INSTRUMENTATION & PROCESS CONTROL LAB MANUAL (7th Semester)

LAB INCHARGE:

Prof. Dr. Arshad Chughtai

FACULTY TEAM:

Ms. Rabya Aslam

Institute of Chemical Engineering & Technology

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

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

C. Control Loops:
7. Report the response and variations in the process variable PV( flow of water)output in i. Proportional Mode (P- mode) by giving the values of gain as 1.00, 0.6 and 1.6 while the output of controller set on 30 % i.e. set point = 30 %. Proportional Integral mode (PI mode) by giving the values of Reset time, as 0.1, 0.15 and 0.5 while the output of controller set on 30 %. Proportional Integral Derivative mode (PID mode) by giving the values of rate minute as 1, 2, 3 while the output of controller set on to 30 %.

ii.

iii.

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

Table of Contents:
Contents 1. Calibration of Bourdon gauge using Manometer 2. Calibration of Bourdon gauge using dead weight tester 3. Calibration of RTD using thermometer 4. Calibration of thermocouple using thermometer 5. Time constant of thermometer 6. Time constant of liquid level system 7. Flow control loop 8. Temperature control loop Page no. 4 8 12 15 18 22 26 32

Experiment # 1: Calibration of Bourdon Gauge using Manometer Objective:

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

Apparatus:
Bourdon gauge Mercury filled thermometer Air compressor

Procedure:
Start the air compressor before performing the experiment. Mercury level in the U-shaped manometer is checked. The Manometer shows the value of the change in pressure by inches of mercury and Bourdon gauge report the value of same pressure in psi or bar. The readings of both the manometer i.e., inches of mercury and Bourdon gauge i.e., psi or bar are noted after the alteration in the pressure by means of controlling valve. The readings of manometer i.e., in inches of mercury are converted into psi by multiplying with an appropriate factor. The graph between manometer readings at X-axis and the Bourdon gauge reading at Y-axis is plotted. A straight line at 45 form origin is drawn. The maximum difference between the actual plotted line and the 45 line is the Span error. Formulae Used: 1. Pressure Reading using Manometer

 ( Hg air ) gh P = gc

Where Hg is density of Mercury air is density of Air h = difference in height between two limbs of manometer 2. Average Error
n E AvgError = i =1 n

Where E = Error for ith observation n = number of observations 3. Accuracy:

X = % Error =

S tan dard Value Measured Value 100 S tan dard Value i =1

n

Accuracy = X % Bourdon Gauge is X % inaccurate

Observations and calculations:

Density of Air = air = 1.2 kg/m3 Density of Mercury = Hg = 13,650 kg/m3
Differential No. of obs. Gauge Pressure (kg/cm2) Gauge Pressure (X1) (kPa) Manometer Reading, H (inHg) pressure measured by manometer X2 (kPa) Error (X1-X2) (kPa)

RESULT:

Results Accuracy Range Average Error

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

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

Apparatus:
Bourdon gauge Dead weight tester Weights.

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

Procedure:
1. 2. 3. 4. 5. 6. 7. Initially the gauge which is to be calibrated is connected with the dead weight tester. The lever is moved outward completely After putting a pressure plate of suitable weight upon dead weight tester, the lever is During closure of lever, Bourdon gauge showed increase in pressure. The piston is moved At that point Bourdon gauge reading is noted. Again the same procedure is repeated right from the beginning by placing another pressure plate on the top of already placed pressure plate. The graph between dead weight tester reading on X-axis and Bourdon gauge reading on Y-axis is plotted.

gradually moved outwards. inwards until the scale of Bourdon gauge stops with the jerk.

Formulae used:
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1. Accuracy:

X = % Error =

S tan dard Value Measured Value 100 S tan dard Value i =1

n

Accuracy = X % inaccurate 2. Average Error

n E AvgError = i =1 n

Where E = Error for ith observation n = number of observations Observations & Calculations: Pressure applied Sr. No. by weights, P1 kg/cm2 Bourdon gauge Reading P2 kg/cm2 Error, E=P1-P2 kg/cm2

Calibration Curve:

Result:
Results Accuracy Range Average Error

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SUMMARY OF BOURDON GAUGE

Category Working Principle Pressure Measuring Device Mechanical displacement due to pressure on fluid. Berylium Copper Material of construction steel chrome alloy steel stainless steel Accuracy Limits of application 1-5% of full span Up to 100 MPa. Low cost with reasonable accuracy. Advantages wide limits of application can be used in harsh environment affected by shock and vibrations Disadvantages have slow response time as compared to bellow

Experiment # 3: Calibration of RTD Objective:

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

Apparatus:
Resistance Thermometer (Platinum) Beaker Oil bath Thermometer Avometer

Procedure: Initially the Avometer is standardized by joining the two ends of the wires of RTD to Avometer and then wires are short circuited in order to set the pointer at zero. The resistance thermometer is inserted in the oil beaker which already had the mercury filled thermometer. The oil in the beaker is heated and different sets of readings are taken for resistance and the temperature for every five degree centigrade temperature rise. Finally a graph between temperature and the resistance is plotted. The straight line drawn showed the fitness of the resistance thermometer under consideration for the required purpose.

