Department of Chemical Engineering, IIT Delhi

II Semester 2016-2017
Course Code: CLL 361
Course Title: Instrumentation & Automation
Course Coordinator: Dr. Munawar A. Shaik, Office: II-290, Tel: 1038, E-mail: munawar[at]iitd.ac.in
http://web.iitd.ac.in/~munawar
Course Credit: 2.5 (L-T-P Structure: 1 0 3)
Course Timings: Weekly Lectures: Wed, 8 am 8:50 am, LH-114
Practical: M,T,Th,F 2 pm 5 pm, I-303 (Process Control Lab)
Instructors for Practical:
Mon: Prof. A.K. Gupta (AKG)
Tue: Dr. M.C. Ramteke (MCR)
Thu: Dr. M.A. Shaik (MAS) & Prof. A.K. Saroha (AKS)
Fri: Dr. D. Bhatia (DB) & Prof. S.K. Gupta (SKG)
Lab Instructor for Process Control Lab: Mr Pardeep Kumar
Course Objective: To introduce the basics of instrumentation and principles of operation of different measuring
devices for temperature, level, pressure, flow, PH, humidity, density, and viscosity; to impart knowledge of
transmitters, transducers, converters, control valves, digital and analog components related to PLC, DCS, SCADA
systems with emphasis on practical hands-on training.
Course Contents and Layout:
Topics
Lectures
Basics of control system components, signals and standards
1
Pressure measuring instruments/sensors
1
Level measurement
1
Flow measuring instruments
1
Temperature measuring devices
1
Humidity, density, viscosity and PH measuring devices
2
Pressure controllers: regulators, safety valves
1
Flow control actuators: different types of valves
1
Electrical and pneumatic signal conditioning and transmission
1
Computer process control, PLC, DCS, SCADA
4
14
Experiments
Dynamics of Lagged Thermometer
Dynamics of a Stirred Tank Heater
Temperature Control
Level Control
Pressure Control
Cascade Control
Flow Control
Interacting & Non-Interacting Two-tank System
Control Valve Characteristics
Time Constant of Manometer
Time Constant for Thermocouple & Thermometer
Level Measurement by Capacitance Method
Grading:
Regular Labwork: 60 %
Quiz (end of semester): 40 %

Name
PC1
PC2
PC3
PC4
PC5
PC6
PC7
PC8
PC9
PC10
PC11
PC12

The weekly lectures will be held on Wednesdays. For the practical part there will be about 12 experiments in total.
The 60% of in-laboratory evaluation will be done for each turn based on your weekly report that is submitted. The
experiments will be conducted in subgroups of max 3 students. Each cycle will have max 10 subgroups.
Handouts of all experiments can be downloaded from the link
http://privateweb.iitd.ac.in/~munawar/CLL361.pdf
All the students are required to come prepared for the experiment. A common cover page (as per template on page
3 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. 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. All lab reports should
be neatly hand written (on A4 paper) with diagrams drawn manually using pencil.
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. Students who wish to
change their lab turn to other days, because of time table reasons, should find a mutual exchange with other
students. Change is allowed only once in the beginning of the semester.
References:
William C. Dunn, Fundamentals of Industrial Instrumentation and Process Control, Mc-GrawHill (2005).
S.K. Singh, Industrial Instrumentation and Control, 3rd edition, McGraw-Hill (2008).
Seborg, D.E., Edgar, T.F., Mellichamp, D.A. Process Dynamics and Control, 2nd edition, John Wiley (2003).
Stephanopoulos, G. Chemical Process Control: An Introduction to Theory and Practice, Pearson Education
(1984).
Dr. Munawar A. Shaik
(Course Coordinator)

CLL 361: Instrumentation & Automation Laboratory

II Semester 2016 - 2017

EXPERIMENT NAME AND NO.
(AS GIVEN IN HANDOUT):

GROUP NO.:
SUBGROUP NO.:

DATE AND DAY (Submitted)

LAB TURN (date and day)

NAMES OF GROUP MEMBERS

PRESENT ON THE LAB TURN:

REMARKS (IF ANY):

Name of
LAB INSTRUCTOR:

MARKS (TO BE FILLED BY LAB

INSTRUCTOR/TA):

CLL 361: Instrumentation & Automation lab

Experiment PC 1: Transient Response of a Lagged Thermometer
OBJECTIVE :

To determine the transient response of a distributed parameter system and to

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: A mercury thermometer is embedded in a long cylindrical wooden

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: If several identical interacting systems are arranged in series, the response is
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 =

vs t for both heating and cooling experiments. Here

the initial and ultimate temperatures respectively.

and

are

2. To approximate the response of two and three first order systems in series, determine
the time to reach 74% and 80% response respectively. Let these be t0.74 and t0.8. Then
time constant of two first order systems in series will be approximately, =

/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

and Td plot the

theoretical response from equation (2) and match with the actual response and
comment.

