R POLYT A K EC D HN BE M A

CURRICULUM FOR DIPLOMA COURSE IN INSTRUMENTATION & CONTROL THIRD YEAR (TERM V & TERM VI)

IC

UNDER MULTIPOINT ENTRY AND CREDIT SYSTEM (MPECS) (1996 - Scheme) FOR DELHI STATE

GOVT. OF DELHI

AMBEDKAR POLYTECHNIC
PATPAR GANJ ROAD, SHAKARPUR, DELHI - 110 092

INSTRUMENTATION & CONTROL ENGINEERING DETAILED CONTENTS OF VARIOUS SUBJECTS THIRD YEAR

Sr. No. SEMESTER-V

Subjects

Page No (S)

5.1 5.2 5.3 5.4 5.5

Industrial Automation Industrial Electronic Principle of Automatic Control Process control & Instrumentation Optical & Analytical Instrument

01 02 04 05 06

SEMESTER-VI 6.1 6.2 6.3 6.4 Advanced Control Systems Microprocessor & System Design Instrumentation Workshop Major Project (Industry Based) 08 09 10 10

FROM ACADEMIC SESSION 2005-06 INSTRUMENTATION AND CONTROL ENGG. UNDER MULTIPOINT ENTRY AND CREDIT SYSTEM (PATH WAYS)

FIRST TERM (10th BASE) SUBJECT CREDITS THEORY PRACT

C.T. A.M.-1 A.P. B.E. E.D.C.-1 W/Shop Pr -1 I.T.C. TOTAL 3 4 3 3 3 0 0 0 0 1 1 2 3 4 27

LOAD
3 5 5 5 7 6 7 38

FIRST TERM (12th BASE) SUBJECT CREDITS THEORY PRACT

D.E. I.I. B.E. E.D.C.-1 W/Shop Pr-1 I.T.C. TOTAL 3 3 3 3 0 0 26 2 2 1 2 3 4

LOAD
7 7 5 7 6 7 39

SECOND TERM (10th BASE) SUBJECT CREDITS THEORY PRACT

A.M.-2 E.E. ECM Engg. Draw. W/Shop Pr-2 E.D.C.-2 TOTAL 4 3 4 3 0 3 24 0 1 0 0 4 2

LOAD
5 5 4 6 8 7 35

SECOND TERM (12th BASE) SUBJECT CREDITS THEORY PRACT

A.M.-2 E.E. ECM Engg. Dwaw. E.D.C.-2 (MS) TOTAL 4 3 4 3 3 3 25 0 1 0 0 2 2

LOAD
5 5 4 6 7 7 34

THIRD TERM (10th BASE) SUBJECT CREDITS THEORY PRACT

D.E. I.I. N.A. E.F.T.. E.I.M. E.D.C.-3 TOTAL 3 3 3 0 3 3 27 2 2 1 4 1 2

LOAD
7 7 7 7 5 7 40

THIRD TERM (12th BASE) SUBJECT CREDITS THEORY PRACT

PAC NA EFT E.I.M. E.D.C.-3 W/Shop pr-2 TOTAL 3 3 3 3 3 0 25 1 1 1 1 2 4

LOAD
5 7 7 5 7 8 39

FOURTH TERM (10th BASE) SUBJECT CREDITS THEORY PRACT

AME I.T.M. (M.S.) IMED Min. Proj. TOTAL 3 3 3 4 0 20 1 1 2 0 3

LOAD
5 5 7 4 6 27

FOURTH TERM (12th BASE) SUBJECT CREDITS THEORY PRACT

ELECTIVE-1 I.T.M. ACS IMED MIN. PROJ. I.W/SHOP AME TOTAL 3 3 3 4 0 0 3 27 1 1 2 0 3 3 1

LOAD
5 5 6 4 6 6 5 37

FIFTH TERM (10th BASE) SUBJECT CREDITS THEORY PRACT

I.A. I.Ec. PAC PCI Elective-2 TOTAL 3 3 3 3 3 20 1 1 1 1 1

LOAD
5 5 5 5 5 25

FIFTH TERM (12th BASE) SUBJECT CREDITS THEORY PRACT

I.A. I.Ec. PCI Elective-2 Maj Proj. TOTAL Elective - 1 Elective - 2 3 3 3 3 3 21 1 1 1 1 2 MSD OAI

