for different inlet flow rates.
7. Plot a graph of deviation variable of level in the tank, H1(t) (on Y axis) vs deviation
variable of outlet flow rate, Q1(t) (on X axis) and determine the slope. Slope is the
resistance R1 of the tank.
8. The product of the resistance and capacitance gives the time constant τ1.
Part B: Determination of time constant from response study for a step change in the
input flow rate.
1. Maintain a low inlet flow rate and after steady rate is reached, note down the level in the
tank and the corresponding outlet flow rate. This is the initial steady state condition at
time t = 0.

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2. Now increase the inlet flow rate to a higher value and simultaneously start the stop
watch.
3. Note down the change in the level of the tank with time.
4. Continue noting down the readings till tank level reaches a steady state.
5. Plot the percentage change in the level of the tank vs time. This is the required
experimental response curve.
6. Calculate theoretical percentage change and plot the theoretical response curve.
Observations for Part A:

Table 1: Determination of time constant of the system
Sl. No. Rotameter Reading Inclined level, h1' (m) Volume Collected Time (s)
(LPM) (mL)
1
Model Calculation:
1. Area of Tank 1 = A1 = , m2
Volume
2. Volumetric flow rate ( q1) = , m3/s
Time
3. Vertical level, ℎ1 = ℎ1′ sin 40, m

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4. Deviation Variable, H1= h1(t)-h1s= m
5. Deviation Variable, Q1 = q1(t) - q1s = , m3/s
6. Resistance R1 of the tank ( obtained as slope of the H1(t) vs Q1(t) plot.
7. Time constant of the tank,  1= A1  R 1 = ,s.
Table 2: Result table
Sl. Outlet Volumetric Q = q1(t) - q1s Level, h1 (m) H1= h1(t)-h1s

No. flow rate, (m3/s) (m)
q1(t)
(m3/s)

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Observations for Part B:

Table 1: Step Response
Sl. No. Time Inclined level, h1'

(s) (m)
1
Model Calculations:
1. Vertical level, ℎ1 = ℎ1′ sin 40, m
2. Magnitude of step change in inlet flow rate, m = Final rotameter reading  Initial
rotameter reading, m3/s.
1 𝐻 (𝑡)
3. Percentage level change experimental, ( 𝑚𝑅 ) × 100 =
1 𝐸𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙
−𝑡
1 𝐻 (𝑡)
4. Percentage level change theoretcial, ( 𝑚𝑅 ) × 100 = (1 − 𝑒 𝜏1 ) × 100 =
1 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙
5. Time constant = The time required for step response to reach 63.2 % of its steady-
state value, τ1 = , s.

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Table 4: Results for Part B
SL. Time Vertical H1= h1(t)- 𝐻1 (𝑡) 𝐻1 (𝑡)

( ) ( )
NO. (s) Level, h1s 𝑚𝑅1 𝐸𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 𝑚𝑅1 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙
h1=h1’sinα (m) × 100 × 100

(m) (%) (%)
1 0
Result:
1. The time constant of the single tank system was calculated by evaluating the
resistance and capacitance of the tank and it was determined to be
s.
2. The time constant of the single tank system from response study for a step change in
the input flow rate was determined to be s.
Inference:

PCE Lab
Experiment 2 Time Constant Determination of a Thermometer
Aim:
(a) Determination of the time constant of the thermometer from its step response.
Apparatus: Experimental setup, stop watch, thermometer.
Theory: A thermometer is an example of a simple first order system. Its transfer function
may be obtained by obtaining a heat balance in its unsteady and steady states, and solving
the differential equation that results from them. The value of time constant will determine
how quickly the system moves toward a new steady state. The heat exchange between the
thermometer and the measured medium takes time. That is why there is always a delay in the
thermometer registering the prevailing temperature of the medium.
The unsteady and steady state heat balance equations are written and solved to obtain the
transfer function of the form,
𝑌(𝑆) 1
=
𝑋(𝑆) 𝜏𝑆 + 1
The response to a step change of magnitude M in the temperature of the measured medium
is of the form,
−𝑡
𝑌(𝑡) = 𝑀(1 − 𝑒 𝜏 )
𝑚𝐶
Where τ is the time constant and is defined as 𝜏 = , where m is the mass of mercury, C is
ℎ𝐴
the specific heat of mercury, h is the film heat transfer coefficient and A is the surface area of
the thermometer bulb.
The percentage response of the thermometer is

