CLL 361: Instrumentation & Automation Laboratory

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 CLL 361: Instrumentation & Automation Lab
Experiment PC 1: Temperature Control
OBJECTIVE: To study the tuning of the PID controller by the Open Loop method and the Closed
Loop method using (a) Cohen and Coon (C-C) and (b) Ziegler-Nichols (Z-N) tuning rules.
APPARATUS: Process tank having temperature controlling unit.
THEORY: The open-loop method of tuning in which the control action is removed from the
controller by placing it in manual mode and an open-loop transient is induced by a step-
change in the signal. Fig.1 shows a typical control loop in which the control action is removed
and the loop opened to introduce a step-change (M/S). The step response is recorded at the
output of the measuring element. The step change to the valve is conveniently provided by
the output from the controller, which is in manual mode. The response of the system is called
the process reaction curve.

Fig: 1. Block Diagram of a Control Loop for Measurement of Process Reaction Curve.

A typical process curve exhibits an S- shape as shown in Fig: 2. It is represented by equation

(1).

e− L s
G(s)=K (1)
1+ Ts

Zeigler and Nichols suggested setting the values of Kc, Ti, and Td according to the formula
shown in Table 1. Refer to Fig. 2 for the symbol meaning for tuning the controller via Z-N
settings.
Table 1. Z-N Settings for Tuning Different Controllers

Type of Controller Kc Ti Td
Proportional (P) T/L
Proportional - Integral (PI) 0.9T/L L/0.3
Proportional - Integral – Derivative (PID) 1.2T/L 2L 0.5L
 Fig: 2. Typical Process Reaction Curve (First Order with Transportation lag)

Similarly, Cohen and Coon suggested controller parameters as given in Table 2.

Table 2. C-C Settings for Tuning Different Controllers

Types of Control Parameter Settings

Proportional (P) Kc = (T/(Kp*L) ) * ( 1+L/3T)

Proportional - Integral (PI) Kc = (T/(Kp*L)) * (0.9 + L/12T)

Ti = L * (30 + 3L/T) / (9 +20L/T)

Proportional - Derivative (PD) Kc = (T/(Kp*L))* (1.25 + L/6T)

Td = L*(6-2L/T) / (22+3L/T)

Proportional - Integral – Derivative (PID) Kc = (T/(Kp*L)) * (1.33 + L/4T)

Ti = L*(32 + 6L/T) / ( 13 +8L/T)
Td = 4L / (11 + 2L/T)

The value of Kp can be found using Kp = Bu / M, where Bu is the ultimate value of B at large
time t. (Refer to Fig. 1).

PROCEDURE:

1. Process Tank filled with water is made available. Temperature Control Trainer is
active.
2. Log in the system and select the “INTERFACE” mode for experimentation.
3. Turn on the water supply and maintain the inlet flow rate of water to the process tank
through a rotameter maintained at 20-30 LPH. Please verify it.
4. Due to some external disturbances, the liquid flow rate may show some significant
change in its value. Please keep an eye on the rotameter reading to dampen such
changes by careful adjustment of the rotameter itself. Please note that a change in
mass flow rate is not desired in the undertaken experiment.
5. Run the process as directed below:
• Select the MANUAL MODE with an output of 0 %.
 • Wait till a steady state is reached for the process value.
• Log on to a file for saving transient data.
• Start saving data. Wait for approximately 2 mins.
• Give a STEP RESPONSE to the output. Change it from 0% to 100%.
• Wait till a steady state is reached. Please do not rush.
• Log Off from the data-saving procedure.
• Make the output 0%.
6. With the help of the saved data file, draw the Process Reaction Curve between process
value and time.
7. Find the control setting parameters from Cohen-Coon (C-C) & Ziegler-Nichols (Z-N)
rules.
8. Tabulate the control setting parameters for each type of controlling mode e.g. P-
mode, PI-mode, PID-mode; obtained from both the rules, C-C & Z-N.
9. Run the process with the suggested controlling parameters for each type of control
mode, obtained from both methods. Please follow the instructions directed below
carefully.
▪ Select the MANUAL MODE with an output of 0%.
▪ Set P / PI / PID parameters as obtained from Z-N rules. For the first time, set for P-
mode. You will have the opportunity of tuning PI & PID modes in the next RUN
sequences.
▪ Wait till a steady state is reached.
▪ Once a steady state is reached, make the set point equal to the process value. LOG
on to a file for saving the transient response of the system. It is advised to save the
data file with a name explaining: the group name, controller mode, etc.
▪ Start saving data, with the file name as suggested above, if possible.
▪ Give a STEP change of 10 units to the set point.
▪ Select AUTO MODE.
▪ Wait till a steady state is reached. Please do not rush.
▪ Log Off from the data saving procedure.
▪ Put on the manual mode.
10. Repeat the procedure for obtaining the process transient response for different
control mode e.g. PI and PID.
11. Repeat for controlling parameters as obtained previously from C-C rules.
12. Draw the excel plots for all the above set of transient responses. Plot process value
and the set point of the process on the same graph against time.
13. Report the best possible controlling mode for the step-change made. Justify your
decision on both, qualitative and quantitative scale.
 CLL 361: Instrumentation & Automation Lab
Experiment PC 2: Level Control