LOAD
5 5 5 5 9 29

SIXTH TERM (10th BASE) SUBJECT CREDITS THEORY PRACT

ACS Elective-1 I.W/Shop Maj. Proj. TOTAL 3 3 0 0 17 2 1 3 5

LOAD
6 5 6 9 25

IC 532 INDUSTRIAL AUTOMATION L T P 3 - 2 (8 Hrs.) 1. Introduction to Automation :Need for automation, various automation strategies, concept of flexible manufacturing systems (FMS), Components of FMS and its various layouts. Brief idea of Numerical Control (NC & CNC). Introduction of CAD and interfacing technique (Synchronous, Asynchronous, RS 232, RS 485 and line driver). 2. Programmable Logic Controllers (PLC) :(8 Hrs.) Development of ladder diagram and flow chart for simple processes, examples of simple programming in PLC's using ladder logic, interfacing PLCs to PC, operation of PLCs, Comparison of PLCs and PCs (Personal Computer).

3. Introduction to Robotics Technology:(8 Hrs.) Robot anatomy, classification of robots, various control loops, sensors used in robotics, Introduction to intelligent robots and vision system, robot programming methods. simple exercise of OFF line programming in any high level language.

4 Introduction to Electrical Drives :(10 Hrs.) Concept of electrical drives, general classification of electrical drives, brief review of characteristic of dc shunt, series, and 3-phase induction motors. Starting of electrical motors; effect of starting on power supply, motor itself and load, methods of starting electrical moors, methods to reduce energy loss during starting. Breaking of Electrical Motors; types of braking, brakinq of d.c. shunt, series motors, regenerative braking of 3-phase induction motors. Speed Control; closed loop speed control of d.c. motor drives.

5. Industrial Applications of electrical Drives in steel mills and cement kiln. (5 Hrs.) )One typical application of electrical drives in each of the following industries is to be studied. (i) Steel Mills, (iI) Paper Mills, (iii) Cement, (iv) Petro-Chemical, (v) Machine tool. REFERENCE BOOKS: 1. Automation Production System and Computer - Integrated Manufacturing by M.P Groover (PHI) 2. Robotics Technology and Flexible Automation By : S.R. Deb (PHI) 3. Process Control Instrumentation in Technology By: Curtis Johnson (PHI) 4. A First Course on Electrical Drives SK Pillai 5. Electrical Drives by U.K. Dubey (PHI) 6. Electric Drives by M. Chilkin (Mir Publisher)

LIST OF EXPERIMENT 1. Speed Control of DC Motor a Armature Voltage control b Field Weakening 2. Speed Control of 3-phase induction motor a. Frequency Control b. Rotor resistance Control 3. Speed Control of D.C. motor using Chopper Circuit. 4. Speed Control of D.C. motor using Single phase controlled interface. 5. Braking of D.C. motors. 6. D.C. dynamic braking of 3-phase induction motor. 7. Plug braking of 3-phase IM (Induction motor) 8. Exercise on CAD (Auto CAD) 9. Experiment on PLC. 10 Study of Robots. EX 538 INDUSTRIAL ELECTRONICS L T P 3 - 2 Rationale Electronics adapted to industrial plant, in terms of timing action switching action or parameter control, is called Industrial Electronics. Other common areas of application where electronics is increasing its interface with other branches of engineering, include temperature control, welding control, speed regulation of motor and soldering. The student should study this subject with a view to understand the use of electronics to bring about faster and more accurate response in industrial plants. Detailed Contents 1. Name symbol, characteristic and working principles of SCR Triac, Diac, SCS, SBS and LASCAR. Mention of their applications. 2. Thyristor rating and gate ratings. Turn on methods - DC gate, AC Gate and Pulse Gate Triggering and R-C trigger circuits. Turn off methods - Natural and Forced turn off methods. 3. Internal power dissipation and need for heat Sinks in thyristors. Definition of following terms and their relationship with the power dissipation of the device (no derivation) a) Heat Sink efficiency b) Heat sink transfer co -efficient c) Heat dissipating area of a Heat Sink. Connect of Thermal resistance of Heat sinks. Various types of Heat sinks and techniques of mounting devices on heat sinks. 4. Basic structure, principle of operating and V-I characteristic of UJT. Explanation of working of UJT as relaxation oscillator and it's use in thyristor triggering.

