VELAMMAL ENGINEERING COLLEGE:: CHENNAI-66.
DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING
ACADEMIC YEAR 2013-2014
EVEN SEMESTER
LAB MANUAL
SUB CODE: EI 2356
SUB NAME: PROCESS CONTROL SYSTEMS LABORATORY
PREPARED BY
APPROVED BY
S.N.SIVARAJ
Dr.N.BHARATHI
AP-2/EIE
HOD/EIE
LIST OF EXPERIMENTS
CYCLE-I
1. Closed loop response of flow control loop
2. Closed loop response of level control loop
3. Closed loop response of temperature control loop
4. Closed loop response of pressure control loop
5. Operation of interacting system
6. Operation of non interacting system
7. Characteristics of control valve with and without positioner
CYCLE-II
8. Study of mat lab
9. Study of cascade control system
10. Tuning of controllers using Ziegler -Nichols method
11. Tuning of controllers using Cohen coon method
12. Response of different order process with and without transportation lag
13. Study of ratio control system
14. Study of feed-forward control system
EXPT NO: 1
CLOSED LOOP RESOPNSE OF FLOW CONTROL LOOP
AIM:
To obtain the closed loop regulatory response of flow process station for PID and ONOFF mode of control actions.
APPARATUS REQUIRED:
1. Flow process station, 2.Data acquisition system, 3.Personal computer, 4.Compressor
PROCEDURE:
1. Ensure the flow process station is connected as per the P&I diagram.
2. Keep the valve HV1 10% open and close the valve placed in the orifice line connected
with manometer tube.
3. Ensure the connection between PC, data acquisition system and flow process station.
4. In the PC select the ICON flow process station by double clicking on it.
5. Switch on the pump after ensuring the storage tank is filled with water up to overflow
mark
6. Switch on the compressor and regulate the air filter regulators of the flow process station
to the required values
7. In the software select the control action mode as on-off.
8. Configure the controller with its parameters and define the set point.
9. Put the process in run mode by selecting start ICON in the software and observe the
response.
10. After the control action produce satisfactory (i.e., process variable settles in the set point)
response click stop to stop the process.
11. Save the response as a file by selecting save icon by giving a file name.
12. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
13. Compare the results.
RESULT:
The closed loop response for flow process station with nominal disturbance for various
modes of control action was obtained and the process performances for various modes were
inferred.
P&I DIAGRAM
S.P
FIC
D.P.T
AFR
ORIFICE
ROTAMETER
CV
RESERVOIR
TANK
PUMP
BLOCK DIAGRAM OF FLOW CONTROL SYSTEM
SET POINT
(S.P)
CO
e=S.P-P.V
+-
M.V
CONTROLLER
F.C.E
ON-OFF/PID
CONTROL VALVE
P.V
TRANSMITTER
ORIFICE + D.P.T
P.V
PROCESS
FLOW
TABULATION:
S.P=______________LPH; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs
S.No
TIME
PV
(SECS)
(ENGG UNITS=LPH)
MODEL GRAPH
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE
SET POINT
FLOW IN LPH
LOWER LIMIT
TIME IN SECS
FLOW IN L.P.H
P MODE & PD MODE
SET POINT
TIME
FLOW IN L.P.H
PI & PID MODE
SET POINT
TIME
EXPT NO: 2
CLOSED LOOP RESOPNSE OF LEVEL CONTROL LOOP
AIM:
To obtain the closed loop regulatory response of level process station for PID and ONOFF mode of control actions.
APPARATUS REQUIRED:
1. Level process station, 2.Data acquisition system, 3.Personal computer, 4.Compressor
PROCEDURE:
1.
2.
3.
4.
5.
Ensure the level process station is connected as per the P&I diagram.
Keep the valve HV1 and HV2 10% open
Ensure the connection between PC, data acquisition system and level process station.
In the PC select the ICON level process station by double clicking on it.
