PDC Lab Manual - Edited-1 PDF

LAB MANUAL
PROCESS DYNAMICS & CONTROL
FOR
B.TECH. DEGREE IN CHEMICAL ENGINEERING
OFFERED BY
DEPARTMENT OF CHEMICAL ENGINEERING

Government Engineering College, Trichur
Thrissur -680009
6
LAB MANUAL - PROCESS DYNAMICS CONTROL
for B.Tech. degree in Chemical Engineering
(Fourth Revision, 2019)
Published by Department of Chemical Engineering, Govt. Engineering College, Thrissur, Kerala.
No part of this publication may be reproduced or distributed in any form or by any means without the
permission of the publisher.
Department of Chemical Engg., GEC Thrissur 1

MISSION OF THE INSTITUTION
To be a premier institution of excellence in engineering education and research for

sustainable development.
VISION OF THE INSTITUTION
 Provide Quality Education in Engineering and Technology

 Foster Passion for Research
 Transform the Students into Committed Technical Personnel for the Social and
Economic wellbeing of the Nation
MISSION OF THE DEPARTMENT
To make the Department of Chemical Engineering a centre of excellence in

Chemical Engineering and allied fields giving thrust to research and consultancy
activities. Comment [G1]: Inserted: D
Comment [G2]: Deleted:d
VISION OF THE DEPARTMENT
To provide students with unique academic foundation on which to continue

developing intellectual capacity and the scholarly training needed to address
complex problems in Chemical Engineering with emphasis on interdisciplinary
fields.

BACHELOR OF TECHNOLOGY
IN
CHEMICAL ENGINEERING
PROGRAMME EDUCATIONAL OBJECTIVES
The educational objective of the programme is to produce
1. Graduates who can effectively manage chemical process industries to address the
global challenges and demands by ensuring quality and sustainability.
2. Graduates with a passion for chemical engineering to pursue higher studies,

research and development, innovation and lifelong learning.
3. Graduates with the basic knowledge in interdisciplinary areas such as

biotechnology, health, safety, environment, energy to take up and solve real-life
problems. Comment [G3]: Inserted: -
4. Graduates with good management and leadership skills, discipline, confidence, self-
esteem, teamwork and communication skills and strong adherence to ethical values
and social commitment. Comment [G4]: Inserted: -
5. Graduates with sound knowledge to prepare detailed project reports for chemical
industries and acquire entrepreneurship capabilities.

CONTENTS
Sl. No. Name of Experiment Page No.
1 Calibration of Thermocouple 4
2 Dynamic Response of Thermocouple 8
3 Dynamic Response of Thermometer 12
Dynamic Response of
4 15
Thermometer with Thermowell
5 Liquid Level Dynamics- Single Tank System 19
Liquid Level Dynamics- Two Tank

6 24
Non- Interacting System
Liquid Level Dynamics – Two Tank Interacting
7 29
System
8 Dynamic Response of Mixing Process 33
9 Calibration of U-Tube Manometer 37
10 Study of U-Tube Manometer Dynamics 39
11 Study of Control valve Inherent Characteristics 46
12 Study of Control valve Installed Characteristics 51
Comparison of Different Controllers for Thermal

13 54
System
14 Control of Thermal Process System
15 Control of Liquid Level Process

1. CALIBRATION OF THERMOCOUPLE
Objective
To study the calibration of different types of thermocouple and to find the accuracy of the
same
Equipments/Apparatus
Thermocouples
Mill voltmeter
Thermometer (0 to 200oC),
Heating system etc.
Theory
A thermocouple consists of a pair of conductors of different metals or alloys joined

together at both ends. One end, the measuring junction is placed where the temperature is to
be measured. The two conductors extend out of the measurement area to the reference
junction. An electromotive force (emf) is produced which is a function of the temperature
difference between the two junctions.
In the simplest arrangement, the thermocouple is connected directly to the indicating

instrument. The terminals of the instrument form the cold junction of the thermocouple.
Seven types of thermocouples have been given letter designation. These are listed below.

TEMPERATURE
TYPE COMPOSITION
RANGE,oC
B Pt-6% Rh vs Pt-30% Rh 0 1820
R Pt vs Pt-13% Rh -50 1768
S Pt vs Pt-10% Rh -50 1768
J Iron vs Constantan -210 760
K Chromel vs Alumel -2701372
T Copper vs Constantan -270 400
E Chromel vs Constantan -2701000
Constantan is a generic name for copper-nickel alloys having a copper content

anywhere between 45% and 60%. In type J, the alloy has 55% copper and 45% nickel.
Chromel is an alloy of approximately 90% nickel and 10% chromium. Alumel is an alloy of
approximately 95% nickel plus aluminium, silicon and manganese. Type K is the most
commonly used thermocouple in industry.
The major requirements of thermocouple materials are:

1. They must not deteriorate.
2. They must produce a measurable, stable electrical output.
3. They must be economical.
4. They must be mechanically strong.
The thermocouples circuit can be represented as given below.

Thermocouples are available in a large variety of designs for many diverse applications.
In the most common design, the conductors are joined together usually by welding to form a
measuring junction. The wires are separated beyond the welded junction and insulated,
usually by fibrous glass, ceramic insulators etc.
The calibration of thermocouple is done by observing the mill volts developed across
the measuring junction for a range of temperature of a liquid being heated. A thermometer is
used as a reference temperature. A plot of mill volts versus temperature is the calibration
curve. The sensitivity (slope) of calibration curve is different for different types of
thermocouple and none has a perfectly linear rate of change of emf output per degree of
temperature change. Each type of thermocouple has a unique non-linear response to
temperature.
Procedure
Starting procedure
Make sure that all switches given on the panel are at off position. Insert the desired
thermocouple into the thermocouple pocket. Connect the lead wires from Thermocouple to
milli-volt meter.
Switch on the panel. Note the initial millivoltmeter reading corresponding to ambient
temperature. Switch on the power supply and set the temperature of the bath to 160oC. Note
down the reading of voltage in the millivoltmeter against temperature. Repeat the experiment Comment [G5]: Deleted:-
for different types of Thermocouple

Closing procedure
When experiment is over switch off the panel. Switch off the power supply. Remove the
thermocouples and clean the Apparatus .
To calculate accuracy each of the thermocouple is inserted to the boiling water kept in a
beaker. The milli-volt reading is noted. From the corresponding calibration curve, the
temperature is noted. As the temperature of boiling water is 100 oC, the deviation and %
accuracy is calculated for each thermocouple.
Observations and calculations
OBSERVATION TABLE
Type of thermocouple:
T(oC)
V(mV)
Plot a graph of T vs V
Boiling point of water measured using thermometer =
Type of Milli-volt reading Temperature from Accuracy

thermocouple calibration curve
(+- %)
J
K
T
Result
Temperature- milli-volt calibration curve of three thermocouples- J, K and T plotted.
Accuracy of thermocouples J= , K= , T=
 Exercises
1. Why calibration of equipment is necessary.