5. Principle of operation and working of the following switching circuits, using SCRs and Triacs a) Automation Battery Charger b) Voltage regulator c) Emergency light d) Alarm circuit e) Time delay relay circuit f) Circuit for over voltage and over current 6. a) Explanation of the working of a 3 phase half wave and full wave bridge rectifier with the help of wave forms and appropriate mathematical derivations b) Explanation of working of following controlled rectifier using SCRS and resistive and inductive loads with the help of wave forms and appropriate mathematical expression (no derivation) - Single phase; half wave full wave and bridge rectifier - Three phase; Half wave, full wave and bridge refctifier 7. Principle of working of AC phase control circuit using triac 8. Application of phase controlled rectifications and AC phase control circuits in: a) Illuminating Control b) Fan speed control c) Temperature Control d) Speed control of DC and small AC motors 9. Principles of operation of basic inverter circuits. Basic series and parallel commutated inverters 10. Principles of induction and dielectric heating and their typical applications 11. Introduction Basic Measurement System function of its elements namely the transducer, signal conditioner, display or readout and power supply. 12. - Digital system architecture - Factory communication - LAN/WAN/INTERNET - Network to Network Interconnection. 13. Signal Conditions Characteristic of instrumentation amplifiers in respect of input impedance, output impedance, drift, DC offset. noise gain, common mode rejection ratio, frequency response etc. Relating the suitability of these characteristic amplifying signals from various transducers. Difference between instrumentation Amplifier and OP-AMPS. Need and working of a typical isolation amplifier. 14. Operational Amplifier 15. Linear Integrated Circuit 3

LIST OF PRACTICAL 1. Identification of various types of packages and terminals of various low and high power thyristors (SCR and Triac) 2. To determine and plot firing characteristic of SCR a) By varying the anode to cathode voltage b) bay varing the gate current. 3. Observing waveshape and measuring voltage at various points of a UJT relaxation osacillator circuit 4. Observation of waveshapes and measurement of voltage relevant points of an SCR based single phase half wave control rectifier circuit using resistive (in phase gate trigger circuit) 5. Observation of waveshapes and measurement of voltages relevant points of an SCR based single phase half wave controlled recifier using R-C phase shift ..... triggering circuit. 6. Observation of waveshapes and measurement of voltages relevant points of an SCR based single phase half wave controlled rectifiers circuit using UJT relaxation oscillation for gate triggering. 7. To plot the firing characteristic of a triac in different modes namely mode 1+ Mode 1+, Mode 111+ and Mode 1118. Observation of wave shapes and measurement of voltage at relevant points of an SCR based single phase full-wave controlled rectifier circuit. 9. Observation of waveshapes and measurement of voltage at relevant points of an SCR based single phase controlled bridge rectifier circuit 10. Observation of waveshapes and measurement of voltage at relevant points in a triac based AC phase control circuit used for lamp intensity and/or AC fan speed control 11. Observe the waveforms and measure voltages at various points of a circuit for over voltage protection using SCR. 12. Observe the waveshapes and measure voltage at various point levels. IC 534 PRINCIPLE OF AUTOMATIC CONTROL L 3 T P 2