CLL 361: Instrumentation & Automation Lab

Experiment PC 2: Dynamics of Stirred Tank Heater
OBJECTIVE:

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 following assumptions can be made:

1. The temperature of water in the cooling coil is the average of inlet and outlet temperatures.
2. Perfect mixing exists in the tank i.e. same temperature throughout.

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.

CLL 361: Instrumentation & Automation Lab

Experiment PC 3: Temperature Control
OBJECTIVE: To study the tuning of PID controller by Open Loop method using (a) Cohen
and Coon (C-C) (b) Ziegler-Nichols (Z-N) tuning rules.
APPARATUS: Process tank having temperature controlling unit.
THEORY: The open loop method of tuning in which the control action is removed from the
controller by placing it in manual mode and an open loop transient is induced by a step
change in the signal. Fig.1 shows a typical control loop in which the control action is
removed and the loop opened for the purpose of introducing a step change (M/S). The step
response is recorded at the output of the measuring element. The step change to the valve
is conveniently provided by the output from the controller, which is in manual mode. The
response of the system is called the process reaction curve.

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)

Proportional - Integral (PI)

Kc = (T/(Kp*L)) * (0.9 + L/12T)

Ti = L * (30 + 3L/T) / (9 +20L/T)

Proportional - Derivative (PD)

Kc = (T/(Kp*L))* (1.25 + L/6T)

Td = L*(6-2L/T) / (22+3L/T)

Proportional - Integral Derivative (PID)

Kc = (T/(Kp*L)) * (1.33 + L/4T)

Ti = L*(32 + 6L/T) / ( 13 +8L/T)
Td = 4L / (11 + 2L/T)

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
o
o
o
o
o

Wait till steady state is reached.

Log on to a file for saving transient data.
Start saving data. Wait for approximately 5 mins.
Give a STEP RESPONSE to controller output. Change it from 0% to 100%.
Wait till steady state is reached. Please do not rush.
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.

CLL 361: Instrumentation & Automation Lab

Experiment PC 4: Level Control
OBJECTIVE: Optimizing the tuning parameters of Level Control Trainer via simulation
interface and comparing the transient response obtained from the simulation with real time
response for the same set of controlling parameters obtained as above.
APPARATUS: Process tank having level control trainer, rotameter, pump, sump-tank etc.
THEORY: The open loop method of tuning in which the control action is removed from the
controller by placing it in manual mode and an open loop transient is induced by a step
change in the signal. Fig.1 shows a typical control loop in which the control action is
removed and the loop opened for the purpose of introducing a step change (M/S). The step
response is recorded at the output of the measuring element. The step change to the valve
is conveniently provided by the output from the controller, which is in manual mode. The
response of the system is called the process reaction curve.

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)

Proportional - Integral (PI)

Kc = (T/(Kp*L)) * (0.9 + L/12T)

Ti = L * (30 + 3L/T) / (9 +20L/T)

Proportional Derivative (PD)

Kc = (T/(Kp*L)) * (1.25 + L/6T)

Td = L*(6-2L/T) / (22+3L/T)

Proportional - Integral Derivative (PID)

Kc = (T/(Kp*L)) * (1.33 + L/4T)

Ti = L*(32 + 6L/T) / ( 13 +8L/T)
Td = 4L / (11 + 2L/T)

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
Amplitude
Period Reference Point Control Mode
1.
Sine Wave
10
10
40
a. P-mode
Kc = 1
b. P-mode
Kc = 5
c. P-mode
Kc = 50
2.
Sine Wave
10
100
40
P-mode, Kc = 5
3.
Triangle
10
10
40
PI-mode;
Wave
Kc= 100, Ti = 10.
8. Repeat step 4 for simulation conditions as mentioned in Table 3.

