Professional Documents
Culture Documents
60%
40%
There will be 12 practical (6 each in PC and CRE) in all. The 60% of in-laboratory evaluation will be done with 5% weightage for
each turn based on your weekly report that is submitted. We will start with PC experiments in the first half of semester followed by
CRE experiments in the second half.
The experiments will be conducted in groups of 3 or 4 students. Handouts of all experiments can be downloaded from the link
http://privateweb.iitd.ac.in/~munawar/CHP303.pdf. All the students are required to come prepared for the experiment. A common
cover page (as per template on page 2 of the document in link) is to be used while submitting report for each experiment
All experiments, calculations and final report writing will have to be completed and submitted before leaving the laboratory
(except on the first turn of the semester). Each sub-group of students needs to submit only one report, but it must be a joint effort.
If some experiment is not completed or only partially done, you have to still submit the report for whatever was accomplished on
that day.
As this is a lab course 100 % attendance (including make-up) is required. There will be one extra turn at the end of the semester
for catching up or re-doing one experiment, only if needed, with prior permission of the instructor. Lack of attendance automatically
gets you a zero score for that turn. This also includes late arrival/absence from the laboratory without prior permission of the
laboratory instructor/TA for some part or entire laboratory. As a safety measure it is mandatory to use gloves, lab coats, safety
glasses and shoes during practical.
GROUP NO.:
SUBGROUP NO.:
Name of
LAB INSTRUCTOR:
(ii)
(iii)
EXPERIMENTAL PROCEDURE:
(i)
Add 400 ml of sodium hydroxide solution into the reaction vessel and stir its
contents slowly with the stirrer
(ii)
Add the calculated amount of ethyl acetate for concentration ratio of 1:1 or
1:2 into the reactor vessel and note the time as starting time for reaction.
Immediately take a simple of 2 ml from the reactor and quench it.
(iii)
At specified time intervals, i.e. 1, 2, 3, 4, 5, 7, 10, 12, 15, 20, 25 min take
samples of 5 ml from the reactor and quench them in ice bath.
(iv)
Titrate the samples with standard oxalic acid solution for determining the
concentration of the sodium hydroxide as a function of time.
THEORY:
Reaction :
NaOH + CH3 COOC2 H5 CH3 COONa + C2 H5 OH
(A)
(B)
(C)
(D)
It is reported that the reaction is irreversible and the reaction orders with
respect to the reactant is unity. The rate expression is given by (elementary reaction):
dC A
= k C A CB = K C A [ (CBO C AO ) + C A ]
dt
dC A
= K C A2
for
C AO = CBO
dt
for
C AO CBO
(1)
(2)
(ii)
(iii)
(iv)
(v)
Calculate the rate constant, if the data gives a straight line passing
through the origin, from the slope of the line.
(vi)
When the reactants are present in equimolal concentrations, plot ln(dCA /dt) vs. ln CA and determine the rate constant from the slope and
the overall order from the intercept.
Integral Method:
Integration of the equations (1) and (2) gives the following equations.
ln
C AO {(C BO C AO ) + C A }
= (C BO C AO ) k t
C BO C A
1
1
=K t
C A C AO
(3)
(4)
(i)
Plot
(CBO
C AO {(CBO C AO ) + C A ]
1
ln {
vs. t
C AO )
CBO C A
(ii)
(iii)
FURTHER WORK :
(a)
(b)
Determine the order of reaction by half life method. Check the value of the
rate constant with that obtained above in your procedure.
(c)
Connect the reaction flask and the gas measuring cylinder with rubber
tubing with the condenser in between.
(ii)
Add 100/150 ml of distilled water in the flask and heat it up to the desired
temperature (i.e., 35 40 - 45 50 C) and add 5 to 10 ml of the given
H2O2 solution and a pinch of KI salt.
(iii)
Immediately turn the 3-way stop cock to connect the reactor with the gas
measuring cylinder and note the time as zero time.
1
(iv)
Keep the overflow glass bottle next to the measuring cylinder and note the
times for change in volume of gas in the measuring cylinder by
maintaining equal levels of water in the cylinder and bottle.
(v)
Note the time and volume of the gas collected at regular volume change in
the cylinder also.
THEORY
Reaction :
2H2 O2 2H2 O + O2
(B) + (O)
(A)
It is reported that the reaction is irreversible and first order. The rate equation is:
dC A
= k CA
dt
CH 2O2 =
VO 2 2
( gm mole / ml )
22,400 5
CH 2O2 VH 2O2
(V
H 2O
+ VH 2O2
V Vt
V
C AO
Differential Method:
(1)
Plot Vt vs. t
(2)
Plot CA vs. t
(3)
(4)
(5)
Calculate the order and the rate constant from the intercept and the slope
Integral Method:
(a) Repeat the experiment at a fixed temperature and at 2-3 different initial
concentration of H2 O2 and determine order by half life method.