2. Explain the principle of operation of a thermocouple.
3. List the industrially important temperature measuring devices.

2. DYNAMIC RESPONSE OF THERMOCOUPLE
Objective
To study the dynamic response of the given thermocouple and to determine the time
constant of the system.
Equipment/Apparatus
Thermocouple, Thermometer ( 0 to 300 oC), Milli- voltmeter, Heating system, Stopwatch
Theory
A thermocouple consists of a pair of conductors of different metals or alloys joined

together at both ends. One end, the measuring junctions is placed where the temperature is to
be measured. The other end, the reference junction will be located within the temperature
detecting device. The operation of the thermocouple is based on Seebeck effect. These are
self-powered devices, the emf developed in the circuit being proportional to the difference of Comment [G6]: Inserted: -
temperature between the measuring and reference junctions. The temperature indicating
instrument has inbuilt calibration facilities to convert the emf to the corresponding
temperature.
The dynamic response of the thermocouple is obtained by affecting a step decrease in

temperature from the temperature of the heated liquid to atmospheric temperature. A
thermocouple without a thermowell is a first order system with transfer function
Y ( s) 1

X ( s)  s  1
1
For a step change in temperature of magnitude A, Y ( s) 
s ( s  1

 
t

And the response is y (t )  A  1  e  
 
When t = τ, Y (t) = 1-e-1 = 0.632

A
Step input
1.0
.0
0.632
Y(t)
A

t
Therefore the time constant τ of the thermocouple can be obtained as the time
required to complete 63.2% of the ultimate value of response.
Procedure
Starting procedure
Make sure that all switches given on the panel are at off position. Insert the desired
thermocouple into the thermocouple pocket. Connect the lead wires from Thermocouple to
milli-volt meter
Switch on the panel. Switch on the power supply and set the temperature of the bath to
160oC. When temperature is steady around 160oC temperature, take out the thermocouple and
keep it in ambient air by suspending it freely from a stand. Immediately start a stopwatch and
progressively note down the mill volt reading against time till the thermocouple reaches
ambient temperature.

Closing procedure
When experiment is over switch off the panel. Switch off the power supply. Remove the
thermocouples and clean the Apparatus .
Observations and calculations

Room temperature =
Millivolt corresponding to room temperature, yR = Comment [G7]: Deleted:-
Time, t emf Y(t) = y - ys Y(t) / A

seconds millivolt Comment [G8]: Deleted:-
0
10
20
30
40
50
60
90
120
150
180
…
300
360
420
…
Sample Calculation

ys = the emf at 160oC =
Magnitude of step change, A = ys - yR =
y = the emf at any time t

t= y=
| Y(t) | = | y – ys | =
Y(t) / A =
A graph of Y(t) /A versus time is plotted and the time constant is determined.
Time constant = time taken for the response to reach 63.2 % of the ultimate value
=
Conclusion
The dynamic response of thermocouple is studied and plotted.

Time constant of the thermocouple(………. type) =
 Exercises
1. Explain Seebeck and Peltier effects.

2. Define time constant. What is its physical significance?
3. Define transfer function. Why is it useful in process control?
4. What is a first order transfer function?
5. Write the differential equation representing a thermocouple operation.

3. DYNAMIC RESPONSE OF THERMOMETER
Objective
To obtain the time constant of the given bare mercury thermometer from the step
response curve in various media.
Equipment/Apparatus
Thermometer ( 0 to110 oC ), 500ml beaker, Stopwatch, Heating System, Stand
Theory
A thermometer without thermowell is a first-order dynamic system whose transfer

function is Comment [G9]: Inserted: -
Y ( s) 1

X ( s)  s  1
and for a step change of magnitude A, the response is
 
t

y (t )  A  1  e  
 
where τ is the time constant. For such a system, 63.2 % of the step response will be
completed within a time period equal to one time constant.
Step input
1.0
.0
0.632
Y(t)
A
 t

Procedure
Note the room temperature. Boil water in a beaker, keeping the thermometer
immersed in it by suspending it from a stand and allow the thermometer to reach steady
boiling temperature. A step decrease in input can be caused by taking it out from the boiling
water and keeping it in atmospheric air. A record of the thermometer reading against time will
be the step response data. Since rate of drop of mercury level is very fast in the beginning, the
following procedure can be adopted.
Tie a coloured thread around the thermometer at the 90 oC mark. Take out the
thermometer from the bath and simultaneously start a stopwatch. Note the time to reach the
thread mark. Keep the thermometer again in boiling water to bring it back to the original
steady state temperature. The time to reach the thread mark is noted twice more by following
the same procedure. The average value of the time is recorded. The whole procedure is
repeated for observing the time to reach 85oC, 80oC and 75oC. From 75oC onwards, the drop
in temperature can be noted along with the time in a continuous manner till the temperature
reaches room temperature. Use the response data to find the time constant.
Similarly obtain the response data by cooling the thermometer in running cold water.
As the drop in this case is very fast, note down the reading starting from 80oC onwards.
Observations and Calculations
Medium: Ambient air

Room temperature =
Time, s Temperature, oC Deviation, Y(t) Y(t)/A

0

Medium: Cold Water
Cooling water temperature =
Time, s Temperature, oC Deviation, Y(t) Y(t)/A
0
Magnitude of step change, A =
A graph of Y(t) /A versus time is plotted and the time constant is determined.
Time constant = time taken for the response to reach 63.2 % of the final value
=
Conclusion
The step response curves are drawn.

