INSTRUMENTATION & PROCESS CONTROL

LAB MANUAL (7th Semester)

LAB INCHARGE:

Prof. Dr. Arshad Chughtai

FACULTY TEAM:

Mr. Mudassar Azam

Ms. Rabya Aslam

Institute of Chemical Engineering & Technology

Experiments List:

A. Calibration of Instruments:
1. Calibrate the given Bourdon Gauge using the Mercury Filled Manometer. Also find
out the span, error and accuracy of the bourdon gauge.
2. Calibrate and report the accuracy of the given Bourdon Gauge using Dead Weight
Tester.
3. Calibrate the Given Resistance Temperature Detector using the mercury filled
Thermometer.
4. Calibrate the given Thermocouple using Thermometer.

B. Process Analysis:
5. Find out the time constant of the given Mercury Filled Thermometer and also find
the response y(t) of the system when t =, t = 2, t = 3
6. Find out the time constant of the Liquid Level System

C. Control Loops:
7. Report the response and variations in the process variable PV( flow of water)output
in
i.

Proportional Mode (P- mode) by giving the values of gain as 1.00, 0.6 and
1.6 while the output of controller set on 30 % i.e. set point = 30 %.

ii.

Proportional Integral mode (PI mode) by giving the values of Reset time, as
0.1, 0.15 and 0.5 while the output of controller set on 30 %.

iii.

Proportional Integral Derivative mode (PID mode) by giving the values of

rate minute as 1, 2, 3 while the output of controller set on to 30 %.

8. Study the response of the process variable (temperature) in the on-off algorithm.
Also plot the graph between time and temperature during heating and cooling.

Table of Contents:
Contents

Page no.

1. Calibration of Bourdon gauge using Manometer

2. Calibration of Bourdon gauge using dead weight tester

3. Calibration of RTD using thermometer

12

4. Calibration of thermocouple using thermometer

15

5. Time constant of thermometer

18

6. Time constant of liquid level system

22

7. Flow control loop

26

8. Temperature control loop

32

Experiment # 1: Calibration of Bourdon Gauge using Manometer

Objective:
To calibrate the given Bourdon gauge using the Mercury Filled Manometer also report
the accuracy of the Bourdon gauge.

Apparatus:

Bourdon gauge

Mercury filled thermometer

Air compressor

Procedure:

Start the air compressor before performing the experiment.

Mercury level in the U-shaped manometer is checked.

The Manometer shows the value of the change in pressure by inches of mercury and Bourdon
gauge report the value of same pressure in psi or bar.

The readings of both the manometer i.e., inches of mercury and Bourdon gauge i.e., psi or
bar are noted after the alteration in the pressure by means of controlling valve.

The readings of manometer i.e., in inches of mercury are converted into psi by multiplying
with an appropriate factor.

The graph between manometer readings at X-axis and the Bourdon gauge reading at Y-axis
is plotted. A straight line at 45 form origin is drawn. The maximum difference between the
actual plotted line and the 45 line is the Span error.

Formulae Used:

1. Pressure Reading using Manometer

( Hg air ) gh
P

gc

Where
Hg is density of Mercury
air is density of Air
h = difference in height between two limbs of manometer

2. Average Error

n
E
AvgError i 1
n

Where
E = Error for ith observation
n = number of observations

3. Accuracy:

S tan dard Value Measured Value

100
S tan dard Value
i 1

X % Error

Accuracy = X %
Bourdon Gauge is X % inaccurate

Observations and calculations:

Density of Air = air = 1.2 kg/m3
Density of Mercury = Hg = 13,650 kg/m3

Differential

No. of
obs.

Gauge

Gauge Pressure

Manometer

Pressure

(X1)

Reading, H

(kPa)

(inHg)

(kg/cm )

pressure
measured by
manometer
X2

Error
(X1-X2)
(kPa)

(kPa)

RESULT:

Results
Accuracy
Range
Average Error

Experiment # 2: Calibration of Bourdon Gauge Using Dead Weight Tester

Objective:
To calibrate and report the accuracy of the given Bourdon gauge, using dead weight tester.