(b) Repeat the experiment at different temperatures and determine the activation
energy and frequency factors from Arrhenius plot.
RELEVANT BACKGROUND READING:
Fogler, H. Scott, Elements of Chemical Reaction Engineering, 3rd Ed., PHI India Pvt.
Ltd. (1999).
(Chapters 3, 5)
Levenspiel, O., Chemical Reaction Engineering, 3rd Ed., John Wiley and Sons (1999).
(Chapter 3)
Prepare approximately 0.1N solution of sodium hydroxide and fill the storage
tank with it.
(ii)
Prepare ethyl acetate solution of about 0.1N concentration and fill the storage
tank with it.
(iii)
Prepare standard oxalic acid (or any other standard acid stock solution as
directed by the lab. technician) of about 0.1N.
(iv)
PROCEDURE:
(i)
Take NaOH in the reactor to fill it to an appreciable level (seek guidance from
the lab. technician or instructor).
(ii)
Start the stirrer slowly and maintain a suitable speed so as not to spill the
liquid in the reactor.
(iii)
Adjust the flow rate of the ethyl acetate solution from the storage tank to about
30-50 ml/min.
(iv)
Allow the ethyl acetate flow to the reactor at the prefixed flow rate.
(v)
(vi)
Start collecting the samples from the exit overflow until steady state is
attained, i.e. the composition of the last two samples has the same value (and
essentially the NaOH, which was in batch, has been flushed out of the system
by the flowing ethyl acetate solution).
(vii)
Titrate the samples obtained with standard acid for determining the
concentration of the sodium hydroxide.
THEORY:
Reaction:
NaOH + CH3COOC2H5 CH3COONa
(A)
(B)
(C)
+
+
C2H5OH
(D)
k CA CB
(1)
Design equations for semi-batch reactor need to be derived from first principles, with
help from books by Fogler and Levenspiel. The derivation should be shown in the
report.
DATA AND CALCULATIONS:
Calculate the steady state exit concentration/conversion of the reactant (A) ie. Sodium
hydroxide. Measure the volume of the reactor and volumetric flow rate of the
reactants. Calculate the rate constant from the equations derived above.
FURTHER WORK:
Repeat the experiment with different flow rates/concentrations of the reactants and
verify the rate constant.
RELEVANT BACKGROUND READING:
Fogler, H. Scott, Elements of Chemical Reaction Engineering, 3rd Ed., PHI India Pvt.
Ltd. (1999).
(Chapter 4)
2
(ii)
Adjust the capillary tubes such that they are in zero/50 ml mark level in the
burettes and the liquid flows through them into the subsequent burettes
(burettes kept downstream), smoothly.
(iii)
Close the stop-cocks of the burettes and fill the top most burette to the zero
level mark.
(iv)
Open the stop cocks of the burettes except the lower-most burette and note
down times for changes in water levels of known values in each of the
burettes.
Note:
To avoid the difficulty of noting level vs. time data in the three burettes
simultaneously, first note time vs. level in the top most burette only. Repeat the
experiment noting down level vs. time in the middle burette. The level vs. time data in
the lower most burette can be determined from material balance for the three burettes.
The level vs. time data in the first burette is independent of the flows into the second
and third burettes.
1
(v)
Repeat
the
same
procedure
for
parallel
reaction
arrangement
of
(4)
exp
exp
(5)
(6)
The maximum concentration of the intermediate and the time at which the maximum
occurs are, respectively, given by:
/
(7)
(8)
From fluid mechanics principles, a first order irreversible reaction can be represented
by emptying of a tank with a pipe line having laminar flow conditions (through
Hagen-Poiseulles equation). The equation relating level fall with time is given by
(please derive this relationship in your report):
dh
= k1 ' h
dt
(9)
k1 ' = g d 4 / 32 L D 2
(10)
k1
A
k2
(1)
(2)
(3)
(4)
exp
(5)
exp
(6)
Measure the height of the burettes w.r.t. the capillary tube level (centerline of
horizontal capillary). Measure the length and diameter of the capillary tube.
(ii)
(iii)
(iv)
Note down the value of hmax for the second burette and the corresponding time.
(v)
(vi)
Calculate k1 /k2 ratio from equation (7) or (8) by trial and error.
(vii)
(viii) Calculate the numerical values of k1 and k2 from equation (10) and verify
with the above values.
