Experiment no. ‘Aim: To examine the response of the thermometer to a step up and step down input in temperature a thin film around the bulb i.e., neglecting the thermal resistance of glass & mercury. * All thermal capacity is in the mercury. * Mercury always has uniform temperature. * The glass wall does not expand or contract, ‘Applying the energy balance on thermometer dE _dE+K+P)_ dU _ di Ge OR a To natal) - @ Where ft and yt represents the suroundng temperature and mercury temperature at any ime oto me, ZO = hateto - 0) ® ‘mis the mass of the mercury, Cy is the constant specific heat of mercury, A isthe surface area of the envelope containing mercury, hi film heat transfer coefficient surrounding the mercury envelop. ‘cw temper patie tarp tenpr rile Rearranging the above equation Meer — (ate) ¥(0) © 2 eO-y0) @ ‘ty is the time constant Writing the energy balance equation for steady state (i.e x, = ys)Te ap = (s— ye) (3) Subtracting Eq, 5 from 3 to obtain the energy balance equation in terms of deviation variables as av(e) &O-YO) (©) tp, eae Where X(t) = x(e) — x4; ¥(0) = y(0) — yy Taking the Laplace transform of this ODE gives 1)9¥ (5) + ¥(s) = X(s) a On rearranging above the transfer functor y)_ 1 = 6 YO yst1 by ‘To examine the response of the thermometer to a step-up input of magnitude A In surrounding temperature, we know that 4 x0) =F Putting in Eq. (8) v 9 Olea | o To obtain the solution taking inverse Laplace using that partial factions ¥@=A(1-e Me) (ao) Some terms associated with Tpand A systems response to a step change Elapsed Time Wor thermometer Remarks temperature response ity > 623 : By > 365 i 3p > 35 : tp 3 38 = Sty 9 39 Usually defined as Steady-State Step input X(t) Output ¥/t) J—~__19) z44-—_ a} — 2 7 - ov T y Procedure:Experiment no. 2: Aim: To study level measurement by alr purge method ‘Objectives: After completing this experiment students will be able to know the method of level measurement working on hydrostatic principle. Equipments: Level measuring instrument, Sc Theory: Materials: Water There are direct and indirect Level Measuring instruments like Visual Gauge glass, Float type, Float activated, Level and shaft mechanism, Magnetic float, Head measurement. Air purge method falls under head measurement category. Ifthe density or specific gravity of liquid in the open type vessel is known the only Pressure measurement can lead for measurement of liquid level. This is the indirect method of liquid level measurement device. This system is satisfactory for al iquids. The only limitation is the Clogging of bubble pipe in a sinusoidal system such as chemical slurries etc. A pressure gauge or a manometer of suitable range is connected separately to the upper end of a bubbler system. It operates by building up a pressure in the feed line until the gas escapes and flow stabilizes at a rate onsen] || Proms tnk AFPae determined by valve in the feed line. The pressure in bubbler pipe necessary to cause flow is just equal to the pressure exerted by liquid head above the tip of feed line. So by knowing specific gravity of the liquid, its level can be measured in the open vessel Procedure: 1. Fill the tank with water. 2. Start the compressor to allow the airflow & adjust the flow such that a known no. of bubbles (i.e. one by one after 3 sec) are coming out of bubbler pipe 3, Toke the readings of water level in the tank and level difference in manometer. Observation table: S.No, | Liquid level] Level Difference inmamnometer | Calculation em. (H=h~hs) OP = dHpg (cm of water column) Caleulation: Hea) = oan GRAPH : - Plot graph of AP Vs level as well as H and Hass. CONCLUSION: quiz: 1. Describe different methods for direct level measurement. 2. Write brief description of hydrostatic methods used for level measurement. 3. Explain different methods used for level measurement of solids. EVLUATION : i ‘Observation & Presentation Quiz Discipline Total Inference1. Take 250 ml water in a glass beaker, put it. Heat the water up to 100°C. 2. Dip the given thermometers in the boiling water and wait til the thermometer indicates 100°C. '3. Note down the time required by the thermometer for every 10°C ralse in temperature from room temperature to tll it iter tieTinal steady state for the above step up change. 4, Take out the thermometer from beaker and allow i to cool up to room temperature . 5. Note down the time required for for every 10°C 2&¢fa temperature from room temperature to tilt aeRO the final steady state for the above step-down change. 6. Repeat the same procedure for two different temperatures (80°C and 60°C). 7. Now take olin the beaker and repeat the above procedure (Step no. 1 to 6) for three different temperatures (200°c, 80°C and 60°C). 7. Now take ol in the beaker and repeat the above procedure (Step no. 1 t0 6) for three different temperatures (200°C, 80°C and 60°C). 8, Repeat (step 1-7) for CCleilled thermometers. OBSERVATION TABLE: Room temperature: c ‘Thermometer type: ‘Sr.No. | Fluid ‘Steady state temp. | Time taken during | Thermometer reading “ rise (Second) *c z Results: Plot a graph between response and time and find the value of time constant graphically from 63.2% A of response and practically using equation (10). Calculate h, for different systems CONCLUSION: aur: 1. Explain meaning of First Order System 2, Describe Time Constant and its significance. 3, Show graphical representation of response of first order system to step input. 