CLL 361: Instrumentation & Automation Lab

Experiment PC 5: Pressure Control
OBJECTIVE: Optimizing the tuning parameters of PID controller for Pressure Control Trainer
via simulation interface using Ziegler-Nichols (Z-N) tuning rules and to study the closed loop
response for servo and regulatory problems.
APPARATUS: Process tank having pressure control trainer, interfacing unit with computer,
air supply through compressor.
The basic objective is to control the pressure in the process tank shown in Fig. 1. The
interfacing unit is basically a medium for communicating with the equipment from the
computer. The assembly has various supporting components on the front panel i.e. pressure
gauges which is used to measure the pressure, current to pressure converter in the range 3
to 15 psi for current in the range of 4 to 20 mA which is given to the I/P converter by digital
indicating controller. The setup also contains a pneumatic actuator. The pressure in the
process tank is sensed by the pressure transmitter with the help of pressure sensor fitted in
the line. The data is transmitted by the pressure transmitter to the computer through the
interfacing unit which shows the value of the process variable. The control valve performs
the function of controlling the input of air pressure in the process tank. It has a diaphragm
type pneumatic actuator which varies the flow of air according to the movement of the
stem at a pressure range of 3 15 psi received from I/P converter.

Fig. 1. Schematic Diagram of Experimental Setup

THEORY: In the open loop method of tuning the control action is removed from the
controller by placing it in manual mode and an open loop transient is induced by a step
change in the signal. Fig.2 shows a typical control loop in which the control action is
removed and the loop opened for the purpose of introducing a step change (M/S). The step
response is recorded at the output of the measuring element. The step change to the valve
is conveniently provided by the output from the controller, which is in manual mode. The
response of the system is called the process reaction curve.

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. All the drains should be closed.
2. Switch on the main supply.

3. Check whether all the valves are properly working or not.

4. Switch on computer and the interfacing unit.
5. Select the auto mode to perform experiment automatically and in manual mode to
change the values manually.
6. Connect the equipment with compressed air supply.
Shut-down:
1. Exit from the software.
2. Switch off the interfacing unit.
Procedure:
1.
2.
3.
4.

Start the set-up (as mentioned in start-up)

Select open loop option for control.
Select a value of set point to some desired value.
Apply 20-30 % change to controller output. Record the step response. Wait for the
steady state.
5. Start data logging and from the readings draw the step response curve.
6. Calculate T and L (refer to Fig.3)
7. Calculate PID settings from Table 1.
8. Now select auto mode option for control.
9. Change the set point. And input the controller settings calculated earlier. Plot the
closed loop response.
10. Repeat the same for regulatory problem by changing the disturbance.

CLL 361: Instrumentation & Automation Lab

Experiment PC 6: Flow-Level Cascade Control
OBJECTIVE: Optimizing the tuning parameters of Flow-Level Control Trainer via simulation
interface and comparing the transient response obtained from the simulation with real time
response using Cascade control scheme.
APPARATUS: Process tank having flow and level control trainer.
THEORY: In cascade control an intermediate process variable is used that responds to both
the manipulated variable and some disturbances to achieve more effective control over the
primary process variable. Fig.1 shows the general block diagram of a cascade control
scheme.

Fig: 1. Block Diagram for Cascade Control Loop

Two controllers are used but only one process variable is manipulated. The output of one
controller can be used to manipulate the set point of another. Each controller has its own
measurement input, but only the primary controller has an independent set point and only
the secondary controller has an output to the process. The advantages are that the
disturbances affecting secondary variable can be connected by the secondary controller
before a pronounced effect is felt by the primary variable. Also closing the control loop
around the secondary part of the process reduces the phase lag of primary controller and
this increases speed of response.
In this experiment, cascading of flow and level controllers is done. Level controller is the
primary controller with an independent set point, and controlling level in the tank is the
primary variable. The level transmitter transmits the level of tank to primary controller
which gives its output as set point to the secondary controller i.e. the flow controller. The
flow controller gets the process value of flow from the flow transmitter. Responding to both
it gives an output to the control valve through an E/P converter and adjusts the flow into the
level tank. The flow transmitter forms the secondary loop while level transmitter forms
primary loop.

PROCEDURE: Cascade control using PC as PID controller

switch
mains
pump
flow-cascade / level PC
PID / PC
FR knob (E/P in)

position
OFF
OFF
level PC
PC
Fully anti clockwise

1. Ensure that the drain valve of sump tank (V1) is fully closed.
2. Close the bypass valve (V2) partially. Partially open the drain valve (V3) of the level
tank.
3. Fill clean water in the sump tank till the maximum level of the sump tank.
4. Connect the communication cable from output of the interface card to PC.
5. Connect the 230 V A.C. supply to the trainer. Switch ON the Mains supply.
6. Ensure that pneumatic supply (to the trainer) is ON and it is more than 2 kg/cm2.
7. Ensure that position of the switches is as per the table mentioned above
8. Switch on the pump on the panel marked as PUMP
9. 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.