Apparatus:

Bourdon gauge

Dead weight tester

Weights.

Working Principle:
The working principle of the above depicted Dead weight tester is based on Pascal
Law. This law states that if pressure is applied on a fluid at rest, the pressure is equally
distributed to all directions, i.e. one to the piston of the dead weight tester and the other to the
Bourdon gauge.

Procedure:
1.

Initially the gauge which is to be calibrated is connected with the dead weight tester.

2.

The lever is moved outward completely

3.

After putting a pressure plate of suitable weight upon dead weight tester, the lever is
gradually moved outwards.

4.

During closure of lever, Bourdon gauge showed increase in pressure. The piston is moved
inwards until the scale of Bourdon gauge stops with the jerk.

5.

At that point Bourdon gauge reading is noted.

6.

Again the same procedure is repeated right from the beginning by placing another
pressure plate on the top of already placed pressure plate.

7.

The graph between dead weight tester reading on X-axis and Bourdon gauge reading on
Y-axis is plotted.

Formulae used:
1. Accuracy:

S tan dard Value Measured Value

100
S tan dard Value
i 1

X % Error

Accuracy = X % inaccurate

2. Average Error

n
E
AvgError i 1
n

Where
E = Error for ith observation
n = number of observations

Observations & Calculations:

Sr. No.

Pressure applied

Bourdon gauge

by weights,

Reading

P1

P2

kg/cm2

kg/cm2

Error,
E=P1-P2
kg/cm2

Calibration Curve:

Result:

Results
Accuracy
Range
Average Error

10

SUMMARY OF BOURDON GAUGE

Category
Working Principle

Pressure Measuring Device

Mechanical displacement due to pressure
on fluid.
Berylium
Copper

Material of construction

steel
chrome alloy steel
stainless steel

Accuracy

1-5% of full span

Limits of application

Up to 100 MPa.
Low cost with reasonable accuracy.

Advantages

wide limits of application

can be used in harsh environment
affected by shock and vibrations

Disadvantages

have slow response time as compared to

bellow

11

Experiment # 3: Calibration of RTD

Objective:
To calibrate the given Resistance Temperature Detector using the Mercury Filled
Thermometer.

Apparatus:

Resistance Thermometer (Platinum)

Beaker

Oil bath

Thermometer

Avometer

Procedure:

Initially the Avometer is standardized by joining the two ends of the wires of RTD to
Avometer and then wires are short circuited in order to set the pointer at zero.

The resistance thermometer is inserted in the oil beaker which already had the mercury
filled thermometer.

The oil in the beaker is heated and different sets of readings are taken for resistance and
the temperature for every five degree centigrade temperature rise.

Finally a graph between temperature and the resistance is plotted. The straight line drawn
showed the fitness of the resistance thermometer under consideration for the required
purpose.

12

Observations:

Sr. No.

Temperature

Resistance

(C)

(ohm)

Calibration Curve:

13


Summary Of RTD
Category

Temperature sensor
Resistance of metal increase with increase

Working Principle

Material of construction
Sensitivity

in temperature.
Platinum
Nickel
0.004/C to 0.005/C
Up to 650C for Platinum

Limits of application

Up to 300C for Nickel

High accuracy.
Wide Range of application

Advantages

Good reproducibility
Higher signal to noise ratio.
Can be used in radiation environment
Slower response time

Disadvantages

Expensive

14

Experiment # 4: Calibration of Thermocouple using Thermometer

Objective:
To calibrate the given Thermocouple with the help of Thermometer

Apparatus:

Potentiometer

Thermocouple

Oil bath

Mercury filled Thermometer

Procedure:
1. The standardization of potentiometer is done, when the thermocouple is not connected to
it.
2. After connecting the thermocouple with potentiometer, the thermocouple and a mercury
filled thermometer are inserted into oil beaker.
3. The oil in beaker is heated up to 180 C then for every 5 C drop in temperature a
corresponding change in E.M.F. is noted via potentiometer.
4. The change in E.M.F. along with the change in temperature of the system is plotted on a
graph.