4, List the errors related with thermometers. EVLUATION : ‘Observation & Presentation ‘Quiz Discipline Total Inference, Signature with dateExperiment no. 3: ‘Aim: To Study the Transient Response of Single Tank System ©) To Determine the Transient Response of single System for step change. 4d) Impulse change. Theory: Assumptions: 2) The desired output forthe systems the head required to handle the flowinto the “. tank 1 b) The tank has a uniform crosssection = 6) The output from the tank has a constriction {valve limiting ts flow 4) volumetric flow rate through the resistance, isrelated to head h by a linear relationship Then: tn g= the Input volumetric flow rate (volume/time) {go= the outlet volumetric flow rate (volume/time) A= the resistance of the constriction ‘n= the head created inthe tank ‘Ay the cross-sectional aea of the tank ‘Analysis ofthis system is based on a mass balance where ‘Mass Flow In ~ Mass Flow Out = Rate of Mass Accumulation in the Tank Torelate the mass balance to the flow rate, we use the density ofthe fluid, p. The density is assumed to be constant. Then the mass balance becomes: At unsteadystate an(o at) — pat) = Ap a Assuming go(0) h_ ance) pate) p= A @ Atsteady state =pls paso ® To obtain the material balance in terms of deviation term, subtracting the steady-state version of the equation from the general form of the equation, yielding dH@ ae @ ‘Where QC) = (0) — agvand HCO he) =,= aCe) @ RQ(t) — H(t) = A, R- ae “Taking the Laplace transform of this ODE gives ‘pSH(s) + H(s) = RQ(s) o tp = AR istime constant (On rearranging above the transfer function is {Oe © AS) ~TsF1 ‘To.examine the response of the thermometer toa step-up input of magnitude Ain in the inlet flow rate, we know that . ~~ A ee =$ Puttingin Ea (8) 4 o = Systt To obtain the solution taking inverse Laplace using that partial factions H@ =AR(1- For impulse (of A magnitude): Qs) =A => Ps = Putting in 5: ; moss Taking inverse Laplace 5 2 “Tranwert response of engl tank site Impulse input X(t) ‘Output Yit) Yo. xProcedure 1) For transient response to step change a, Start up the set up. b. Aflexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the top Tank. Keep the outlet valves of tank (Ri) & Adjust the flow rate at a suitable value and allow the level of the tank to reach the steady state and record the flow and level at steady state, 4. Apply the step change by increasing the Rotameter flow to a suitable value. Immediately start recording the level of the tank at the interval of 15 sec, until the level reaches at steady state, {. Carry out the calculations and compare the predicted and observed values ofthe tank level Repeat the experiment by throttling outlet valve (R1) to change resistance. 1) For transient response to Impulse change Repeat all the above steps except d. wherein add 250 mL of water immediately to the tank without disturbing the inlet and outlet flow rates. Observations Diameter of tank mm: ID mm. Initia flow rate (LPH): Initial steady state tank level (mm): Final flow rate (LPH): Final steady state tank level (mm): Sr. NI Time Level | H(t) observed H(t) predicted (Sec) (mm) (mm) (mm) 1 0 ' ~ 2 15 3 30 a ry 5 = (CALCULATIONS ) «10-3 m evel at any time, t - level attime, H(tHorseres A Hlthreseea = AR(L— 2 Fe) (For step change) itn = 22" (orimpus change where Hednciess level predicted a time tin m-flo after step input na flow ate in m/secPlot the graph of Hit) Vs time for observed and predicted levels. Precautions Observed response fairly tallies with theoretically calculated response. Deviations observed may be due to following factors: Nonlinearity of valve resistance. 1._ Step change is not instantaneous. 2. Visual errors in recording observations. 3. Accuracy of Rotameter. CONCLUSION: quiz: 1. Explain meaning of liquid evel system. 2. Explain difference between step input and impulse input. 3. How we can increase or decrease time constant of liquid level system? EVLUATION : Observation & Presentation Inference ‘Quiz Discipline Total Signature with date References [1] D. R. Coughanowr and L. 8. Koppel, Process Systems Analysis and Control. New York: Mc-Graw Hill Book Company.Experiment no. 4: he ‘Aim: To Determine the Transient Response of two Tanks (interacting) System for ©). Step change. 4d) Impulse change, ‘THEORY Assumptions: 2) The tanks have uniform cross sectional area b) The flow resistance is linear. To find out the transfer function of the system that relates 2” tank head hy to the inlet flow rate to first tank q, "writing a mass balance around the tanks, firstly transfer functions of both the systems has to be obtained as follows | ree J ! Tet eapmttrimecr in For first tanks Atunsteady-state dhy(t) a(t) — pa(®) = Ap @ Atsteady state ahas( POs ~ Pays = Ap @ ‘Subtraction Eq. 2 from eq. 1 we have ait 0-09 = 4, HO @ Taking Laplace transformation Q(S) = (8) = Ays (5) ® since Qy(s) = 22 so Be © Where tpi = ALR For second tank assuming ©Where hy, ah) Pa) — p= Arp Atsteady state fag _ gy ilas Pas ~ PRE = APG ” ® To obtain the material balance in terms of deviation term, subtracting the steady-state version of the equation from the general form of the equation, yielding 0,9 2-4, HO Qu(0) = auCt) ~ aassand Ha(0) = he — hag ait RaQ (0) — Ha = Aah O Toking the Laplace transform ofthis ODE eves TpaSH(s) + Has) = R2Qa(3) ty2 = ALR2 is (on rearranging above the transfer function is Has) Re a(S) tps +1 constant since Qs) OCS) Cs) overall ransfer function wing ea $ and 2 canbe aelated as foliows Hes) Os) (s+ D,5+)) For a step change of magnitude, A Q(e) = Au(and Q(s) =4 AYR, Oe Heat time tis given by tits nao ani- ® ao an aa (14) (as) (6)For a impulse change of magnitude, A ical, the apse TonGion of magni Taena,eTe Tacin ma vomtnan X(t) = AS(t) Where 5(¢) is the unit impulse function IoStee Laplace transformation of unit impule functions 4 een x) 5 “ae = Fora impulse change of magnitude V (volume) is added to the system X() = Putting in eq 14 VOR, Fl) = ese) Taking inverse Laplace transformation Ral Find out H(t) Predicted from above equation and plot the graph of Hit). PROCEDURE Step response of first order systems arranged in non-interacting mode HAO) and H (t]ouanesVs time. 1. Arrange the Apparatus for non-interacting system. 2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the top Tank 1. Keep the outlet valves (R:& Ri) of both Tank 3 & Tank? slightly closed. Switch on the pump and adjust the flow. Allow the level of both the tanks (Tank 1 & Tank 2) to reach at steady state and record the intial flow and steady state levels of both tanks, Apply the step change with increasing the Rotameter flow by a suitable value. Record the level of Tank2 atthe interval of 30 sec, until the level reaches at steady state. Record final flow and steady state level of Tanka. Carry out the calculations as mentioned in calculation part and compare the predicted and observed values of the tanklevel. 8. Repeat the experiment by throttling outlet valve (R1) to change resistance. OBSERVATIONS Diameter of tanks: 10__mm Inia low ate (LPH Initial steady state level of Tank 1 (mm):Initial steady state level of Tank 2 (mm): Final flow rate (LPH): Final steady state level of Tank 1 (mm): Final steady state level of Tank 2 (mm): Sr.No. |Time | Leveloftank2 | Hit) observed H(t) predicted (se) | (mm) (rom) (ram) 1 o 2 30 3 60 4 90 5 120 6 150 7 180 a 5 CALCULATIONS H (t) observed = (Level at time t - level at time 0) x 10 aa sa a tend] An {tis level in Tank2 predicted at time tin m, Hye Where ‘A= magnitude of step change = Flow after step input - Initial flow rate in m?/sec. Where tis time constant of Tanki, Asis area of Tankl and Rss resistance of outlet valve of tankl. tis time constant of Tank2, Aris area of Tank2 and Rz is resistance of outlet valve of Tank2 ‘Area oftank1= 7/4 (42) nm? Area of tank 2= 2/4 (din m? Put the values in equation to find out H(t) mesces and plot the graph of H(t) nesnd and H (tomers Vs timeExperiment no. 5: ‘Aim: To Determine the Transient Response of two Tanks (interacting) System for 2) Step change. b) Impulse change. THEORY ‘Assumptions: a) The tanks have uniform cross sectional area b) The flow resistance is linear, €). The liquid to be of constant density THEORY ‘A mass balance on tank 1 gives pat past = Ap 2O ® ‘A mass balance on tank 2 gives aby pas(t)~ pant) = Ayo 2 @ The fowhea relationships forthe twolner resistances are gen by the expressions hacky hs aca ett and aa) =F (Gand 4) At steady state, equations (1) and (2) can be written dius Pas — Pass = APH © dhas(t) as Ptas = Aap © hschas hs aug SME and tas = BE (and 8) ‘subtracting equations (5) from equation (1) and equation (4) from equation (2) and introducing deviation variables ives dH 0) - (0 =e o atis(©) ae Q(t) — Q2(t) = Az ao)ao and Q:() =F (and 12) HL O- Hr) HA, Ry Re ‘Taking Laplace transformation for equation 9-12 Qs) = Qu(s) = Ars Hg(s) (a3) Quls) — 026s) = Aas HC) as) RiQi(s) = Hy (5)— Hs) as) ReQ2(5) = Has) a6) ‘The analysis has produced four algebrafe equations containing five unknowns: (Q, Q4, Qs, Hs and H,). These equations ‘may be combined to eliminate Qs, Qs, and Hs and arrive atthe desire transfer function: For Interacting Tank system, the overall transfer function is given by: R —— 47 tata Gn tt PAR )eeT a Where pr = AiRy is time constant for tank 1 Tpz = AgRp is time constant for tank 2 The response of tank system for step change and impulse change can be calculated by using above transfer function. For Step Input of magnitude A tpi — tpn on) He) = Rea [2+ as) tp2 Tp For unit impulse Input tin Raertin HQ = Be as) Te PROCEDURE: 1L. Arrange the Apparatus for interacting system 2. A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the Tank1. Keep the outlet valve (As) of Tank2 slightly closed. 3. Switch on the pump and adjust the flow to suitable value. Allow the level of both Tank and Tank2, to reach the steady state and record the initial flow and steady state levels of both tanks. Apply the step change with increasing the Ratameter flow by a suitable value. Record the level of the Tank1 at the interval of 30 sec, until the level reaches at steady state. Record final steady state flow and level of Tank2. Carry out the calculations as mentioned in calculation part and compare the predicted and observed values of the tank level. Repeat the experiment by throttling outlet valve (RI) to change resistance, 9. Repeat whole the procedure except at point 4 wherein apply impulse input by adding 0.5 It of water in Tank 2 OBSERVATIONS Diameter of tanks: 1D mm Initial flow rate (LPH: Initial steady state level of Tank 4 (mm): Initial steady state level of Tank 2 (mm):PROCEDURE IMPULSE RESPONSE OF FIRST ORDER SYSTEMS ARRANGED IN NON-INTERACTING MODE 1. Arrange the Apparatus for non: A flexible pipe is provided at the Rotameter outlet. Insert the pipe in to the cover of the top Tankl. Keep the outlet valves (Rs & Ra) of both Tank & Tank2 slightly closed. 