Switch on the pump after ensuring the storage tank is filled with water up to overflow
mark
6. Switch on the compressor and regulate the air filter regulators of the level process station
to the required values
7. In the software select the control action mode as on-off.
8. Configure the controller with its parameters and define the set point.
9. Put the process in run mode by selecting start ICON in the software and observe the
response.
10. After the control action produce satisfactory (i.e., process variable settles in the set point)
response click stop to stop the process.
11. Save the response as a file by selecting save icon by giving a file name.
12. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
13. Compare the results.
RESULT:
The closed loop response for level process station with nominal disturbance for various
modes of control action was obtained and the process performances for various modes were
inferred.
P&I DIAGRAM
S.P
LIC
AFR
SENSOR
HV1
CV
PROCESS TANK
RESERVOIR
TANK
HV2
TO RESERVOIR
PUMP
BLOCK DIAGRAM OF LEVEL CONTROL SYSTEM
SET POINT
(S.P)
CO
e=S.P-P.V
+-
M.V
P.V
CONTROLLER
F.C.E
PROCESS
ON-OFF/PID
CONTROL VALVE
LEVEL
P.V
TRANSMITTER
D.P.T
TABULATION:
S.P=______________cm; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs
S.No
TIME
PV
(SECS)
(ENGG UNITS=cm)
MODEL GRAPH:
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE
SET POINT
LEVEL IN CM
LOWER LIMIT
TIME IN SECS
LEVEL IN C.M
P MODE & PD MODE
SET POINT
TIME
LEVEL IN C.M
PI & PID MODE
SET POINT
TIME
EXPT NO: 3 CLOSED LOOP RESOPNSE OF TEMPERATURE CONTROL LOOP
AIM:
To obtain the closed loop regulatory response of temperature process station for PID and
ON-OFF mode of control actions.
APPARATUS REQUIRED:
1. Temperature process station, 2.ON-OFF/PID controllers, 3.Stop clock
PROCEDURE:
1. Ensure the temperature process station is connected as per the P&I diagram.
2. Keep the valve HV3 and HV2 100% open
3. Switch on the pump after ensuring the storage tank is filled with water up to overflow
mark and pump the water into overhead tank and regulate the water in to process vessel
through the valve HV2 select
4. Select the mode of control action either ON-OFF or PID by following the steps given
below
ON-OFF mode
5. Select the control action mode as on-off using toggle switch
6. Connect the node A and CO through a patch cord
7. Configure the controller with its parameters and define the set point with indicating meter
switch at SV
PID mode
4. Select the control action mode as on-off using toggle switch
5. Connect the node A and CO through a patch cord
8. Configure the controller with its parameters and define the set point with indicating meter
switch at SV
6. Switch on the stirrer and heater
7. Turn the meter switch to PV mode
8. Note down the temperature for every 30 seconds till the control action produce
satisfactory (i.e., process variable settles in the set point) response
9. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
10. Compare the results.
RESULT:
The closed loop response for temperature process station with nominal disturbance for
various modes of control action was obtained and the process performances for various modes
were inferred.
P&I DIAGRAM
12V
SW
OVER HEAD TANK
STIRRER
HV 3
To sump
ON/OFF
HV2
RTD SIGNAL
CONDITIONE
R
T1
T2
INTEGRAL
TIME
RTD
SENSOR
GND
80%
P
PUMP
TRIGGER
40%
SCOPE
TO DRAIN
OFF
EXT
SVD
INT
SVD
0%
B
100%
T4
80%
40%A
0% C
100%
ON
DERIVATIVE
TIME3
THYRISTOR POWER
CONTROL
BLOCK DIAGRAM OF TEMPERATURE CONTROL SYSTEM
SET POINT
(S.P)
THYRISTOR
POWER
CONTROL
UNIT
ON-OFF/PID
CO
e=S.P-P.V
+-
CONTROLLER
TEMPERATURE
M.V
F.C.E
P.V
TRANSMITTER
R.T.D
P.V
PROCESS
TABULATION:
S.P=______________C; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs
S.No
TIME
PV
(SECS)
(ENGG UNITS= C )
MODEL GRAPH:
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE
SET POINT
TEMP IN DEG C
LOWER LIMIT
TIME IN SECS
TEMP IN C
PID MODE
SET POINT
TIME
EXPT NO: 4
CLOSED LOOP RESOPNSE OF PRESSURE CONTROL LOOP
AIM:
To obtain the closed loop regulatory response of pressure process station for PID and
ON-OFF mode of control actions.