OBJECTIVE: Study the effect of the increasing value of Kc for the proportional mode
controller, both quantitatively and qualitatively for a level control system.

APPARATUS: Process tank having level control trainer, rotameter, pump, sump tank, etc.

THEORY: The open-loop method of tuning in which the control action is removed from the
controller by placing it in manual mode and an open-loop transient is induced by a step-
change in the signal. Fig.1 shows a typical control loop in which the control action is removed
and the loop opened to introduce a step-change (M/S). The step response is recorded at the
output of the measuring element. The step-change to the valve is conveniently provided by
the output from the controller, which is in manual mode. The response of the system is called
the process reaction curve.

Fig: 1. Block Diagram of a Control Loop for Measurement of Process Reaction Curve.

A typical process curve exhibits an S- shape as shown in Fig: 2. It is represented by equation

(1).

e− L s
G(s)=K (1)
1+ Ts

Fig: 2. Typical Process Reaction Curve (First Order with Transportation lag)
Start-up:
1. All the drains should be closed.
2. Switch on the main supply.
3. Check whether all the valves are properly working or not.
4. Switch on the computer and the interfacing unit.
5. Select the auto mode to experiment automatically and manual mode to change the
values manually.
6. Connect the equipment with a compressed air supply.
Shut-down:
1. Exit from the software.
2. Switch off the interfacing unit.
Procedure:
1. Process Tank filled with water is made available. Level Control Trainer is active.
2. Log in to the system and select the “INTERFACE” mode for experimentation.
3. Turn on the water supply and maintain the inlet flow rate of water to the process
tank through a rotameter maintained at 30-40 LPM. Please verify it.
4. Due to some external disturbances, the liquid flow rate may show some significant
change in its value. Please keep an eye on the rotameter reading to dampen such
changes by careful adjustment of the rotameter itself. Please note that a change in
mass flow rate is not desired in the undertaken experiment.
5. Run the process as directed below:
• Select the MANUAL MODE with an output of 30 %.
• Select the P mode of the controller with Kc=1.
• Wait till a steady state is reached.
• Once a steady state is reached, make the set point equal to the process value.
• Log on to a file for saving transient data.
• Start saving data.
• Give a STEP RESPONSE to the set point. Change it by 10 %.
• Select the Auto mode.
• Wait till a steady state is reached. Please do not rush.
• Log Off from the data-saving procedure.
• Put on the manual mode.
6. Repeat step 5 for different values of Kc (2,10).
7. Plot the data sets of process value vs time for performed values of k.
8. Plot the Bode diagram for performed data sets.
 CLL 361: Instrumentation & Automation Lab

Experiment PC 3: Control Valve Characteristics

OBJECTIVE: To study the characteristics of different control valves to understand flow
coefficient and hysteresis.
Apparatus: The set-up consists of three pneumatic control valves as shown in Fig 1. One
control valve is with equal % characteristics (air to close type), the second is with quick
opening characteristics (ON/OFF), and the third is linear characteristics (air to open type). A
sump tank with a pump is provided for continuous water circulation. The manometer is
provided at the inlet of valves to measure pressure. Valves are given for water supply to the
control valve. Valves are provided for air supply to control valves. The air regulator and
pressure gauge are given for regulating air pressure.

Fig. 1. Schematic Diagram of Experimental Setup

THEORY: If a 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 actuators, and pneumatic actuators are used for control valves. Spring opposed
the 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 as
described below.
(i) Direct-acting actuators (Air to close): Direct-acting actuators 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 the upper diaphragm case that exerts a force on the diaphragm and the
actuator assembly. By selecting the proper spring rate or stiffness, load carrying
capacity, and initial compression, desired stem displacement can be obtained for any
given input signal.
(ii) Reverse acting actuator (Air to open): In the case of reverse acting actuators, the stem
gets retracted with an increase in pressure.
Types of Control Valve: A valve is essentially a variable orifice. The control valve is a valve
with a pneumatic / hydraulic/electric (excluding solenoids) or another 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 purposes. Depending upon the vale plug
design the control valve can be divided into three categories: (i) Equal % type, (ii) Quick
opening type (On/Off type), (iii) Linear type.