Parallel Reaction Network:
(i)
(ii)
(iii)
Calculate (k1 + k2) from the slope of the line of the above plot.
(iv)
Calculate (k1/k2) ratio from the ratio of the maximum heights of the plot of the
graphs of the second and third burettes (CB and CC).
(v)
FURTHER WORK
Repeat the experiment with some liquid initially present in the second and third
burettes, i.e. CBO = 0 and CC0 = 0 at t = 0 and verify h vs. t data from the solutions of
the equation (1), (2) and (3).
RELEVANT BACKGROUND READING:
Fogler, H. Scott, Elements of Chemical Reaction Engineering, 3rd Ed., PHI India Pvt.
Ltd. (1999).
(Chapter 6)
Levenspiel, O., Chemical Reaction Engineering, 3rd Ed., John Wiley and Sons (1999).
(Chapter 8)
PROCEDURE:
(i)
Add the two reactants into the reaction flask and close the lid. Note the time as
the starting time for reaction.
(ii)
Note the temperature vs. time date at regular intervalsuntil there is no change
in the temperature of the reaction mixture.
THEORY:
A simple thermos flask acts as a very good adiabatic batch reactor, particularly is the
reaction is fast and the rate of heat transfer from the flask is slow in comparison.
Reaction:
2 Na2 S2 O3 + 4 H2 O2 Na 2 S3 O6 + Na 2 SO4 + 4 H2 O
It is reported that the reaction is irreversible and first order w.r.to each reactant.
Rate equation is:
-rA=kCACB
(1)
(2)
where, MT
Cp
heat of reaction
Note that the reaction rate constant k, itself is a function of temperature, and is
related via Arrhenius law:
/
Taking the reactants in stoichiometric proportions, the rate equation (1) can be
expressed as:
- rA
k C A2
(3)
Solving equations (2) and (3) together with the boundary condition:
At t = 0, T = T0 and CA = CA0
Gives:
1
(T T ) 2
dT
dt
k 0 C AO
T TO )
e E / RT
(4)
, the
C
2(T TO ) E / RT
dT
= k O C AO (T T ) [ BO
]e
dt
C AO
(T TO )
(5)
(ii)
(iii)
Plot ln[
(iv)
(v)
(vi)
1
T )2
dT
]
dt
1
.
T
vs
in which case you have to get the parameters from equation (5).
FURTHER WORK:
Repeat the experiment with different initial concentrations of the reactants such that
(Chapter 9)
2
CaCO3 CaO
+ CO2
B(S)
C(S)
A(g)
For chemical reaction rate controlling, the time of reaction for conversion X is given
by:
t =
B L X
(1)
Kr
B L
B L2 X
t
=
+
2 Deff C AE
x K g C AE
( 2)
Where:
B
conversion
Kg =
Kr =
Deff =
CAE =
The rate parameters are obtained by data according to equation (1) and (2). For
determining the chemical reaction rate constant, the experiments are conducted at
lower temperature 650-7500C and mass transfer coefficients the temperature are 750
to 9000C.
DATA AND CALCULATIONS:
From the experiments with each pellet, the time versus weight loss is determined.
Then conversion is given by:
X =
WO Wt
WO W
(3)
Where W0, Wt, W are weight of the solid at zero time, any time and infinite time
i.e. completion of reaction. The time versus conversion for the different pellets is used
to calculate the rate parameters corresponding to one temperature.
For the calculations, the molecular diffusion coefficient DCO2-air can be calculated
using Chapman-Enskog equation and porosity can be calculated from true density and
bulk densities of the solid pellet and assuming tortuosity factor as 2.
2
(4)
The Deff values can be compared with the experimental value obtained according to
equation (2).
FURTHER WORK: Repeat the experiments at other temperatures for determining
the activation energies for reaction and diffusion constants.
RELEVANT BACKGROUND READING:
Fogler, H. Scott, Elements of Chemical Reaction Engineering, 3rd Ed., PHI India Pvt.
Ltd. (1999). (Chapter 11)
Levenspiel, O., Chemical Reaction Engineering, 3rd Ed., John Wiley and Sons (1999).
(Chapter 25)
show that it can be approximated by a first order system followed by a time delay and n-first
order systems in series using a lagged thermometer.
EXPERIMENTAL SETUP:
block. The transient response to change in the surrounding temperature is determined by the
temperature at the centre line of this block. A hot temperature bath is provided for this
purpose. You may try different types of materials around the thermometer.