Observations:

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Sr. No.

Temperature (C)

Resistance (ohm)

Calibration Curve:

Summary Of RTD
Category Temperature sensor 13

 Resistance of metal increase with increase Working Principle Material of construction Sensitivity Limits of application in temperature. Platinum Nickel 0.004/C to 0.005/C Up to 650C for Platinum Up to 300C for Nickel High accuracy. Wide Range of application Advantages Good reproducibility Higher signal to noise ratio. Can be used in radiation environment Slower response time Disadvantages Expensive

Experiment # 4: Calibration of Thermocouple using Thermometer Objective:

To calibrate the given Thermocouple with the help of Thermometer 14

Apparatus:
Potentiometer Thermocouple Oil bath Mercury filled Thermometer

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

Observations & calculations:

Temperature, T C

No. of Obs.

E.M.F. mV

Calibration Curve:

15

Summary of thermocouple

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Category Working Principle

Temperature Sensor

SEEBECK effect Chromel-Alumel

Material of construction

Copper-Constantan Platinum,Rhodium-Platinum

Limits of application

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

Advantages

Good reproducibility Good accuracy Cannot be used for radiation environment

Disadvantages

Low value of emf is corrupted with noise Temperature is not exactly linear with emf
Type E- Type E (chromelconstantan) Type K- Type K (chromel{90 percent nickel and 10 percent chromium}alumel)

Thermocouple types

Type J- Type J (ironconstantan) Type N- Type N (NicrosilNisil) Type R- Type R thermocouples use a platinumrhodium alloy containing 13% rhodium

Type S- Type S thermocouples are of 90% Platinum and 10% Rhodium

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Experiment # 5: Time Constant of Mercury Filled Thermometer Objective:

Determine the time constant of the given mercury filled thermometer dipped in an oil bath. Draw graph between Y(t)/A and t/ and report response Y(t) of the system when t=, t=2, t=3.

Apparatus:
Two mercury filled thermometer Oil bath Heating device Stop watch.

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

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Observations and Calculations:

Room temperature= y(s) = C Maximum temperature for heater oil bath = y() = 220C Amplitude = A = y() - y(s) Temperature Time Sr. No t of Thermometer y(t), (sec) C Y(t)= y(t)y(s) C Y(t)/ A t/ = - ln(1- (Y(t)/A))

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Response of system at when t=, t=2, t=3. At t/ = 1, Y(t)/A = 0.63 (From graph) Y(t) = 0.63 x A C Results: Results (sec) Y(t) when t/ = 1 Y(t) when t/ = 2 Y(t) when t/ = 3

Time Constant

C C C

Response of System

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Summary of thermometer
Category Working Principle Material of construction Temperature Measuring Device Expansion of fluid with increase in temperature. Ordinary Soda Lime Fused Quartz Hg is opaque. Hg is good conductor. It does not wet the glass surface Up to 350C for mercury Less than 120C for alcohol Low cost Can be used easily. Advantages Used as STANDARD equipment for calibration of temperature sensors Good accuracy Disadvantages Cannot be used in industry for automatic control.

Advantages of mercury

Limits of application

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Experiment # 6: Liquid Level System Objective:

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

Apparatus:
Storage tank, Tubes (of certain lengths), Beaker, Scale Stop watch.

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

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Formulae Used:
1. Area of tank A= Where d = diameter of tank 2. Time Constant: =RxA Where A = Area of Tank R= Resistance to flow 3. Resistance (from graph): cm2

Observations & Calculations:

Diameter of the storage tank = d cm Area of the storage tank = A cm2 1. Length of tube = L1 cm Initial level of water (h1) in 7.5 6.5 5.5 Final level of water (h2) in 6.5 5.5 4.5

Serial # 1 2 3 4

Mean Level (H) in 7 6 5 cm

Volume (ml)

Time of flow (sec)

Flow rate Q (ml/sec)

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5 6 7

4.5 3.5 2.5

3.5 2.5 1.5

4 3 2

12

TimeConstant of Liquid Level Systemwith tube of length L1

10

) s / m ( Q , e t a r w o l F
4 2 0 2 4 6 8 10 12

Mean L evel (cm )

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

Result were repeated for different tube lengths and diameters.