(1) Control Valve Flow Coefficient: A control valve changes the flow rate by changing the
pressure in the flow system because it introduces constriction in the delivery system. There
is a close relationship between the pressure and the flow rate in a fluid stream passing
𝐾
through a pipe so that if pressure is changed, the flow rate will also change as Q= where
√∆𝑃
k is the correction factor that allows the selection of the proper size of the valve to
accommodate the rate of flow that the system must support. This correction factor is called
a valve coefficient and is used in valve sizing. The flow coefficient (Cv) of a control valve is
given by
G
𝐶𝑉 = 11.7 𝑄√∆𝑃
where
Q = discharge of fluid (m3/h),
ΔP= Pressure drop in manometer (KPa)= 0.0098×H (mm of H2O),
G = specific gravity of fluid relative to water (G=1)

Procedure for Control Valve 1:

• Close all the valves V1-V10.
• Fill the sump tank up to 3/4th with water.
• Connect the air supply to the setup.
• Switch ON the power supply and the pump. Wait for the tank to fill with water.
• Open valve V4. Open valve V1 and adjust the flow rate.
• Open valve V6 completely. Partially open valve V5 and wait for some time (2 min).
• Record manometer reading. Record rotameter reading.
• Repeat the experiment by adjusting valve V1 at different flow rates. Plot flow vs
pressure drop.
•
Procedure for Control Valve 2:
• Close all the valves V1-V10.
• Fill the sump tank up to 3/4th with water.
• Connect the air supply to the setup.
• Switch ON the power supply and the pump. Wait for the tank to fill with water.
• Open valves V2 and V4, and adjust the flow rate.
• Open valve V7 completely. Partially open valve V5 and wait for some time (2 min).
• Record manometer reading. Record rotameter reading.
 • Repeat the experiment by adjusting valve V2 at different flow rates. Plot flow vs
pressure drop.

Procedure for Control Valve 3:

• Close all the valves V1-V10.
• Fill the sump tank up to 3/4th with water.
• Connect the air supply to the setup.
• Switch ON the power supply and the pump. Wait for the tank to fill with water.
• Open valves V3 and V4, and adjust the flow rate.
• Open valve V8 completely. Partially open valve V5 and wait for some time (2 min).
• Record manometer reading. Record rotameter reading.
• Repeat the experiment by adjusting valve V3 at different flow rates. Determine the Cv
for all three control valves. Plot flow vs pressure drop.

(2) Study of 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 the case of control valves for the same
actuator signal, different stem travel (hence valve coefficients) are obtained
depending upon the direction of change in signal. The maximum error in stem
travel expressed in % for the same actuator pressure while opening and closing
the valve is indicated as hysteresis.
Procedure for Control Valve 1:
• Close all the valves V1-V8.
• Fill the sump tank up to 3/4th with water.
• Connect the air supply to the setup.
• Switch ON the power supply and the pump. Wait for the tank to fill with water.
• Open valve V1 and adjust the flow rate.
• Open valve V6 completely. Partially open valve V5 and wait for some time (2 min).
• Adjust the pressure regulator so that the valve stem reaches its minimum value.
• Note down the reading of the pressure gauge and position of the valve stem by scale.
• Now slowly change the air pressure until the highest position is achieved for the valve
stem and simultaneously note down the pressure and the valve stem readings.
• Again change the pressure until the lowest position is achieved for the valve stem and
simultaneously note down the pressure and the valve stem readings.

Procedure for Control Valve 2:

• Close all the valves V1-V8.
• Fill the sump tank up to 3/4th with water.
• Connect the air supply to the setup.
• Switch ON the power supply and the pump. Wait for the tank to fill with water.
• Open valve V2 and adjust the flow rate.
• Open valve V7 completely. Partially open valve V5 and wait for some time (2 min).
• Adjust the pressure regulator so that the valve stem reaches its minimum value.
 • Note down the reading of the pressure gauge and position of the valve stem by scale.
• Now slowly change the air pressure until the highest position is achieved for the valve
stem and simultaneously note down the pressure and the valve stem readings.
• Again change the pressure until the lowest position is achieved for the valve stem and
simultaneously note down the pressure and the valve stem readings.