Time constant τ of bare thermometer in;
a) Ambient air =
b) Cold water =
 Exercises
1. Explain the theoretical time constant of a thermometer. Compare it with time constant
of an RC circuit.
2. What is the physical significance of time constant.
3. How does the time constant of the thermometer will be affected if it is cooled in water
instead of air.
4. Derive the differential equation representing thermometer operation.
5. Explain lumped parameter system with reference to thermometer.
6. Plot the step response against time, t/τ for a first order system and indicate the %
completion at different times .

4. DYNAMIC RESPONSE OF THERMOMETER
WITH THERMOWELL
Objective
To obtain the time constant of the given thermometer with thermowell using the
step response curve
Equipment/Apparatus
Thermometer, Thermowell, 500ml beaker, Stopwatch, Heating System
Theory
A thermometer without thermowell is a first-order dynamic system whose transfer
function is Comment [G10]: Inserted: -
Y ( s) 1

X ( s)  s  1
For a step change of magnitude A, the response is Y(t) = A{1-e-t/τ}, where τ is the time
constant. For such a system, 63.2 % of the step response will be completed within a time
period equal to one time constant. In the case when a thermowell is also used, the nature of
dynamics changes to second order overdamped system whose transfer function is
Y ( s) 1

X ( s) ( 1s  1)( 2 s  1)
where τ1 and τ2 are the effective time constants which can be determined by various methods
like semi-log method, method of Cold well and Oldenbourg etc. The semi-log plot method is Comment [G11]: Inserted: -
Comment [G12]: Inserted: r
described below.
Comment [G14]: Deleted:n
Comment [G13]: Inserted: -
Semi-log plot method Comment [G15]: Inserted: -
In this method, (Reference P 297-298, Process System Analysis and Control,

Coughanowr) the logarithm of incomplete response is plotted against time. This applies for
systems with τ1 τ2. The step by step procedure can be outlined as follows.
Plot the incomplete response against time and take the time at which the process reaction
curve first departs from time axis as transportation lag τd.
1. Plot the fractional incomplete response I, against shifted time t1 starting from τd .
Bu  Y Y (t )
I   1 ,
Bu A
t1 = t - d and
Bu = the ultimate value of response.
2. The tangent through large values of t1 (Ia) is extended and its intersection with
the vertical axis at t1 = 0 is taken as P.
3. The time constant is the time at which Ia = 0.368 P
4.  = Ia – I is plotted against shifted time t1. For second-order systems, it will fall on a
straight line intersecting the vertical axis at t1 = 0 at R Comment [G16]: Inserted: -
5. Time constant is the time at which  = 0.368 R
Figure: Semi-log plot Comment [G17]: Inserted: -
Procedure

Note down the room temperature. By suspending the thermometer with thermowell
from a stand, keep it immersed in water taken in a beaker. Boil the water and allow the
thermometer to reach steady boiling temperature.
A step decrease in input can be introduced by taking the thermometer out from the
boiling water and keeping it in atmospheric air. A record of the thermometer reading against
time will be the step response data. Also, note the initial time delay for the drop in
thermometer reading. Record the response till steady state at room temperature.

Room temperature =
Time, t Temperature Deviation, Y(t)/A % incomplete

o
C Y(t) response, I
0 0 0 1.0
Shifted time, % incomplete Ia ∆ = Ia- I

t1 = t - d response, I

The Semi log plot is made for the system. From the plot,
P =
0.368 P =
τ1 =
R =
0.368 R =
τ2 =
Conclusion
The process reaction curve is drawn.

Time constants (thermometer with thermowell τ1 =
τ2 =
 Exercises
1. Why a thermowell is used in industry. What is its effect on speed of response.

2. What is a second order system. Write the differential equation representing the system
of two first orders in series.
3. Compare the nature of second-order systems obtained by adding a PI controller to a Comment [G18]: Inserted: -
first order system and two first-order systems in series. Comment [G19]: Inserted: -

5. LIQUID LEVEL DYNAMICS - SINGLE TANK SYSTEM
Objectives
1. To obtain the step response of a single tank liquid level system to a step change in
input flow and compare it with the theoretical response.
2. To determine the time constant of the system from the step response curve and
compare it with the theoretical value.
Single tank liquid level system, Measuring jar, Stopwatch
Theory
Figure: The experimental setup
A single tank liquid level system is first order in nature. The transfer function
relating deviation of liquid level in the tank to deviation in inlet flow rate is
H (s) R

Q( s )  s  1
where τ = AR is the time constants of system.
For a step input of magnitude P in the inlet flow to the first vessel, Q(s) = P/S
H(s) = PR
s (τs+1)
 
t

Taking the inverse Laplace Transform, H(t) = P R  1  e 
 
This equation gives the theoretical variation of liquid level in the tank with
respect to time for a step input of magnitude P in the inlet flow rate. The experimental value
of τ is obtained from the step response curve in which 63.2 % of the step response will be Comment [G20]: Inserted: he t
completed within a time period equal to one time constant.

A liquid level system is non-linear in nature. The discharge from the vessel is
proportional to the square root of the liquid level in the vessel, qo = C h1/2 where C is a
constant. In the linear region of the operation, the above equation becomes q o = h / R, Comment [G21]: Inserted: ,
where R is reciprocal of the slope of the tangent line to discharge vs head curve at the first
steady-state value. Comment [G22]: Inserted: -
Comment [G23]: Inserted: the
Procedure
Maintain the liquid level in the vessel at a steady state value around the lower middle
part of the level gauge by properly adjusting the inlet and outlet flow rates using valves HV1
and HV3. Adjust the flow rate to around 50 LPH. At steady state condition note down the
liquid level and corresponding discharge rate. The outlet valve should not be disturbed now
onwards till the experiment is completed. Introduce a step change in inlet flow of such a
magnitude that the change in final flow will not exceed 20%, by opening the cock valve
(HV2) provided at the bypass of the inlet valve. Simultaneously start a stopwatch and note the
rise in the level with time until the level reaches a new steady state value. At new steady state,

note the level and outlet flow rate. The difference between the final flow rate and the initial
flow rate gives the magnitude of the step change.
Resistance R
The flow rate is reduced from the final value by operating the inlet valve and allow
the system to come to a new steady state. At steady state note the levels and the flow rate
from the tank. Repeat this for different inlet flow rates. Then, make a plot of discharge (q) vs
level (h) of liquid. The resistance of the outlet valve (HV 3), is the reciprocal of the slope of
the tangent line passing through the operating flow rate
Step Response Data
Time Level Deviation Experimental Theoretical response