Observations & calculations:

No. of Obs.

Temperature,
T

E.M.F.
mV

15

Calibration Curve:

16

Summary of thermocouple
Category

Temperature Sensor

Working Principle

SEEBECK effect
Chromel-Alumel

Material of construction

Copper-Constantan
Platinum,Rhodium-Platinum

Limits of application

-100 to 1100C
Low cost with reasonable accuracy.
Wide Range of application

Advantages

Good reproducibility
Good accuracy
Cannot be used for radiation environment

Disadvantages

Low value of emf is corrupted with noise

Temperature is not exactly linear with emf

Type E- Type E (chromelconstantan)

Type K- Type K (chromel{90 percent nickel and 10

percent chromium}alumel)

Thermocouple types

Type J- Type J (ironconstantan)

Type N- Type N (NicrosilNisil)

Type R- Type R thermocouples use a platinumrhodium

alloy containing 13% rhodium

Type S- Type S thermocouples are of 90% Platinum and

10% Rhodium

17

Experiment # 5: Time Constant of Mercury Filled Thermometer

Objective:

Determine the time constant of the given mercury filled thermometer dipped in an oil
bath.

Draw graph between Y(t)/A and t/ and report response Y(t) of the system
when t=, t=2, t=3.

Apparatus:

Two mercury filled thermometer

Oil bath

Heating device

Stop watch.

Procedure:
1. Initially the room temperature is noted.
2. The mercury filled thermometer is dipped in the oil bath which is placed on the heating
arrangement.
3. The whole arrangement is heated till the temperature of the bath is reached to 220C. The
attained temperature is maintained.
4. Another thermometer, whose time constant is to determine is dipped in the same oil bath
and the rise in temperature after every 5 seconds is noted along with time.
5. The required parameters are calculated and a graph between above mentioned quantities
is plotted.

18

Observations and Calculations:

Room temperature= y(s) = C
Maximum temperature for heater oil bath = y() = 220C
Amplitude = A = y() - y(s)

Time
Sr. No

(sec)

Temperature of
Thermometer

Y(t)=

y(t),

y(t)-y(s)

Y(t)/A

t/ = - ln(1- (Y(t)/A))

19

Response of system at when t=, t=2, t=3.

At t/ = 1,
Y(t)/A = 0.63 (From graph)
Y(t) = 0.63 x A C

Results:

Results
Time Constant

(sec)
Y(t) when t/ = 1

Response of System Y(t) when t/ = 2

Y(t) when t/ = 3

20

Summary of thermometer
Category

Temperature Measuring Device

Working Principle

Expansion of fluid with increase in

temperature.

Material of construction

Ordinary Soda Lime

Fused Quartz

Advantages of mercury

Limits of application

Hg is opaque.
Hg is good conductor.
It does not wet the glass surface
Up to 350C for mercury
Less than 120C for alcohol
Low cost
Can be used easily.

Advantages

Used as STANDARD equipment for

calibration of temperature sensors
Good accuracy

Disadvantages

Cannot be used in industry for automatic

control.

21

Experiment # 6: Liquid Level System

Objective:
Find the Time Constant of the given Liquid Level System, also report the effect of dia and
length of tube on time constant of system

Apparatus:

Storage tank,

Tubes (of certain lengths),

Beaker,

Scale

Stop watch.

Procedure:
1. A tube of certain length and diameter was fitted at the bottom of tank. Storage tank was
filled up to a certain level (say h1). A finger was put at the end of the tube so that no
water can flow.
2. Then a beaker was placed under the tube and the finger was removed from the lower end
of the tube. The water began to flow and at the same time, a stopwatch was operated and
the time for which the level of water fell to a certain height in the storage tank (say h2)
was noted. The volume of the water that fell into the beaker was measured.
3. The mean of height or level of water was also noted.
4. Diameter of Storage tank was also measured.
5. By drawing a graph of mean level of water (along X axis) vs. the flow rate(along Y-axis),
the resistance was noted.
6. The time constant of the system can be noted by the formula.
Time Constant = Resistance x Storage Capacitance
7. The experiment was repeated by taking tubes of different length and diameter.