Procedure for Control Valve 3:

• Close all the valves V1-V10.
• Fill the sump tank up to 3/4th with water.
• Connect the air supply to the setup.
• Switch ON the power supply and the pump. Wait for the tank to fill with water.
• Open valve V3 and adjust the flow rate.
• Open valve V8 completely. Partially open valve V5 and wait for some time (2 min).
• Adjust the pressure regulator so that the valve stem reaches its minimum value.
• Note down the reading of the pressure gauge and position of the valve stem by scale.
• Now slowly change the air pressure until the highest position is achieved for the valve
stem and simultaneously note down the pressure and the valve stem readings.
• Again change the pressure until the lowest position is achieved for the valve stem and
simultaneously note down the pressure and the valve stem readings.

Plot x vs pressure on a simple graph for both increasing pressure and decreasing pressure
cases for all three valves.
Where,
x is the fraction of maximum valve lift, x = ΔL / Lmax;
ΔL is valve lift (in mm), ΔL = L – Li; Li = initial position of valve stem(mm), L = position of valve
stem (mm);
Lmax = max value of valve lift.
 CLL 361: Instrumentation & Automation Lab
Experiment PC 4: Time Constant of Thermocouple & Thermometer

OBJECTIVE: To study the characteristics of thermometer and thermocouple and to calculate

the time constant of thermometer and thermocouple from the step response curve.
APPARATUS: The setup consists of a heater, which is controlled by a digital temperature
controller. A pocket is provided to insert the thermometer or thermocouple in it. Thermowell,
Thermocouple, and Thermometer are provided.
THEORY: Mercury thermometer is a widely used temperature-measuring element for manual
purposes whereas a thermocouple is used for control purposes. A thermocouple is composed
of two dissimilar wires welded together at one end. When the temperature at the welded
junction changes, an electrical potential is generated and it appears at the free ends of the
wires. This potential is the result of two distinct functions – the Thomson effect and the Peltier
effect.
A thermometer without a thermowell is a first-order dynamic system whose transfer function
is:
𝑌(𝑆) 1
=
𝑋(𝑆) (1 + 𝑇𝑆)
and for a step change of magnitude A, the response is:
−𝑡
Y (t) = A(1-𝑒 𝜏 )

where τ is the time constant, which can be estimated from step response data as the time
required to reach 63.2% of the ultimate response. In case when a thermo-well is used, the
nature of the dynamics changes to a second-order transfer function
𝑌(𝑆) 1
=
𝑋(𝑆) (1 + 𝑇1 𝑆)(1 + 𝑇2 𝑆)
where τ1 and τ2 are effective time constants which can be obtained from Fig 1.

Fig 1. Fractional Incomplete Response

where I = % fractional incomplete response, Ia = fractional incomplete response for calculation
of τ1, P = maximum value of fractional incomplete response, R = maximum value of fractional
incomplete response difference, ΔI = fractional incomplete response difference, ΔIa =
fractional incomplete response difference for calculation of τ2.

PROCEDURE:
Startup:
1. Clean the apparatus and check all accessories thoroughly.
2. Ensure that all switches given on the panel are in the OFF position.
3. Switch ON the main power supply.
4. Set the desired temperature (start from slightly above ambient to 100oC) on the DTC.
5. Switch On the heater.
6. Wait till the steady state is achieved.
7. Insert the Thermometer into the pocket.
8. Record its temperature variations with time.
9. Repeat the same procedure for a thermocouple.
10. Repeat the same procedure using a thermowell having a little amount of mercury in
it.
Closing:
 When the experiment is over, switch OFF the heater and power supply.
 Clean the apparatus properly.

OBSERVATION & CALCULATIONS:

For thermometer/ thermocouple without thermowell:

Note the initial temperature (Ti). Note temperature (T) vs time(t). Calculate the temperature
difference, Y = (T– Ti), and note the final steady-state value (Yf).
From the plot of Y vs time, determine the time constant (τ) corresponding to 63.2 % of Y.

For thermometer/ thermocouple with thermowell:

Note the initial temperature (Ti). Note temperature (T) vs time (t). Calculate temperature
difference, Y = (T – Ti) and note the final steady-state value (Yf).
From the plot of Y vs time, and find out the time constant with thermowell (τ’) find out
transportation lag (τd), the value that departs from the time axis.
τd= Difference between τ and τ’.
Calculate shifted time (t1), t1 = t - τd. Calculate % fractional incomplete response, I = (Yf-Y)/ (Yf-
Yi).
Now plot a graph of I vs t1 and draw a tangent from the maximum value of t1 to vertical axis
at (t1=0) and find P as shown in Fig 1.
Calculate Ia = 0.368 P and read corresponding time constant τ1.
Calculate ΔI = Ia – I. Plot a graph of ΔI vs t1 and find R as shown in Fig 1. Calculate Ia = 0.398 R
and read the corresponding time constant τ2.