Rationale The students are required to know about the process system which is an important factor of a plant. It is a prerequisite for understanding the total plant controls, In this subject introduction to theory in control system has been given which will enable the student to understand the process control concepts to be covered in the subsequent semesters. Faculty is advice to teach the subject by citing the practical examples. Detailed contents 1. Introduction to automatic control : Basic elements of control system. Definition of terminology used in control system. Definition terminology used in control system. Open loop and closed. loop system concept of feedback. Functional block diagram of a control system. Time lag, dead time, Hysterisis, linearity. Self regulating and non self regulating system. Practical examples of the above 2. Block diagram and transfer Function Review of Laplace transform. Transfer function of simple control components like mass-spring damper, thermometer, single and multi-capacity processes Single feedback configuration. 4

3. Time Response of System : Order of systems Test inputs, step response of Ist and IInd Order system - overshoot and under shoot, rise time damping ratio. Simple example of 1 order and II order system. Steady state response and error. 4. Introduction to stability Analysis characteristic equation, "Rouths" table, Nyquist criteria, relative stability, phase margin and gain margin. 5. Routh - Hurwitz criterque Root locus technique Bode Plot Polar Plot. Gain margin and Phase margin List of Practical 1. To find time lag, overshoot and other parameters of both the above circuits. 2. To design and fabricate a first order system for temperature or flow or pressure of level from simulated input. 3. To find transfer function of RC circuit by Bode plot 4. To study LVDT 5. To study torque speed characteristic of AC servo motor with help of magnetic/mechanical loading. 6.To study synchro 7. To study stepper motor. 8. To study the frequency domain techniques using MATLAB of Bode Plot, Polar Plot, Root Locus, Time lag, Routh Hurwitz. IC 633 PROCESS CONTROL & INSTRUMENTATION L 3 T P 2 1. Basic Control loops and characteristic of (a) Single capacity flow loop system. (b) Single capacity temp loop system. (c) Single capacity level loop system. (d) Single capacity pressure loop system. Dead - Time process lag-First order approx. of process system and transfer function of simple process. Control valve definition, valve terminology, types (solenoid, diaphragm, butterfly, ball, needle, sliding gate, etc.) Characteristic, Selection of valves based on process dynamic, actuator and positioners, booster, plug types, other types, other final control elements, specification of a control valve. Calibration procedure of control valve, current to pneumatic converter, Delta Cell Transmitter and Converters : Pneumatic to electrical, electrical to pneumatic, Buoyancy Transmitters, Signal conditioning (V to I, I to V), 2-Wire and 4-Wire Transmitter SMART Transmitters (introduction and their application), Standard Signals used in instrumentation (such as 4 to 20mA, 3 to 15 psi etc.) Interlocking (Boiler, Compressor, etc.), Intrinsic Safety, Symbols in process control, Piping and instrument diagram, Annunciators (Types, sequence of operation) (12 Hrs.) 2. Controllers - Types of control actions (On-Off, single speed floating, Proportional, Integral, derivatives, PI, PD, P I D) their selection and application. Electronic and pneumatic controllers (Principle of working, Equations circuitry used) specifications of a controller. Programmable logic controller, Tuning of controller, Process reaction curve, Zieler - Nichol's Method with simple calculation problem. (10 Hrs.) 3. Multi - Loop System : Definition and application of feedback, Feedforward, cascade, ratio control 4. Computer Control System (Process line diagram, function of different elements.) 5. Case study of Process Instrumentation for Distillation Column. (5 Hrs.) Reference Books : 1 Process Control Instrumentation Technology. By Curtis Johnson (PHI) 2. Process / Industrial Instrumentation Control Hand Book, By CONSIDINE 3. Instrument Engineering Handbook, By : Bela. G. Liptak 4. Applied Instrumentation in Process Industrial. By Andrews. 5. Process Control System By F.G. Shinskey 6. Chemical process control by Geogre Stephanopoulos (PHI) 5