−𝑡
𝑌(𝑡)
× 100 = (1 − 𝑒 𝜏 ), %
𝑀
Procedure:
1. The water bath heater is switched on.
2. Thermometer is placed in the water filled test tube inside the water bath. Temperature is
allowed to reach the steady state and is noted down.
3. The room temperature is also noted down.
4. The thermometer is then removed from the test tube and is allowed to cool to the room
temperature.
5. Once this is done, the thermometer is placed in the water filled test tube again and

PCE Lab
immediately the stop watch is started.

6. The temperature indicated by the thermometer is noted for every 5 seconds until it
reaches a new steady state value.
7. Next the thermometer is placed in the oil filled - test tube inside the water bath.
I t i s allowed to attain steady state.
8. The thermometer is then removed from the test tube and is allowed to cool to the room
temperature.
9. Once this is done, the thermometer is placed in the oil filled - test tube again and
immediately the stop watch is started.
10. The temperature indicated by the thermometer is noted for every 5 seconds until it
reaches a new steady state value.
Observation:
Room Temperature = To = , oC ; Bath Temperature = Tn= , oC
Table 1: Temperature indicated by the thermometer
Water filled – test tube Oil filled – test tube

Sl. No. Time, t Temperature, Ti Time, t Temperature, Ti
[s] [oC] [s] [oC]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

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Model Calculation:
𝑻 −𝑻
Percentage response of the thermometer = (𝑻 𝒊 −𝑻𝒐 ) × 𝟏𝟎𝟎
𝒏 𝒐
Result: Table 2: Percentage response of the thermometer
Sl. Water filled tube Oil filled tube

No. Time, t % change in Temp, % Time, t % change in Temp, %
[s] [s]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Graph:
 Plot a graph of % change vs. time in order to determine τ for both water and oil
mediums.
 Time constant of the thermometer in water medium, τ = The time required for step
response to reach 63.2 % of its steady-state value = , s.
 Time constant of the thermometer in oil medium, τ = The time required for step
response to reach 63.2 % of its steady-state value = , s.

PCE Lab
Experiment No: 3 Non-interacting tanks
Aim:
To study the step - response of a two tank non-interacting tank system.
Apparatus: Experimental setup, stop watch, bucket and measuring flask.
Theory:
When mass or energy flows through a series of two capacities, the behavior of the system is
described by second order dynamics. Non-interacting capacities always results in an over
damped or critically damped second order system.
Assuming that the liquid is of constant density, the tanks are of uniform cross sectional area
and the flow resistances to be linear, the transfer function of a non-interacting system is of the
form,
𝐻2 (𝑠) 𝑅2
=
𝑄(𝑠) (1 + 𝜏1 𝑠)(1 + 𝜏2 𝑠)
which is the product of the first-order transfer functions of the individual tanks.
The step response of this system is of the form,

𝑡 𝑡
− −
𝐻2 (𝑡) 𝜏1 × 𝜏2 𝑒 𝜏1 𝑒 𝜏2
× 100 = 1 − ( − ) × 100
𝑚𝑅2 𝜏1 − 𝜏2 𝜏2 𝜏1

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Procedure:
1. Keep the bypass valve fully open and switch on the pump.
2. Part A:
a. Set the rotameter to 5 LPM.
b. Wait for the liquid levels in the tanks to become steady. Note down the steady
state slant liquid levels in the tanks reading.
c. Measure and note down the volume of water collected from each tank for 10s.
d. Repeat this for different rotameter settings upto 40 LPM.
3. Part B:
a. Set the rotameter to 5 LPM and wait for the liquid level of tank2 to become
steady.
b. Note down the steady state slant liquid level in the tank2.
c. Measure and record the volume of water collected from tank2 for 10s.
d. Increase the rotameter reading to 40 LPM.
e. Note down the slant liquid level in tank2 for every 5s until it reaches its steady
state.
Observation for Part A:

Table 1: Determination of time constant of tank1
(LPM) (mL)
1

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(LPM) (mL)
1
Model Calculation:
Part A:
1. Tank1
a. Area of Tank 1 = A1 = , m2
Volume
b. Volumetric flow rate ( q1) = , m3/s
Time
c. Vertical level, ℎ1 = ℎ1′ sin 40, m
d. Deviation Variable, H1= h1(t)-h1s= m
e. Deviation Variable, Q1 = q1(t) - q1s = , m3/s
f. Resistance R1 of the tank ( obtained as slope of the H1(t) vs Q1(t) plot.
g. Time constant of the tank,  1= A1  R 1 = ,s.

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2. Tank 2
a. Area of Tank2 = A2 = , m2
Volume
b. Volumetric flow rate ( q2 ) = , m3/s
Time
e. Deviation Variable, Q2 = q2(t) – q2s = , m3/s
f. Resistance R1 of the tank 1( obtained as slope of the H2(t) vs Q2(t) plot.
g. Time constant of the tank 1,  2= A2  R 2 = ,s.
Table 3: Result - Determination of time constant of tank1

q1(t)
(m3/s)

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q2(t)
(m3/s)


(s) (m)
1

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(s) (m)
5
Model Calculation:
Part B:
a. Vertical level, ℎ2 = ℎ2′ sin 40, m

b. Magnitude of step change in inlet flow rate, m = Final rotameter reading  Initial
rotameter reading, m3/s.
2 𝐻 (𝑡)
c. Percentage level change in tank2 experimental, ( 𝑚𝑅 ) × 100 =
d. Percentage level change in tank2 theoretical,

𝑡 𝑡
− −
𝐻2 (𝑡) 𝜏1 ×𝜏2 𝑒 𝜏1 𝑒 𝜏2
i. ( 𝑚𝑅 ) × 100 = 1 − ( − ) × 100 =
2 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝜏1 −𝜏2 𝜏2 𝜏1
Table 6: Result - Step Response

( ) ( )
H2=h2’sinα (m) × 100 × 100

(m) (%) (%)
1 0

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( ) ( )
H2=h2’sinα (m) × 100 × 100

(m) (%) (%)
Result:
Plot the experimental response curve and the theoretical response curve.

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Experiment No: 4 Interacting tanks
Aim:
To study the step - response of a two tank interacting system.
Apparatus: Experimental setup, stop watch, bucket and measuring flask.
Theory:
When mass or energy flows through a series of two capacities, the behavior of the system is
described by second order dynamics. Non-interacting capacities always results in an over
damped or critically damped second order system.
Fig. 1 Interacting tanks

Assuming that the liquid is of constant density, the tanks are of uniform cross sectional area
and the flow resistances to be linear, the transfer function of a non-interacting system is of the
form,
𝐻2 (𝑠) 𝑅2
=
𝑄(𝑠) [𝜏1 𝜏2 𝑠 + (𝜏1 + 𝜏2 + 𝐴1 𝑅2 )𝑠 + 1]
2
The step response of this system is of the form,