THEORY:
practically the same as that of a distributed system, which is one where resistance and
capacity are associated with each incremental length of the system. That is to say that transfer
function of a distributed parameter system can be approximated by
( )
( )
Where
as n
(1)
is the time constant of a first order system. Another useful approximation of the
transfer function of a distributed parameter system is a first order system followed by a time
lag, i.e;
( )
( )
(2)
Where Td is the time delay and is the time constant of the first order system.
PROCEDURE : Measure the initial reading of the thermometer and then place the lagged
thermometer inside the hot bath which is maintained at constant temperature. Measure the
temperature with time until the steady state has been reached. This completes one set of the
experiment. Remove the lagged thermometer from the hot bath and allow it to cool in the
atmosphere. Once again, note the temperature versus time until the new steady state has
been reached.
RESULTS TO BE REPORTED:
1. Plot Q =
and
are
/4
and the time constant for three first order systems in series will be, =
/9.
Using these time constants, determine the theoretical response from equation (1) and
match with the actual responses and comment.
3. To approximate the response by a first order system followed by a time delay, find the
inflection point of the transient response plot and draw a tangent at the inflection
point. The intercept of the x-axis provides the value of Td, while the inverse of the
slope gives the value of the time constant. Using the values of
theoretical response from equation (2) and match with the actual response and
comment.
To study the response of a stirred tank heater using a step change in heater input.
EXPERIMENTAL SET-UP: The stirred tank has a diameter of 22.6 cm and a height of 28 cm. Water is
filled upto a certain level and is continuously agitated by a stirrer with a diameter of 5 cm rotating at
1100 rpm. The bottom of the tank contains heating coils whose input is controlled by means of variac.
Cooling water flows through a long helical coil. There are 15 turns in all, the diameter of the helix being
4.2 cm and the coil thickness is 6mm. Cooling water is obtained from an overhead tank and there is a
valve to regulate the flow. Temperature of the tank is measured using a thermometer.
THEORY:
Draw a block diagram of the stirred tank heater. Cooling water enters at a temperature Ti
and mass flow rate Mc (measured using measuring cylinder). The outlet temperature of the cooling
water changes when a step change is introduced into the system by altering the heater input Q. Derive
the transfer function (refer any book on process control like Coughanowr) between the tank
temperature T and the heater input Q.
The value of heat transfer coefficient between tank and coil, U, is a function of several parameters like
stirrer rpm and diameter, Prandtl number etc. The exact correlation can be obtained from Perrys
handbook.
PROCEDURE:
The study is to be conducted by changing the heater input in a step fashion and
noting the change in tank temperature. (It is also possible to change cooling water flowrate and note
the resultant effect on the system)
1. Set up the apparatus and start the flow of cooling water.
2. Set variac reading (say 80 V) and wait for steady state to be attained.
3. Give a step change to the variac reading (hence heater input ) and start noting temperature
vs time.
4. Plot the temperature vs time curve. Compare the experimental and theoretical curves (with
the one obtained from the transfer function). Identify possible sources of error.
Fig: 1. Block Diagram of a Control Loop for measurement of Process reaction curve.
A typical process curve exhibits an S- shape as shown in Fig: 2. It is represented by equation
(1).
G ( s) = K
e L s
1 + Ts
(1)
Zeigler and Nichols suggested setting the values of Kc, Ti, Td according to the formula shown
in Table 1. Refer Fig. 2 for symbol meaning for tuning the controller via Z-N settings.
Table 1. Z-N Settings for tuning different Controllers
Type of Controller
Proportional (P)
Proportional - Integral (PI)
Proportional - Integral Derivative (PID)
Kc
T/L
0.9T/L
1.2T/L
Ti
Td
L/0.3
2L
0.5L
Fig: 2.Typical process reaction curve (First Order with Transportation lag)
Similarly, Cohen and Coon suggested controller parameters as given in Table 2.
Table 2. C-C settings for tuning different controllers
Types of Control
Proportional (P)
Parameter Settings
Kc = (T/(Kp*L) ) * ( 1+L/3T)
The value of Kp can be found using Kp = Bu / M, where Bu is the ultimate value of B at large
time t. (Refer to Fig. 1).
PROCEDURE :
1. Process Tank filled with liquid water is made available. Temperature Control Trainer
is active.
2. Log in the system and select INTERFACE mode for experimentation.
3. Turn on the water supply and maintain the inlet flow rate of water to process tank to
approximately 600-700 mL per min. Please note that attached Rotameter is not
calibrated. Corresponding reading in Rotameter will be around 20-25 LPM. Please
verify it.