PROCESS CONTROL & INSTRUMENTATION PRACTICALS Students are expected to perform minimum eight experiment based on the above topics on a Process Trainer (1) Study of Flow. Temperature, Pressure Control loops (2) Calibration of Control valve (Pneumatic/Electrical type) in a On-line system. (3) Study of flow characteristic of Control valve in a On-Line system. (4) Study of Differential Pressure Transmitter in a On-line system and its calibration. (5) Study of Electronic Controller (P, PI and PID). (6) Study of Pneumatic controller. (7) Study of I to P Converter and its calibration. (8) Study of open and closed loop system. (9) Study of Cascade and Ratio Control System in a On-line system. (10) Study of tuning of PID Controller. (11) Study of On-Off flow, level control loop. Elective IC 632 OPTICAL & ANALYTICAL INSTRUMENT L T 3 -

P 2

RATIONAL The syllabus has been designed to give an opening to a student to make up a topic of his choice for specialization Optical and analytical instrument branch is used in the industries for checking and testing in-coming or final product for quality techniques such as lasers, radioactive isotopes etc. Have been used. Detailed Contents 1. Introduction to optical glass, optical flat, mirrors, lens and prism. principle of microscopy. Light Fiurescent, phase contrast, electron, photomicrographic equipment. Use of slide projector, Introduction to fibre optics 2. Spectrophotometry : Ultraviolet, visible, infra-red,atomic absorption, Emission spectrocsopy. Mass spectrometer and MMR Spectrophotometer. 3. Principle of colorimetry, photometry and flame photometry and use of various types of colorimeters, photometers and flame photometers. 4. Basic principle of radio active isotopic techniques to mechanical measurement, nature and sources of radio isotopes , measurement of radioactivity, application to density and thickness measurement, safety consideration G.M. counters and liquid scientillation counters. 5. PH and redoxpotential, use of PH meters. 6. Viscosity measurement, capillary tube, rotational cone and plate viscometers / reheometers. 7. Chromatography gas- liquid chromatoraphy, gas analysis and analyser, Ionexchange 8. Humidity and moisture indicating, recording and controlling devices. 9. Density Analysis. 10. Electrical conductivity analysers. 11. Paramagnetic analysis. 12. Laser based instruments. 6

Practical List 1. To generater monochromatic light and to check the range 2. To use laser for testing and checking different parameters used in process control, packings etc. e.g. size checking and sampling, homogenuity of following liquid, checking of proper quantity in mixing of two or more liquids etc. 3. PH measurement using PH measuring equipment. 4. To find the impurity contents in the gases such as (i) so2 (ii) so3 (iii) co2 by making use of gas analysers. 5. To find out the conductivity of a liquid by electrical conductivity analyser. 6. To find the humidity content in the room and RH by hygrometer. IC 631 ADVANCE CONTROL SYSTEM L 4 T P - 2

Detailed Contents 1. Analysis of non Linear Central System Introduction to non linear control system, describing function and functional analysis of non linear control system 2. State Variable characterisation : concept of state. matrix representation of state equation, state transition matrix, relation between state equation and transfer function. 3. LIA Punov Stability. Analysis. Introduction to stability. asymptotic stability and instability, second methods of lia punov. LIA PUNOV stability analysis of linear time invariant system, krasovskiis method. 4. Optimal and Adaptive Control System. : Controllability, observability, time optimal control system, definition of adaptive control system, representation of adapting control system, model reference control system. 5. Compensation Techniques Definition of system compensation, series and feed back compensation, effect of additional of zero's and pole lead compensation, lag compensation, lag-lead compensation, lead-lag compensation. 6. a) Introduction to descret time system, Z- transformation, solving differential equation by the Z-transformation, Block diagram of sampled data and its analysis with samples and Z.O.H. (zero order hold) b) Sampled Data System with digital computer: Introduction to difference equation, and analysis of stability in case of sampled data system. c) Stepper Motor Study of stepper motor variable reluctance stepper motor, permanent magnet stepper motor, important parameters of stepper motor operational features of stepper motor, interfacing of stepping motors to micro-processors. List of Practical 1. Test the stability of a given system using software by LIA PUNOV stability rule 2. Test for controllability of given system/observability of a given system using software on a computer. 3. Interfacing of a stepper motor with a computer 4. Study various types of stepper motors. 7