3. Switch on the pump and adjust the flow to a suitable flow rate. Allow the level of both Tank and Tank 2, to reach the steady state and record the intial flow and steady state levels of both tanks. 4. Apply impulse input by adding 05 it of water in Tank 1. 5. Record the level ofthe Tank 2 atthe interval of 30 sec, until the level reaches to steady state 6. Record final steady state level of Tankt. 7. Carry out the calculations and compare the predicted and observed values of the tank level. 8. Repeat the experiment by throttling outlet valve (Ri) to change resistance. ‘OBSERVATION Diameter of tanks: 1D mm Initial flow rate (LPH): Initial steady state tank 1 level (mm): Initial steady state tank 2 level (mm: Volume added (lt): Final steady state tank 1 level (mm): Final steady state tank 2 level (mm): St.No. |Time | teveloftank2 | H(t) observed Hit) predicted (Sec) | (mm) (mm) * (mm) 1 ° 2 30 3 60, 4 90 s = CALCULATIONS: H (0) ewnee = (Level at time t-level at time, t= 0)x107\V= Volume of liquid added as an impulse input (in m’) Putthe values in above equation to find out Ht) Predicted and plot the graph of H(trmscus and H(tlmenea V5 He PRECAUTIONS Observed response far tales with theoretically calculated response. Deviations observed may be due to folowing factors: + Hon-linearity of valve resistance. + Step change is not instantaneous. + Visual errors in recording observations. + Accuracy of Rotameter. RESULTS: conctusion; Oe quiz: 1. Explain meaning of non-interacting tanks in series. 2. Draw three non interacting tanks in series. 3. f we increase no. on tanks in series, what effect we could see on response? Explain with graphical representation. EVLUATION: ‘Observation & Presentation Quiz Discipline Inference Total Signature with date References [1] D. R. Coughanowr and. B. Koppel, Process Systems Analysis and Control, New York: Mc-Graw Hill Book Company.Experiment no. 6: ‘Aim: To study of step response of manometer filled with ©) Mercury 4) Water Theory: ‘The dynamic response of a second order system to a step change can be described by a second-order differential ‘equation. The solutions to above equation involve three cases: an under damped condition Every system has a tendency to oppose the oscillatory behavior of the system which is called damping. The damping is measured by a factor called damping ratio of the system. If the damping is very high then there will not be any oscillations in the output. The output is purely exponential. Such system is called an aver damped system [Z <2] and ‘other systems are critical damped condition [¢ =1] and over damped condition [¢>1}. ‘The response for under damped system [i.e. <1] can be written as swf ESE) gen (HSE) a Following figure shows response of second order system for different damping coefficient. 20 18 16 4a 12 10 os 06 04 02 00 Y/KM * Damping coefficient % @ ‘Where, L= Column length in meter, yynamie viscosity in Kg/ms. p= Mass density of the manometer fluid in kg/m? tube diameter inm ravitational acceleration in m/sec? = =2 insec. Characteristics time,r = 2 oFinal flow rate (LPH): Final steady state level Tank 3 (mm): Final steady state level Tank 2 (mm): sr. No] Time Level of Tank 2) __ H(t) Observed] H(t) predicted (see) (mm) (rm) (rom) 1 ° 2 30 3 60 a caLcULATION HUthonenes = (Level at time t- level at time, t= 0) x 10m ‘ Hilti = Ha (0) H2tNreaaee = Ha(C) for impulse change Put the values in above equation to find out H(t) Predicted and plot the graph of H{t)mesaes aNd Hit)ooenee VS time. LUTION: Observed response fairly tallies with theoretically calculated response. Deviations observed may be due to following factors: Non-linearity of valve resistance. Step change is not instantaneous. Impulse change is not instantaneous. Visual errors in recording observations ‘Accuracy of Rotameter. RESULTS: ; CONCLUSION: ee EVLUATION: ‘Observation & Presentation Quiz Discipline Total Inference Signature with date References [1] D. R. Coughanowr and. 8. Koppel, Process Systems Analysis and Control. New York: Me-Graw Hil Book Company.Frequency of damped oscillation, f = ay x FE incps (a) Where w, inrad/sec (5) 1. Rise time (t)is the time the indicated value takes to first reach the new SteadyState value. 2. Time to first peak (ty lis the time required for the indicated value to reach its first maximum value. 3. Response/settling time (tis defined as the time required for the indicated value to reach and remain inside a band whose width is equal to +/-5% of the total change in 8. The term 95% response time sometimes is used to refer to this case. Also, values of +/-1% sometimes are used. 4. Decay ratio (OR) = c/a (Where c is the height of the second peak) on 00( 5) 6 overshoot = 5 = VDE Py 5. Period of oscillation = P is the time between two successive peaks or two successive valleys of ‘the response. a aed Oc) i rrcete 1. Ensure that mercury level in manometer is set at ‘0’ on the scale, 1. Close vent connection by putting finger on it. 3, Adjust the needle valve and vent to raise the mercury level to @200mm from level |. Note the mercury level reading and quickly open the vent to apply step change. 5. Note the top peak and bottom peak readings. Also simultaneously note the perlod of oscillation. (This can be noted by measuring time required for 4-5 oscillationsand then calculating for each oscilation) 6. Repeat process 2-3 times for different step changes. 