Process Dynamics Pracs Iitr

LAB MANUAL
Process Dynamics and Control Lab

(Undergraduate Level)
Chemical Engineering Department, IIT Roorkee
CHN 303: CHEMICAL ENGINEERING LABORATORY

PROCESS DYNAMICS AND CONTROL (UNDERGRADUATE LEVEL)
ii

TABLE OF CONTENTS
Experiment
No
Experiment topics
Page
No
Dynamics of stirred tank with proportional ON/OFF temperature

controller
Dynamics of evacuated tank
Dynamics of thermometer
Control valve characteristics
17
(A)
Study of control valve flow coefficient (Cv)
19
(B)
Study of inherent characteristics of linear control valve
23
(C)
Study of installed characteristics of control valve
27
(D)
Study of Hysteresis of control valve
29
(E)
Study of Rangeability
33
Dynamics of pressurized tank
35
Interacting and Non-Interacting System
39
Step response of single capacity system
41
(A)
(B)
(C)
Step response of first order systems arranged in non-interacting

mode
Impulse response of first order systems arranged in non-interacting
mode
47
53
(D)
Step response of first order systems arranged in interacting mode
57
(E)
Impulse response of first order systems arranged in interacting

mode
61
Dead weight pressure gauge calibrator
65
iii

iv

EXPERIMENT NO. 1
DYNAMICS OF STIRRED TANK TEMPERATURE CONTROLLER
OBJECTIVE
1. To study the dynamics of a stirred tank system fitted with electric heating assembly.
2. To study the response of an ON/OFF temperature controller thermostat fitted to the tank.
3. To estimate temperature band within which it controls the temperature of the tank.
THEORY
When a step input in terms of heat (by switching the electrical heater ON) is applied to the stirrer tank
vessel its temperature gradually increases and finally attains a constant value depending upon the
magnitude of step input and flow rate of water through the stirred tank. By recording the temperature
history of the vessel, the time constant ( ) of the system can be computed.
f, To
Controller
Thermocouple
T
V
f, T
Figure 1.1: Sketch of the stirred tank system for mass balance
Let,
C = Specific heat capacity of the fluid entering the tank (J/kg.K)

f = Volumetric flow rate of the fluid (in m 3 /s)
To = Initial temperature (in K)
T = Final temperature (in K)
T = Reference temperature (in K)
= Density of the fluid (kg/m 3 )

Q in = Rate of heat input (J/s)
Making an energy balance on the tank as shown in the Figure 1.1 above we get,
f C (To T ) f C (T T ) + Qin =
d
CV (T T )
dt
.(1)

f C (To ) f C (T ) + Qin = CV
Qin
dT
=
Cf
dt
(To T ) +
V
f
=
At steady state,
dT
dt
.(2)
.(3)
.(4)
dT
=0
dt
(To T s ) +
s
Q s in
=0
C f
.(5)
From equation (3) and equation (5) we get
(To To ) (T T s ) +
s
Qin Q s in
d
= (T Ts )
fC
dt
.(6)
Lets we define the deviation variables,
To To = o
s
.(7)
T T s =
.(8)
Qin Qin = H
s
( o ) +
H
d
=
fC
dt
.(9)
.(10)
Suppose we assume there is no variation in temperature of input stream then o = 0 then
H
d
=
fC
dt
.(11)
H (s)
( s ) = s ( s )
fC
.(12)
Now taking Laplace operator both sides we get,
(s)
(1 / fC )
(s + 1)
.(13)
H ( s) =
A
s
.(14)
(s) =
A(1 / fC )
s (s + 1)
.(15)
H (s)
For a step input to heat

1
s( s + 1 / )
( s) =
A
fC
(s) =
A 1
1
fC s ( s + 1 / )
(t ) =
A
1 e t /
fC
.(16)
....(17)
Taking inverse Laplace we get,
Hence from eq.(8) and eq.(18)
T =Ts +
A
(1 e t / )
fC
.(18)
.(19)
When the thermostat is used to control the temperature of the stirrer tank vessel heated by electric heater
it controls the temperature within the band. By studying the temperature-time history of the stirrer tank
vessel when controller pressed into action this temperature band can be estimated.
APPARATUS
1. Overhead constant head water tank.
2. Tank fitted with variable speed stirrer.
3. Immersion type electrical heater (3 kW).
4. Electronic type ON/OFF temperature controller.
PROCEDURE
1. Open valve (VC) so as to fill the overhead tank. Once the water level in the overhead tank attains
a constant level, water from the overflow line starts flowing in the bottom reservoir from where it
is pumped back to the overhead tank.
2. Open the valve (VA) to allow the flow of water from overhead tank to stirred tank. Slowly the
water level in the tank rises and through valve (VB) it drains out.
3. Switch ON the stirrer and switch ON the electric heater. Fix the value of set point temperature in
the controller at 90 C. This will ensure the heater to remain on as due to the low capacity of the
heater the final temperature will never reach 90 C with time.
4. Monitor the rise in temperature in the stirrer tank. Continue monitoring the temperature and time
till the temperature in the tank stabilizes.
5. Switch OFF the heater and note the fall in the temperature with time till it attains a constant
value.

Over Head Tank
Switch (Electric)
Liquid Level Indicator
VC
Cooling Water
Thermostat
(Thermal Switch)
Stirrer
Thermometer
On/Off Type Temp. Controller

Main phase
VA
Overflow line
To over head
Bulb
Electric Heater
VB
To Drain
Recirculating
pump
Bottom reservoir
Figure 1.2: Schematic diagram of the apparatus (Note: the dashed lines show suggested changes that
dont currently exist)
6. Fix the set point temperature between (40-50) C in the controller and start recording the
temperature of the stirred tank with time. After a few minutes the electric bulb attached to the
controller will stop glowing indicating that electric heater has been switched OFF by the
thermostat. Keep on noting the temperature-time history of the tank. After a few minutes the bulb
will again glow indicating that the heater has been switched ON. Keep on noting the temperaturetime history till the electric bulb stops glowing for the second time.

OBSERVATION AND CALCULATIONS

A) When the electric heater was switched ON (without controller operating)
Time, in s
Temperature, in C
Draw a plot between temperature and time for the case and from this plot compute the time
constant of the stirred tank.
B) When the electric heater was switched OFF (without controller operating)
Time, in s
Temperature, in C
Draw a plot between temperature and time for the case and from this plot compute the time
constant of the stirred tank.
C) When the controller was pressed into service to control tank temperature
Time, in s
Temperature, in C
Draw a plot between temperature and time for the case and compute the temperature control band
from the plot, i.e., the temperature drop in tank observed between the ON and OFF states of the
controller.
DISCUSSIONS
1. Explain how a controller works and what type of controller is it?
2. Explain the statement ______ For high liquid flow rates from the tank the controller may fail to
control the temperature of the tank especially when the set point temperature is high.
REFERENCES
Steven E. LeBlanc, Donald R. Coughanowr, Process systems analysis and control, 3rd Ed.,
McGraw Hill, NY, 2009, pg.168-172.