Sec h(t), cm H(t) response, H/PR H/PR= [ 1 - e-t/ τ]
0
10
20
30
40
50
60
90
120
150
…
300
360
…
Diameter of the tank =

C/s area of the tank =
Initial steady flow rate =
Final steady flow rate =
Magnitude of step change ΔQ =

Head vs flow relationship to determine the resistance
Sl. No. Level in tank ,h Flow rate , q
cm cc/sec
Resistance, R
(from q vs h graph) =
Plots of theoretical response and experimental value are made.
Theoretical Time constant τ =
Experimental Time constant τ =
Sample Calculation
Time =
Deviation =
Experimental response = H/PR =
Theoretical response =
Conclusion
The step response of a single tank liquid level system is obtained and it is
compared with the theoretical response.
Time constant of the system; theoretical =

experimental =
 Exercises
1. Distinguish between linear and non-linear systems. Give examples for both.
2. What is a self-regulating system? Comment [G24]: Inserted: ?
3. Develop the transfer function for the system with non-linear outlet valve q0 = C h 1/2
Comment [G26]: Deleted:.
where C is a constant.
4. If the output valve is replaced by a pump, what is the response for a step change in
input.
5. Explain linearization and its importance in process control.

6. LIQUID LEVEL DYNAMICS- TWO TANK
NON-INTERACTING SYSTEM
Objective
To obtain the step response of a two tank non-interacting liquid level system
experimentally and to compare it with the theoretical response.
Non-interacting trainer, Stopwatch, Measuring cylinder
Theory
The experimental set up is as shown in the figure below. Comment [G27]: Inserted: the
When the response of the first system is independent of conditions in the second
system, the two systems are said to be non-interacting. The transfer function relating the
changes in the liquid level in the second tank to changes in the inlet flow to the first tank is Comment [G28]: Inserted: the
H 2( s ) R2
 where τ1=A1R1 and τ2=A2R2
Q( s ) ( 1s  1)( 2 s  1)

are the time constants of tank 1 and tank 2 respectively. For a step input of magnitude P in the
inlet flow to the first vessel, Q(s) = P/s
PR 2
H 2( s ) 
s( 1s  1)( 2 s  1)
Taking the inverse Laplace Transform,
 
H 2(t )  PR 2 1 
  2
1
  1
 1et / 1   2et / 2  

If τ1 = τ2,
 t 
H 2(t )  PR 2 1  e  t /  e  t / 
  
This equation gives the theoretical variation of liquid level in tank 2.
Procedure
Switch ON the system after keeping the hand valves (HV1 & HV2) partially open.
Adjust the flow rate to around 50 LPH by varying valve HV3. Allow the levels in the two
tanks to come to a steady state value around the lower part of the tank. Note the steady-state
liquid levels in the two tanks and the discharge from the second tank. Now, introduce a step
change in input to the first tank of magnitude not exceeding 10 LPH (flow rate 60 LPH) by
increasing HV3 valve opening. Simultaneously start a stopwatch. Note down the change in
liquid level in tank two with respect to time. After attaining steady state note the
corresponding discharge. The difference between the final flow rate and the initial flow rate
gives the magnitude of the step change. Comment [G29]: Inserted: -
To find the resistance R1 and R2

Reduce the flow rate from the final value by operating the inlet valve and allow the
system to come to a new steady state. At steady state note the levels and the flow rate from
the tank 2. Repeat this for different inlet flow rates to cover the entire lower part of the tank.

Then, a plot of discharge (q) vs level (h) of liquid is made for both the tanks. The resistance is
the reciprocal of the slope of the tangent line passing through the operating flow rate.

Initial flow rate =
Final flow rate =
Magnitude of step change ΔQ =
Initial level in tank 1 =
Initial level in tank 2 =
Area of c/s of tanks, A =
Response in level in tank 2

Time, t Level, Deviation Experimental Theoretical response
sec h2(t) H2(t) response
cm H2/PR2

Head vs flow relationship to determine the resistances
Sl. No. Level in Level in Flow rate , cc/sec
tank 1, h1s tank 2, h2s q2s
R1 (from graph) =
R2 (from graph) =
Time constant τ1 = A R1 =
Sample Calculation
Time,t =
Deviation , H(t) =

Experimental response H2/PR2 =
Conclusion
The step response of two tank non-interacting liquid level system is obtained and it is
 Exercises
1. Show that two first order non- interacting systems in series will always result in an
overdamped or critically damped second order system.
2. What is the effect on step response as the number of capacities in a non-interacting Comment [G30]: Inserted: -
system increases.
3. Differentiate between interacting and non-interacting systems. Comment [G31]: Inserted: between
4. What is transfer lag? Demonstrate by plotting the step response of 1, 2, and 3 Comment [G32]: Inserted: ?
non - interacting system in series.

7. LIQUID LEVEL DYNAMICS - TWO TANK
INTERACTING SYSTEM
Objective
To obtain experimentally the step response and to compare the experimental
and theoretical responses.
Equipment/Apparatus:
Interacting trainer,
Stopwatch,
Measuring cylinder.
Theory
The experimental set up is as shown in figure
HV3
h1 HV1 h2 HV2
R1 R2
The two tanks are identical. In this arrangement, the flow through R 1 depends Comment [G34]: Inserted: ,
on the difference between h1 and h2. If the response of one system depends on conditions in
the other system, then the two systems are said to be interacting.
In this arrangement the transfer function relating the change in liquid level in tank 2 to
changes in the inlet flow to the first tank is

H2(s) = R2
Q(s) τ1 τ2 s2 + (τ1 + τ2 + A1R2 ) s+ 1
where, τ1 = A1R1 and τ2 = A2R2 are the time constants of the two tanks.
If τ1 = τ2 = τ ,this equation becomes,
H2(s) = R2
2 2
Q(s) τ s + 3 τ s +1
For a step input of magnitude P is the inlet flow to the first tank,
Q(s) = P/s
ie H2 (s) = PR2 = PR2
2 2
s (τ s + 3 τ s +1) s(0.38 τ s +1) (2.62 τ s +1)
Taking inverse Laplace transformation, Comment [G35]: Inserted: L