22

Formulae Used:

1. Area of tank
cm2

A=
Where

d = diameter of tank

2. Time Constant:
=RxA
Where
A = Area of Tank
R= Resistance to flow

3. Resistance (from graph):

Observations & Calculations:

Diameter of the storage tank = d cm
Area of the storage tank = A cm2
1. Length of tube = L1 cm

Serial #

Initial
level of
water
(h1)

Final level
of water
(h2)

in

in

in

7.5

6.5

6.5

5.5

5.5

4.5

4.5

3.5

3.5

2.5

2.5

1.5

Mean Level
(H)
cm

Volume

Time
of
flow

Flow rate
Q

(ml)

(sec)

(ml/sec)

23

12

Time Constant of Liquid Level System with tube of

length L1

Flow rate , Q(ml/s)

10

0
2

10

12

Mean Level (cm)

From graph:
R=Resistance to flow =
Time constant:
=R

Result were repeated for different tube lengths and diameters.

24

Results:

Results
Dia of tube = constant = d cm
Time Constant for L1 =

Time Constant for L2 =

Time Constant for L3 =

Length of tube = constant = L cm

Time Constant for d1 =

Time Constant for d2 =

Time Constant for d3 =

25

Experiment # 7: Flow Control Loop

Objectives:
Report the response and variations in the process variable PV (flow of water) output in
1. Proportional Mode (P- mode) by giving the values of gain as 1.00, 0.6 and

1.6

while the output of controller set on 30 % i.e. set point = 30 %.

2. Proportional Integral mode (PI mode) by giving the values of Reset time, as 0.1,
0.15 and 0.5 while the output of controller set on 30 %.
3. Proportional Integral Derivative mode (PID mode) by giving the values of

rate

minute as 1, 2, 3 while the output of controller set on to 30 %.

Procedure:
1.

The pump should not be energized/ operated until your control setting is complete and
whenever you are giving new values/changing values of gain or etc the pump should
be switched off.

2.

Initially the controller is to be set in Auto mode.

3.

Then the set point is brought to 30 % by increasing or decreasing keys without

touching any other keys.

4.

Then the setup key is to be pressed once to have tuning mode of controller, value of
Gain is adjusted by increasing/ decreasing keys and give a specified value i.e. 1.0.

5.

Now press function key once and adjust value of Rate minute at 0.00.

6.

Again press the function key to adjust value of Reset Rate (of integral mode) to 0.10 or
a high value than this.

7.

The pump is still not started. When the pump is started immediately one person will
record the readings of magnetic flow transmitter and other person simultaneously

26

record the reading (maxima and minima)of the output displayed with reference to the
time i.e. readings can be taken after every 5 seconds or any other time which may be
suitable. Also observes how quickly the system stabilizes.
8.

When set point is achieved and approximately oscillations are stopped then the pump
is to be stopped from the control panel switch. Same procedure is repeated for
different gain values (0.6, 1.6) and keeping other parameters constant.

Procedure:
Methodology adopted would be the same and the variables will have the following values:

Gain = 0.6 for all the three inputs

Rate minute = 0.00 for all the three inputs

Reset min = 0.1, 0.15 and 0.5

Same procedure will be followed to develop the graph.

3) PID Mode
Procedure:
Methodology adopted would be the same and the variables will have the following values,

Gain = 0.6 for all the three inputs

Rate minute = 1, 2, 3

Reset min = 0.1 for all the three inputs

Same procedure will be followed to develop the graph..

27

Block Diagram:

28

Flow Diagram:
FC
1

Alternative
Connection
PI
1

LC
4

FT
1

3
FT
2

Flow Diagram

1. Storage Tank
2. Pump
3. Control Valve
4. Restriction Valve
5. Bottom valve
FT-1: Flow Transmitter
FC-1: Flow Controller
LC-2: Positioner
PI-1: Pressure gauge
FT-2: Flow Transmitter (Magnetic)

29

2) PI mode
Tuning
Parameters
Time
(s)
0
5
10
15
20

Gain = 0.6

Gain =1.0

Gain =1.6

Controlled
Variable
(%TO)

Controlled
Variable
(%TO)

Controlled
Variable
(%TO)

Proportional Controller
Set point=30%
Plot Graph for all gains by taking time against x-axis and Controller Output across Y axis.