EXPERIMENT NO. 2
DYNAMICS OF EVACUATED TANK
OBJECTIVE
1. To study the dynamics of evacuated tank
THEORY
The following figure shows a sketch of the major parts of the instruments.
Vent cock
Vacuum pressure
gauge
Manometer
Vacuum
Tank
Vacuum pump
Mercury
reservoir
Figure 2.1: Schematic of the evacuated tank assembly
APPARATUS
1.
2.
3.
4.
Mercury Reservoir and U-tube

Vacuum Pressure Gauge (0 to -760 mmHg)
Vacuum tank with vent cock
Vacuum pump
PROCEDURE
1. Start the vacuum pump and observe the rise of mercury in the tube. The vent cock on the vacuum
tank should remain closed while vacuum is being created. Note the levels at some proper time
intervals till the maximum vacuum has been achieved (Condition-1).
2. After steady state is attained, note the level of the mercury in the U-tube manometer attached to
the reservoir and also the vacuum pressure indicated by the pressure gauge.
3. Crack open the vent cock approximately half-way suddenly, so that the vacuum starts falling very
slowly. Note the fall in vacuum in the vessel (pressure gauge) and inlet line (U-tube manometer),
as a function of time, till a new steady state is reached i.e. the pressure ceases to vary (Condition2).
7

4. Give the next step input by suddenly closing the vent cock and observe the change in pressure
with time P(t) (Condition-3).
5. Plot the pressure as a function of time (i.e P(t) vs time(t)) and discuss the results with
mathematical analysis.
6. Report the time constants at three different conditions and compare them.
7. Repeat Condition-3 for another two valve opening and perform similar analysis.
OBSERVATIONS AND CALCULATIONS
Condition 1: Initial evacuation of tank calibration of pressure gauge using mercury manometer.
S. No.
Pressure, in mm Hg
Time, in s
Level of mercury, in mm Hg
Condition 2: After crack opening the vent cock half way

S. No.
Pressure, in mm Hg
Time, in s
Condition 3: Completely closing vent cock valve

S. No.
Pressure, in mm Hg
Time, in s
Repeat the tables for condition 2 and condition 3 with varied openings of vent cock.
DISCUSSIONS
1. How does the height of mercury in the reservoir/pot affect the manometer readings? What
precaution should you take to avoid error associated with it?
REFERENCES

EXPERIMENT NO. 3
DYNAMICS OF THERMOMETER
OBJECTIVE
1. To study the dynamics of a thermometer with and without thermowell.
THEORY
The following figure shows a schematic of the experimental set-up. The set up consists of a blower with
heater. The blower can be operated with/without the heater ON. The blower blows air into the channel
from one end and has a thermometer that is inserted and held in place using a rubber plug at the other end.
Optionally a thermowell can be inserted on to the thermometer to study higher order dynamics.
Thermometer
Air blower
Thermowell
Channel
For Heater
For Blower
Figure 3.1: Schematic of the experimental set-up for studying dynamics of thermometer.
A simple mercury thermometer is a first order system under the following assumption.
1. All the resistance to heat transfer resides in the film surrounding the bulb.
2. All the thermal capacity is in the mercury.
3. The glass wall containing the mercury does not expand or contract during the transient response.
The transfer function for this system is as follows:
Y (s)
1
=
X (s) s + 1
where, is the time constant given by (mC/hA), m is the mass of mercury, C is the specific heat capacity,
h is heat transfer coefficient and A is the area of heat transfer. The introduction of thermowell leads to a
second order system due to additional resistance of the oil. The transfer function is of the form:

1
Y (s)
= 2 2
X ( s ) ( s + 2s + 1)
The system is over damped with the values of and calculated using methods such as slope and
intercept method, method of moments, method of Harriot, etc.
The time response of the first order system to a step input is given by
A
is given by
s
when t < 0
0
Y (t ) =
t
A(1 e ) when t 0
X ( s) =
The step response of a second order system is as follows:

t
A t 1
1e
Y (t ) = A +
2e 2
( 2 1 )
where 1 = - 2 1 and 2 = + 2 1
APPARATUS
1. Thermowell
2. Glass bulb thermometer
3. Hot air blower
PROCEDURE
1. Make sure the thermometer bulb is clear of oil and dirt.
2. Note the steady state temperature of the thermometer before switching on the hot air blower.
3. Switch on the hot air blower and note the change in temperature with respect to change in time till
the steady state value is attained.
4. Switch off the hot air blower and record the fall in the temperature with respect to time as in
previous step till the steady state is attained.
5. Repeat the above steps with the introduction of the thermowell.
6. Calculate the time constants for the first order as well as the second order system respectively
using graph.
CALCULATIONS
1. Thermometer without thermowell:
10

During heating:
The initial steady state value of temperature is Ti = ________ C.
Time, in s
Temperature, in C
The final steady state value of temperature T is Tf = ________ C.
Therefore, step change is
A = (Tf - Ti ) = _________ C
And step response of thermometer without thermowell is
Y(t ) = A (1 - e
-t
),
where, Y is deviation variable. The value of Y(t) at different time (t)
A(1 - e -1 ) = _________ o C when t =
Y(t ) = A(1 - e -2 ) = _________ o C when t = 2

A(1 - e -3 ) = _________ o C when t = 3
are noted from the graph of Y(t) vs t for experimental data, we can calculate different value of time (t).
= ______ s
2 = _______ s
3 = ________ s
+ 2 + 3
= ________ s
6
Therefore, =
During Cooling:
Similarly, the cooling curve is obtained with a forcing function of step input of negative magnitude.
Time, in s
Temperature, in C
Therefore, step change is
11

A = (Ti - Tf ) = _________ C
Y ( s ) =
s (s + 1)
Y (t ) = - A (1 - e
-t
where, Y(t) is deviation temperature.
- A(1 - e -1 ) = _________ o C when t =
Y(t ) = - A(1 - e -2 ) = _________ o C when t = 2

- A(1 - e -3 ) = _________ o C when t = 3
Now from cooling curve: we can calculate different value of time (t),
= ________ s
2 = _______ s
3 = _ _____ s
+ 2 + 3
= _________ s
6
Therefore, =
2. Thermometer with thermowell

Time, in s
Temperature, in C
Therefore step change is
A = (Tf - Ti ) = _________ C
And step response of thermometer with thermowell is
t
A t 1
1e
Y (t ) = A +
2e 2
( 2 1 )
where 1 = - 2 1 and 2 = + 2 1
The value of Y(t) at different time (t) can be obtained from the plot of experimental data. The following
method can be used for determining the time constants:
i)
Slope and Intercept Method
12

This method works if the time constants are very different from each other i.e. |1| >> |2|, the
larger the difference the better the method works.
a) Since, |1| >> |2|, we can ignore the first term in the second bracket and rewrite the
equation as
t
t
t 1
Y (t )
1
1e
2 e 2 e 1
=
A
( 1 2 )
For large values of time, the fractional incomplete response is close to a first order
system. Therefore, we fit an exponentially decreasing curve to data at large times and
extend to the y-axis and find the intercept (say P). The time corresponding to (0.368 P)
gives the larger of time constants.
b) Next to find the smaller time constant, subtract the exponential fit from the overall curve
that the experimental data fits. From the resulting curve, find the intercept with y-axis
(say R). The time corresponding to (0.368R) gives the smaller time constant.
The procedure is illustrated in the plot shown in Figure 3.2.
1.40
Slope Intercept Method
1.20
Exponential Fit
1.00
Original Experimental Data
0.80
0.60
Difference of the two curves
0.40
0.20
0.00
-0.20
100
200
300
400
500
Fractional Incomplete Response
600
700
First order system
800
900
1000
Delta
Figure 3.2: Illustration of slope and intercept method

ii)
Semi-Log Method
Follow the procedure given on page 297 in Process Systems Analysis and Control by D. R.
Coughanowr, 2nd Edition to identify the process transfer function.
iii)
Method of Harriott
a) When the fractional response (Y(t)/A) is plotted with t/(1+2) for various time constant
ratios (2/1 = 0, 0.1, 0.2, ), at Y(t)/A = 0.73, all the curves intersect and the
13

corresponding value of t/(1+2) = 1.3. Therefore, from our experimental data, find the
time (t0.73) corresponding to (Y(t)/A = 0.73), then (1+2) = (t0.73)/1.3.
b) Another plot of values of (Y(t)/A) at t/(1+2) = 0.5 from the above plots Vs
corresponding (2/1) was prepared. Now calculate t = 0.5 x (1+2) using (1+2)
determined above. Find value of (Y(t)/A) for this time from data. Then find (2/1) from
the second plot corresponding to this (Y(t)/A).
c) From the sum of time constants and product of time constants determine the time
constants 1 and 2.
iv)
Method of Oldenbourg and Sartorius