Comment [G36]: Deleted:l
H2 (t) = 1 + 0.17 e-t/ 0.38 τ – 1.17 e-t/2.62τ
This expression gives the theoretical variation of the liquid level in tank 2 with respect to time
for a step input of magnitude p, in the inlet flow rate to tank 1. Comment [G37]: Inserted: the
Procedure
Keep the valves HV1 and HV2 partially open. Switch ON the system power
supply. Adjust the flow rate to around 50 LPH by varying valve position HV 3. Allow the
levels in the two tanks to come to a steady state value around the lower part of the tank. Note
down the steady state liquid levels in tank 2 and the flow rate . Now introduce a step change
in flow rate in input to the first tank, of magnitude not exceeding 10 LPH by increasing HV 3
valve opening. Simultaneously start a stopwatch and note the liquid level in tank 2 with
respect to time. Note the final steady-state level and the corresponding liquid flow rate. The
difference between final and initial flow rates gives the magnitude of the step change. Comment [G38]: Inserted: the

Resistance R2
Decrease the flow rate slightly by means of valve HV3. For different flow rates, note the
steady level in tank 2. Make a plot of discharge Vs level. The resistance is the reciprocal of
the slope of the tangent line passing through the operating flow rate.
Observations and Calculations:
Initial flow rate =

Initial steady-state level in tank 2, hs = Comment [G40]: Inserted: -
Final flow rate =

Magnitude of step change, P =
Time, t Height, h H2=h-hs Experimental Theoretical response

Sec Cm responseH2/PR2 1+0.17 e-t/ 0.38 τ – 1.17 e-t/2.62τ

To find the resistance of valve, R2 Comment [G41]: Inserted: the
Head
Cm
Flow rate
Cm/sec
Slope of q vs h graph =
R2 =
Sample Calculation
Time, t =
Deviation , H(t) =
Experimental response H2/PR2 =
Conclusion
The step response of two tanks interacting liquid level system is obtained and
 Exercises
1. Give examples for systems with inherent second-order dynamics. Comment [G42]: Inserted: -
2. Explain why two interacting capacities have a more sluggish response than two
equivalent but non-interacting capacities. Comment [G43]: Inserted: a
3. Explain interaction factor.

4. What is effective time constant for an interacting system? Comment [G44]: Inserted: ?

8. DYNAMIC RESPONSE OF MIXING PROCESS
Objective
To obtain the impulse response of a mixing process involving a single tank and
compare it with the theoretical response.
Equipment/Apparatus:
Mixing tank, Stirrer, Overhead tank

Measuring Jar, Test tubes, Stopwatch
Theory
Consider the mixing process as shown in the figure below:
In this arrangement, a stream of solution containing dissolved salt flows

at a constant volumetric flow rate q into a well-mixed tank. The hold-up volume in the tank is
V liters. Mixing is a first order process and the transfer function is given by Comment [G46]: Inserted: -
Comment [G48]: Inserted: ,
C2 ( s) 1

C1 ( s)  s  1
V
where,   , is the time constant of the system.
q
For an impulse input of magnitude A, in the inlet concentration, C1(s)=A
A C 2(t ) 1 t
C2 ( s)  and  e
 s 1 A 
This expression represents the theoretical response. Actual response is obtained by measuring
the measuring the concentration of the dissolved salt in the outlet stream at different time
intervals.
Procedure
Admit pure water to the mixing tank from the overhead tank and make the hold up in the
tank at a steady level. Note the steady-state level and discharge. (Average hold up time of
tank may be adjusted to 10 min.). Keep about 20 test tubes ready. Switch on the stirrer. Add
highly concentrated NaOH solution (50g/100cc) into the tank as an impulse input. Comment [G49]: Inserted: -
Simultaneously start a stopwatch. Collect samples of the tank liquid at 0.5,1,2,3,5 minutes
time and continue sample collection every 5 minutes till 5  .
The concentration of NaOH in each test tube is determined by titrating with 0.1N
HCl solution.
Diameter of mixing tank, D =

Volumetric flow rate, q =
D h 2
Volume of tank V = =
4
Water level in the tank, h =
V
Theoretical time constant ,   =
q
Concentration of NaOH in the outlet stream at t =0, c2s =

Weight of NaOH added =
Magnitude of impulse change, A = Moles of NaOH
Volumetric flow rate
Normality of HCl used =
Time t, min Volume of Con.of Deviation Experimental Theoretical

HCl, ml NaOH variable response response
c2 moles/lit C2=c2-c2s  C2/A et /
moles/lit

Sample Calculation
Time =
c2 =
C2 = c2-c2s
 C2/A =
et / =
Conclusion
The impulse response of a single tank mixing process is obtained. Theoretical and
experimental responses are compared. Comment [G50]: Inserted: The i
Comment [G51]: Deleted:I
 Exercises
1. Develop the transfer function for the system if a first-order reaction takes place in the Comment [G52]: Inserted: -
mixing tank. Compare the time constants with and without chemical reaction.
2. Is it justifiable to neglect the mixing delay? Explain.
3. What are the common forcing functions in process control? Give the response of a
first order system to each forcing function.
4. Differentiate between impulse and pulse forcing functions.

9. CALIBRATION OF U-TUBE MANOMETER
Aim:
1. To measure the displacement of mercury in U-tube manometer for applied gauge

pressure.
2. To measure the displacement of mercury in U-Tube manometer using Pressure

Transducer.
Apparatus Required:
Foot pump
Pressure Gauge
U – tube manometer pressure measurement Kit
Pressure Sensor
Air regulator
Theory:
Pressure measuring devices using liquid columns in vertical or inclined tubes are called
manometers. This manometer is very easily constructed. It consists of a tube of glass bent
into a U shape. It is then filled with a fluid. The density of the fluid dictates the range of
pressures that can be measured. Both ends of the tube are pressure ports. If one port is left
open to the atmosphere and the other port is connected to the pressure to be measured, the
device acts as a gauge pressure meter. If both ports are connected to two different unknown
pressures, the instrument acts as a differential pressure gauge
Liquid column gauges consist of a column of liquid in a tube whose ends are exposed
to different pressures. The column will rise or fall until its weight (a force applied due to
gravity) is in equilibrium with the pressure differential between the two ends of the tube (a
force applied due to fluid pressure). A very simple version is a U-shaped tube half-full of
liquid, one side of which is connected to the region of interest while the reference pressure