𝑡 𝑡
− −
𝐻2 (𝑡) 𝜏𝑎 𝜏𝑏 𝜏𝑎 × 𝜏𝑏 𝑒 𝜏 𝑎 𝑒 𝜏𝑏
× 100 = 1 − [ ( ( − ))] × 100
𝑚𝑅2 𝜏1 𝜏2 𝜏𝑎 − 𝜏𝑏 𝜏𝑏 𝜏𝑎
Where
 m is the magnitude of the step change.
 𝜏𝑎 𝑎𝑛𝑑 𝜏𝑏 are effective time constants of the system {defined as 𝜏𝑎 = −1/
𝑃1 𝑎𝑛𝑑 𝜏𝑏 − 1/𝑃2 where P1 and P2 are roots of the [𝜏1 𝜏2 𝑠 2 + (𝜏1 + 𝜏2 + 𝐴1 𝑅2 )𝑠 +
1=0

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Procedure:
1. Keep the bypass valve fully open and switch on the pump.
2. Part A:
a. Set the rotameter to 5 LPM.
b. Wait for the liquid levels in the tanks to become steady. Note down the steady
state slant liquid levels in the tanks reading.
c. Measure and note down the volume of water collected from tank2 for 10s.
d. Repeat this for different rotameter settings upto 40 LPM.
3. Part B:
a. Set the rotameter to 5 LPM and wait for the liquid level of tank 2 to become
steady.
b. Note down the steady state slant liquid level in the tank2.
c. Measure and record the volume of water collected from tank2 for 10s.
d. Increase the rotameter reading to 40 LPM.
e. Note down the slant liquid level in tank2 for every 5s until it reaches its steady
state.
Observations for Part A:

(LPM) (mL)
1

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(LPM) (mL)
1
Model Calculation:
Part A:
1. Tank1
a. Area of Tank 1 = A1 = , m2
Volume
b. Volumetric flow rate ( q1) = , m3/s
Time

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e. Deviation Variable, Q1 = q1(t) - q1s = , m3/s
f. Resistance R1 of the tank ( obtained as slope of the H1(t) vs Q1(t) plot.
g. Time constant of the tank,  1= A1  R 1 = ,s.
2. Tank 2
a. Area of Tank2 = A2 = , m2
Volume
b. Volumetric flow rate ( q2 ) = , m3/s
Time
e. Deviation Variable, Q2 = q2(t) – q2s = , m3/s
f. Resistance R1 of the tank 1( obtained as slope of the H2(t) vs Q2(t) plot.
g. Time constant of the tank 1,  2= A2  R 2 = ,s.

q1(t)
(m3/s)

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q2(t)
(m3/s)


(s) (m)
1

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(s) (m)
2
Model Calculation:
Part B:
a. Vertical level, ℎ2 = ℎ2′ sin 40, m

b. Magnitude of step change in inlet flow rate, m = Final rotameter reading 
Initial rotameter reading, m3/s.
2 𝐻 (𝑡)
c. Percentage level change in tank2 experimental, ( 𝑚𝑅 ) × 100 =
d. Percentage level change in tank2 theoretical,

𝑡 𝑡
− −
𝐻2 (𝑡) 𝜏𝑎 𝜏𝑏 𝜏𝑎 × 𝜏𝑏 𝑒 𝜏 𝑎 𝑒 𝜏𝑏
× 100 = {1 − [ ( − )]} × 100 =
𝑚𝑅2 𝜏1 𝜏2 𝜏𝑎 − 𝜏𝑏 𝜏𝑏 𝜏𝑎

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Table 6: Result - Step Response

( ) ( )
H2=h2’sinα (m) × 100 × 100

(m) (%) (%)
1 0
Result:
Plot the experimental response curve and the theoretical response curve.