This method is based on the point of maximum slope and inflection in the fractional response
curve.
a) Plot the fractional response curve (Y(t)/A) Vs time. Draw a tangent at the point of
inflection and extend it to Y(t)/A = 0 and Y(t)/A = 1.0 (horizontal lines) to get
intersection points A and B respectively. The time duration from point A to point B is A
and time duration from point of inflection to point B is B. These time durations are
related to time constants as follows:
2
b) Let
1
2
1 1 2
= 1
2
= 1 + 2
= , we can get the relationship
1
= (1 + )
(1 )
c) Plot L.H.S and R.H.S and find the intersect points (which are also solutions satisfying the
above equation). The intersection points are 1 and 2 . Using the intersection
v)
points and = 1 + 2 , determine the time constants.
Method of Moments
a) Plot the fractional incomplete response vs time and find the area under the curve. The
value obtained is the zeroth moment ( ) = 1 + 2 .
b) The mean value of the curve is the first moment (1 ) = 12 + 1 2 + 22 .
c) From the values of moments determine the time constants.

DISCUSSIONS
1.
How does the thermowell affect the temperature readings? What will be effect of empty
thermowell and thermowell filled with oil? What about different material of thermowell?
14

REFERENCES
Donald R. Coughanowr, Process systems analysis and control, 2nd Ed., McGraw Hill, NY,
1991, pg.297-299.
15

16

EXPERIMENT NO. 4
CONTROL VALVE CHARACTERISTICS (THREE VALVES)

OBJECTIVE
1. To study control valve characteristics

INTRODUCTION
VALVE ACTION AND ACTUATOR MECHANISM
If the control valve is used to control fluid flow, some mechanism must physically open or close
the valve. Different types of actuators are used to control the stem travel of the valve, like
electrical actuator, pneumatic actuator, hydraulic actuator etc. In present set-up, pneumatic
actuators are used for control valves. Spring opposed diaphragm actuator positions the valve plug
in response to the controller signals. Mostly the controller signals are in the range of 3-15 psig.
There are two types of actuators described below.
1. Direct acting actuator (Air to close):
Direct acting actuators basically consists of a pressure tight housing sealed by a flexible
fabric reinforced elastomer diaphragm. A diaphragm plate is held against the diaphragm
by a heavy compression spring. Signal air pressure is applied to upper diaphragm case
that exerts force on the diaphragm and the actuator assembly. By selecting proper spring
rates or stiffness, load carrying capacity and initial compression, desired stem
displacement can be obtained for any given input signal.
2. Reverse acting actuator (Air to open):
In case of reverse acting actuators the stem gets retracted with increase in pressure.
The Figure 4.1 shows an air to open type of control valve to control the flow rate. The air to
move the diaphragm is regulated through the pressure regulator. The air is supplied from an air
compressor. The flow of water takes place from a constant head tank that is equipped with an
overflow line. For the valve plug type shown in the figure, increasing the air pressure from the
regulator, the valve stem is moved down thus opening the control valve.
17

Air pressure
regulator
Air compressor
Flow inlet valve
Pump
Figure 4.1: A general scheme showing an air actuated control valve.
TYPES OF CONTROL VALVE

Valve is essentially a variable orifice. Control valve is a valve with a pneumatic, hydraulic
electric (excluding solenoids) or other externally powered actuator that automatically, fully or
partially opens or closes the valve to a position dictated by signals transmitted from controlling
instruments. Control valves are used primarily to throttle energy in a fluid system and not for
shutoff purpose. Depending upon the valve plug design the control valves can be divided in three
categories as under:
1. Equal percentage type:
Flow changes by a constant
percentage of its instantaneous value
for each unit of valve lift.
Q = Flow at constant pressure drop
Q = be ay
y = Valve opening
e = base of natural logarithm
a, b = Constants
Qo= Flow at constant pressure drop
at zero stroke
Constants a & b can be evaluated to

18

give more convenient form
Q = Qo e
2. Linear type:
Flow is directly proportional to valve
lift.
log R
xy
y
max
F
y
=
Fmax
y max
Q = ky
R = Flow range of valve, maximum

to minimum at constant
pressure drop
ymax= Maximum rated valve
opening.
Q = Flow at constant pressure drop.
y = Valve opening
k = constant
3. Quick opening type (On/Off type):

Flow increases rapidly with initial travel reaching near its maximum at a low lift. It is
generally not defined mathematically.
DESCRIPTION
The present set-up consists of three control valves with pneumatic actuators as shown in the
Figure 4.2.
Figure 4.2: Experimental set-up with three control valves

One control valve (CV1) is with equal percentage characteristics (air to close type), second is
quick opening valve (CV2) with On/Off characteristics (air to open type) and third is linear
control valve (CV3) with linear characteristics (air to open type). Apparatus is self-contained
19

water re-circulating unit. Compressed air supply is to be provided from user end. Water from
sump tank is sucked and delivered to a constant level overhead tank by means of a centrifugal
pump. Water flows back from overhead tank to sump tank. Each control valve is provided with a
ball valve at the inlet. Flow rate of water passing through the control valve is measured with the
help of rotameter (FI). A common water manometer is provided for the measurement of water
pressure head at the inlet of control valve. As outlet of control valve is open to the atmosphere,
the pressure at inlet of control valve is considered as pressure drop across the valve. Change in
the stem travel/ position of control valve results in the change in flow through the control valve.
This adjustment is done by regulating the air pressure inside the diaphragm of control valve (3 to
15 psig). For this purpose a pressure regulator (PR) with pressure gauge (PI) is provided in
pneumatic line. Pressure gauge facilitates to get direct reading of pressure inside the diaphragm
of control valve. Individual ball valves are provided to actuate the pneumatic line for each
control valve. For detecting the stem travel/position, scale is provided on each control valve.
UTILITIES REQUIRED
1. Electricity supply: Single phase, 220V AC, 50Hz, 5-15 A. Socket with earth connection.
2. Compressed air supply: 1 CMH at 2 bar
3. Water supply
4. Drain
PRECAUTION & MAINTAINANCE INSTRUCTION
1. Never run the apparatus if power supply is less than 180 volts & greater than 230 volts.
2. If the apparatus will not be in use for more than one month, drain the apparatus
completely and fill pump with cutting oil.
3. To prevent clogging of moving parts, run pump at least once in a fortnight.
4. Always use clean water.
5. Always keep apparatus free from dust.
TROUBLESHOOTING
1. If pump gets choked, open the back cover of pump and rotate the shaft manually.
20

REFERENCE
McGraw Hill, NY, 2009, pg. 441.
21

22

EXPERIMENT NO. 4(A)
STUDY OF CONTROL VALVE FLOW CO-EFFICIENT (CV)
OBJECTIVE
1. To determine flow coefficient CV of the control valve.