4. Due to some external disturbances, liquid flow rate may show some significant
change in its value. Please keep an eye on the rotameter reading to dampen such
changes by careful adjustment of rotameter itself. Please note that change in mass
flow rate is not desired in the undertaken experiment.
5. Run the process as directed below:
o Select the MANUAL MODE with controller output 0 %.
o Wait till steady state is reached.
o Log on to a file for saving transient data.
o Start saving data. Wait for approximately 5 mins.
o Give a STEP RESPONSE to controller output. Change it from 0% to 100%.
o Wait till steady state is reached. Please do not rush.
o Log Off from data saving procedure.
6. With the help of saved data file, draw the Process Reaction Curve.
7. Find the control setting parameters from Cohen-Coon (C-C) & Ziegler-Nichols (Z-N)
rules.
8. Tabulate the control setting parameters for each type of controlling mode e.g. Pmode, PI-mode, PID-mode; obtained from both the rules, C-C & Z-N.
9. Run the process with the suggested controlling parameters for each type of control
mode, obtained from both the methods. Please follow the instructions directed
below carefully.
Select the MANUAL MODE with controller output 0%.
Have the set point of 25 oC.
Wait till steady state is reached.
Select the AUTO MODE.
Set P / PI / PID parameters as obtained from Z-N rules. For the first time, set
for P-mode. You will have the opportunity of tuning PI & PID mode in next
RUN sequences.
Wait till steady state is reached. Please do not rush.
Once steady state is reached, LOG on to a file for saving transient response of
system. It is advised to save the data file with name explaining: controller
mode, set pointy change, control parameter values.
Start saving data, with file name as suggested above, if possible.
Wait till approximately 5 mins.
Give a STEP change by changing the set point from 25 oC to 35 oC.
Wait till steady state is reached. Please do not rush.
Log Off from data saving procedure.
10. Repeat the procedure mentioned in STEP-8 for obtaining the process transient
response for different control mode e.g. PI and PID.
11. Repeat STEP-8 and STEP-9 for controlling parameters as obtained previously from CC rules.
12. Draw the excel plots for all the above set of transient responses. Plot process value
and set point of the process on the same graph against time.
13. Report the best possible controlling mode for the step change made. Justify your
decision on both, qualitative and quantitative scale.
14. Last step of experiment is to observe the frequency response of the system. Do as
directed below:
Select AUTO MODE.
Set for PI Mode of control. Set the controlling parameters with Kc= 4*Kc(ZN) and Ti = 1.85*Ti (Z-N).
Turn on Function Generator.
Select Signal type as Sine Wave of Amplitude: 5, Period: 10 sec, Reference
point 30.
Wait for steady state.
Log on to data file for saving data.
Save the transient frequency response for approximately 15 mins.
Log Off from data saving procedure.
Shut down the unit. Please make sure Heater is turned off.
Make a plot showing the transient response of process value, set point
value and control output value against time. Please make sure that they are
plotted on same graph.
Fig: 1. Block Diagram of a Control Loop for measurement of Process reaction curve.
A typical process curve exhibits an S- shape as shown in Fig: 2. It is represented by equation
(1).
e L s
G ( s) = K
1 + Ts
(1)
Zeigler and Nichols suggested setting the values of Kc, Ti, Td according to the formula shown
in Table 1. Refer Fig. 2 for symbol meaning for tuning the controller via Z-N settings.
Table 1. Z-N Settings for tuning different Controllers
Type of Controller
Proportional (P)
Proportional - Integral (PI)
Proportional - Integral Derivative (PID)
Kc
T/L
0.9T/L
1.2T/L
Ti
Td
L/0.3
2L
0.5L
Fig: 2.Typical process reaction curve (First Order with Transportation lag)
Similarly, Cohen and Coon suggested controller parameters as given in Table 2.
Table 2. C-C settings for tuning different controllers
Types of Control
Proportional (P)
Parameter Settings
Kc = (T/(Kp*L)) * ( 1+L/3T)
The value of Kp can be found using Kp = Bu / M, where Bu is the ultimate value of B at large
time t. (Refer to Fig. 1).
It is the open loop method of tuning control parameter, which is widely used in industrial
practices. However, we will divert from this approach in this experiment. Students will have
an opportunity to exercise the above mentioned open loop algorithm in Temperature
Control Trainer experimentation.
Currently, the area of focus will be doing a set of suggested simulation on INTERFACE
panel of the trainer. Transient data will be observed and analyzed for step, frequency &
square wave responses given to the system. You will be given a set of controlling
parameters for different modes of controller. You are required to come up with the best
control logic from the given set.