PCE Lab
Experiment 5 Valve Characteristics

Aim:
(a) Determination of the valve characteristics of Quick Opening Valve, Linear Valve
and Equal Percentage Valve.
Apparatus: Experimental setup, stop watch.
Theory: The control action in any control loop system, is executed by the final control
element. The most common type of final control element used in chemical and other process
control is the control valve.
A control valve essentially consists of a plug and a stem. The stem can be raised or lowered
by air pressure and the plug changes the effective area of an orifice in the flow path. A typical
control valve action can be explained using Fig. 1. When the air pressure increases, the
upward force of the diaphragm moves the stem upward against the spring.
Flow Characteristic of a valve describes how the flow rate changes with the movement or lift
of the stem. The flow characteristic of a valve is expressed as

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𝑚 = 𝑓(𝑥)
𝑞 𝑧
where, m= 𝑞 and x= 𝑧
𝑚𝑎𝑥 𝑚𝑎𝑥
q is the maximum flow rate, when the valve is fully open and z is the corresponding
max max
maximum lift.
In this way, the control valves can be classified in terms of their m vs. x characteristics, and
three types of control valves are normally in use. They are:
(a) Quick opening (ON-OFF Valve)
(b) Linear
(c) Equal Percentage.
Procedure:
1. The compressor was switched on and the air regulator output pressure was set to 20 psi.
2. The ammeter was adjusted to set different valve stem lifts (opening), namely 0%, 25%,
50% , 75% and 100 % .
3. Subsequently, the ammeter was adjusted to set different valve stem lifts (closing), namely

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75%, 50% and 25% .

4. Volumetric flow rate from the valve was determined by measuring the time required for
2cm rise in water level in the discharge tank.
5. The same procedure is repeated for all the three valves.
Observation:
Table 1: Valve characteristics of Quick Opening Valve, Linear Valve and Equal
Percentage Valve.
Quick Opening Valve Linear Valve Equal Percentage Valve
Sl. Stem Time for tank Stem Time for tank Stem Time for tank
No. lift, % level rise of 2 lift, % level rise of 2 lift, % level rise of 2
cm, t cm, t cm, t
[s] [s] [s]
1 0
2 25
3 50
4 75
5 100
6 75
7 50
8 25
9 0
Model Calculation:
𝐀×𝐡
Volumetric flow rate = Percentage response of the thermometer 𝒒 = where
𝒕
A= Cross sectional area of teh discharge tank, m2

h = 0.02 m rise in tank level
t = Time taken for 0.02 m rise in tank level, s
Result:

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Table 2: Valve characteristics of Quick Opening Valve, Linear Valve and Equal
Percentage Valve.
Quick Opening Valve Linear Valve Equal Percentage Valve
Sl.
Stem Vol. flow (q/qmax ) * Stem Vol. flow (q/qmax ) Stem Vol. flow (q/qmax ) *
No.
lift, % rate, q, 100 lift, % rate, q, * 100 lift, % rate, q, 100
3 3 3
m /s m /s m /s
1 0
2 25
3 50
4 75
5 100
6 75
7 50
8 25
9 0
Graph:
Plot a graph of percentage stem lift versus percentage volumetric flow rate.

PCE Lab
Experiment 6 Dynamics of U-Tube Manometer

Aim:
To study the dynamic behavior of a U-tube manometer and to determine the properties like
overshoot, decay ratio, rise time, period and natural frequency.
Apparatus: Experimental setup, stop watch.
Theory: A second order process is a process whose output is modeled by a second order
differential equation.
𝑑 2 𝑦(𝑡) 𝑑𝑦(𝑡)
𝑎2 2
+ 𝑎1 + 𝑎𝑜 𝑦(𝑡) = 𝑏𝑢(𝑡)
𝑑𝑡 𝑑𝑡 2
where, u(t) and y(t) are input and output of the process respectively.
Defining the following:
𝑎2 𝑎 𝑏
𝑎0
= 𝜏 2 , 𝑎1 = 2𝜀𝜏 , , 𝑎 = 𝐾𝑝
0 0
𝑑 2 𝑦(𝑡)
2
𝑑𝑦(𝑡)
𝜏 + 2𝜀𝜏 + 𝑦(𝑡) = 𝐾𝑝 𝑢(𝑡)
𝑑𝑡 2 𝑑𝑡
Subtracting the steady state equation and taking Laplace Transform we obtain,
𝑌(𝑠) 𝐾𝑝
= 2 2
𝑈(𝑠) 𝜏 𝑠 + 2𝜀𝜏𝑠 + 1
A U-tube manometer is an example of a second order process. The dynamic behavior of the
U-tube liquid manometer with equal diameter columns corresponds to an under-damped
dynamic system.