THEORY
A control valve is used to control the flow rate in a fluid delivery system to control the process.
There is a close relation between pressure and the flow rate in fluid stream passing through the
pipe so that if the pressure is changed, the flow rate will also be changed. A control valve
changes the flow rate by changing the pressure in the flow system because it introduces the
constriction in the delivery system. So we can say that the flow rate through the constriction can
be given as:
Q=
K
P
.(1)
The most important factor associated with control valve is correction factor K of the above
equation. This correction factor allows selection of proper size of valve to accommodate the flow
that the system must support. This correction factor is called the valve coefficient and is used in
valve sizing.
CONTROL VALVE FLOW COEFFICIENT
The valve coefficient is measured as the number of USGPM (US Gallon per minute) that flows
through a fully open valve with a pressure drop of 1 psig. (1 US gallon = 3.785 Liters)
In SI units the formula for calculating CV is:
Q = KV
Pv
G
.(2)
where, Q is flow rate, m3/hr and Pv is pressure drop across valve, kgf/cm2
Relation between KV & CV is:
K V = 0.856 CV
23
.(3)

CV = 11.6 Q
G
P
.(4)
where, Q is discharge rate of fluid in m3/h, P= Pressure drop across the wide-open valve, kPa,
G = Specific gravity relative to water. G=1 for water
Note: To convert P in cm of H2O to kPa divide by 10.33
PROCEDURE
1. Start the setup for control valve of equal percentage characteristics.

2. Open pneumatic line for the control valve
3. Open the control valve fully. As the control valve is air to close so pressure in
diaphragm should be 0 psig.
4. Adjust the rotameter for 500 LPH flow by regulating the valve provided at the inlet line
of the control valve and wait for 5 minutes to steady the flow.
5. Record the rotameter and manometer readings.
OBSERVATION & CALCULATION
OBSERVATION TABLE:
P, cm H2O
S.NO.
Valve Type
Q, LPH
Cv (on valve)
1.
Equal Percentage Valve
2.
Linear Valve
3.
Quick Opening Valve
Cv (calculated)
CALCULATION
Make the calculation for Cv as per equation (4) and tabulate in observation table above.
When conducting the experiment for the linear control valve keeping in mind that it is air to
open which means pressure in diaphragm should be more than 15 psig. Adjust this pressure in
diaphragm by opening the pressure regulator. Do not increase this pressure to more than 20 psig.
NOMENCLATURE
P = Pressure drop in kPa.

24

Pv= Pressure drop across valve, kgf/cm2

CV = Flow coefficient of control valve.
G = Specific gravity of fluid (for water G = 1).
Q = Flow rate, LPH.
REFERENCES
McGraw Hill, NY, 2009, pg. 423-440.
25

26

EXPERIMENT NO. 4(B)
STUDY OF INHERENT CHARACTERISTIC OF CONTROL VALVES
OBJECTIVE
1. To study the inherent characteristics of control valves

THEORY
The amount of flow passing through a valve at any time depends upon the opening between the
plug and the seat. Hence there is a relationship between stem position, plug position, and the rate
of flow, which is described in terms of the flow characteristics of a valve. Inherent and installed
are two types of flow characteristics of a control valve.
INHERENT CHARACTERISTIC
The inherent characteristic of control valve is the relation between the flow and the valve travel
at constant pressure drop across the valve. Following are the inherent characteristics for different
10 20 30 40 50 60 70 80 90 100
Quick opening
Lnear
Equal
Flow % of maximum
types of valves.
10
20
30
40
50
60
70
80
90
100
Valve lift % of full lift

Figure 4(B).1: Comparison of inherent characteristics of three types of control valves
PROCEDURE
1. Start the setup for linear control valve.

27

2. Open pneumatic line for the control valve and start increasing the pressure to open the
valve (as the control valve is air to open). Stop as soon as the valve is fully open (flow
rate and stem position will not change beyond this point).
3. Adjust the rotameter for 490 LPH flow by regulating the flow inlet valve provided at the
inlet line of the control valve and wait for 5 minutes to steady the flow. Make sure the air
compressor is running to maintain pressure in the diaphragm.
4. Record the manometer reading in cm of water and the rotameter reading.
5. Now slowly decrease the air pressure by regulating pressure in small steps as given in
observation table, so that the stem travels towards closing position.
6. The pressure drop across the valve will increase. Throttle the flow inlet valve at the inlet
of the control valve to maintain pressure drop constant.
7. Again note down the reading of rotameter and stem position.
8. Repeat the procedure till the valve is fully closed (pressure down to 0 psig).
9. Plot the graph of % of maximum flow vs. % of full lift to show inherent characteristic of
the control valve
10. Perform the same procedure for other two valves too.
OBSERVATION TABLE:
S.No.
Pressure
Regulator
Reading, in psig
Stem lift in mm
Q, LPH
The constant pressure drop across the control valve P, in cm H2O = ___________
CALCULATION
Perform the experiment for the other two valves. As the equal percentage control valve is air to
close pressure in diaphragm should be 0 psig for fully open condition. Repeat the experimental
procedure same as above, but pressure in the diaphragm will be increased gradually.
28

REFERENCES
29

30

EXPERIMENT NO. 4(C)
STUDY OF INSTALLED CHARACTERISTIC OF CONTROL VALVE

OBJECTIVE
1. To study installed characteristics of control valve

THEORY
The amount of flow passing through a valve at any time depends upon the opening between the
plug and the seat. Hence there is a relationship between stem position, plug position, and the rate
of flow, which is described in terms of flow characteristics of a valve. Inherent and installed are
two types of flow characteristics of a control valve.
INSTALLED CHARACTERISTIC
The installed characteristic of control valves described is subjected to distortion due to variations
in pressure drop with flow. Line resistance distorts linear characteristics towards that quick
opening valve and equal percentage to that of linear control valve.
PROCEDURE
1. Start the setup for equal % control valve.

2. Open pneumatic line for the control valve and start increase the air flow to close the valve
(as the control valve is air to close). At fully open condition the pressure in diaphragm
should be 0 psig.
3. Adjust the rotameter for 500 LPH flow by regulating the flow inlet valve provided at the
inlet line of the control valve and wait for 5 minutes to steady the flow.
4. Record the manometer reading in cm of water and the rotameter reading.
5. Now slowly increase the air pressure by regulator in small steps as given in observation
table, so that the stem travels towards closing position.
6. Wait for 5 minutes at each step to steady the flow and note down the reading of
rotameter, manometer and stem travel.
7. Repeat the procedure till the valve is fully closed (pressure up to 15 psig).
8. Plot the graph of % of maximum flow vs. % of full lift to show installed characteristic of
the control valve.
9. Perform the same procedure for other two valves too.
31


OBSERVATION TABLE:
S.No.
Pressure Regulator
Reading, in psig
Stem lift in mm
Q, LPH
P, in cm H2O
DISCUSSION:
Installed characteristics of the linear valve slightly approaches to the characteristics of quick
opening valve and that of equal percentage valve approaches to the linear characteristic because
of the pipe friction and other resistance to the flow.
REFERENCES
32

EXPERIMENT NO. 4(D)
STUDY OF HYSTERESIS OF CONTROL VALVE

OBJECTIVE
1. To study the hysteresis of the control valve.
THEORY
Hysteresis is the difference in reading while opening and closing the valve. In case of control
valves for same actuator signal different stem level (hence valve coefficients) are obtained
depending upon the direction of change. The maximum error in stem travel (or valve coefficient)
expressed in percent for same actuator pressure while opening and closing the valve is indicated
as hysteresis.
EXPERIMENTAL PROCEDURE
1. Start the setup for equal percentage control valve.
2. Open pneumatic line for the control valve
3. Open the control valve fully. As the control valve is air to close so pressure in
diaphragm should be 0 psig.
4. Adjust the rotameter for 500 LPH flow by regulating the valve provided at the inlet line
of the control valve and wait for 5 minutes to steady the flow.
5. Record the manometer reading in mm of water.
6. Record the rotameter reading.
7. Now slowly increase the air pressure using the regulator up to 3 psig.
8. Wait for 5 minutes to steady the flow and note down the reading of rotameter, manometer
and pressure in psig.
9. Repeat the procedure and take the reading at each at +3 psig till the valve is fully closed
(pressure up to 15 psig).
10. Now increase the pressure up to 20 psig and start decreasing the pressure gradually down
to 0 psig.
11. Wait for 5 minutes to steady the flow.
12. Record the manometer reading in mm of water.
13. Record the rotameter reading.
33