CLL 361: Instrumentation & Automation Lab

Experiment PC 7: Flow Control
OBJECTIVE: PID control of Flow Control Trainer via simulation interface and to study the
closed loop response for servo and regulatory problems.
APPARATUS: Flow control trainer, interfacing unit with computer, air supply through
compressor.
THEORY: The basic objective is to control the flow rate to a process tank shown in Fig. 1.
The assembly has various supporting components on the panel: differential pressure
transmitter (DPT) connected across an orifice plate for flow measurement, pneumatic
control valve for adjusting the desired flow rate, rotameter for manual measurement of
flow rate, centrifugal pump for water circulation.
Control valve
Interfacing unit

Orifice plate
Rotameter

HV-2

HV-1

Water tank
Pump

Fig. 1. Schematic Diagram of Experimental Setup

The pressure drop data is transmitted by the differential pressure transmitter to the
computer through the interfacing unit which shows the value of the process variable. The
control valve performs the function of controlling the input of air pressure to adjust the
stem position. It has a diaphragm type pneumatic actuator which varies the flow of air
according to the movement of the stem at a pressure range of 3 15 psi received from I/P
converter.
The interfacing unit between the apparatus and computer has several components: smart
micro controller input/output (MCIO) card, current-to-voltage (I-V) card, Voltage-to-Current
(V-I) card, on/off switch for pump, power supply, on/off switch for panel. The signal
(pressure drop) is sensed by the sensors (transducers & transmitters) from the actual
process. These signals are in the form of electrical signals of 4-20 mA which are processed
by the signal conditioning card and converted to 0-10 volts. Then, the 0-10 volt signal is
processed in the MCIO card where analog signals are converted to digital through ADC
(analog to digital) channel. These digital signals are transferred through RS232
communication bus to the computer where PID controller algorithm computes the signal
and value. The control signal generated from the PID algorithm is fed back to the MCIO card
through RS232 and is passed to DAC (digital to analog) section which further converts the

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.

Fill up the feed tank with water up to 80% of the capacity.

Keep recirculation valve (HV-2) to full open position.
Switch on the PC and Panel main switch (if not done already)
Run the interface software. Select appropriate option for different application and
go to Bar graph page.
5. Set some PID values on the Flow Indicating Controller.
6. Switch the controller from MANUAL mode to AUTO mode. After a few minutes (wait
for steady state) the flow rate will approach the initial set point value.

Procedure:
1.
2.
3.
4.

Start the set-up (as mentioned in start-up)

Select auto mode option for control.
Select a value of set point to some desired value (SERVO problem)
Record the closed loop step response for (i) P (ii) PI and (iii) PID controllers. In each
case wait for the new steady state and later bring the set point back to the original
value and wait for steady state before changing the controller from P to PI or PID.
Effectively, for the same step change compare the responses of P, PI and PID
controllers
5. Now consider REGULATORY problem and close the HV-1 valve partially to introduce
a disturbance. Once again plot the closed loop response for (i) P (ii) PI and (iii) PID
controllers as explained in step 4 so that for the same value of disturbance you are
comparing the responses of P, PI and PID controllers.

CLL 361: Instrumentation & Automation Lab

Experiment PC 8: Interacting & Non-interacting Two-tank System
OBJECTIVE: To study the dynamic open loop response of liquid level in single tank, two tank
interacting and two tank non-interacting systems.
Apparatus: It is a self-contained recirculating unit consisting of a sump tank, three tanks
and an overhead tank. The sump and overhead tanks are connected by pump. Level
indicators with scale are provided for each Tank1, Tank2 and Tank3. Rotameter is provided
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
resistance such as a valve attached to it. The volumetric flow rate through the resistance is
related to the head by a linear relationship. The principle distinction to be made in multicapacity processes is in how the capacities are joined. If they are isolated they are said to be
non-interacting as the capacities behave exactly as they would do alone. But if coupled, they
interact with one another in which case the contribution of each is altered due to
interaction. In non-interacting system the two tank levels do not interact because the flow
from first tank to the second tank is independent of level in the second tank. In an
interacting system the levels in both tanks interact because any change in the downstream
level will affect the upstream level as well. Overall, both interacting and non-interacting two
tank systems are examples of second order systems.