PCE Lab
Consider the U tube manometer as in Fig. above. The liquid inside the manometer has been
shown in a pressurized state. Initially mercury levels at both the legs were at the same height.
The present pressurized state is obtained upon exerting a pressure of on Leg I.

Applying force balance on both the legs of the manometer across plane of initial pressurized
state, we obtain:
Force due to pressure differential + Force due to pressure head on leg II (Gravity) + Force
due to fluid friction = Mass of manometric liquid * Acceleration
𝐿 𝑉2 𝑑𝑉
𝑝1 𝐴 − 𝑝2 𝐴 − 𝜌𝑔(2ℎ)𝐴 − [4𝑓 ( ) 𝜌] 𝐴 = 𝑚
𝐷 2 𝑑𝑡
𝜋𝐷 2
Where = , is the cross-sectional area of the manometer legs,
4
𝜌 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑚𝑎𝑛𝑜𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑢𝑖𝑑,

𝑓 = 𝐹𝑎𝑛𝑛𝑖𝑛𝑔 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝐹𝑎𝑐𝑡𝑜𝑟
𝑉 = 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑚𝑎𝑛𝑜𝑚𝑒𝑡𝑟𝑖𝑐 𝑙𝑖𝑞𝑢𝑖𝑑
𝑚 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑛𝑜𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑢𝑖𝑑
Assuming laminar flow inside the manometer, the friction factor can be expressed as
16 16 𝜇
𝑓= =
𝑁𝑅𝑒 𝜌𝐷𝑉
The velocity of manometer liquid is rate of change of h. Hence, 𝑣 = 𝑑ℎ/𝑑𝑡
2
𝑑2 ℎ 𝑑ℎ 𝑑 𝑑ℎ
𝜏 2
+ 2𝜀𝜏 + ℎ = 𝜌𝐴𝐿 ( )
𝑑𝑡 𝑑𝑡 𝑑𝑡 𝑑𝑡
Where
𝐿 2 𝜇√2𝐿 1
𝜏=√ , 𝜀= , 𝐾𝑝 =
2𝑔 𝜌𝑅 2 √𝐺 2𝜌𝑔
Procedure:
1. Switch on the vacuum pump and adjust the system to a particular vacuum.
2. Set the manometer level to zero by operating the valve above the manometer.
3. Press the solenoid valve and note down the time taken for each peak and trough of one
leg of the manometer.

PCE Lab
4. Repeat the procedure for a different vacuum pressure.

Observation:
Table 1: Dynamics of U-Tube Manometer for vacuum of 100mm Hg.
S. Position of the Time, t

No. manometer leg [s]
(Peak/Trough),
cm
1
2
3
4
5
6
7
8
Table 2: Dynamics of U-Tube Manometer for vacuum of 300mm Hg.
S. Position of the Time, t

No. manometer leg [s]
(Peak/Trough),
cm
1
2
3
4
5
6
7
8

PCE Lab
Model Calculation:
𝜋𝜀
−( )
Overshoot = A/B = 𝑒 √1−𝜀2
Damping coefficient, 𝜀 =
Decay Ration = Overshoot 2 =
Time period, T (Obtained from response plot) =
Cyclic frequency, f = 1/T
Rise time, tr =
Response time =
Graph:
Plot the response curve and note down the overshoot, decay ratio, frequency etc.
Result:
The dynamic behavior of a U tube manometer has been studied and properties such as
overshoot, decay ratio, cyclic frequency, damping factor, rise time and response time have
been determined.