14. Repeat the procedure and take the reading at each at -3 psig till the valve is fully opened
(Pressure down to 0 psig).
15. Calculate the valve flow coefficient for actuator pressure for every reading.
16. Plot the graph of actuator pressure vs. flow coefficient. The ratio of maximum difference
between flow coefficients at same actuator pressure to that of maximum flow coefficient
is termed as hysteresis.
17. Repeat the experiment for the other valves.
OBSERVATION AND CALCULATION
OBSERVATION TABLE:
Pressure (psig)
Increase pressure
P, mm H2O
Decrease pressure
Q, LPH
P, mm H2O
Q, LPH
3
6
9
12
15
CALCULATION
CV = 11.6Q
Hysteresis% =
G
P
CV at decreasing pressure - C V at increasing pressure

100
Maximum C V
.(1)
.(2)
Repeat the experiment for the linear control valve. As the control valve is air to open so
pressure in diaphragm should be 15 psig.
NOMENCLATURE
P = Pressure drop in kPa.
34


G = Specific gravity of fluid.
Q = Flow rate, LPH.
REFERENCES
35

36

EXPERIMENT NO. 4(E)
STUDY OF RANGEABILITY
OBJECTIVE
1. To study the rangeability of equal percentage valve.

THEORY
Equal percentage valve has characteristics such that flow changes by a constant percentage of its
instantaneous value for a given percentage change in stem position. Generally this type of valve
does not shut off the flow completely in its limit of stem travel. The rangeability (R) is defined as
the ratio of maximum to minimum controllable flow.
R=
Fmax
Fmin
.(1)
where, Fmax is the flow when the valve stem is at nearly extreme open position foe maximum
controllable flow and Fmin is the flow when valve stem is at nearly extreme closed position for
minimum controllable flow. Fmax and Fmin represent flow rates measured at constant pressure
drop across control valve. Hence, rangeability R also can be defined as ratio of Cv,max to Cv,min.
For equal percentage valve flow has exponential characteristics of rangeability:
= 1
R is the rangeability of the valve and m is its fractional stem position.

PROCEDURE
1. Start the setup for equal percentage control valve.

2. Adjust the rotameter valve and set 500 LPH flow.
3. Set actuator air pressure to 3 psig.
4. Note down the flow rate and pressure at inlet of control valve.
5. Set actuator air pressure to 15 psig.
6. Note down the flow rate and pressure at inlet of control valve.
37
.(2)


OBSERVATION TABLE:
Pressure (psig)
P, mm H2O
Q, LPH
Cv
Remarks
Nearly 3
Nearly 15
CALCULATION
R=
C v max
= ........
C v min
.(3)
R=
Fmax
= ........
Fmin
.(4)
Repeat the experiment by keeping constant pressure drop across the control valve and note the
flow rates.
NOMENCLATURE
P = Pressure drop in bar.
G = Specific gravity of fluid.
Q = Flow rate, LPH.
REFERENCES
38

EXPERIMENT NO - 5
DYNAMICS OF PRESSURIZED TANK
OBJECTIVE
1. To study the dynamics of a pressurized tank.
THEORY
The following figure shows the schematic of the experimental set-up. The objective is to study the
changing pressure dynamics of the tank under varied flow conditions and determine its time constant.
Relief Valve
PG2
V5
V4
V1
PG1
Tank
V2
V3
V6
Air compressor
Figure 5.1: Schematic diagram for the study of dynamics of pressurized tank system
The compressed air to the tank is provided through the valves V1, V2 and V3 and pressure in the inlet line
can be measured by the pressure gauge (PG1). The main instrument is the tank which is provided with a
pressure gauge (PG2), a relief valve (V4), outlet valves (V5 and V6). For pressurizing the tank, first the
pressure is built in the inlet line. The valve (V3) is closed and using valves (V1 and V2), bring the pressure
in the inlet line to say 20 psig. Then keeping both outlet valves (V5 and V6) closed, slightly open valve V3
to let air into the tank, thus pressurizing it. Caution: while letting air into the tank, the inlet line pressure
might fall. In order to maintain the constant pressure inlet condition, you may adjust valves V1 and V2.
Readings are taken until the pressure in the tank reaches the line pressure of say 20 psig.
The process can be continued with valve V5 slightly opened and until a new steady state is reached.
Experiment with different openings of V5 to get different steady states and determine the time constant for
the tank.
39

The transfer function for the system can be derived from the mass balance of air for the general flow
system where we will assume certain flow through valve V5. Consider the following simplified system for
purpose of mass balance of air
P2
P1
V3
V5
P2, V
fin
Pa
fout
Figure 5.2: Simplified diagram for mass balance

Let the volume of the tank be V and gauge pressure inside the tank be P2. The inlet line gauge pressure be
P1. The inlet valve V3 has a valve coefficient of Kv3 and outlet valve V5 has a valve coefficient of Kv5.
Then the flow rate of air through these valves are related to pressure drops across them as follows
=
1 2
Assuming density of air is constant at = (2 + ) . The mass balance then gives,

3
1 2
2 =
1
2
(2 + )
Multiply by (P2 +Pa) and linearize this equation to get a first order system.
3
1 2, 2, + + 1 2,
2, +
2 2,
21 2,
2, +
2 2,
2, 2, + +
+ 2, 2 2, =
22,
As the experimenter will hold P1 constant and steady state values are constant we can simplify the
equation as follows with deviation variables for pressure in the tank as 2
3
[1 + 1 2 ]
40
[2 + 2 2 ] =

Taking Laplace of the equation and simplify we get

2 () =
where,
=
+ 1
3 1 5 2
and =
5 2 3 1
5 2 3 1
Taking inverse Laplace of the first order system, we get
2 () = 2, +
Using various experiments as detailed above we can experimentally find the time constant and compare
with the simplified first order approximation derived.
APPARATUS
1. Air Compressor
2. Tank to hold pressurized air
3. System of valves to regulate air
PROCEDURE
1. Initially the tank and entire line is supposed to be at atmospheric conditions.
2. Close inlet valve to tank (V3), outlet valves from the tank (V6, V5). Adjust the valves V1, V2 and
V3 in such a way that a pressure of 20 psig is maintained in pressure gauge (PG1).
3. With valve V5 closed, note pressure reading (PG2) vs. time till pressure in vessel is equal to line
pressure.
4. Provide a step change in outflow of air by crack opening V5 slightly. Note the value of vessel
pressure as a function of time as it falls and reaches a new steady state.
5. Again close valve V5 and note vessel pressure reading till it reaches steady state.
6. Repeat the step change in outflow (different magnitudes) two more times for quarter open and
half open valve V5.
OBSERVATIONS AND CALCULATIONS
Given data from the valve manufacturer:
Valve coefficient for valve (V3), 3 = __________________
Valve coefficient for valve (V5), 5 = __________________
41

Condition 1: the valve V5 is completely closed

Take readings of tank pressure P2(t) with time (t) and obtain the steady state value (P2,s).
Time, t in s
Pressure, P2, in Pa
Condition 2: the valve V5 is cracked open by a quarter turn.