Precautions:
• Never exceed the set point of DTC more than 150oC
• Ensure that there is a little amount of mercury lying in thermowell and bath
before inserting the thermometer.
• Always take precaution while handling mercury
 CLL 361: Instrumentation & Automation Lab
Experiment PC 5: Time Constant of Manometer
OBJECTIVE: To study the characteristics of the U-tube manometer by estimating the
theoretical time constant and damping coefficient and to plot the graphs for overshoot, decay
ratio, and frequency of oscillation vs damping coefficient.
APPARATUS: The setup consists of a U-tube manometer with a scale. An air pressure
regulator with a pressure gauge is provided to change the pressure in the manometer. Valves
are provided for the supply and release of air as shown in Fig 1.
Air from the pressure regulator

V2
Manometer
Pressure
Regulator

V1

Fig 1. Block Diagram of Experimental Setup

THEORY: Systems with inherent second-order dynamics can exhibit oscillatory (under-
damped) behavior but are rather rare in chemical processes. Here, we will study the dynamics
of a manometer which can be modeled as a second-order system. When the pressures at the
top of the two legs are equal, the two liquid levels are on the same horizontal plane. Let us
assume that suddenly a pressure difference ∆p = p1-p2 is imposed on the two legs of the
manometer. By using force balance and using Poiseuille’s equation for laminar flow in a pipe,
it can be shown that the transfer function relating the deviation of liquid level (h) to applied
pressure difference (∆p) is
𝐻(𝑆) 𝐾𝑃
=
𝑃(𝑆) τ2 + 2 ζτ + 1 ∆

Calculate theoretical values of ζ and τ from the following equations:

𝐿
τ2= (L= length of fluid in the column) (1)
2𝑔

2ζτ = 4 µL/ρg R2 ; Kp= 1/(2 ρg) (R = radius of manometer tube, ρ = density

of
manometer fluid, µ =viscosity of manometer fluid) ;
Calculate L using eq (2)
L = 2hs+x+4R (2)
where hs = steady-state height of manometric fluid, x = horizontal distance between two legs
of the manometer. The dynamic response of a second-order system depends on the value of
ζ. For ζ > 1, the response is overdamped, while for ζ<1 the response is underdamped. For ζ=
1, the response is called critically damped. For the case of the manometer, the response often
falls under the category of underdamped response as shown in Fig 2. The overshoot is defined as
A/B and the decay ratio as C/A in Fig 2.

Fig 2. Characteristics of Underdamped Response of Second Order System

PROCEDURE:
1. Close all the valves V1-V2.
2. Set the pressure with the pressure regulator.
3. Open the valve V1 and supply the air.
4. Now a step change in pressure is introduced by releasing the air by opening valve
V2.
5. Record the height of manometric fluid at a higher level and lower level.
6. Also, record the time taken from the higher level to the lower level.
7. The final steady-state level of the manometric liquid is also noted.
8. Repeat the experiment for two more different step changes.
9. Plot the responses with time for all three changes.
Closing procedure:
After completing the experiment stop the supply of air
Release all air by opening valve V2.

RESULTS:

Calculate decay ratio, the ratio of the amounts above the ultimate value of two successive
peaks and the period of oscillation from the experimentally measured response. Using the
following equations (3 & 4) solve for ζ and τ (experimental values).
 Decay Ratio = exp{(-2πζ)/ √1 − ζ2 = (overshoot)2 (3)

Time period of oscillation is given by T = 2πτ/√1−ζ2 (4)

Compare the experimentally obtained values of ζ and τ with the theoretical predictions from

the equation (1) & (2) and comment.

Precautions:
• Don’t give pressure to the manometer above 0.4 kg/cm2 in case of mercury and not
more than 0.1 kg/cm2 in case of water and CCl4
• Accidentally if the manometer fluid comes in the catch pot fill it again into that and
note down the time and height one by one.
 CLL 361: Instrumentation & Automation lab

Experiment PC 6: Transient Response of a Lagged Thermometer

OBJECTIVE: To determine the transient response of a distributed parameter system and to

show that it can be approximated by a first-order system followed by a time delay and first-
order systems in series using a lagged thermometer.

EXPERIMENTAL SETUP: A mercury thermometer is embedded in a rubber cork and m-seal.

The transient response to changes in the surrounding temperature is determined by the
temperature at the centerline of this block. A hot temperature bath is provided for this
purpose. You may try different types of materials around the thermometer.