Tuning
Parameters
Time
(s)
0
5
10
15
20

Gain = 0.6
Integral time=0.1
Controlled
Variable
(%TO)

Gain =0.6
Integral time=0.15
Controlled
Variable
(%TO)

Gain =0.6
Integral time=0.5
Controlled
Variable
(%TO)

30

Proportional Integral Derivative Controller:

Set point=30%
Gain = 0.6

Gain =0.6

Gain =0.6

Tuning

Integral time=0.1

Integral time=0.1

Integral time=0.1

Parameters

Rate min=1

Rate min=2

Rate min=3

Controlled

Controlled

Controlled

Time

Variable

Variable

Variable

(s)

(%TO)

(%TO)

(%TO)

0
5
10
15
20
25

31

Experiment # 8: Temperature Control Loop

Objectives:
To study the response of the process variable (temperature) in the on-off
algorithm. Also plot the graph between time and temperature during heating and cooling.

Procedure:
1. Initially the water supply tube from the cooling element is connected to the main water
supply.
2. The outlet tube from the solenoid valve is connected to the drainage.
3. The process container is filled with water so as to cover the cooling element.
4. The electric power supply is connected.
5. The controller is set according to the following procedure.
6. The set point Select key is pressed until Algorithm is displayed.
7. The set point value is set to the required value (according to heating or cooling system)
8. For the above set point, note down reading of temperature against time.
9. Plot a graph b/w temperature (along y-axis and time (along x-axis) both for cooling and
heating process.

32

During heating:Set Point=55oC

Sr no.

Time (sec)

1.

2.

10

3.

15

4.

20

5.

25

6.

30

7.

35

8.

40

9.

45

10.

50

Sr no.

Time (sec)

Temperature (oC)

During Cooling:
Set Point=46.7 oC
Temperature (oC)

1.
2.
3.
4.
5.
6.
7.
8.
9.

33

Reference:
1.

Coughanowr, D. R.:Process Systems Analysis and Control, 2nd ed., McGraw-Hill.

2.

Fribance, A. E.: Industrial Instrumentation Fundamentals, McGraw-Hill, 1962.

3.

Luyben, W. L.: Process Modeling, simulation, and Control for Chemical Engineers,
3rd ed,McGraw-Hill, Inc., 1997.

4.

Seborg, D. E. et al.: Process Dynamics and Control, 2nd ed, John Wiley & Sons, Inc.,
1989.

5.

Stephanopoulos, G.: Chemical Process Control, An Introduction to Theory and

Practice, Prentice-Hall, Inc., 1984.

6.

Bela G Liptac.:,Instrument Engineers Handbook, Process Control and Optimization,

Vol 2, 4th ed. Taylor & Francis, 2006.

7.

Smith C.A. and Corripio B.A., Principles and Practice of Automatic Process
Control. 3rd Edition, J.W. & Sons, New York, USA. 2006.

8.

Richardson J.F. and Peacock D.G.: Chemical Engineering, Volume 3, 3rd Edition,
Butterworth Heinemann, 2010

9.

Padmanabhan T.R.: Industrial Instrumentation Principles & Design. Springer, 2008

10.

AIChE, Guidelines for Safe Automation of Chemical Processes, Center for Chemical Process
Safety, New York, 1993.

11.

Marlin, Thomas, Process Control, Designing Processes and Control Systems for Dynamic
Performance,3rd Ed., McGraw-Hill, New York, 2000

Websites:
1.

http://www.isa.org/

2.

http://www.manchester.ac.uk

3.

(www.fieldbus.org/endusersupport/enduserpresentations/interkama2004/presentations/chris
baltus_ffbenefits.pps)

4.

http://www.sensotec.com/intrinsically_safe_rated.asp#ex

5.

http://www.omega.com/thermocouples.html

34