Take readings of tank pressure P2(t) with time (t) and obtain new steady state value (P2,sq).
Time, t in s
Pressure, P2, in Pa
The change in outlet valve flow rate caused a pressure magnitude change of (P2,s - P2,sq).
Condition 3: the valve V5 is closed and again tank pressure is brought back up to P2,s. After attaining
steady state value, the valve is cracked open one more time by half turn.
Take readings of tank pressure P2(t) with time (t) and obtain new steady state value (P2,sh).
Time, t in s
Pressure, P2, in Pa
The change in outlet valve flow rate caused a pressure magnitude change of (P2,s - P2,sh).
Plot vessel pressure (P2) vs. time for all the cases of valve openings you experiment with.
Compute time constant of the system using different methods for rising and decreasing pressures
separately for all the cases.
DISCUSSIONS
REFERENCES
42

EXPERIMENT NO. 6
INTERACTING AND NON-INTERACTING SYSTEMS

INTRODUCTION
The setup is design to study dynamic response of single and multi capacity process when
connected in interacting and non-interacting mode. It is combined to study
1. Single capacity process
2. Non-interacting process and
3. Interacting process.
The observed step response of the tank level in different mode can be compared with
mathematically predicted response.
Tank 1
R1
Tank 2
Rotameter
Tank 3
R3
R2
Pump
Supply tank
Figure 6.1: Overall schematic of the interacting and non-interacting tank system
APPARATUS
1.
2.
3.
4.
5.
Supply tank
Pump for water circulation.
Rotameter for flow measurement.
Valves for controlling fluid flow.
Transparent tanks with graduated scales, which can be connected in interacting and noninteracting mode.
The components are assembled on frame to frame tabletop mounting.
43

44

EXPERIMENT NO. 6(A)
STEP RESPONSE OF SINGLE CAPACITY SYSTEM

OBJECTIVE
1. To study the response of a single capacity system to step input
THEORY
Step function: Mathematically, the step function of magnitude A can be expressed as

X (t ) = Au (t )
where, u(t) is a unit step function.
It can be graphically represented as in Figure 6(A).1:
where,
A
X(t)
0 when t < 0
X (t ) =
A when t 0
and X ( s ) =
A
s
Figure 6(A).1: Step input function

To study the transient response for step function, consider the system consisting of a tank of
uniform cross sectional area A1 and flow resistance R1 such as for a valve. Qo, volumetric flow
rate through the resistance, is related to head h1 by a linear relationship.
q
A1
qo
h1
R1
Figure 6(A).2: Schematic of single capacity system

45

qo =
h1
R1
(1)
Writing a transient mass balance around the tank:

(Mass flow in) (Mass flow out) = Rate of accumulation of mass in the tank
q (t ) q o (t ) = A 1
dh1
dt
(2)
Combining equation (1) and (2) to eliminate qo(t) gives the following linear differential equation:
q
h1
dh
= A1
R1
dt
..(3)
Initially the process is operating at steady state, which means that
qs
dh1
=0
dt
h1s
=0
R
(4)
where, the subscripts indicates the steady state value of the variable.
Subtracting equation (4) from equation (3), we get
(q q s ) =
Defining deviation variable:
(h1 h1s )
d (h1 h1s )
+ A1
R1
dt
..(5)
q q s = Q and h1 h1s = H 1 equation (5) can be written as:

Q=
H1
dH 1
+ A1
R
dt
(6)
Taking a transform of equation (6) gives,

Q( s) =
H 1 (s)
+ A1 sH 1 ( s )
R
..(7)
Equation (7) can be rearranged into standard form of first order system as:
H 1 ( s)
R1
=
Q( s)
(s + 1)
For a step change of magnitude A, we can write,

46
where 1 = A1 R1 .
..(8)

Q(t ) = Au (t ) or Q( s ) =
A
s
(9)
Now from equation (8) we can write
H 1 (s) =
A R1
s ( 1 s + 1)
.(10)
By taking Laplace transformation of equation (10) we get,
H 1 (t ) = AR1 1 e
.(11)
According to above equation (11) we can find the nature of curve as shown in Figure 6(A).3
H1(t) in m
below.
Single tank
t in s
Figure 6(A).3: Transient response of single tank system
APPARATUS
See the list of apparatus in the introduction to experiment 6. In addition we need:
1. Stop watch
PROCEDURE
1. Start the setup by inserting the flexible pipe provided at the rotameter outlet in to the
cover of the top tank 1. Keep the outlet valve R1 of the tank 1 fully open and R2 of the
tank 2 slightly closed.
2. Switch on the pump. Adjust rotameter flow rates in steps of 10 LPH from 40 to 70 LPH
and note steady state levels for tank 1 against each flow rate.
47

3. From the data obtained select a suitable band for experimentation, say 50-60 LPH in
which we will be getting more readings of tank level.
4. Adjust the flow rate at lower value of the band selected, say 50 LPH and allow the level
of the tank 1 to reach steady state and record the flow and level at steady state.
5. Apply the step change by increasing the rotameter flow by 10 LPH.
6. Immediately start recording the level of the tank 1 at the interval of 15 sec, until the level
reaches at steady state.
7. Carry out the calculations as mentioned in calculation part and compare the predicted and
observed values of the tank level.
8. Repeat the experiment by throttling outlet valve (R1) to change resistance.
OBSERVATIONS
Diameter of tank (in mm)
= ID 92 mm
Initial flow rate (LPH)
= .
Initial steady state tank level (in mm)
= .
Final flow rate (LPH)
= .
Final steady state tank level ( in mm)
= .
Fill up columns H1(t) observed and H1(t) predicted after calculations:

S.No.
Time (s)
Level (in mm)
H1(t) observed (in mm)
H1(t) predicted (in mm)
15
30
45
CALCULATIONS
Magnitude of step change.

Let A =
3
Flow after step input Initial flow rate in m /s
Outlet valve resistance in s/m 2
R1 = dH 1
dQ (When considering non linear resistance at outlet.)
48

time constant in s
1 =
2
2
A 1 R1 where A 1 is the area of the tank in m and R 1 is resistance of outlet valve in s/m
where, dH1 = change in level (Final steady state level Initial steady state level)
dQ = change in flow (Final flow rate after step change Initial flow rate).
H 1 (t ) observed = (Level at time t level at time t = 0)

t
H 1 (t ) predicted = AR1 1 e 1
= Level predicted at time t in meter.

Plot the graph of H1(t) vs. time(t) for observed and predicted levels.
DISCUSSIONS
Observed response fairly tallies with theoretical calculated response. Deviations observed may
be due to following factors:
1. Non-linearity of valve resistance.
2. Step change is not instantaneous.
3. Visual errors in recording observations.
4. Accuracy of Rotameter.
REFERENCES
49

50

EXPERIMENT NO. 6(B)
STEP RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN NONINTERACTING MODE

OBJECTIVE
1. To study the step response of two first order systems arranged in non-interacting mode
THEORY
In non-interacting systems we assume the tanks have uniform cross sectional area and the flow resistance
is linear. To find out the transfer function of the system that relates h2 to q, writing a mass balance around
the tank, we proceed as follows.
q(t)
A1
q1
R1
h1
A2
q2
R2
h2
Non interacting system
Figure 6(B).1: Schematic of two first orders systems in non-interacting mode

We can write mass balance at tank 1
q q1 = A1
dh1
dt
..(1)
A mass balance at tank 2 is given as
q1 q 2 = A2
dh2
dt
..(2)
The flow head relationships for the two linear resistances in non-interacting system are given by the
expressions.
51

q1 =
q2 =
h1
R1
.(3)
h2
R2
..(4)
From equation (1) & (3) we get
Q1 ( s )
1
=
Q( s) 1 s + 1
where
..(5)
Q1 = q1 q1s
Q = q q s
= A R
1 1
1
..(6)
From equation (2) & (4) we get
H 2 ( s)
R2
=
Q1 ( s ) 2 s + 1
where
..(7)
H 2 = h2 h2 s
2 = A2 R2
..(8)
Overall transfer function can be calculated as follows
H 2 ( s)
R2
=
Q( s)
( 2 s + 1) ( 1 s + 1)
..(9)
For a step change of magnitude A
Q(t ) = Au (t ) so
..(10)
A
s
..(11)
Q( s) =
H 2 ( s) =
AR2
s ( 2 s + 1) ( 1 s + 1)
..(12)
H2 at time t is given by
H 2 (t ) = AR2 1 1 2
1 2
1 t 1 t
e1 e2
2
1
According to above equation we can find the nature of curve as shown below.
52
..(13)
H2(t) in m
Non interacting
tanks
t in s
Figure 6(B).2: Transient response of non-interacting system

PROCEDURE
cover of the top tank 1. Ensure that the valve (R3) between tank 2 and tank 3 is fully
closed.
2. Switch on the pump and adjust the flow rate to 40 LPH. Allow the level of both the tanks
(tank 1 and tank 2) to reach a steady state and record the initial flow and steady state
levels of both tanks.
3. Apply the step change with increasing the rotameter flow by 10 LPH.
4. Record the level of tank 2 at an interval of 15 s until the level reaches steady state.
5. Record final flow and steady state level of tank 1.
OBSERVATIONS
Diameter of tanks (in mm)
= ID 92 mm
= .
Initial steady state level of tank 1 (in mm)
= .
= .
= .
Final steady state level of tank 1 ( in mm)
= .
53

= .