THEORY: If several identical interacting systems are arranged in series, the response is
practically the same as that of a distributed system, which is one where resistance and
capacity are associated with each incremental length of the system. That is to say, that the
transfer function of a distributed parameter system can be approximated by
𝑌(𝑆) 1
= (1+𝑇𝑆) as n → ∞ (1)
𝑋(𝑆)

Where T is the time constant of a first-order system. Another useful approximation of the
transfer function of a distributed parameter system is a first-order system followed by a time
lag, i.e.;
𝑌(𝑆) 𝑒 −𝑇𝑑.𝑆
= (1+𝑇𝑆) (2)
𝑋(𝑆)

PROCEDURE: Measure the initial reading of the thermometer and then place the lagged
thermometer inside the hot bath which is maintained at a constant temperature. Measure
the temperature with time until the steady-state has been reached. This completes one set
of the experiment. Remove the lagged thermometer from the hot bath and allow it to cool in
the atmosphere. Once again, note the temperature versus time until the new steady-state
has been reached. Repeat the experiment with another lagged thermometer.

RESULTS TO BE REPORTED:
T−Ti
1. Plot Q =T vs. t for both heating and cooling experiments for both materials. Here
f−Ti

Ti and Tf are the initial and ultimate temperatures respectively

2. To approximate the response of two and three first-order systems in series, determine
the time to reach 74% and 80% response respectively. Let these be t0.74 and t0.8. Then

the time constant of two first-order systems in series will be approximate, τ2=t0.74/4
and the time constant for three first-order systems in series will be, τ3=t0.8/9
Using these time constants, determine the theoretical response from equation (1) and
match with the actual responses and comment.

3. To approximate the response by a first-order system followed by a time delay, find

the inflection point of the transient response plot and draw a tangent at the inflection
point. The intercept of the x-axis provides the value of Td, while the inverse of the
slope gives the value of the time constant. Using the values of and Td plot the
theoretical response from equation (2) and match with the actual response and
comment.
 CLL 361: Instrumentation & Automation Lab

Experiment PC 7: Interacting & Non-interacting Two-tank System

OBJECTIVE: To study the dynamic open-loop response of liquid level in a single tank, two tanks
interacting, and two tank non-interacting systems.
Apparatus: It is a self-contained recirculating unit consisting of a sump tank, three tanks, and
an overhead tank. The sump and overhead tanks are connected by the pump. Level indicators
with scale are provided for each Tank1, Tank2, and Tank3. Rotameter is provided to measure
the flow rate of water. Valves are provided for connection and drainage purposes.
THEORY: The single tank liquid level system is a physical example of the first-order system.
Consider a system comprising of a tank of a uniform cross-sectional area with a flow
resistance such as a valve attached to it. The volumetric flow rate through the resistance is
related to the head by a linear relationship. The principle distinction to be made in multi-
capacity processes is in how the capacities are joined. If they are isolated they are said to be
non-interacting as the capacities behave exactly as they would do alone. But if coupled, they
interact with one another in which case the contribution of each is altered due to interaction.
In the non-interacting system, the two tank levels do not interact because the flow from the
first tank to the second tank is independent of the level in the second tank. In an interacting
system, the levels in both tanks interact because any change in the downstream level will
affect the upstream level as well. Overall, both interacting and non-interacting two-tank
systems are examples of second-order systems.

Fig. 1. Schematic Diagram of Experimental Setup

Data: Inner diameter of each tank (D1) = 0.108 m. The outer diameter of the downcomer in
each tank (D2) = 0.022m. Cross-section area of each tank, A = π[(D1) 2-(D2)2]/4.
Nomenclature: V1 = flow control valve (Rotameter); V2 = Valve for water supply to Tank2; V3
= Valve for water supply to Tank3; V4 = drain valve for Tank2; V5 = drain valve for Tank3; V6
= drain valve for the overhead tank; V7 = drain valve for sump tank.

Procedure for Two-Tank Interacting System (Tank2-Tank3):

1. Close all the valves V1-V7. Fill the sump tank with water. Switch ON the power supply
and the pump. Wait till there is overflow from the overhead tank. Now open valve V1
and adjust the flow rate (50 LPH).
2. Open valve V2 completely and partially open valves V3 & V5 and wait till a constant
height is achieved by the liquid in Tank2 and Tank3. Note down the inlet flow rate (qi)
and height of Tank2 (h2i) and Tank3 (h3i) (this is the initial height).
3. Now increase the inlet flow rate (step change: 5-10 LPH) through valve V1.
Simultaneously start the stopwatch and record the heights of liquid level in Tank2 and
Tank3 with time, till a steady state is reached (constant height). Note down the final
constant heights (h2f and h3f) and flow rate (qf).
4. Plot the curves h2 vs time and h3 vs time.
5. Using deviation variables H2=h2f-h2i, H3=h3f-h3i, Q=qf-qi. Determine resistances
R2 = (H2-H3)/Q, R3 = H3/Q and find time constants τ2=A2R2 and τ3=A3R3. After
completing the experiment switch OFF the pump and power supply. Open the drain
valves V4-V5.