ELECTIVE EX 634 MICROPROCESSOR AND SYSTEM DESIGN L 3 DETAILED CONTENTS 1. Block diagram of Microprocessor - based system, Bus structure, Selection criteria of Microprocessor for different applications. 2. Review of Microprocessors : S085 and 8086/8088, their architecture, programming models, addressing modes and instruction set. 3. Memory interfacing: characteristics, Timing consideration & Address decoding, Interfacing of static and dynamic RAMs, Interfacing of ROMs. 4. I/O interfacing: Interfacing of keyboard, display, ADC and DAC 5. Perpheral Interfacing chips : Block diagram operation programming and interfacing consideration of the following chips : 8255, 8253, 8251, 8259A, 8279 and 8237. 6. System design Consideration : steps for design of Microprocessor based system, System specification and design constraints, various design alternatives, Noise filtered & signal conditioning. Cost effectiveness system flow diagram & Block diagram. Partioning of hardware & software and their trade offs. 7. Development Tools : Software Tools and Methods: Emulator, Simulator, Assembler, Debugger, MDS 8. Interfacing standards : RS232, IEEE488, current loop, S100 9. Microprocessor Troubleshooting : Typical Faults, instruments for fault finding : Logic Pulser, Logic Probe, Logic analyzer, Signature analyzerr. 10. Design example and case Studies like Multichannel DAS, Temperature monitoring and control system, CNC machine control List of Practical 1. Practice on use of software tools : assembler and debugger. 2. Practice on working of hardware development tools : Emulator, MDS. 3. Interfacing of a multichannel A to D converter. 4. Interfacing of Stepper motor. 5. Design & implementation of a 16 channel DAS system. 8 T P 2

IC 543 INSTRUMENTATION WORKSHOP L T P 6

RATIONALE The purpose of this practical subject is to give thorough practice and skill training in the fabrication of thromocouple, handling, pressure gauges, various types of valves and flow meters. Also the student is acquinted with various types of proximate switches, sensors, timers and counters. DETAILED CONTENTS 1. Making different type of thermocuples and their testing. 2. study of different industrial thermometers, dial thermometers. 3. Study of bourden pressure gauges, liquid or oil filled pressure gauges, diaphragm gauges, capsul gauges, bellow gauges, transmitting pressure gauges and master pressure gauge. 4. Study of immersion probes prick probes, bow probe, gas probes and leaf probes. 5. dismetalling and assembling all the transducers as many as possible. 6. Study of different type of bronze/gun metal control values. 7. Study of different type of flowmeter such as rotameter, manometer etc. 8. Study of different type of solenoid valves. 9. Study of proximity switches, sensors, counters, timers, programmable logic controller programmable timer, programmable counters, multi range timers, rate indicators, mini temperature controller. 10. Making different types of liquid level controller for filling and draining the sumps. 11. Making a pH meter. 12. Troubleshooting, repair and fabrication fo process control instruments.

IC 636 MAJOR PROJECT L T P 8 To be started after IInd year, the project should be based on design fabrication and testing preferably related to instrumentation & Control systems under the guidance of one faculty member of the institute. ASSESSMENT: Attendance and punctuality Problem solving skill Inter personal relation Live Demo Viva-Voce Report Writing 20% 30% 10% 20% 10% 10%

Necessary Certificate Should be issued by Industry person / Internal fatuity member / guide should be attached in the report. There will be internal & external Assessments. 9