(which might be the atmospheric pressure or a vacuum) is applied to the other. The difference
in liquid level represents the applied pressure.
The pressure exerted by a column of fluid of height h and density ρ is given by the
hydrostatic pressure equation, P = hgρ. Therefore, the pressure difference between the applied
pressure Pa and the reference pressure P0 in a U-tube manometer can be found by
solving Pa − P0 = hgρ. In other words, the pressure on either end of the liquid (shown in blue
in the figure) must be balanced (since the liquid is static) and so Pa = P0 + hgρ.
In most liquid column measurements, the result of the measurement is the height, h,
expressed typically in mm, cm, or inches. The h is also known as the pressure head. When
expressed as a pressure head, the pressure is specified in units of length and the measurement
fluid must be specified. When accuracy is critical, the temperature of the measurement fluid
must likewise be specified, because liquid density is a function of temperature. So, for
example, pressure head might be written "742.2 mmHg" or "4.2 inH2O at 59 °F" for Comment [G53]: Inserted: the
measurements taken with mercury or water as the manometric fluid, respectively. The word
"gauge" or "vacuum" may be added to such a measurement to distinguish between a pressure
above or below the atmospheric pressure. Both mm of mercury and inches of water are
common pressure heads which can be converted to S.I. units of pressure using unit
conversion and the above formula.
Pressure Sensor
A pressure sensor is a device which senses pressure and converts it into an analog
electric signal whose magnitude depends upon the pressure applied. Since they convert
pressure into an electrical signal, they are also termed as pressure transducers.
Procedure:
 Fill the Pressure process tank for 30psi using Foot Pump.
 Connect the pressure process tank to the Pressure regulator and Pressure regulator
output connected to U-Tube manometer input. Comment [G54]: Inserted: the
 Connect the power supply to the U- tube pressure process trainer kit as well as PC. Comment [G55]: Inserted: the
 Open the PROCESS MEASUREMENT SOFTWARE in PC and save the graph plot
in the required location. Comment [G56]: Inserted: the

 Select the COM3 port to establish the communication between Pressure process kit
and PC.
 Click SAVE button to save the process data in .txt file.
 Click START in PROCESS MEASUREMENT SOFTWARE.
 Pressure Regulator should be completely opened before starting the experiment (no
pressure input should be given to U-tube manometer).
 Adjust the pressure input to U-tube by pressure regulator slowly in steps of 20 mm
displacement of Hg, and note down the corresponding gauge pressure.
 Care has to be taken while increasing pressure in steps, such that displacement of
mercury shouldn’t exceed 115 mm.
 Plot the graph between applied gauge pressure in the x-axis and displacement in mm
of Hg in the y-axis. Comment [G57]: Inserted: the
 Plot the graph between Displacement of mercury and the corresponding voltage
Observation Table:
Applied Pressure, psi Displacement in mm. of Hg Voltage (mV)
Result:
The displacement of mercury is studied for applied gauge pressure and the pressure
transducer is calibrated for the displacement of mercury. Comment [G59]: Inserted: the

10. STUDY OF MANOMETER DYNAMICS
Objective
To find the characteristics of U tube manometer and to plot the graphs of decay
ratio, overshoot and frequency of oscillation versus damping coefficient.
Theory
A manometer is an example of a physical system with inherent second order dynamics. It

can exhibit oscillatory or underdamped behavior. Comment [G60]: Deleted:u
In the U tube manometer when the pressure at the top of the two legs is equal the level
of the liquid in the two limps are in the same horizontal plane. If a pressure difference is
introduced the manometer will exhibit dynamics. Comment [G61]: Inserted: is
Comment [G62]: Deleted:are
Application of Newton's law and Poiseuelle's equation for laminar flow in a pipe gives
a second-order dynamics. The transfer function between the deviation of the liquid level
and the pressure difference is Comment [G63]: Inserted: the
H(s) Kp
=
P(s) 2 s2 + 2   s + 1
where,  is the damping coefficient.
H ( s) Kp n 2
If n = 1/  the above equation can be written as 
P( s) s 2  2 ns   n 2
For a step change in  P and for < 1 , the system gives an underdamped response given by
 1  t 
h(t )  Kp 1  e  sin t    
 1  2 
 
It should be noted that the underdamped response is initially faster than critically damped
or overdamped responses but it is oscillatory. The oscillatory behavior becomes more
pronounced with smaller values of damping coefficient. Comment [G66]: Deleted:u

Characteristics
The figure below shows the underdamped response of a second order system. Comment [G67]: Inserted: The f
Comment [G68]: Deleted:F
A C
+5%
h(t) B
Kp
T
tr, Rise time ts, response time
time, t
Overshoot
It is the ratio A/B where B is the ultimate or final value of the response and A is the
maximum amount by which the response exceeds the ultimate value.
  
Overshoot = exp  
 1  2 
 
It is an indication of the largest error between input and output during the transient
state. From the experiment the overshoot A/B is calculated and hence  can be
calculated. Overshoot is a function of  and increases with decreasing  .
As   1 overshoot  0.

Decay Ratio
It is the ratio of the amounts above the ultimate value of two successive peaks. It is a
useful parameter in the study of system transients and stability. From the experiment it is
calculated as C/ A. It is the square of overshoot Comment [G69]: Inserted: i
 2 
Decay ratio = exp   = (overshoot )2
 1  2 
 
Period of Oscillation
The radian frequency of oscillation is given by
 = n 1   2 radian/ time
where, n = 1/  is the natural frequency.