Having done with search for best controlling action, students are advised to replicate their
simulations model for real time experimentation. This will help in realizing and appreciating
the real time differences with ideal simulation conditions, if any.
EXPERIMENTAL PROCEDURE :
1. Run the process with the suggested controlling parameters (same as for simulation)
for each type of control mode. Please follow the instructions directed below
carefully.
2. Log in the system with INTERFACE mode this time.
3. Select AUTO mode.
4. Make sure all the system component e.g. pump, rotameter, sump-tank are in
working conditions.
5. Repeat step 4 for real time analysis for all the above done simulations.
6. Plot the responses, both simulation & experiments, on the same graph for
comparison.
7. Plot the Bode diagram for frequency response.
8. Explain the effect of increasing value of Kc for P-mode controller, both qualitatively
and quantitatively.
9. What happens to phase lag with decrease in frequency of the sine wave signal.
Justify your reasoning on simulation and experimental results obtained.
SIMULATION PROCEDURE:
1. Level Control Interface Panel is made available.
2. Log in the system and select SIMULATION mode
3. Select AUTO mode.
4. Do as directed below:
o Adjust set point to 30%.
o Select P-mode of controller with Kc = 1.0.
o Wait for steady state. Please do not rush.
o Log on to a file for saving system transient response.
o Induce a step change by changing set point to 50%.
o Wait for steady state. Please do not rush.
o Log off from data saving protocol.
5. Repeat step 4 for Kc = 2, 10, 30.
6. Please observe the sustained oscillations for Kc = 30. Justify it.
7. Turn ON the Function Generator module.
OPTIONAL:
Table 3. Input Response Parameter for Simulation
S.No. Signal Type
1.
Sine Wave
Amplitude
10
Period
10
Reference Point
40
2.
Sine Wave
10
100
40
3.
Triangle
Wave
10
10
40
Control Mode
a. P-mode
Kc = 1
b. P-mode
Kc = 5
c. P-mode
Kc = 50
P-mode
Kc = 5
PI-mode;
Kc= 100, Ti = 10.
Fig: 2. Block Diagram of a Control Loop for measurement of Process reaction curve.
A typical process curve exhibits an S- shape as shown in Fig: 3. It is represented by equation
(1).
G ( s) = K
e L s
1 + Ts
(1)
Zeigler and Nichols suggested setting the values of Kc, Ti, Td according to the formula shown
in Table 1. Refer to Fig. 3 for meaning of symbols for tuning the controller via Z-N settings.
Table 1. Z-N Settings for tuning different Controllers
Type of Controller
Proportional (P)
Proportional - Integral (PI)
Proportional - Integral Derivative (PID)
Kc
T/L
0.9T/L
1.2T/L
Ti
Td
L/0.3
2L
0.5L
Fig: 3.Typical process reaction curve (First Order with Transportation lag)
The value of K can be found using K = Bu / M, where Bu is the ultimate value of B at large
time t. (Refer to Fig. 2).
Start-up:
1.
2.
3.
4.
5.
Shut-down:
1. Exit from the software.
2. Switch off the interfacing unit.
Procedure:
1.
2.
3.
4.
position
OFF
OFF
level PC
PC
Fully anti clockwise
Ensure that the drain valve of sump tank (V1) is fully closed.
Close the bypass valve (V2) partially. Partially open the drain valve (V3) of the level tank.
Fill clean water in the sump tank till the maximum level of the sump tank.
Connect the communication cable from output of the interface card to PC.
Connect the 230 V A.C. supply to the trainer. Switch ON the Mains supply.
Ensure that pneumatic supply (to the trainer) is ON and it is more than 2 kg/cm2.
Ensure that position of the switches is as per the table mentioned above
Switch on the pump on the panel marked as PUMP
Gradually turn the knob of FR clockwise till the pressure gauge marked E/P IN shows
20 psi. (WARNING: Sudden application of pressure or application of high pressure may
damage E/P converter.)
10. Switch ON the PC and the interface device. Select the experiment Cascade Flow/Level.
11. Make following settings. (Take two readings with set points 200 and 300)
Primary loop (level loop): set point: 300, PB: 80%, It: 10 s-1, Dt: 0 s-1.
Secondary Loop (flow loop): PB: 25%, It: 45 s-1, Dt: 5 s-1.
Low alarm: 275 lph, High alarm: 400 lph
12. Ensure that both the PID controllers are in Manual Mode. Keep the output of the
secondary loop to 0 %. This means the control valve is fully open. Let the level reach
near set point.
13. Change the secondary PID and primary PID to Auto mode
14. See the graphical trend display where you will observe graphs of level vs time, set point
vs time, output vs time, etc. Observe if the level is under control. Note if there are
oscillations or offset, note if the response time is faster or slower. Depending on this
data, tune the PID controller.
