IC1352 Process Control Laboratory Syllabus

IC 1352 PROCESS CONTROL LABORATORY 0 0 3 100
AIM
To experimentally verify the process control concepts on the selected process control loops.

1. Study of interacting and non-interacting systems.
2. Response of different order processes with and without transportation lag.
3. Response of P+I+D controller.
4. Characteristics of control valve with and without positioner.
5. Closed loop response of flow control loop.
6. Closed loop response of level control loop.
7. Closed loop response of temperature control loop.
8. Closed loop response of pressure control loop.
9. Tuning of PID controller.
10. Response of cascade control system.

P = 45 Total = 45

Detailed Syllabus

1. Study of interacting and non- interacting systems

Aim
To study the operation of interacting and non- interacting systems

Exercise
1. Connect the two tank system (Level process) in series (as non- interacting system)
2. Check whether level in tank is affected due to changes made in the second tank.
3. Connect the two tank system in series (as interfacing as system).
4. Check whether level in tank 1 is affected due to changes made in the second tank.
5. Determine the transfer function of individual and overall system.

Equipment
1. Two tank system with provision for making them as interfacing and non- interfacing. – 1 No
2. Level transmitters – 1 No
3. Recorder – 1 No

2. Response of different order processes with and without transportation delay

Aim
To determine the transient response of a first order process with and without transportation delay and second order process with and without transportation delay to step change in input.

Exercise
1. Record the transient response to a step change of first order process and second order process (Level or thermal (or) any process) with and without transportation lag.
2. Calculate the process gain, time constant and dead time of the process from the step response.

Equipment
1. Two tank system with provision for transportation delay (Non – interacting process)
2. Level transmitter – 1 No
3. Recorder – 1 No

3. Response of P+I+D controller

Aim
To investigate the operation of an electronic controllers with P, P+I and P+I+D
action.

Exercise
1. Plot the response of P, P+I, P+D and P+I+D controllers to step and ramp inputs.
2. Determine the calibration of the proportional, Integral and derivative adjustments.

Equipment
1. Electronic PID controller – 1 No
2. Source for generating step and ramp inputs – 1 No
3. Recorder – 1 No
4. Digital Multimeter – 1 No

4. Characteristics of control valve with and without valve positioner

Aim
To determine the flow – lift characteristics (Internet / Installed) of a control valve equipped with and without valve positioner.

Exercise
1. Plot the flow – lift characteristics of the given valve without positioner keeping
(i) Constant ΔP
(ii) Variable ΔP
2. Compute the valve gain at different operating points.
3. Plot the flow – lift characteristics of the given with positioner keeping.
i. Constant ΔP
ii. Variable ΔP
4. Compute the valve gain at different operating points.

Equipment
1. Control valve trainer (with position for varying ΔP across the valve) - 1 No
2. Flowmeter - 1 No

5. Closed loop response of flow control loop

Aim
To obtain the closed loop response of flow control loop for servo and regulator
Operation.

Exercise
1. Closed – loop connection is made in the flow process station.
2. The flow controller (P+I) is tuned using any one of the tuning techniques.
3. The response of the control loop is obtained for changes in the set point.
4. The response of the control loop is obtained for changes in the load variable.
5. The step 3 and 4 are repeated for different controller modes and settings.

Equipment
1. Flow process station with all accessories - 1 No
2. Analog / Digital PID controller - 1 No
3. Recorder - 1 No

6. Closed loop response of level control loop

Aim
To obtain the closed loop response of level control loop for servo and regulator
operation.

Exercise
1. Closed loop connection is made in the level process station.
2. The level controller (P+I) is tuned using any one of the tuning techniques.
3. The response of the control loop is obtained for changes in the set point.
4. The response of the control loop is obtained for changes in the load variable.
5. The step 3 and step 4 are repeated for different controller modes and settings.

Equipment
1. Level process station with all accessories - 1 No
2. Analog / Digital PID controller - 1 No
3. Recorder - 1 No

7. Closed loop response of temperature control loop

Aim
To obtain the closed loop response of temperature control loop for servo and regulator operation.

Exercise
1. Closed-loop connection is made in the temperature process station.
2. The temperature controller (P+I+D) is tuned using any one of the tuning techniques.
3. The response of the control loop is obtained for changes in the set point.
4. The response of the control loop is obtained for changes in the load variable.
5. The step 3 and 4 are repeated for different controller modes and settings.

Equipment
1. Temperature process station with all accessories - 1 No
2. Analog / Digital PID controller - 1 No
3. Recorder - 1 No

8. Closed loop response of pressure control loop

Aim
To obtain the closed loop response of pressure control loop for servo and regulator operation.

Exercise
1. Closed – loop connection is made in the pressure process station.
2. The pressure controller (P+I) is tuned using any one of the tuning techniques.
3. The response of the control loop is obtained for changes in the set point.
4. The response of the control loop is obtained for changes in the load variable.
5. The step 3 and 4 are repeated for different controller modes and settings.

Equipment
1. Pressure process station with all accessories - 1 No
2. Analog / Digital PID controller - 1 No
3. Recorder - 1 No

9. Tuning of PID controller

Aim
To determine the controller settings of a given process using two popular tuning
techniques.

Exercise
1. Plot the process reaction curve for the given process (higher order process)
2. From the reaction curve, calculate the process gain, time constant and dead time using the above process parameters calculate the Kc, Ti, Td valves using the appropriate thumb rules.
3. Conduct the closed loop test as per Z-N method [continuous cycling method] and determine the ultimate gain (Ku) and ultimate period (Pu), calculate the controller parameters (Kc, Ti, Td) using Ziegler Nichol’s closed loop tuning approach.

Equipment
1. Process control trainer / real time process (level / thermal process) - 1 No
2. Recorder - 1 No
3. PID controller - 1 No

10. Response of cascade control system

Aim
To determine the closed loop performance of a cascade control system and
compare it with that of conventional control system.

Exercise
1. The secondary and primary controllers are tuned using any one of the tuning techniques.
2. Obtain the closed loop response of cascade control system with the load variable entering the inner loop.
3. Obtain the closed loop regulating response with conventional control system.
4. Compare the performance of conventional control system and cascade control system internal of peak overshoot, setting time, I&E etc

Equipment
1. Cascade control system with flow as inner variable and liquid level as outer variable with following accessories.
2. Level transmitter - 1 No
3. Flow transmitter - 1 No
4. Control valve - 1 No
5. Analog / Digital PID controller - 1 No
6. Recorder - 1 No
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