PCE Lab
Experiment 6 Types of Controllers
Aim:
To study the transient response of a liquid flow system for a step change in the set point using
different controllers like Proportional (P), Proportional–Integral (PI), and Proportional–
Integral-Derivative (PID) controllers.
Apparatus: Experimental setup.
Theory:
Proportional (P) controller:

The simplest type of controller is the proportional controller. The proportional controller
produces an output signal (pressure in the case of a pneumatic controller, current, or
voltage for an electronic controller) that is proportional to the error. The output of the P
controller can be expressed is described by the equation
𝑝(𝑡) = 𝑝𝑠 + 𝐾𝐶 ∈ (𝑡)
Where,
𝐾𝐶 = Proportional gain
∈ (𝑡)= Error
The transfer function of a proportional controller is
𝑃(𝑠)
= 𝐾𝐶
∈ (𝑠)
The proportional controller can reduce the error, but cannot eliminate it. The proportional
controller has only one adjustable parameter, the controller gain (kc). Offset can be
reduced by increasing the proportional gain; but that may also cause instability in the
system. Often, the proportional gain term, kc is expressed in terms of “Proportional Band”.
It is inversely proportional to the gain and expressed in percentage.
100
𝑃𝑏 =
𝐾𝐶
Proportional–Integral (PI) controller:
If integral control is added to a proportional controller, the P-I, or proportional–integral
controller is obtained. The integral mode ultimately drives the error to zero. This controller
has two adjustable parameters, the gain and the integral time.
1 𝑡
𝑝(𝑡) = 𝐾𝐶 {∈ (𝑡) + ∫ ∈ (𝑡)}
𝜏𝐼 0
The transfer function of a Proportional-Integral Controller is

PCE Lab
𝑃(𝑠) 1
= 𝐾𝐶 {1 + }
∈ (𝑠) 𝜏𝐼 𝑠
Proportional–Integral - Derivative (PID) controller:
The output of the PID controller can be described by the equation
𝑑∈(𝑡) 1 𝑡
𝑢(𝑡) = 𝐾𝐶 {∈ (𝑡) + 𝜏𝑑 + ∫0 ∈ (𝑡)}
𝑑𝑡 𝜏𝑖
Where,
𝐾𝐶 = Proportional gain
𝜏𝑑 = Derivative time
𝜏𝑖 = Integral time
∈ (𝑡)= Error
The transfer function of a PID controller is
𝑃(𝑠) 1
= 𝐾𝐶 {1 + 𝜏𝐷 𝑠 + }
∈ (𝑠) 𝜏𝐼 𝑠
Procedure:
1. The flow control module is switched on.
2. Set the log interval to 25 seconds.
3. The desired value (Set Value) of flow rate is entered in the software.
4. The bandwidth, integral time and derivative time are entered in the software. (Range for P
= 50 to 150, I = 50 to 240, D = 30 to 100).
5. The system is set to RUN.
6. From the graph of flow rate (controlled variable) versus time generated by the software,
note down the offset.
7. Repeat the procedure for a different set of P, I, D values.
Observation:
Table 1: Proportional (P) controller:
S. Time, s Controlled Controlled Controlled
No. Variable for Variable for Variable for
P=50, lpm P=100, lpm P=180, lpm
1
2
3
4
5

PCE Lab
6
7
8
Table 2: Proportional–Integral (PI) controller:
S. Time, s Controlled Variable for Controlled Controlled

No. P=50 & TI = 50, lpm Variable for Variable for
P=50 & TI = 150, P=50 & TI = 240,
lpm lpm
1
2
3
4
5
6
7
8
Table 3: Proportional–Integral–Derivative (PID) controller:
S. Time, s Controlled Variable for Controlled Controlled

No. P=50, TI = 50 & TD = 30, Variable for Variable for
lpm P=50, TI = 50 & P=50, TI = 50 &
TD = 50, lpm TD = 100, lpm
1
2
3
4
5
6
7
8