Fig. 1. Schematic Diagram of Experimental Setup

Data: Inner diameter of each tank (D1) = 0.108 m. Outer diameter of the down comer in
each tank (D2) = 0.022m. Cross-section area of each tank, A = [(D1)2-(D2)2]/4.
Nomenclature: V1 = flow control valve (Rotameter); V2 = Valve for water supply to Tank2;
V3 = Valve for water supply to Tank3; V4 = drain valve for Tank2; V5 = drain valve for Tank3;
V6 = drain valve for overhead tank; V7 = drain valve for sump tank.
Procedure for Single-Tank System Tank2 (or Tank1):
1. Close all the valves V1-V7. Fill the sump tank with water. Switch ON the power supply and
the pump. Wait till there is overflow from overhead tank. Now open the valve V1 and adjust
the flow rate (10-20 lph).
2. Open the valve V2 completely and partially open the valve V4 and wait till a constant height
is achieved by liquid in Tank 2. Note down the inlet flow rate and height of liquid (hi) in the
tank (this is initial height).
3. Now increase the inlet flow rate (step change: 10-20 lph) through valve V1. Simultaneously
start the stop watch and record the height of liquid level in tank with time, till steady state is
reached (constant height). Note down the final constant height and flow rate.
4. Repeat the same experiment for different step changes. After completing the experiment
switch OFF the pump and power supply. Open the drain valve V4.
5. Determine the valve resistance (R2) by plotting flow rate Vs head. The resistance is the
reciprocal of slope of discharge vs head curve.

Procedure for Two-Tank Interacting System (Tank2-Tank3):

1. Close all the valves V1-V7. Fill the sump tank with water. Switch ON the power supply and
the pump. Wait till there is overflow from overhead tank. Now open the valve V1 and adjust
the flow rate (10-20 lph).
2. Open the valve V2 completely and partially open the valve V3 & V5 and wait till a constant
height is achieved by liquid in Tank2 and Tank3. Note down the inlet flow rate (qi) and height
of Tank2 (h2i) and Tank3 (h3i) (this is initial height).
3. Now increase the inlet flow rate (step change: 10-20 lph) through valve V1. Simultaneously
start the stop watch and record the heights of liquid level in Tank2 and Tank3 with time, till
steady state is reached (constant height). Note down the final constant heights (h2f and h3f)
and flow rate (qf).
4. Using deviation variables H2=h2f-h2i, H3=h3f-h3i, Q=qf-qi, determine resistances R2 = H2-H3/Q,
R3 = H3/Q and find time constants 2=A2R2 and 3=A3R3. Compare the experimental response
(H3 vs time) with theoretical response. After completing the experiment switch OFF the
pump and power supply. Open the drain valves V4-V5.

Procedure for Two-Tank Non-Interacting System (Tank1-Tank2):

1. Close all the valves V1-V7. Fill the sump tank with water. Switch ON the power supply and
the pump. Wait till there is overflow from overhead tank. Now open the valve V1 and adjust
the flow rate (10-20 lph).
2. Partially open the valve V2 & V4 and wait till a constant height is achieved by liquid in Tank 1
and Tank 2. Note down the inlet flow rate (qi) and height of Tank1 (h1i) and Tank2 (h2i) (this is
initial height).
3. Now increase the inlet flow rate (step change: 10-20 lph) through valve V1. Simultaneously
start the stop watch and record the heights of liquid level in Tank1 and Tank2 with time, till
steady state is reached (constant height). Note down the final constant heights (h1f and h2f)
and flow rate (qf).
4. Using deviation variables H1=h1f-h1i, H2=h2f-h2i, Q=qf-qi, determine resistances R1 = H1/Q, R2 =
H2/Q and find time constants 1=A1R1 and 2=A2R2. Compare the experimental response (H2
vs time) with theoretical response. After completing the experiment switch OFF the pump
and power supply. Open the valves V2 & V4.

CLL 361: Instrumentation & Automation Lab

Experiment PC 9: Control Valve Characteristics
OBJECTIVE: To study the characteristics of different control valves to understand flow
coefficient, hysteresis and rangeability.
Apparatus: The set-up consists of three pneumatic control valves as shown in Fig 1. One
control valve is with equal % characteristics (air to close type), second is with linear
characteristics (air to open type), and third is quick opening characteristics (ON/OFF). Sump
tank with pump is provided for continuous water circulation. Manometer is provided at the
inlet of valves to measure pressure. Valves are given for water supply to the control valve.
Valves are provided for air supply to control valves. The air regulator and pressure gauge is
given for regulating air pressure.