7. Repeat the whole procedure for the water filled manometer. Observations: Constants: Manometer fluid = Mercury Dynamic viscosity (u) = 0.0016Ke/m.s. ‘Mass density (p) = 13550Ke/m3. Column length (L) = 0.760m ‘Tube diameter (d) = 0.005 meter ‘Step change (mmm): Period of oscillation (sec): Sr No, | Aetual response* (mm) Period of oscillation**(see) 1 2 3 Note peak values observed during oscillations. ‘+: Measure the period of 4-5 oscillations and note average time required for each oscillation. Cateulations + Calculate natural frequency of oscillations using equation no. 5 += Caleulate damping cberficient using equation no. 2 * Calculate period of oscillations using equation no.8 + Caleulate decay ratio using equation no. 6 + Calculate overshoot using equation no. 7 + Calculate frequency of damped oscillations using equation no. 4 «+ Caleulate characteristics time using equation no. 3 + Calculate theoretical response for different time values using equation no.1 Graphs Plot the graphs of Actual & Theoretical response Vs Time. RESULTS: Sample calculations & results Refer MS Excel program for calculation and graph plotting. conctusion: EVLUATION : ‘Observation & Presentation Quiz Inference Total Signature with datetxperiment no. 7: ‘Aim: For pneumati contol valve (Unel Equa and n/a, to stody i) Valve flow coefficient 1) tnherent characteris 0) stale characterise im) Hysteresis conte! vave ond Ranges of equal valve Theory: ‘Types of Control valves Valves essential variable once, Contrl vets a valve with : a Bneumatic, hyraulc, elect (excluding sleneds) or other ya exteraly powered actuator that automaticaly, uly or partly oens or closes the vale to a poston diated by sine oe trasmited rm controling instrument, Cont valves se ned : primal to throttle energy Intl system and not for shot Durpose. The figure shows bast elements and inter! pats af ‘ypcl pneumatic cont valve, Depending upon the valve plug design the contol valves canbe cssied as ik opening neat and eau percent ype Uneae : Flows direct proportionate vave it = ant where (= ow t constant pressure drop = lve opening stant Equa : : Flow changes by a constant percentage of ts istantaneous value foreach unt ofvavef comer Where i flow at constant pressure dop ave opening eof natural logarthms a and constants Constanta and b canbe evaluated to gv more convenient form rr) Where Ca Flow at constant ropa eo stroke 1 Flow range ave maximum fo minimum 3 constant drop Yau masimur rated ave opening Aik opening Fw nents ty whi vel eng nar smu a owe envy nt Seine thematic, Valve actors and ectustor mechanism Diferent types of actuators ate used to contol the stem travel ofthe actuator Hydra actuators ee Preumatc actuators are eed for cose valve, like electrical actuators, pneumatic valves. Spring opposed diaphragm actuatorin the range of 3-15, positions the valve plug in response to the controller signals. Mostly the controller signals are in the range of 3 sig Direct acting actuator (air to close): Direct acting actuators basicaly consist of a pressure tight housing sealed by a flexible fabric reinforced elastomer iaphragm. A diaphragm plate is held against the diaphragm by a heavy compression spring. Signal air pressure Is applied to upper diaphragm case that exerts force on the diaphragm and the actuator assembly. By selecting proper pring rate or stiffness, load carrying capacity, and initial compression, desired stem displacement can be abtained for ‘any given input signa. Reverse acting actuator (al to open): In case of reverse acting actuators the stem gets retracted with increase in pressure. Control valve flow coefficient A control valve regulates the flow rate in a fluid delivery system. In general, a close relation exists between the pressure along the pipe and the flow rate so that if pressure is changed, then the flow rate is also changed. A contro! valve changes the flow rate by changing the pressure in the flow system because it introduces the constriction in the delivery system. The flow rate through the constriction can be given as OP The correction factor K in above equation 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, Q Valve coefficient: Where G is specific gravity of liquid, Q flow in m*/h, AP pressure drop in bar. Valve Characteristics ‘The amount of fluid passing through a valve at any time depends upon the opening between the plug and seat. Hence there is relationship between stem position, plug position and the rate of flow, which is described in terms of flow characteristics ofa valve. Inherent and Installed are two types of valve characteristics. Inherent characteristics: The inherent flow characteristic of control valve is the relation between the flow and the valve travel at constant pressure drop across the valve. Following are the inherent characteristics for different types of valves.: on Q = Flow (m?