SL No.
Time (sec)
H2(t) observed ( in mm)
Level of tank 2
(in mm)
.
30
60
90
CALCULATIONS

Let A =
3
Outlet valve resistance in s/m 2 of tank 1
R1 = dH 1
dQ (When considering non linear resistance at outlet).
R2 = dH 2
dQ (When considering non linear resistance at outlet )
time constant (in s) of tank 1.
1 = A 1 R1 where A1 = (d 1 2 ) is the area of the tank 1 in m 2 and R 1 is resistance of

4
outlet valve (in s/m 2 ) of tank 1


4
2
outlet valve (in s/m ) of tank 2
Where, dH1 = change in level of tank 1

= (Final steady state level Initial steady state level)
dH2 = change in level of tank 2
H 2 (t ) observed = (Level at time t level at time t = 0) x 10-3

54

H 2 (t ) Pr edicted
= AR2 1 1 2
1 2
1 t 1 t
e1 e2
2
1
= Level in tank 2 predicted at time t in meter.

Plot the graph of
1. H2(t) Predicted vs. time(t) and
2. H2(t) observed vs. time(t).
DISCUSSIONS
REFERENCES
55

56

EXPERIMENT NO. 6(C)
IMPULSE RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN NONINTERACTING MODE
OBJECTIVE
1. To study the impulse response of two first order systems arranged in non-interacting mode
THEORY
Mathematically, the impulse function of magnitude A is defined as
X (t ) = A (t )
..(1)
where, (t ) is the unit impulse function. Graphically, it can be described as:
Where,
0 when t < 0
A
when 0 < t < b

X (t ) =
b
0 when t > b
X(t)
A/b
and
Lim X (t ) = A (t )
b 0
L[ A (t )] = A
Figure 6(C).1: Impulse input function

Overall transfer function of the system as described in the previous experiment
H 2 ( s)
R2
=
( 2 s + 1) ( 1 s + 1)
Q( s)
For a impulse change of magnitude V (Volume added to the system)
Q(t ) = V (t )
Q( s) = V
Hence we find
H 2 ( s) =
57
VR2
( 2 s + 1) ( 1 s + 1)
..(2)
..(3)
..(4)

t
t
2
1
e e
For impulse change H2 at time t is given by H 2 (t ) = VR2
2
1
..(5)
Considering linear resistance at outlet valve of the tank 2, the value of R2 can be calculated as:
H 2, s
R2 =
..(6)
where H2,s is the steady state level of tank 2 and Q is the steady flow through the system from the pump.
Before and after the impulse the tank levels and flow rates will return to this steady state value and hence
these are used for calculating resistance of the valve.
Put the values in equation (3) to find out H(t) predicted and plot the graph of
1. H2(t) predicted vs. time (t) and
2. H2(t) observed vs. time (t).
PROCEDURE
cover of the top tank 1. Ensure that the valve (R3) between tank 2 and tank 3 is fully
closed.
(tank 1 and tank 2) to reach at steady state and record the initial flow and steady state
3. Apply impulse input by adding 0.5 liters of water in tank 1.
4. Record the level of tank 2 at an interval of 15 s, until the level reaches steady state (same
as before impulse is added).
OBSERVATIONS
= ID 92 mm
= .
= .
= .
58

Volume added (liters)
= .

SL No.
Time (sec)
Level of tank 2
(in mm)
.
30
60
90
CALCULATIONS
Let
R1 = H 1, s
Q (When considering non linear resistance at outlet).
R2 = H 2 , s
Q (When considering non linear resistance at outlet )

4
outlet valve (in s/m 2 ) of tank 1


4
2
Where, H1,s , H2,s = steady state level of tanks 1 and 2

Q = steady state flow through the system.
H 2 (t ) observed = (Level at time t Level at time t = 0) x 10-3
H 2 (t ) Pr edicted
t
t
2
1
e e
= VR2
2
1
59

V= Volume of liquid added as an impulse input (in m3).

Plot the graph of
DISCUSSIONS
4. Accuracy of rotameter.
REFERENCES
McGraw Hill, NY, 2009, 123-130.
60

EXPERIMENT NO. 6(D)
STEP RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN

INTERACTING MODE
OBJECTIVE
1. To study the step response of two first order systems arranged in interacting mode
THEORY
Assuming the tanks of uniform cross sectional area and valves with linear flow resistance the transfer
function of interacting system can be written as:
q(t)
A2
q2
A3
R2
h2 R
3
q3
h3
Figure 6(D).1: Schematic of two first order systems in interacting mode

We can find the relation between H2(s) and Q(s) as follows:
H 2 ( s)
R2
=
2
Q( s ) 3 2 s + ( 3 + 2 + A3 R2 ) s + 1
..(1)
Let,
b=
A3 R2
..(2)
3 2
b 2 1

2 3 2
..(3)
b 2 1
b

=
2
2 3 2
..(4)
b
+
2
For a step change of magnitude A
[(1 / ) e t ] [(1 / ) e t ]
H 2 (t ) = AR2 1
[1 / 1 / ]
61
..(5)

In terms of transient response the interacting system is more sluggish than the non-interacting system.
According to above equation we can find the nature of curve as shown below.
H2(t) in m
Non interacting
tanks
Interacting
tanks
t in s
Figure 6(D).2: Transient response of interacting system

PROCEDURE
cover of the top tank 3. Keep the outlet valve (R2) of tank 2 slightly closed. Ensure that
the valve (R3) between tank 2 and tank 3 is also slightly closed.
(tank 2 and tank 3) to reach at steady state and record the initial flow and steady state
3. Apply the step change with increasing the rotameter flow by 10 LPH.
4. Record the level of tank 2 at the interval of 15 s, until the level reaches steady state.
5. Record final steady state flow and level of tank 3.
OBSERVATIONS
= ID 92 mm
= .
= .
62

= .
= .
= .
= .

S.No.
Time (s)
Level of tank 2
(in mm)
.
30
60
90
CALCULATIONS

Let A =
3
R2 = dH 2
dQ (When considering non linear resistance at outlet )
R3 = dH 3
dQ (When considering non linear resistance at outlet).

4
2

4
2
Where, dH2 = change in level of tank 2

dH3 = change in level of tank 3
63


H 2 (t ) observed = (Level at time t Level at time t = 0) x 10-3
[(1 / ) e t ] [(1 / ) e t ]
H 2 (t ) Pr edicted = AR2 1
[1 / 1 / ]
= Level in tank 2 predicted at time t in meters.