Fig. 1. Schematic Diagram of Experimental Setup

THEORY: If a control valve is used to control fluid flow, some mechanism must physically open
or close the valve. Different types of actuators are used to control the stem travel of the valve,
like electrical actuators, pneumatic actuators are used for control valves. Spring opposed
diaphragm actuator positions the valve plug in response to the controller signals. Mostly the
controller signals are in the range of 3-15 psig. There are two types of actuators as described
below.
(i) Direct acting actuator (Air to close): Direct acting actuators basically consist of a
pressure tight housing sealed by a flexible fabric reinforced elastomer diaphragm. 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 spring rate or stiffness, load carrying
capacity, and initial compression, desired stem displacement can be obtained for any
given input signal.
(ii) Reverse acting actuator (Air to open): In case of reverse acting actuators the stem gets
retracted with increase in pressure.

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:

Close all the valves V1-V10.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valve V4. Open valve V1 and adjust the flow rate.
Open valve V6 completely. Partially open valve V5 and wait for some time (5 min).
Record manometer reading. Record rotameter reading.
Repeat the experiment by adjusting valve V1 at different flow rates.

Procedure for Control Valve 2:

Close all the valves V1-V10.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valve V2 and adjust the flow rate.
Open valve V7 completely. Partially open valve V5 and wait for some time (5 min).
Record manometer reading. Record rotameter reading.
Repeat the experiment by adjusting valve V2 at different flow rates.

Procedure for Control Valve 3:

Close all the valves V1-V10.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valve V3 and adjust the flow rate.
Open valve V8 completely. Partially open valve V5 and wait for some time (5 min).
Record manometer reading. Record rotameter reading.
Repeat the experiment by adjusting valve V3 at different flow rates.

Determine Cv for all three control valves.

(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:

Close all the valves V1-V8.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valves V1 and V3 and adjust the flow rate.
Open valve V5 completely. Partially open valve V4 and wait for some time (5 min).
Note down the reading of pressure gauge and position of valve stem by scale.
Now slowly decrease the air pressure by pressure regulator.
Repeat the last two steps until the valves is fully closed (pressure upto 0 psi).

Procedure for Control Valve 2:

Close all the valves V1-V8.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valves V2 and adjust the flow rate.
Open valve V6 completely. Partially open valve V5 and wait for some time (5 min).
Note down the reading of pressure gauge and position of valve stem by scale.
Now slowly decrease the air pressure by pressure regulator.
Repeat the last two steps until the valves is fully closed (pressure upto 0 psi).

Procedure for Control Valve 3:

Close all the valves V1-V10.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valves V3 and adjust the flow rate.
Open valve V8 completely. Partially open valve V5 and wait for some time (5 min).
Note down the reading of pressure gauge and position of valve stem by scale.
Now slowly decrease the air pressure by pressure regulator.
Repeat the last two steps until the valves is fully closed (pressure upto 0 psi).

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:

Close all the valves V1-V8.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valves V1 and adjust the flow rate. Open valve V3.
Open valve V5 completely. Partially open valve V4 and wait for some time (5 min).
Record manometer reading. Record rotameter reading.
Now slowly decrease the air pressure by pressure regulator.
Adjust valve V1 to keep pressure drop constant.
Note down rotameter reading.
Repeat the last three steps until the valves is fully closed (pressure upto 0 psi).

Procedure for Control Valve 2:

Close all the valves V1-V8.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valves V2 and adjust the flow rate.
Open valve V6 completely. Partially open valve V4 and wait for some time (5 min).
Record manometer reading. Record rotameter reading.
Now slowly decrease the air pressure by pressure regulator.
Adjust valve V2 to keep pressure drop constant.
Note down rotameter reading.
Repeat the last three steps until the valves is fully closed (pressure upto 0 psi).

Procedure for Control Valve 3:

Close all the valves V1-V10.

Fill the sump tank up to 3/4th with water.
Connect air supply to the setup.
Switch ON the power supply and the pump. Wait for tank to fill water.
Open valves V3 and adjust the flow rate.
Open valve V8 completely. Partially open valve V5 and wait for some time (5 min).
Record manometer reading. Record rotameter reading.
Now slowly decrease the air pressure by pressure regulator.
Adjust valve V3 to keep pressure drop constant.
Note down rotameter reading.
Repeat the last three steps until the valves is fully closed (pressure upto 0 psi).