/h}= Qin LPH/1000 ‘OP = Pressure drop across valve (bar}= AP in mm of Hs0X1,013/(10.33X10"). G = Specific gravity = 1 for water Sample calculations & results: Use MS Excel” for calculation and graph plotting Conclusions Keep the valve opening undisturbed and vary the flow rate. Note that the valve coefficient remains constant for different flow rates. b) Study of inherent characteristics 1. Start up the set up and follow step 2-4 as described above in part (1) 2. Note the pressure drop at control valve at full open condition, 3. Slowly increase/decrease air pressure by regulator and close the control valve to travel the stem by 4mm, Note the pressure drop at control valve and corresponding flow rate. 4. Repeat above step and take the readings at each 4mm stem travel tll the valve is fully closed. For studying other valve (equal %/ Quick opening) remove the air connection connected to the actuator and connect it to actuator of other valve. (In case of set up with valve positioner remove connection at the “IN” ort of the valve positioner and connect to the actuator of the other control valves). Repeat the steps above. Observations ‘Type of control valve: Linear/ Equal%/ Quick opening (Fill up the column “valve co:-fficient" after calculations) ScNo | tft Flow Pressure drop Flow | Valve coefficient (mm) (wey AP (mm of H:0) (PH) w z 2 3 4 Plot the graph of valve coefficient versus lift to obtain Inherent characteristic ofthe control wave Calculations: where, Q= Flow (m*/h)= Qin LPH/1000Installed characteristics: ‘The Inherent characteristics of the valves described are subject to distortion due to varlations in pressure drop with flow. Line resistance distorts linear characteristics towards that of quick opening valve and equals to that of linear. Hysteresis of control valve Hysteresis is a 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 the signal. The maximum error in stem travel (or valve coefficient) ‘expressed in % for same actuator pressure while opening and closing the valves indicated as hysteresis. Rangeabilty of equal % valve Equalt valve has characteristics such that given percent change in stem position produces an equivalent change in flow. 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. Fnax Fin ‘Where Finax is the flow when the valve stem is at extreme open position F min is the flow when valve stem is at extreme closed position. (Fnaxs Fintepresents flow rates measured at constant pressure drop across control valve. Hence rangeabilty R also can be defined as ratio of Cnn Corn) For equal percent valve flow has exponential characteristics of rangeability, pa Where Ris the rangeability ofthe valve and mis its fractional stem position, Procedure 2) Study of valve low coefficient 1. Start up the set up. Open the inlet valve of the Linear control valve, Open the respective hose cock for pressure indication. 2. (Close the inlet valves and hose cocks of other control valves.) 3. Ensure that pressure regulator outlet is connected to the valve actuator of the linear control valve under study, Keep the control valve fully open by adjusting air regulator. (In case of control valve with valve positioner: Ensure that the bottom pressure regulator outlet is connected to "IN" port at the valve positioner. 4. Adjust the top pressure regulator to 20-25 psi for air supply to valve positioner). 5. Adjust the regulating valve and set the flow rate, (Set 400 LPH flow for linear/equal% valve or 600 LPH for ‘quick opening valve). Note for measuring lower flow rates below rotameter minimum range use measuring, jar. 6. For studying other valve (equal %/ Quick opening) remove the air connection connected to the actuator and Connect it to actuator of other valve. (In case of set up with valve positioner remove connection at the “IN’ port of the valve positioner and connect to the actuator of the other control valves). Repeat the steps above. ‘Observations ‘Type of control valve: Linear/ Equal2é/ Quick opening (Fill up the column "valve coefficient" after calculations)Port of the valve positioner and connect to the actuator of the other control valves). Repeat the steps above. ‘Observations ‘Type of control valve: Linear/ Equalté/ Quick opening (Fil up columns "valve coefficient" and" Hysteresis" after ealeulations) | Actuator | Flow | Pressure Valve | Flow | Pressure | Valve | Hysteresis, No.| pressure | (LPH) | drop | characteristes | (LPH) | drop | coefficient | (%) teas) | tno) (c) (mmofe) | _(C) increasing actuator pressure Decreasing actuator pressure t+ actuator pr a i 2 [73 3] 6 a| 9 s [12 6 | 15 7 | 18 Plot the graph of actuator pressure versus valve coefficient. Ratio of maximum difference between flow coefficients at same actuator pressure, to that of maximum flow coefficient is termed as hysteresis. Calculations: where, Q= Flow (m’/h}= Qin LPH/1000 AP = Pressure drop across valve (bar}= AP in mm of H,0X1.013/(10.33x10") G = Specific gravity = 1 for water Sample calculations & results: USE MS Excel for calculation and graph plotting, Conclusions: ‘The experiment gives idea about hysteresis of control valve. Study of rangeability of equal percent control valve Procedure 1. Start up the set up. Open the inlet valve of equal % control valve. Open the respective hose cock for pressure indication, (Close the inlet valves and hose cocks of other control valves.) 2. Ensure that pressure regulator outlet is connected to the valve actuator of the equal % valve. Keep the control valve fully open by adjusting ar regulator, ‘Adjust the regulating valve and set the flow rate to 400 LPH. Set actuator air pressure to 3 psig. Note the flow rate and pressure at inlet of control valve. Set actuator air pressure to 15 psig Note down the flow rate and pressure at inlet of control valve.