APPARATUS REQUIRED:
1. Pressure process station, 2.Data acquisition system, 3.Personal computer, 4.Compressor
PROCEDURE:
1.
2.
3.
4.
5.
Ensure the pressure process station is connected as per the P&I diagram.
Keep the valve HV5 and HV6 100% open AND HV3 and HV4 10% open
Ensure the connection between PC, data acquisition system and pressure process station.
In the PC select the ICON level process station by double clicking on it.
Switch on the compressor and regulate the air filter regulators of the pressure process
station to the required values
6. In the software select the control action mode as on-off.
7. Configure the controller with its parameters and define the set point.
8. Put the process in run mode by selecting start ICON in the software and observe the
response.
9. After the control action produce satisfactory (i.e., process variable settles in the set point)
response click stop to stop the process.
10. Save the response as a file by selecting save icon by giving a file name.
11. Repeat the above steps for PID controller with its various control modes such as P, PI,
PD, and PID.
12. Compare the results.
RESULT:
The closed loop response for pressure process station with nominal disturbance for
various modes of control action was obtained and the process performances for various modes
were inferred.
P&I DIAGRAM
AIR INLET
150 PSI
G2
AT1
AT2
G3
PR1
I
P
G1
PRESSURE
TRANSMITTER
G4
RV1
PR2
AIR MUFFLER
HV5
PROCESS TANK
1
HV1
HV3
RV2
G5
CONTROL
VALVE
HV6
PROCESS TANK
2
HV2
HV4
BLOCK DIAGRAM OF PRESSURE CONTROL SYSTEM
SET POINT
(S.P)
CO
e=S.P-P.V
+-
M.V
P.V
CONTROLLER
F.C.E
PROCESS
ON-OFF/PID
CONTROL VALVE
PRESSURE
P.V
TRANSMITTER
CAPACITIVE PROBE
TABULATION:
S.P=______________PSI; Kc=___________;
Ki=_______________ Secs-1;Kd=____________Secs
S.No
TIME
PV
(SECS)
(ENGG UNITS=PSI )
MODEL GRAPH:
ON-OFF CONTROL MODE
UPPER LIMIT
NEUTRAL ZONE
SET POINT
PRESSURE IN PSI
LOWER LIMIT
PRESSURE IN P.S.I
TIME IN SECS
P MODE & PD MODE
SET POINT
TIME
PRESSURE IN P.S.I
PI & PID MODE
SET POINT
TIME
EXPTNO: 5
OPERATION OF INTERACTING SYSTEM
Aim:
To study the operation of two tank interacting system.
Apparatus Required;
1. Interacting system station, 2.Stop clock
Procedure:
1. Ensure to maintain the water level in storage tank is always kept fully filled up to the
overflow level.
2. Switch on and run the Pump and continuously to fill the overhead tank up to its
overflow level
3. Keep the valves HV5, HV2 at fully open and HV3 at 10% open condition.
4. Set a constant flow rate of X LPH through the Rota meter with the help of valve HV1
5. Note down the readings in tank 1 and tank 2 for every 30 seconds till steady is
reached in both the tanks
6. Plot the graph
Result:
The behavior of two tank interacting system was studied.
P&I DIAGRAM
TABULATION:
TIME
HEIGHT IN TANK-1
HEIGHT IN TANK-1
(SECS)
H1
H2
(CM)
(CM)
S.No
MODEL GRAPH
LEVEL IN TANK-2 ( h2 c.m)
LEVEL IN TANK-I ( h1 c.m)
TANK-I
TANK-2
TIME IN SECS
EXPTNO: 5
OPERATION OF NON-INTERACTING SYSTEM
Aim:
To study the operation of two tank Non-interacting system.
