COURSE HANDOUT

B. Tech (Chemical Engineering) – 5th Semester

Course Title : Process Dynamics & Control Lab Dated: 29-06-2015

Course Code : CHEM 3220 Academic Year: 2015-16

Course Structure : 0-0-3-2

1.Instructors : Mr. P. S. Sagar & Mr.G.Babu Rao

Course description

In this course, provides introduction to dynamic behavior and automatic control of industrial processes; lab includes

open loop, closed loop, and control of process variables by using conventional hardware and real-time digital

computers. Experiments are planed; Students will collect and analyze the experimental data using the theoretical

principles of process control. Additionally, students will learn to conduct a laboratory experiment safely and will have

the opportunity to improve their communication skills through preparation of laboratory reports.

Course Objectives:

1. To understand the dynamic behavior of the systems

2. To evaluate response of fist and higher order characteristics.

3. Study the installed characteristics of the valve.

4. Study if there is a hysteresis in the control valve and sensor.

5. Evaluate the tuning of a PID control via manual and automatic tuning.

6. Evaluate the effect controller on the control system

Course Outcomes:

At the end of the course, the students will be able to:

1. Compare mathematical models response with the physical systems

2. Calculate model parameters which explain the dynamic behaviors of the Process and Control systems

3. Test the range of process variables where the process in stable and controllable.

4. Utilize/select available control valves to meet process needs.

5. Choose PID modes that give robust control systems.

6. Make use of MIMO Control systems

Experiments: (Students would perform any 12 experiments out of the following 16 experiments)

1. Study of step response of Mercury-in-Glass thermometer

2. Study of control valve flow coefficient

3. Study of installed characteristics of control valve

4. Study of hysteresis of control valve

5. Study of step response of manometer

6. Step response of first order systems arranged in non- interacting mode

7. Step response of first order systems arranged in interacting mode

8. To study impulse response of first order systems arranged in non-interacting mode

9. To study impulse response of first order systems arranged in interacting mode

10. Step response of single capacity system

11. Study of open loop response control system

12. Study of response of Temperature controller with proportional integral derivative controller mode

13. Study of response of Level controller with proportional integral controller mode

14. Study of response of pressure controller with proportional integral derivative controller

15. Study of response of Flow controller with proportional controller mode

16. Closed loop method Tuning of cascade controllers

Course Plan:

Lecture No. Learning Objectives Topics to be covered

1 To outline different experimental setups available in the PDC lab

introduction

2 To calculate time constant of thermometer Study of step response of Mercury-in-Glass thermometer

3 To interpret the average valve flow coefficient

Study of control valve flow coefficient

4 To compare different flow behavior of valves based on % opening

Study of hysteresis of control valve

5 To analyze step response and estimate its time constant and damping co-efficient

Study of step response of manometer

6 To inspect dynamic response of first order systems arranged in non- interacting mode

Step response of first order systems arranged in non- interacting mode

7 To inspect dynamic response of first order systems arranged in interacting mode

Step response of first order systems arranged in interacting mode

8 To examine impulse response of first order systems arranged in interacting mode

To study impulse response of first order systems arranged in interacting mode

9 To construct Step response diagram for single capacity system

Step response of single capacity system

10 To determine effect of derivative mode on controllability of temperature control system

Study of response of Temperature controller with proportional integral derivative controller mode

11 To determine effect of integral action on controllability of Level control system

Study of response of Level controller with proportional integral controller mode

12 To determine effect of proportional action on controllability of pressure control system

Study of response of pressure controller with proportional integral derivative controller

13 To analyze the response of cascade controller with proportional integral derivative controller

Study of response of cascade controller with proportional integral derivative controller

14 To determine effect of proportional action on controllability of Flow controller system

Study of response of Flow controller with proportional controller mode

15 To predict controller settings for PID controller using controller tuning

Closed loop method Tuning of cascade controllers

Evaluation Scheme:

Component Particulars % of weightage

Marks Date & Time

Lab regularity No. of Experimentscompleted &recorded

Internal20%

10+5 As per regular timetable

Internal labExamination

150minutes Internal13.3%

10 Dates will be intimated later

External labExamination

180 minutes External66.7%

50 Dates will be intimated later

Total 75

Chamber Consultation Hour: 4 PM (Monday – Friday)

Notices pertaining to this subject will be displayed in the notice board of Chemical Engineering department notice board.

Signature of the Instructors Signature of the HOD

1. Mr. P. Satya Sagar

2. Mr. G. Babu Rao