‘= Pressure drop across valve (har) AP in mm of 10X3.013/(10.33%10") G «Specific gravity « 1 for water Sample calculations & rsults: USE 5 Fxcel fr calculation and graph plotting Hote thatthe natuce of the graph I: same as Inherent valve characters. Conclusions a Study of installed characterises Procedure 1._ Start up the set up as explained in Start up the set up and follow step 2-4 as described above in part (1) 2. Slowly increase/decrease air pressure by regulator and close the control valve to travel the stem by 4mm. Note the flow rate 3. Repeat above step and take the readings at cach émm stem travel til the valve I uly closed. For studying other valve (equal %/ Quick opening) remove the air connection connected to the actuator and connect it to actuator of another valve. (Incase of set up with valve positioner remove connection at the “IN" port of the valve positioner and connect to the actuator of the other control valves). Repeat the steps: above. Observations: Type of control valve: Linear/ Equalé/ Quick opening Sr.No | ult Flow (mm) teh) Plot the graph of flow versus lit to obtain installed characteristic of the control valve. ‘Sample caleulations & results: Use MS Excel” for calculation and graph plotting Conclusions + installed characteristics of linear valve slightly approaches to the characteristic of quick opening valve because of the pipe friction and other resistance to the flow. « installed characteristics of equal % valve approaches to the characteristics of linear valve because of the pipe friction and other resistance to the flow. 4, study of hysteresis of control valve Procedure 4, Startup the set up as explained Startup the set up and follow step 2-4 as described above in part (a) 2. Slowly increase/decrease ar pressure inthe step of 3 psi by regulator to close the control valve fully. Note the actuator pressure, pressure drop across the control valve and the flow rate. (Do not try to correct the actuator pressure by reversing the regulator direction if t inadvertently exceeds desired value.) 3. Slowly decrease/increase ar pressure inthe step of 3 psi by regulator to open the control valve fully. Note actuator pressure, pressure drop across control valve and the flow rate. 4, For studying other valve (equal %6/ Quick opening) remove the air connection connected to the actuator and ‘connect it to actuator of other valve. (In case of set up with valve positioner remove connection atthe “IN”Experiment no. 8: ‘Aim: For 1/P converter and linearity of P/1 converter to study 1) Linearity ii) Hysteresis ii) Accuracy iv) Repeatability a) UP converter Theory: ‘The /P converter is a force balance device in which a col is suspended in the field of a magnet by a flexure. Current flowing through coil generates axial movement of the coil and flexure. The flexure moves towards the nozzle and creates backpressure, which acts as a pilot pressure to an integral booster relay. Input signal increases (or decreases for reverse acting) cause proportional output pressure increases. The current to pressure (V/P) converter, is very important element in process control. The i/P converter gives us a linear way of translating the 4-20 mA current into 3-15-psig signals. There are many designs for these converters, but the basic principle almost always involves the use of a flapper/nozzle system. The current through coil produces @ force that will tend to pull the flapper down and close off the gap. A high current produces a high pressure so ‘that the device is direct acting. Adjustment of the springs and perhaps the position relative to the pivot to which they are attached allows the unit to calibrated so that 4 mA corresponds to 3 psig and 20 mA corresponds to 15 psig. Current to pneumatic converters are two-wire precision instruments designed to convert standard industrial electrical input signals into proportional pneumatic output signal Input signal: 4-20 mA OC, Output signal: ©) Linearity of /P converter Procedure: 1 Now put current source/sink indicator source mode. 2. Give current inputin the step of 4 mA from 4 to 20 mA by slowly rotating the knob of source indicator: 3. Note down corresponding pressure on output pressure gauge in psig. 4. Tabulate above readings in the observation table given below. S.No. Input ‘Standard Output ‘Actual Output current Pressure Pressure (ma) (sie) (psie) 1 4 3 2 a 6 3 2 3 4 16 2 3 20 15 Calculations Unearit * Linearity of /P converter is 5% maximum of output span between 3 to 15 psig (as stated by manufacturer). Therefore =5-x(15 ~ 3) = 0.6 psig. This is the maximum deviation in the output + Plot graph of input current (mA) on X axis and output pressure (asi) on Y-axis + Drawa straight line that best fit all the points. The graph shows the straight ine. + Observe the maximum deviation in output and compare with specified by manufacturer, Conclusions:Observations: Type of control valve: Equal ‘Actuator pressure | Pressure drop Flow Valve coefficient] Rangeability (Pg) Cymax f (mm of #0) (urn) (c) Z ¢ a6 0) AP where, = Flow (m'/h}= Qin LPH/1000 {P = Pressure drop across valve (bar}= AP in mm of H:OX1.013/(10.33X10") G = Specific gravity = 1 for water Rangeability, R Crim Conclusions ‘+ Many times the control valve remains completely closed at 3 psig actuator pressure and no flow can be measured. Hence it s difficult to calculate the rangeability.Repeat the experiment by keeping constant pressure drop across the control valve and note the flow rates. Try to calculate by selecting different valve opening. + The rangeabilty can also be calculated by keeping constant pressure drop across the valve. EVLUATION ‘Observation & Presentation Quiz Discipline Total Inference Signature with dateWorking Principle Pressure to current (P/l) converters is two-wire precision instrument designed to convert standard pneumatic input signals into proportional output electrical signal. They are compact robust instruments suitable for panel ‘or field mounting applications. Input signal: 3-15 psig ‘Output signal: 4-20 mA DC ‘Supply voltage: 24 VOC 1) Unearity of P/| converter Procedure 1. Startup the setup 2. Now put digital calibrator on measure mode. 3. Give pressure input in the step of 3 psig from 3 t0 15 psig by slowly rotating the air regulator. 