Procedure for Single-Tank System Tank1:

1. Close all the valves V1-V7. Fill the sump tank with water. Switch ON the power supply
and the pump. Wait till there is overflow from the overhead tank. Now open valve V1
and adjust the flow rate (40 LPH).
2. Partially open valve V2 and wait till a constant height is achieved by the liquid in Tank
1. Note down the inlet flow rate and height of liquid (hi) in the tank (this is the initial
height).
3. Now increase the inlet flow rate (step change: 5-10 LPH) through valve V1.
Simultaneously start the stopwatch and record the height of the liquid level in the tank
 with time, till a steady state is reached (constant height). Note down the final constant
height and flow rate.
4. Plot the curve h1 vs time.
5. After completing the experiment switch OFF the pump and power supply. Open the
drain valve V2.

Procedure for Two-Tank Non-Interacting System (Tank1-Tank2):

1. Close all the valves V1-V7. Fill the sump tank with water. Switch ON the power supply
and the pump. Wait till there is overflow from the overhead tank. Now open valve V1
and adjust the flow rate (40 LPH).
2. Partially open the valve V2 & V4 and wait till a constant height is achieved by the liquid
in Tank 1 and Tank 2. Note down the inlet flow rate (qi) and height of Tank1 (h1i) and
Tank2 (h2i) (this is the initial height).
3. Now increase the inlet flow rate (step change: 5-10 LPH) through valve V1.
Simultaneously start the stopwatch and record the heights of liquid level in Tank1 and
Tank2 with time, till a steady state is reached (constant height). Note down the final
constant heights (h1f and h2f) and flow rate (qf).
4. Plot the curves h1 vs time and h2 vs time.
5. Using deviation variables H1=h1f-h1i, H2=h2f-h2i, Q=qf-qi, determine resistances R1 =
H1/Q, R2 = H2/Q and find time constants τ1=A1R1 and τ2=A2R2.
6. After completing the experiment switch OFF the pump and power supply. Open the
valves V2 & V4.
 CLL 361: Instrumentation & Automation Lab
Experiment PC 8: Dynamics of Stirred Tank Heater
OBJECTIVE: To study the response of a stirred tank heater using a step-change in heater
input.
EXPERIMENTAL SET-UP: The stirred tank has a diameter of 22.6 cm and a height of 28 cm.
Water is filled up to a certain level and is continuously agitated by a stirrer with a diameter of
5 cm rotating at 800 RPM. The bottom of the tank contains heating coils whose input is
controlled using a variac. Cooling water flows through a long helical coil. There are 15 turns
in all, the diameter of the helix being 4.2 cm and the coil thickness is 6mm. Cooling water is
obtained from an overhead tank and there is a valve to regulate the flow. The temperature
of the tank is measured using a thermometer.
THEORY: Draw a block diagram of the stirred tank heater. Cooling water enters with a mass
flow rate Mc (measured using a measuring cylinder). The outlet temperature of the cooling
water changes when a step change is introduced into the system by altering the heater input
Q. Derive the transfer function (refer to any book on process control like “Coughanowr”)
between the tank temperature T and the heater input Q.
The following assumptions can be made:
1. The temperature of water in the cooling coil is the average of inlet and outlet
temperatures.
2. Perfect mixing exists in the tank i.e. the same temperature throughout.
The value of the heat transfer coefficient between tank and coil, U, is a function of several
parameters like stirrer rpm and diameter, Prandtl number, etc. The exact correlation can be
obtained from Perry’s handbook.
PROCEDURE: The study is to be conducted by changing the heater input in a step fashion and
noting the change in tank temperature.

1. Set up the apparatus and start the flow of cooling water.

2. Set variac reading (say 80 V) and wait for steady-state to be attained.
3. Give a step change to the variac reading (hence heater input) and start noting
temperature vs time.
4. Plot the temperature vs time curve, both the experimental and theoretical curves
(with the one obtained from the transfer function). Identify possible sources of error.
 CLL 361: Instrumentation & Automation Lab
Experiment PC 9: Pressure Control
OBJECTIVE: Optimizing the tuning parameters of the PID controller for Pressure Control
Trainer via simulation interface using Ziegler-Nichols (Z-N) tuning rules and to study the
closed-loop response for servo and regulatory problems.