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.

CLL 361: Instrumentation & Automation Lab

Experiment PC 10: Time Constant of Manometer
OBJECTIVE: To study the characteristics of U-tube manometer by estimating theoretical time constant
and damping coefficient and to plot the graphs for overshoot, decay ratio, and frequency of oscillation
vs damping coefficient.
APPARATUS: The set up consists of a U-tube manometer with scale. An air pressure regulator with
pressure gauge is provided to change the pressure in the manometer. Valves are provided for supply
and release of air as shown in Fig 1.
Air from pressure regulator

V2
Manometer
Pressure
Regulator

V1

Fig 1. Block Diagram of Experimental Setup

THEORY: System with inherent second-order dynamics can exhibit oscillatory (under-damped)
behavior but are rather rare in chemical processes. Here, we will study the dynamics of a manometer
which can be modeled as a second order system. When the pressures at the top of the two legs are
equal, the two liquid levels are at the same horizontal plane. Let us assume that suddenly a pressure
difference p = p1-p2 is imposed on the two legs of the manometer. By using force balance and using
the Poiseuilles equation for laminar flow in a pipe, it can be shown that the transfer function relating
the deviation of liquid level (h) to applied pressure difference (p) is

Calculate theoretical values of and from following equations:

(L = length of fluid in column)

2 = 4L/g

(1)

(R = radius of manometer tube, = density of manometer fluid, = viscosity

of manometer fluid)

= 1/2g
Calculate L using eq (2)
=2

(2)

where hs = steady state height of manometric fluid, x = horizontal distance between two legs of
manometer.
The dynamic response of a second order system depends on the value of . For > 1, he response is
overdamped, while for <1 the response is underdamped. For = 1, the response is called critically
damped. For the case of manometer, the response often falls under the category of underdamped
response as shown in Fig 2. The overshoot is defined as A/B and decay ratio as C/A in Fig 2.

Fig 2. Characteristics of Underdamped Response of Second Order System

PROCEDURE:
1. Close all the valves V1-V2.
2. Set the pressure by pressure regulator.
3. Open the valve V1 and supply the air
4. Now a step change in pressure is introduced by releasing the air by opening valve V2.
5. Record the height of manometric fluid as higher level and lower level.
6. Also record the time taken by higher level to lower level.
7. The final steady state level of the manometric liquid is also noted.
8. Repeat the experiment for different step changes.
Closing procedure:
After completing the experiment stop the supply of air
Release all air by opening valve V2.
RESULTS:
Calculate decay ratio, the ratio of the amounts above the ultimate value of two successive
peaks and the period of oscillation from the experimentally measured response. Using following
equations (3 & 4) solve for and (experimental values).
Decay Ratio = exp{(-2)/

} = (overshoot)2

Time period of oscillation is given by T = 2/ 1

(3)
(4)

Compare the experimentally obtained values of and with the theoretical predictions from equation
(1) & (2) and comment.
Precautions:

Dont give pressure to manometer above 0.4 kg/cm2 in case of mercury and not more than
0.1 kg/cm2 in case of water and CCl4

Accidentally if the manometer fluid comes in the catch pot fill it again into that and note down
the time and height one by one.

CLL 361: Instrumentation & Automation Lab

Experiment PC 11: Time Constant of Thermocouple & Thermometer
OBJECTIVE: To study the characteristics of thermometer and thermocouple and to calculate time
constant of thermometer and thermocouple from step response curve.
APPARATUS: The set up consists of a heater, which is controlled by digital temperature controller. A
pocket is provided to insert the thermometer or thermocouple in it. Thermowell, Thermocouple, and
Thermometer are provided.
THEORY: Mercury thermometer is a widely used temperature measuring element for manual
purposes whereas a thermocouple used for control purposes. A thermocouple is composed of two
dissimilar wires welded together at one end. When temperature at the welded junction changes, an
electrical potential is generated and it appears at the free ends of the wires. This potential is the result
of two distinct functions Thomson effect and Peltier effect.
A thermometer without thermo-well is a first order dynamic system whose transfer function is:
( )
=
( )

1
+1

and for a step change of magnitude A, the response is

( ) = (1

where is time constant, which can be estimated from step response data as the time required to
reach 63.2% of the ultimate response.
In case when a thermo-well is used, the nature of the dynamics changes to a second order transfer
function
( )
=
( ) (

1
+ 1)(

+ 1)

where 1 and 2 are effective time constants which can be obtained from Fig 1.