15. Once control is achieved and fine tuning is done, create a disturbance in secondary loop
(flow loop) and observe its effect on the level. To do this open the valve V2 slightly and
observe the flow and level. This will increase the flow momentarily leading to increase in
level. However, the primary loop takes care of the minor changes here on its own and
the effect of this is not passed on to secondary loop (level loop). Please note that the
disturbance in the flow should not be more than 10 % of the present value of flow.
16. Switch OFF the pump and shut down the system.
Orifice plate
Rotameter
HV-2
HV-1
Water tank
Pump
signal back to analog form. The output of MCIO card (0-10 volts) is fed to the signal
conditioning card where 0-10 V is converted to 4-20 mA, which is transferred to the final
control element for adjusting the desired air pressure to be supplied to the control valve for
adjusting the stem position.
Precautions:
1. The recirculation valve (HV-2) has to be kept open to at least 60%. (It is recommended
to keep this valve always fully opened).
2. To ensure electrical signal transmission keep the PANEL switch in ON position.
Start-up:
1.
2.
3.
4.
Procedure:
1.
2.
3.
4.
CHP303:PROCESSCONTROLANDREACTIONENGINEERINGLAB
PC8:EXPERIMENT:InteractingandNoninteractingTwotankSystem
OBJECTIVE:Tostudythedynamicopenloopresponseofliquidlevelinsingletank,twotank
interactingandtwotanknoninteractingsystems.
Apparatus: It is a selfcontained recirculating unit consisting of a sump tank, three tanks
and an overhead tank. The sump and overhead tanks are connected by pump. Level
indicatorswithscaleareprovidedforeachTank1,Tank2andTank3.Rotameterisprovided
to measure the flow rate of water. Valves are provided for connection and drainage
purposes.
THEORY: The single tank liquid level system is a physical example of first order system.
Consider a system comprising of a tank of uniform cross sectional area with a flow
resistancesuchasavalveattachedtoit.Thevolumetricflowratethroughtheresistanceis
relatedtotheheadby alinear relationship. Theprincipledistinction to be madeinmulti
capacityprocessesisinhowthecapacitiesarejoined.Iftheyareisolatedtheyaresaidtobe
noninteractingasthecapacitiesbehaveexactlyastheywoulddoalone.Butifcoupled,they
interact with one another in which case the contribution of each is altered due to
interaction.Innoninteractingsystemthetwotanklevelsdonotinteractbecausetheflow
from first tank to the second tank is independent of level in the second tank. In an
interactingsystemthelevelsinbothtanksinteractbecauseanychangeinthedownstream
levelwillaffecttheupstreamlevelaswell.Overall,bothinteractingandnoninteractingtwo
tanksystemsareexamplesofsecondordersystems.
Fig.1.Schematicdiagramofexperimentalsetup
Data: Inner diameter of each tank (D1) = 0.108 m. Outer diameter of the down comer in
eachtank(D2)=0.022m.Crosssectionareaofeachtank,A=[(D1)2(D2)2]/4.
Nomenclature: V1=flowcontrolvalve(Rotameter);V2=ValveforwatersupplytoTank2;
V3=ValveforwatersupplytoTank3;V4=drainvalveforTank2;V5=drainvalveforTank3;
V6=drainvalveforoverheadtank;V7=drainvalveforsumptank.
ProcedureforSingleTankSystemTank2(orTank1):
1. CloseallthevalvesV1V7.Fillthesumptankwithwater.SwitchONthepowersupplyand
thepump.Waittillthereisoverflowfromoverheadtank.NowopenthevalveV1andadjust
theflowrate(1020lph).
2. OpenthevalveV2completelyandpartiallyopenthevalveV4andwaittillaconstantheight
isachievedbyliquidinTank2.Notedowntheinletflowrateandheightofliquid(hi)inthe
tank(thisisinitialheight).
3. Nowincreasetheinletflowrate(stepchange:1020lph)throughvalveV1.Simultaneously
startthestopwatchandrecordtheheightofliquidlevelintankwithtime,tillsteadystateis
reached(constantheight).Notedownthefinalconstantheightandflowrate.
4. Repeat the same experiment for different step changes. After completing the experiment
switchOFFthepumpandpowersupply.OpenthedrainvalveV4.
5. Determine the valve resistance (R2) by plotting flow rate Vs head. The resistance is the
reciprocalofslopeofdischargevsheadcurve.