APPARATUS: Process tank having pressure control trainer, interfacing unit with a computer,
air supply through a compressor.
The basic objective is to control the pressure in the process tank shown in Fig. 1. The
interfacing unit is a medium for communicating with the equipment from the computer. The
assembly has various supporting components on the front panel i.e. pressure gauges which
are used to measure the pressure, current to pressure converter in the range 3 to 15 psi for
current in the range of 4 to 20 mA which is given to the I/P converter by the digital indicating
controller. The setup also contains a pneumatic actuator. The pressure in the process tank is
sensed by the pressure transmitter with the help of a pressure sensor fitted in the line. The
data is transmitted by the pressure transmitter to the computer through the interfacing unit
which shows the value of the process variable. The control valve performs the function of
controlling the input of air pressure in the process tank. It has a diaphragm type pneumatic
actuator which varies the flow of air according to the movement of the stem at a pressure
range of 3 – 15 psi received from the I/P converter.

Fig. 1. Schematic Diagram of Experimental Setup

THEORY: In the open-loop method of tuning the control action is removed from the controller
by placing it in manual mode and an open-loop transient is induced by a step-change in the
signal. Fig.2 shows a typical control loop in which the control action is removed and the loop
opened to introduce a step-change (M/S). The step response is recorded at the output of the
measuring element. The step-change to the valve is conveniently provided by the output from
the controller, which is in manual mode. The response of the system is called the process
reaction curve.

Fig: 2. Block Diagram of a Control Loop for Measurement of Process Reaction Curve.

A typical process curve exhibits an S- shape as shown in Fig: 3. It is represented by equation

(1).

G(s)=K
e− L s (1)
1+ Ts

Zeigler and Nichols suggested setting the values of Kc, Ti, Td according to the formula shown
in Table 1. Refer to Fig. 3 for the meaning of symbols for tuning the controller via Z-N settings.

Table 1. Z-N Settings for Tuning Different Controllers

Type of Controller Kc Ti Td
Proportional (P) T/L
Proportional - Integral (PI) 0.9T/L L/0.3
Proportional - Integral - Derivative (PID) 1.2T/L 2L 0.5L
 Fig: 3. Typical Process Reaction Curve (First Order with Transportation lag)

The value of K can be found using K = Bu / M, where Bu is the ultimate value of B at large time
t. (Refer to Fig. 2).
Start-up:
1. All the drains should be closed.
2. Switch on the main supply.
3. Check whether all the valves are properly working or not.
4. Switch on the computer and the interfacing unit.
5. Select the auto mode to experiment automatically and the manual mode to change
the values manually.
6. Connect the equipment with a compressed air supply.
7. Set the pressure values on the Pressure tank at 50-60 lb/in2 and the Surge tank at 20-
25 lb/in2 using the manual pressure regulators.
Shut-down:
1. Exit from the software.
2. Switch off the interfacing unit.

PROCEDURE: -
Manual Mode:
1. Select the MANUAL MODE with an output of 0 %.
2. Wait till a steady state is reached for the process value.
3. Log on to a file for saving transient data.
4. Start saving data. Wait for approximately 2 mins.
5. Give a step response of 25% to controller output.
6. Wait till a steady state is reached.
7. Log off from the data-saving procedure. Plot the process reaction curve between
process value and time.
8. Make the output 0%.
9. Calculate T and L (refer to Fig.3)
10. Calculate PID settings from Table 1.
 Run the process with the suggested controlling parameters for Servo and Regulatory
controls. Please follow the instructions directed below carefully.

Servo Mode
▪ Select the MANUAL MODE with an output of 0%.
▪ Set PID parameters as obtained from Z-N rules.
▪ Wait till a steady state is reached for the process value. As a steady state is
achieved, make the set point equal to the process value.
▪ LOG on to a file for saving the transient response of the system. It is advised to
save the data file with a name explaining: the group name, controller mode, etc.
▪ Give a STEP change of 10-20 unit to the set point.
▪ Select AUTO MODE.
▪ Wait till a steady state is reached.
▪ Log Off from the data saving procedure.
▪ Put on the manual mode.
▪ Plot the closed-loop response.

Regulatory Mode
▪ Select the MANUAL MODE with an output of 0 %.
▪ Set PID parameters as obtained from Z-N rules.
▪ Wait till a steady state is reached for the process value. As a steady state is
achieved, make the set point equal to the process value.
▪ LOG on to a file for saving transient response of the system. It is advised to save
the data file with a name explaining: the group name, controller mode, etc.
▪ Give a STEP change in process value by opening/closing the outlet valve of the
pressure tank.
▪ Select AUTO MODE.
▪ Wait till a steady state is reached.
▪ Log Off from the data saving procedure.
▪ Put on the manual mode.
▪ Plot the closed-loop response.