Calculate the value of b, and from equations given in the theory part.
Plot the graph of
DISCUSSIONS
REFERENCES
64

EXPERIMENT NO. 6(E)
IMPULSE RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN INTERACTING

MODE
OBJECTIVE
1. To study the impulse response of two first order systems arranged in interacting mode
THEORY
Mathematically, the impulse function of magnitude A is defined as
X (t ) = A (t )
..(1)
where, (t ) is the unit impulse function. Graphically, it can be described as:
Where,
0 when t < 0
A
when 0 < t < b

X (t ) =
b
0 when t > b
X(t)
A/b
and
Lim X (t ) = A (t )
b 0
L[ A (t )] = A
Figure 6(E).1: Impulse input function

Overall transfer function of the system is
H 2 ( s)
R2
=
2
Q( s ) 3 2 s + ( 3 + 2 + A3 R2 ) s + 1
..(2)
For a impulse change of magnitude V (Volume added to the system)
Q(t ) = V (t )
..(3)
Q( s) = V
H 2 ( s) =
..(4)
VR2
3 2 s + ( 3 + 2 + A3 R2 ) s + 1
..(5)
VR2
[ e t e t ]
3 2 ( )
..(6)
For impulse change H2 at time t is given by
H 2 (t ) =
65

where,
b=
A3 R2
..(7)
3 2
b
+
=
2
b 2 1

2 3 2
..(8)
b 2 1

2 3 2
..(9)
=
PROCEDURE
cover of the top tank 3. Keep the outlet valve (R2) of tank 2 slightly closed. Ensure that
the valve (R3) between tank 2 and tank 3 is also slightly closed.
(tank 2 and tank 3) to reach steady state and record the initial flow and steady state levels
of both tanks.
3. Apply impulse input by adding 0.5 liters of water in tank 3.
4. Record the level of tank 2 at an interval of 15 s, until the level reaches steady state (same
as before impulse is added).
OBSERVATIONS
= ID 92 mm
= .
= .
= .
Volume added (lit.)
= .

S. No.
Time (sec)
Level of tank 2
(in mm)
66

30
60
90
CALCULATIONS
Let
R2 = H 2 , s
Q (When considering non linear resistance at outlet )
R3 = H 3, s
Q (When considering non linear resistance at outlet).

4
2

4
2
where, H3,s , H2,s = steady state levels of tank 3 and 2

Q = steady flow through the system.
H 2 (t ) observed = (Level at time t level at time t = 0) x 10-3

H 2 (t ) Pr edicted =
VR2
[ e t e t ]
3 2 ( )
V= Volume of liquid added as an impulse input (in m3).

Plot the graph of
67

DISCUSSIONS
REFERENCES
68

EXPERIMENT NO. 7
DEAD WEIGHT TESTER FOR PRESSURE GAUGE CALIBRATION

OBJECTIVE
1. Calibration of pressure gauge by Dead weight tester
THEORY
D
I
K
F
G
A
Weights table
Reservoir Cap
Screw press
Oil Reservoir
Levelling Screws
Valve
Table
APPARATUS
1. Weights
2. Pressure gauge for calibration
69
Gauge Post

3. Testing apparatus
PROCEDURE
1. Set level by placing a spirit level on the weight table (A) and adjusting the leveling
screws (H).
2. Wind capstan handle of screw press (G) fully in, i.e., clockwise.
3. Remove reservoir cap (D) and pour oil (only castor oil technical grade free from acids
and water traces, not Castrol until nearly full and open valve (F).
4. Screw capstan (G) in and out until bubbles stop appearing in the reservoir.
5. Screw capstan (G) fully out.
6. Close the valve (F).
7. Select correct adopter and fit gauge/instrument (under test) at gauge post (K) using a
proper copper washer or bonded seal. Gauge should never be mounted until the priming
operation (step 4) is done.
8. Ensure that the gauge /instruments to be tested are internally clean, if water, dirt or
chemicals are sucked into the system from contaminated instruments, the ram system will
be seriously damaged.
9. Load the weight table (A) with the weights. The equivalent of the weight table must also
be taken into account.
10. Apply the pressure with the screw press (G) until the weights begin to rise. Spin weight
table by hand and adjust the capstan until weight table skirt floats within the indicator red
band. The red band is easily visible on the piston cylinder from a seated position.
11. It is essential that the weights should be spinning freely whilst taking readings.
12. Never take off weights without removing all pressure in the system by unscrewing the
press (G).
13. After the test is finished stop the weights spinning, wind back the screw press (G) fully
and open the valve (F). The tester is now ready for another test.
14. In high pressure testers, a slight leakage through the cylinder vent hole on the side of the
ram cylinder is normal.
70

OBSERVATION AND CALCULATIONS
Record the weights and pressure readings

S.No. Weights
(decreasing)
Pressure Gauge
Weights
Pressure Gauge
Reading
(increasing)
Reading
1.
2.
:
The weight of the weights table = ___________ kgf/cm2.
DISCUSSIONS
REFERENCES
71

72

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LAB MANUAL

Process Dynamics and Control Lab

Chemical Engineering Department, IIT Roorkee

CHN 303: CHEMICAL ENGINEERING LABORATORY

CHN 303: CHEMICAL ENGINEERING LABORATORY

Dynamics of stirred tank with proportional ON/OFF temperature

Dynamics of evacuated tank

Control valve characteristics

Study of control valve flow coefficient (Cv)

Study of inherent characteristics of linear control valve

Study of installed characteristics of control valve

Study of Hysteresis of control valve

Dynamics of pressurized tank

Interacting and Non-Interacting System

Step response of single capacity system

Step response of first order systems arranged in non-interacting

Step response of first order systems arranged in interacting mode

Impulse response of first order systems arranged in interacting

Dead weight pressure gauge calibrator

CHN 303: CHEMICAL ENGINEERING LABORATORY

CHN 303: CHEMICAL ENGINEERING LABORATORY

DYNAMICS OF STIRRED TANK TEMPERATURE CONTROLLER

C = Specific heat capacity of the fluid entering the tank (J/kg.K)

= Density of the fluid (kg/m 3 )

CHN 303: CHEMICAL ENGINEERING LABORATORY

From equation (3) and equation (5) we get

Lets we define the deviation variables,

Suppose we assume there is no variation in temperature of input stream then o = 0 then

Now taking Laplace operator both sides we get,

CHN 303: CHEMICAL ENGINEERING LABORATORY

Taking inverse Laplace we get,

Hence from eq.(8) and eq.(18)

CHN 303: CHEMICAL ENGINEERING LABORATORY

Over Head Tank

Liquid Level Indicator

On/Off Type Temp. Controller

CHN 303: CHEMICAL ENGINEERING LABORATORY

OBSERVATION AND CALCULATIONS

CHN 303: CHEMICAL ENGINEERING LABORATORY

CHN 303: CHEMICAL ENGINEERING LABORATORY

DYNAMICS OF EVACUATED TANK

Mercury Reservoir and U-tube

CHN 303: CHEMICAL ENGINEERING LABORATORY

Condition 2: After crack opening the vent cock half way

Condition 3: Completely closing vent cock valve

CHN 303: CHEMICAL ENGINEERING LABORATORY

CHN 303: CHEMICAL ENGINEERING LABORATORY

The step response of a second order system is as follows:

CHN 303: CHEMICAL ENGINEERING LABORATORY

where, Y is deviation variable. The value of Y(t) at different time (t)

A(1 - e -1 ) = _________ o C when t =

Y(t ) = A(1 - e -2 ) = _________ o C when t = 2

CHN 303: CHEMICAL ENGINEERING LABORATORY

where, Y(t) is deviation temperature.

- A(1 - e -1 ) = _________ o C when t =

Y(t ) = - A(1 - e -2 ) = _________ o C when t = 2

2. Thermometer with thermowell

Slope and Intercept Method

CHN 303: CHEMICAL ENGINEERING LABORATORY

Slope Intercept Method

Original Experimental Data

Difference of the two curves