PCE Lab
Result:
Table 4: Proportional (P) controller:

S. No. Controlled
Band Width, P Variable at Offset
infinite time, lpm
1 50
2 100
3 180
Table 5: Proportional–Integral (PI) controller:
S. No. Integral Time, Controlled Variable at

Offset
Band Width, P TI, s infinite time, lpm
1 50 50
2 50 150
3 50 240
Table 6: Proportional–Integral- Derivative (PID) controller:
S. No. Integral Derivative Controlled Variable

Band Width, Time, Time, TD, s at infinite time, lpm Offset
P TI, s
1 50 50 30
2 50 50 50
3 50 50 100
Graph:
Plot the process variable (PV) and set value (SV) versus time for each controller.
Result: The transient response of a liquid flow system for a step change in the set point
using different controllers like Proportional (P), Proportional–Integral (PI), and Proportional–
Integral-Derivative (PID) controllers.

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PCE Lab

Department of Chemical Engineering

Process Control Engineering (16CH6DCPCE)

Dr. D. Sreelakshmi Page 1

Department of Chemical Engineering

Name of the Student:

Dr. D. Sreelakshmi Page 2

Sl. No. Title of the Experiment Date Page No.

Dr. D. Sreelakshmi Page 3

Experiment 1 Single Tank System

Dr. D. Sreelakshmi Page 1

Dr. D. Sreelakshmi Page 2

Observations for Part A:

Dr. D. Sreelakshmi Page 3

4. Deviation Variable, H1= h1(t)-h1s= m

5. Deviation Variable, Q1 = q1(t) - q1s = , m3/s

6. Resistance R1 of the tank ( obtained as slope of the H1(t) vs Q1(t) plot.

7. Time constant of the tank,  1= A1  R 1 = ,s.

Table 2: Result table

Sl. Outlet Volumetric Q = q1(t) - q1s Level, h1 (m) H1= h1(t)-h1s

Dr. D. Sreelakshmi Page 4

Observations for Part B:

Sl. No. Time Inclined level, h1'

Dr. D. Sreelakshmi Page 5

Table 4: Results for Part B

SL. Time Vertical H1= h1(t)- 𝐻1 (𝑡) 𝐻1 (𝑡)

h1=h1’sinα (m) × 100 × 100

Dr. D. Sreelakshmi Page 6

Experiment 2 Time Constant Determination of a Thermometer

The percentage response of the thermometer is

Dr. D. Sreelakshmi Page 7

immediately the stop watch is started.

Water filled – test tube Oil filled – test tube

Dr. D. Sreelakshmi Page 8

Result: Table 2: Percentage response of the thermometer

Sl. Water filled tube Oil filled tube

Dr. D. Sreelakshmi Page 9

Experiment No: 3 Non-interacting tanks

Apparatus: Experimental setup, stop watch, bucket and measuring flask.

The step response of this system is of the form,

Dr. D. Sreelakshmi Page 10

Observation for Part A:

Dr. D. Sreelakshmi Page 11

Table 2: Determination of time constant of tank2

Dr. D. Sreelakshmi Page 12

Table 3: Result - Determination of time constant of tank1

Sl. Outlet Volumetric Q = q1(t) - q1s Level, h1 (m) H1= h1(t)-h1s

Dr. D. Sreelakshmi Page 13

Table 4: Result - Determination of time constant of tank2

Sl. Outlet Volumetric Q = q2(t) - q2s Level, h2 (m) H2= h2(t)-h2s

Observations for Part B:

Sl. No. Time Inclined level, h2'

Dr. D. Sreelakshmi Page 14

Sl. No. Time Inclined level, h2'

a. Vertical level, ℎ2 = ℎ2′ sin 40, m

d. Percentage level change in tank2 theoretical,

Table 6: Result - Step Response

SL. Time Vertical H2= h2(t)- 𝐻2 (𝑡) 𝐻2 (𝑡)