4. Note down corresponding current output on digital calibratorin mA. 5. Tabulate above readings in the observation table given below. ‘S.No. Input Pressure ‘Standard Output] Actual Output Current (psig) ‘current (ma) roa) 7 3 i 4 I 2 6 i 3 I 3 3 i 2 1 4 2 T 16 i 5 15 Hl 20 T Calculations Linearity: Plot graph of Input pressure (psig) on X-axis and output current (mA) on Y-axis. Draw a straight line that best fits all the points. The graph shows the straight line. Observe the maximum deviation in output. Conclusions: Ii) Hysteresis of P/I converter. Procedure 1. Startup the setup. 2. Give pressure input in the step of 3 psig from 3 to 15 psig by slowly rotating the air regulator. 3. Note down corresponding current output on digital calibrator in mA. 4. Now note the output current in mA by applying input pressure in decreasing mode from 15 psig to 3 psig. 5, Tabulate above readings in the observation table given below. =o, | Input Output current input | Output current | HysteresismA Pressure (ma) Pressure (ma Hx) (osie) «6 (esie) ™ inereasing Input pressure ‘Decreasing input pressure z 3 15 2 6 FA 3 3 3 a 32 6 5 35 3Calculations ‘Accuracy: Accuracy can be calculated with reference to above definitions in theory part. Conclusions: lv) Repeatability of /P converter, Procedure 1. Start up the set up. 2. Give current input in the step 4 mA from 4 to 20 mA by slowly rotating the 3, Adjust knob on digital calibrator. 4, Note down corresponding output pressure on output pressure gauge in ps 5. Now repeat the above steps for more trials. 6, Tabulate above readings in the observation table given below. Observations S.No, | Input] Output | Output | Devi ‘Output | Output | Deviation current | Pressure | Pressure | inoutput | Pressure | Pressure | in output (ma) | esis) {psie) psig | (psig) | (sie) | psig x Ys OX Ys) Xe Ya __|_ OY) Trial Tiaks_|_Triake za 4 218 3 [2 4 [46 S120 Caleulations Repeatability Note down the values of output for same input in repeated trials. Repeatability can be found out in % of each reading. b) P/iconverter Theory Pressure to be measured is applied to the pressure cell. Diaphragm is used as a seal and pressure gathering number. Due to this applied pressure, there will be change in resistance of the strain gauge. This change in resistance is very small. For measuring this resistance, strain gauge is fixed on the diaphragm to form wheat stone bridge. This change in resistance causes the unbalance in the wheat stone bridge. This gives voltage ‘output, This output voltage is proportional to the change in resistance. The change in resistance is proportional to the pressure applied. So, the output voltage is proportional to the pressure applied. This voltage is converted into the current using voltage to current converter. When the pressure is applied, the resistance of the strain gauge changed from R to REAR, Hence, the change in resistance is directly proportional to the pressure applied. ‘This output voltage is converted into current signal for transmitting over long distance.Calculations Hystersis: Calculate hysteresis by using formula: Hystersis «Output at decreasing Input ~ Output at increasing input. Plot the graph showing hysteresis as input (increasing and decreasing) on X axis and corresponding output on Y- axis. Conclusions: Ti} )Accuracy of P/I converter. Procedure 1. Start up the set up. 2. Give pressure input in the step of 3 psig from 3 to 15 psig by slowly rotating the air regulator. 3, Note down corresponding current output on digital calibrator in mA. 4, Tabulate above readings in the observation table given below. 5. Observations ‘S.No. Input ‘Standard Output] Actual Output ¥ Deviation Pressure current current (ma) (sie) (ma) (ma) xY x 2 3 4 2 6 8 3 2 12 { 4 2 16 5 35 20. Calculations ‘Accuracy: Accuracy can be calculated as mentioned 1/P part Conclusions: lity of P/I converter Start up the set up Give pressure input in the step of 3 psig from 3t0 15 psig by slowly rotating the Note down corresponding current output on digital calibrator in mA. Now repeat the above steps for more trials. ‘Tabulate above readings in the observation table given below. regulator.Observations ‘S.No. Input | Output | Output | Deviation | Output | Output | Deviation Pressure | current | current | in output | current | current sig) | tm) | tra) | current | (rma) | (rma) | current x (oa) (a) % % % Ys) ea) Tisha | Taab2 [aks | Take 2 3 t r t 2 6 t I t 3 3 t I t 4 2 | i i i sas r i I I Caleulations Repeatability: Note down the values of output for same input in repeated trials. Repeatability can be found out in of each reading. Conclusions: EVWATION: Observation & Presentation ae Total Inference | i 1 T t Signature with date