Fig 1. Fractional Incomplete Response

where I = % fractional incomplete response, Ia = fractional incomplete response for calculation of 1,
P = maximum value of fractional incomplete response, R = maximum value of fractional incomplete

response difference, I = fractional incomplete response difference, Ia = fractional incomplete

response difference for calculation of 2.
PROCEDURE:
Start up:
1. Clean the apparatus and check all accessories thoroughly.
2. Ensure that all switches given on the panel are in OFF position.
3. Switch ON the main power supply.
4. Set the desired temperature (start from slightly above ambient to 100oC) on the DTC.
5. Switch On the heater.
6. Wait till the steady state is achieved.
7. Insert the Thermometer in the pocket.
8. Record its temperature with respect to time.
9. Repeat the same procedure for thermocouple.
10. Repeat the same procedure using thermowell having a little amount of mercury in it.
Closing:

When experiment is over, switch OFF the heater and power supply.
Clean the apparatus properly.

OBSERVATION & CALCULATIONS:

For thermometer/ thermocouple without thermowell:
Note initial temperature (Ti). Note temperature (T) vs time(t). Calculate temperature difference, Y = T
Ti and note final steady state value (Yf). From the plot of Y vs time, determine time constant ()
corresponding to 63.2 %.
For thermometer/ thermocouple with thermowell:
Note initial temperature (Ti). Note temperature (T) vs time (t). Calculate temperature difference, Y =
T Ti and note final steady state value (Yf). From the plot of Y vs time, find out transportation lag (d),
the value that departs from the time axis.
Calculate shifted time (t1) , t1 = t - d.

Calculate % fractional incomplete response, =

x100

Now plot a graph of I vs t1 and draw a tangent from maximum value of t1 to vertical axis at (t1=0) and
find P as shown in Fig 1. Calculate Ia = 0.368 P and read corresponding time constant 1. Calculate I
= Ia I. Plot a graph of I vs t1 and find R as shown in Fig 1. Calculate Ia = 0.398 R and read
corresponding time constant 2.
Precautions:

Never exceed the set point of DTC more than 150oC

Ensure that there is little amount of mercury lying in thermo well and bath before inserting
the thermometer.
Always take precaution while handling mercury

CLL 361: Instrumentation & Automation Lab

Experiment PC 12: Level Measurement by Capacitance Method
OBJECTIVE: To study level measurement by capacitance method and understand use of change in
capacitance for water level measurement.
THEORY: Water level can be measured using capacitive sensing. A mechanical arrangement of two
aluminum pipes held parallel to each other and isolated by plastic insulator is used as a capacitor. Both
aluminum pipes are covered with plastic sleeve and sealed at the ends. Two connecting wires are
brought out from both pipes and connected to the panel through 5 pin DIN connector. This capacitor
is dipped in the water tank. As the water level increases the capacitance between two dipped plates
increases and water as a medium acts as short bringing them close to each other. The dielectric
constant of plastic decides the capacitance. Here a slide switch is provided on the PCB to select either
angular capacitor or level capacitor. The schematic diagram is shown in Fig 1.

Fig 1. Experimental Set up

PROCEDURE:
1. Put selector switch to angular displacement position.
2. Connect 12 V power supply to the panel and voltmeter (2 V) at the output terminals
3. Select the angular capacitance using rotary 6 positions switch SW1 at correct location (4th) and
DPDT switch SW2 on OTHER SENSORS.
4. Select level capacitor using slider switch.
5. Switch on the power supply.
6. Place the capacitor assembly in the water tank.
7. Connect 5 pin D connector table to the PCB.
8. Select angular capacitor by selecting position of cap 6 position rotary switch at Keep the slider
switch at level capacitor position.
9. Vary the water level in the tank and observe output voltage at the O/P on the PCB. At first we
will perform span & zero calibration.
10. Adjust water level to 0 cm. Set O/P to 0 V using zero adjustment pot.
11. Now fill the tank up to 50 cm level. Adjust O/P to 0.5 V using span adjustment pot.
12. This is done 2 to 3 times for O/P reading. Now observe the O/P voltage at various water levels
and tabulate capacitance values.
13. Plot graph of level(cm) vs capacitance(pF) and level(cm) vs O/P voltage (V). Measure
capacitance between two plates when it is completely dipped in water (at 50 cm) and when
the water tank is empty (at 0 cm) in steps for every 5 cm.