If, f is the cyclical frequency we have  = 2  f .
From the time elapsed between two successive peaks T, f is calculated as
f = 1/ T cycles / time. Then,

n  1
1  2
and   can be calculated.
n
1  2
Combining the above equations,  T

2
Rise Time
This is the time required for the response to first reach the ultimate value.
 
 sin 1 
1  2 
tr 
n 
 1  2


 
It is the measure of the speed of response. Comment [G70]: Inserted: the
Time of First Peak

This also is a measure of the speed of response.


tp 
n 1   2
Settling Time
It is the time necessary for the decrease and to stay within a specified range of its final
value. 2 to 5 % of the ultimate value is often stated as the tolerable range.
3
ts 
 n
Theoretical Analysis
The theoretical analysis (Refer pages 205-207, Chemical process Control, G.
Comment [G71]: Inserted: he t
L
Stephanopoulos) gives the value of the time constant as,   and the value of
2g
damping coefficient as  =
Procedure
 Fill the Pressure process tank for 30psi using Foot Pump.
 Connect the pressure process tank to the Pressure regulator and Pressure regulator
output connected to U-Tube manometer input. Comment [G72]: Inserted: the
 Connect the power supply to the U- tube pressure process trainer kit as well as PC.
Connect the Trainer kit with PC. Comment [G73]: Inserted: the
 Open the PROCESS MEASUREMENT SOFTWARE in PC and save the graph plot.
 Select the COM port to establish the communication between Pressure process kit and
PC.
 Click START in PROCESS MEASUREMENT SOFTWARE.
 Pressure Regulator should be completely opened before starting the experiment.
 For a step increase,

o Fold the inlet air tube of the manometer and increase the pressure to 6 psi by
adjusting the pressure regulator. Suddenly release the folding so that mercury
in the U-tube will oscillate for the given pressure. Comment [G74]: Inserted: the
 Note the time in the x-axis of PMS screen when the input is given and also note the
final steady voltage and displacement of mercury. Comment [G75]: Inserted: the
 Click LOAD button to save the data in EXCEL file

 Data obtained in PC is used to study of the second-order response of U-Tube
manometer.
 Repeat the experiment for different amplitudes of step by varying pressure to 5,4,3 psi.
 Plot displacement Vs time Comment [G76]: Inserted: -
 Take the readings as indicated below. Plot period of oscillation /n, decay ratio and
overshoot against damping coefficient  .
T
h1
h2
hs
hi
t=0
Constants:
Manometer fluid = mercury
Dynamic viscosity () = 0.0016 kg/m.s.
Mass density () = 13550 kg/m3
Column length (L) = 0.250 meter
Tube diameter (d) = 0.005 meter

Sl. hi h1 h2 hs t, Overshoot  / n =
Coeff. 
A = hs-h1
Damping
B = hi-hs
No s
1  2 
Decay
A/B
ratio
.
Conclusion
Dynamics of a manometer is studied and the characteristics are calculated and plotted.
Theoretical Experimental
Value of time constant :
Value of damping coefficient :
 Exercises
1. What is a second order system? Write its differential equation. Comment [G78]: Inserted: ?
2. Explain the physical significance of  and .
3. Discuss the overdamped, underdamped and critically damped responses of a second
order system.

11. STUDY OF INHERENT CHARACTERISTICS
AIM:
To study the inherent characteristics of Linear, Equal percentage and Quick opening Valves.
APPARATUS REQUIRED:
Control Valve trainers

Compressor
Reservoir tank filled with water
Pressure Regulator
Power Supply
Water pump.
THEORY:
The control valve is essentially a variable resistance to the flow of a fluid, in which the
resistance and flow can be changed by signal form from a process controller. The valve itself
is divided into body and the trim. The body consists of housing for attachment of the valve to
a supply line and delivery line. The trim which is enclosed within the body consists of a plug,
valve set and valve stem.
An increase in signal pressure along the diaphragm exerts a force on the diaphragm and
backplate, which causes the stem to move down. This causes the cross-sectional area for
flow between the plug and seat to decrease. Thereby decreasing or throttling the flow. Such a
flow action is called air to close action. Comment [G80]: Inserted: -

Pneumatically-actuated globe valves and Diaphragm Valves are widely used for control
purposes in many industries, although quarter-turn types such as (modified) ball and butterfly
valves are also used.
Non-pressure-compensated flow-control valves are used when the system pressure is

relatively constant and motoring speeds are not too critical. The operating principle behind
these valves is that the flow through an orifice remains constant if the pressure drop across it
remains the same. In other words, the rate of flow through an orifice depends on the pressure
drop across it.
The relationship between the control valve opening (also known as ‘valve travel') and
the flow through the valve is known as the flow characteristic of that valve. An inherent flow Comment [G81]: Inserted: the
characteristic is the relation between valve opening and flows under constant pressure
conditions. Comment [G82]: Inserted: s
The gain of a valve is defined as the change in flow per unit % change in the valve opening.
 The linear flow characteristic has a constant slope, meaning that valves of this type
have constant gain through the complete range of flows. These valves are often used
for liquid level control and certain flow control operations requiring constant gain. Comment [G83]: Inserted: the
 Equal percentage valves are known by that name because whenever the valve
opening is changed, the percentage change in flow is equal to percentage change in the
valve opening. This means the change in flow proportional to the flow just before the
incremental valve opening is performed. This can also be observed in the following
figure. This type of valves is commonly used for pressure control applications. They
can be considered for applications where high variations in pressure drop are
expected. Comment [G84]: Inserted: be
 Quick opening type of valves does not have a specific mathematical definition. These
valves give a large increment in flow for relatively smaller valve opening, as can be
observed in the following figure. These valves usually find use for on-off service
applications.

PROCEDURE: -
The experiment set up for control valve study is as shown below:
Experiment set up
1. Connect the power supply and start the setup by connecting the required control valve
to be studied.
2. Ensure continuous flow of liquid throughout the process.
3. Keep the control valve in its initial position (i.e. fully open condition) by setting the
inlet pressure to 15 psi.
4. Adjust the rotameter for rated flow rate (500 LPH for linear and equal percentage
valve, 700 LPH for quick opening Valve) by adjusting HV2 valve.
5. Note the flow rate and pressure drop for the initial open condition. Comment [G85]: Inserted: the
6. Decrease the air pressure by the air regulator in steps. Comment [G86]: Inserted: the
7. Adjust the HV2 valve keeping HV1 valve constant, to maintain the flow pressure
drop at a constant value. Comment [G87]: Inserted: a
8. For each step decrease of control valve inlet pressure, the pressure drop across water
column should be held constant. Comment [G88]: Inserted: the

9. Note down the stem position of the control valve and flow rate for each 3 psi pressure
decrease. Comment [G89]: Inserted: the
10. Plot the characteristics curve with flow rate in y- axis and stem position in x-axis.
OBSERVATIONS:
Stem Position of Control Valve Vs Flow Rate

LINEAR VALVE:
Stem position of Control Flow Rate
Sl.No Valve (LPH)
1.
2.
3.
4.
5.
EQUAL PERCENTAGE VALVE:

Sl.No Valve (LPH)
1.
2.
3.
4.
5.
QUICK OPENING VALVE:

Sl.No Valve , mm (LPH)
1.
2.