ProcedureforTwoTankInteractingSystem(Tank2Tank3):
1. CloseallthevalvesV1V7.Fillthesumptankwithwater.SwitchONthepowersupplyand
thepump.Waittillthereisoverflowfromoverheadtank.NowopenthevalveV1andadjust
theflowrate(1020lph).
2. OpenthevalveV2completelyandpartiallyopenthevalveV3&V5andwaittillaconstant
heightisachievedbyliquidinTank2andTank3.Notedowntheinletflowrate(qi)andheight
ofTank2(h2i)andTank3(h3i)(thisisinitialheight).
3. Nowincreasetheinletflowrate(stepchange:1020lph)throughvalveV1.Simultaneously
startthestopwatchandrecordtheheightsofliquidlevelinTank2andTank3withtime,till
steadystateisreached(constantheight).Notedownthefinalconstantheights(h2fandh3f)
andflowrate(qf).
4. Using deviation variables H2=h2fh2i, H3=h3fh3i,Q=qfqi, determineresistances R2 = H2H3/Q,
R3=H3/Qandfindtimeconstants2=A2R2and3=A3R3.Comparetheexperimentalresponse
(H3 vs time) with theoretical response. After completing the experiment switch OFF the
pumpandpowersupply.OpenthedrainvalvesV4V5.
ProcedureforTwoTankNonInteractingSystem(Tank1Tank2):
1. CloseallthevalvesV1V7.Fillthesumptankwithwater.SwitchONthepowersupplyand
thepump.Waittillthereisoverflowfromoverheadtank.NowopenthevalveV1andadjust
theflowrate(1020lph).
2. PartiallyopenthevalveV2&V4andwaittillaconstantheightisachievedbyliquidinTank1
andTank2.Notedowntheinletflowrate(qi)andheightofTank1(h1i)andTank2(h2i)(thisis
initialheight).
3. Nowincreasetheinletflowrate(stepchange:1020lph)throughvalveV1.Simultaneously
startthestopwatchandrecordtheheightsofliquidlevelinTank1andTank2withtime,till
steadystateisreached(constantheight).Notedownthefinalconstantheights(h1fandh2f)
andflowrate(qf).
4. UsingdeviationvariablesH1=h1fh1i,H2=h2fh2i,Q=qfqi,determineresistancesR1=H1/Q,R2=
H2/Qandfindtimeconstants1=A1R1and2=A2R2.Comparetheexperimentalresponse(H2
vs time) with theoreticalresponse. After completing theexperiment switch OFFthe pump
andpowersupply.OpenthevalvesV2&V4.
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 vale plug design the control
valve can be divided in three categories: (i) Equal % type, (ii) Linear type, (iii) Quick opening
type (On/Off type).
(1) Control Valve Flow Coefficient: A control valve changes the flow rate by changing the
pressure in the flow system because it introduces the constriction in the delivery system.
There is a close relation between the pressure and the flow rate in a fluid stream passing
through a pipe so that if pressure is changed, the flow rate will also change as
where
k is correction factor which allows selection of proper size of valve to accommodate the rate
of flow that the system must support. This correction factor is called as valve coefficient and
is used in valve sizing. The flow coefficient (Cv) of a control valve is given by
= 11.7
where Q = discharge of fluid (m3/h), P= pressure drop (KPa), G = specific gravity of fluid
relative to water (G=1)
Procedure for Control Valve 1:
(2) Study of Hysteresis of Control Valve: Hysteresis is predictable error resulting from the
differences in the transfer functions when a reading is taken from above and below the value
to be measured. In case of control valves for same actuator signal different stem travel (hence
valve coefficients) are obtained depending upon the direction of change in signal. The
maximum error in stem travel expressed in % for same actuator pressure while opening and
closing the valve is indicated as hysteresis.
Procedure for Control Valve 1:
Plot x vs p on a simple graph for both increasing pressure and decreasing pressure cases for
all three valves, where x is fraction of maximum valve lift, x = L / Lmax; L is valve lift (in
mm), L = L Li ; Li = initial position of valve stem(mm), L = position of valve stem (mm); Lmax
= max value of valve lift.
(3) Study of Rangeability: Control valves have a characteristic such that flow changes by a
constant of its instantaneous value for given 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.
=
where m is
fraction of max flow rate.
Procedure for Control Valve 1:
Calculate fraction of max flow rate, m = Q / Qmax, where Q is flow rate of water (m3/s), Qmax is
max flow rate of water (m3/s). Determine rangeability =
where mmin is min value of
m and mmax is max value of m.
After completion stop the air supply. Switch OFF pump and power supply. Open valve V5 fully
to release the air.