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Results:

Results Dia of tube = constant = d cm Time Constant for L1 = Time Constant for L2 = Time Constant for L3 = 1 2 3

Length of tube = constant = L cm Time Constant for d1 = Time Constant for d2 = Time Constant for d3 = 1 2 3

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Experiment # 7: Flow Control Loop Objectives:

Report the response and variations in the process variable PV (flow of water) output in 1. Proportional Mode (P- mode) by giving the values of gain as 1.00, 0.6 and while the output of controller set on 30 % i.e. set point = 30 %. 2. Proportional Integral mode (PI mode) by giving the values of Reset time, as 0.15 and 0.5 while the output of controller set on 30 %. 3. Proportional Integral Derivative mode (PID mode) by giving the values of minute as 1, 2, 3 while the output of controller set on to 30 %. rate 0.1, 1.6

Procedure:
1. The pump should not be energized/ operated until your control setting is complete and whenever you are giving new values/changing values of gain or etc the pump should be switched off. 2. 3. Initially the controller is to be set in Auto mode. Then the set point is brought to 30 % by increasing or decreasing keys without touching any other keys. 4. Then the setup key is to be pressed once to have tuning mode of controller, value of Gain is adjusted by increasing/ decreasing keys and give a specified value i.e. 1.0. 5. 6. Now press function key once and adjust value of Rate minute at 0.00. Again press the function key to adjust value of Reset Rate (of integral mode) to 0.10 or a high value than this. 26

7.

The pump is still not started. When the pump is started immediately one person will record the readings of magnetic flow transmitter and other person simultaneously record the reading (maxima and minima)of the output displayed with reference to the time i.e. readings can be taken after every 5 seconds or any other time which may be suitable. Also observes how quickly the system stabilizes.

8.

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

Procedure: Methodology adopted would be the same and the variables will have the following values: Gain = 0.6 for all the three inputs Rate minute = 0.00 for all the three inputs Reset min = 0.1, 0.15 and 0.5

Same procedure will be followed to develop the graph.

3) PID Mode
Procedure: Methodology adopted would be the same and the variables will have the following values, Gain = 0.6 for all the three inputs Rate minute = 1, 2, 3 Reset min = 0.1 for all the three inputs

Same procedure will be followed to develop the graph..

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Block Diagram:

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Flow Diagram:

1. Storage Tank 2. Pump 3. Control Valve 4. Restriction Valve 5. Bottom valve FT-1: Flow Transmitter FC-1: Flow Controller LC-2: Positioner PI-1: Pressure gauge 29

FT-2: Flow Transmitter (Magnetic) Tuning Parameters Time (s) 0 5 10 15 20

Gain = 0.6 Controlled Variable (%TO)

Gain =1.0 Controlled Variable (%TO)

Gain =1.6 Controlled Variable (%TO)

2) PI mode

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

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Proportional Integral Derivative Controller:

Set point=30% Tuning Parameters Time (s) 0 5 10 15 20 Gain = 0.6 Integral time=0.1 Controlled Variable (%TO) Gain =0.6 Integral time=0.15 Controlled Variable (%TO) Gain =0.6 Integral time=0.5 Controlled Variable (%TO)

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Gain = 0.6 Tuning Parameters Time (s) 0 5 10 15 20 25 Integral time=0.1 Rate min=1 Controlled Variable (%TO)

Gain =0.6 Integral time=0.1 Rate min=2 Controlled Variable (%TO)

Gain =0.6 Integral time=0.1 Rate min=3 Controlled Variable (%TO)

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Experiment # 8: Temperature Control Loop Objectives:

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

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

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During heating:Set Point=55oC Temperature (oC)

Sr no. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Time (sec) 5 10 15 20 25 30 35 40 45 50

During Cooling: Set Point=46.7 oC

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Reference:
1. Coughanowr, D. R.:Process Systems Analysis and Control, 2nd ed., McGraw-Hill. Sr no. 1. 2. 3. 4. 5. 6. 7. 8. 9. 2. 3. Time (sec) Temperature (oC)

Fribance, A. E.: Industrial Instrumentation Fundamentals, McGraw-Hill, 1962. Luyben, W. L.: Process Modeling, simulation, and Control for Chemical Engineers, 3rd ed,McGraw-Hill, Inc., 1997.

4.

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

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5.

Stephanopoulos, G.: Chemical Process Control, An Introduction to Theory and Practice, Prentice-Hall, Inc., 1984.

6.

Bela G Liptac.:,Instrument Engineers Handbook, Process Control and Optimization, Vol 2, 4th ed. Taylor & Francis, 2006.

7.

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

8.

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

9. 10.

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

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

11.

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

Websites: 1. 2.
3.

http://www.isa.org/ http://www.manchester.ac.uk
(www.fieldbus.org/endusersupport/enduserpresentations/interkama2004/presentations/chris baltus_ffbenefits.pps) http://www.sensotec.com/intrinsically_safe_rated.asp#ex http://www.omega.com/thermocouples.html

4. 5.

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