3.
4.
5.
MODEL GRAPH:
Flow rate versus Stem position Comment [G90]: Inserted: u
Comment [G91]: Deleted:e
Quick
Equal %
Flow rate
Linear
(LPH)
Stem position (mm)
RESULT:
The inherent characteristics of Linear, Equal percentage and Quick opening valves are
studied and the graph is plotted.

12. STUDY OF CONTROL VALVE INSTALLED CHARACTERISTICS
AIM
To study the installed characteristics of Linear, Equal percentage and Quick opening
Valves.
APPARATUS REQUIRED
Control Valve trainers
Compressor
Reservoir tank filled with water
Pressure Regulator
Power Supply
Water pump.
THEORY:
The installed control valve characteristic curve plots the valve open percent versus
the flow through the valve, and this plot is dependent on the conditions specific to the
system. For example, if the control valve flow set point is fixed at certain LPH, the pressure
drop required by the control valve to achieve that flow rate will be related to the other
sources of pressure drop (and pressure addition) that exist in the system. If there is almost
no pressure drop in the system, the control valve will need to add the majority of the
pressure drop in order to achieve the specified flow, so it’s open percentage will need to be
much smaller than if there were several other sources of pressure drop.

PROCEDURE: -
1. Connect the power supply and start the setup by connecting the required control valve
to be studied.
2. Ensure continuous flow of liquid throughout the process and keep the HV1 valve
partially opened.
3. Keep the control valve in its initial position (i.e. fully open condition) by setting the
inlet pressure to 15 psi.
4. Adjust the rotameter for rated flow rate (500 LPH for linear and equal percentage
valve, 700 LPH for quick opening Valve) by adjusting HV2 valve.
5. Note the flow rate and pressure drop for initial open condition and the HV1, HV2
valves are kept constant.
6. Decrease the air pressure by the air regulator in steps. Comment [G92]: Inserted: the
7. Note down the stem position of the control valve and flow rate for each 3 psi pressure
decrease. Comment [G93]: Inserted: the
8. Plot the characteristics curve with flow rate in y- axis and stem position in x-axis.
OBSERVATIONS:
Stem Position of Control Valve Vs Flow Rate
LINEAR VALVE:
Sl.No Stem position of Control Flow Rate

Valve , mm (LPH)
1.
2.
3.
4.
5.

EQUAL PERCENTAGE VALVE:

Valve, mm (LPH)
1.
2.
3.
4.
5.
QUICK OPENING VALVE:

Valve , mm (LPH)
1.
2.
3.
4.
MODEL GRAPH:
Flow rate vs Stem position
Quick
Equal %
Flow Rate
Linear
(LPH)
Stem Position
RESULT:
The installed characteristics of Linear, Equal percentage and Quick opening valves are
studied and the graph is plotted.

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LAB MANUAL

PROCESS DYNAMICS & CONTROL

B.TECH. DEGREE IN CHEMICAL ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING

Published by Department of Chemical Engineering, Govt. Engineering College, Thrissur, Kerala.

Department of Chemical Engg., GEC Thrissur 1

To be a premier institution of excellence in engineering education and research for

VISION OF THE INSTITUTION

 Provide Quality Education in Engineering and Technology

MISSION OF THE DEPARTMENT

To make the Department of Chemical Engineering a centre of excellence in

VISION OF THE DEPARTMENT

To provide students with unique academic foundation on which to continue

Department of Chemical Engg., GEC Thrissur 2

The educational objective of the programme is to produce

2. Graduates with a passion for chemical engineering to pursue higher studies,

3. Graduates with the basic knowledge in interdisciplinary areas such as

Department of Chemical Engg., GEC Thrissur 3

Sl. No. Name of Experiment Page No.

2 Dynamic Response of Thermocouple 8

3 Dynamic Response of Thermometer 12

5 Liquid Level Dynamics- Single Tank System 19

Liquid Level Dynamics- Two Tank

8 Dynamic Response of Mixing Process 33

9 Calibration of U-Tube Manometer 37

10 Study of U-Tube Manometer Dynamics 39

11 Study of Control valve Inherent Characteristics 46

12 Study of Control valve Installed Characteristics 51

Comparison of Different Controllers for Thermal

14 Control of Thermal Process System

15 Control of Liquid Level Process

Department of Chemical Engg., GEC Thrissur 4

A thermocouple consists of a pair of conductors of different metals or alloys joined

In the simplest arrangement, the thermocouple is connected directly to the indicating

Department of Chemical Engg., GEC Thrissur 5

B Pt-6% Rh vs Pt-30% Rh 0 1820

R Pt vs Pt-13% Rh -50 1768

S Pt vs Pt-10% Rh -50 1768

J Iron vs Constantan -210 760

K Chromel vs Alumel -2701372

T Copper vs Constantan -270 400

E Chromel vs Constantan -2701000

Constantan is a generic name for copper-nickel alloys having a copper content

The major requirements of thermocouple materials are:

The thermocouples circuit can be represented as given below.

Department of Chemical Engg., GEC Thrissur 6

for different types of Thermocouple

Observations and calculations

Boiling point of water measured using thermometer =

Type of Milli-volt reading Temperature from Accuracy

1. Why calibration of equipment is necessary.

Department of Chemical Engg., GEC Thrissur 8

Thermocouple, Thermometer ( 0 to 300 oC), Milli- voltmeter, Heating system, Stopwatch

A thermocouple consists of a pair of conductors of different metals or alloys joined

The dynamic response of the thermocouple is obtained by affecting a step decrease in

Department of Chemical Engg., GEC Thrissur 9

When t = τ, Y (t) = 1-e-1 = 0.632

Department of Chemical Engg., GEC Thrissur 10

Observations and calculations

Time, t emf Y(t) = y - ys Y(t) / A

Department of Chemical Engg., GEC Thrissur 11

y = the emf at any time t

The dynamic response of thermocouple is studied and plotted.