Apparatus Required;
2. Non Interacting system station, 2.Stop clock
Procedure:
7. Ensure to maintain the water level in storage tank is always kept fully filled up to the
overflow level.
8. Switch on and run the Pump and continuously to fill the overhead tank up to its
overflow level
9. Keep the valves HV8 at fully open, HV3, HV4 at 10% open condition and HV2, HV6,
HV5 at fully closed condition.
10. Set a constant flow rate of 10 LPH through the Rota meter with the help of valve
HV1
11. Note down the readings in tank 1 and tank 2 when steady is reached in both the tanks
as H1SS and H2SS
12. After the steady state has reached, increase the flow through the rotameter to 12 LPH
using the valve HV1 and note down the readings in tank 1 and tank 2 for every 30
seconds till a new steady state is reached in both the tanks
13. Plot the graph and calculate the transfer function of the system
Result:
The behavior of two tank non interacting system was studied.
P&I DIAGRAM
TABULATION:
h1 S.S=______________CM; h2 S.S=___________CM;
S.No
TIME
h1
(SECS)
(cm)
MODEL GRAPH
h2
(cm)
H1=h1- h1 S.S
H2=h1- h2 S.S
(cm)
(cm)
LEVEL IN TANK-2 ( h2 c.m)
LEVEL IN TANK-I ( h1 c.m)
TANK-I
TANK-2
TIME IN SECS
EXPT NO: 6
CHARACTERISTICS OF CONTROL VALVE
Aim:
To study the flow-lift characteristics of ON-OFF, linear and equal percentage control
valve with and without positioned.
Apparatus required:
Linear control valve, equal percentage control valve, ON-OFF control valve, compressor,
pressure gauge.
Procedure:
With positioner
1. Fill the storage tank up to the overflow level.
2. Open the control air flow line for linear valve and close the air flow for other control
valves with the help of hand valve
3. Open the water flow line for linear valve and close the water flow line for other control
valve with the help of hand valve HV2, HV3, HV4
4. Set the control pressure signal to 15 P.S.I
5. Note down the flow rate and stem position after maintaining the pressure drop of 1 P.S.I
across the control valve with the help of hand valve connected with linear valve for water
flow control
6. Repeat the above steps for various control signal values till 3 P.S.I
7. Plot the characteristics
8. Repeat the above steps for other control valves.
Without positioner
9. Repeat steps 1 to 8 after bypassing the positioner
Result:
The flow-lift characteristics for control valve with and without valve positioner was
studied
P&I DIAGRAM
TABULATION:
WITH/WITHOUT POSITIONER
Control valve=_____________________ ; S MAX = _______CM;
S.No
Control
signal
(PSI)
Line
pressure
(PSI)
Q MAX =__________LPH
STEM
FLOW
POSITION RATE
S
Q
(CM)
(LPH)
1
15
1
2
12
1
3
9
1
4
6
1
5
3
1
WITH/WITHOUT POSITIONER
Control valve=_____________________ ; S MAX = _______CM;
S.No
Control
signal
(PSI)
Line
pressure
(PSI)
Q MAX =__________LPH
STEM
FLOW
POSITION RATE
S
Q
(CM)
(LPH)
1
15
1
2
12
1
3
9
1
4
6
1
5
3
1
WITH/WITHOUT POSITIONER
Control valve=_____________________ ; S MAX = _______CM;
S.No
1
2
3
4
5
Control
signal
(PSI)
15
12
9
6
3
Line
pressure
(PSI)
1
1
1
1
1
STEM
FLOW
POSITION RATE
S
Q
(CM)
(LPH)
Q MAX =__________LPH
MODEL GRAPH:
2
ON-OFF CONTROL VALVE
Q / QMAX
LINEAR CONTROL VALVE
EQUAL PERCENTAGE CONTROL VALVE
1
S / SMAX
