Process control lab manual

EXPERIMEN
T NO.
01
TITLE:
Study of Flow, Level, Pressure, Temperature processes and construction of
the P&I diagrams in accordance with
ISA guidelines /standards
DATE OF
EXPERIMENT
OBJECTIVE: A) TO UNDERSTAND AND REALIZE DIFFERENT SYMBOLS
.
B) APPLICATION OF P & I SYMBOLS FLOW , LEVEL , PRESSURE, TEMPARETURE
CONTROL LOOP
THEORY: While desigining complex control systems the follwing types of diagrams will be required:
a. Functional Diagram
b. Detailed Schematic Diagram
c. Inter connection Diagram
d. ISA Piping and Instrumentation Diagrams (P & I)
A P & I Diagram should provide information about the following :
1. The variable being measured
2. Indicating , Recording or other services, like control and alarm functions
3. Auxilliary Features of the instrument / the controller
4. Type of connecting lines
5. Approximate location of the point of measurement and control
6. Type of instrumentation to be included in the control centre at the processing end
CONCLUTION:
1

EXPERIMENT
NO.
02
TITLE:
Study of a Temperature Control Loop having Furnace, suitable final control
element, Temperature transmitter, conventional PID controller/Control
System, and data logger/recorder
DATE OF
EXPERIMENT
Objective:
I) To take different readings of the process value by varying the set point
II) To study different elements of Tempareture Control loop
Theory: There is a Muffle Furnace. The design temperature range of the furnace is 0-1000 degree C. The temperature
is sensed by a K-type thermocouple. The mV output (PV) is fed to remotely located SMART Temperature transmitter.
The signal is linearized and converted to 4-20 mA DC. This 4-20 mA DC (PV) is fed to the microprocessor based
single Loop Programmer cum PID controller (Local panel) as well as to DCS panel. The RAMP and SOAK time-temp
profile is programmed in TIC as well as in DCS. The controller process the PV input w.r.t SP and giving the corrective
output signal 4-20mA DC which is fed to the Thyristor power Controller to control the input power as per the temp set
point generated from TIC as well as DCS. There is remote/Local switch available on the Local Panel by which Control
through TIC or DCS can be selected.
In this particular experiment which is basically an example of a single fetch system, the measuring end of the RTD is
connected to the Muffle Furnace and both the voltage generated and temp of the RTD is fed to the control loop and
we can easily see them through the display.
Apparatus Table:
SI no. Name of the apparatus Quantity Specification Maker’s name
Observation Table:
SET POINT PROCESS VALUE
CONCLUTION:
2

EXPERIMENT
NO.
03
TITLE:
Study of a Pressure Control Loop having Pressure source, Pressure
Transmitter, Pneumatic
control valve, and conventional PID controller/Control System
DATE OF
EXPERIMENT
OBJECTIVE:
I) To observe the Pressure Control characteristics
II) To study different elements of Pressure Control loop
THEORY:
The Water is flowing from Bottom Tank through 1 inch pipeline. The pressure of water is measured by online smart
pressure transmitter giving 4 – 20 mA DC output (PV) proportional to Pressure. This 4 -20 mA DC output is fed to the
Microprocessor based Single Loop PID Controller (Local Panel) as well as to DCS panel. The Controller/ DCS
compares the PV input and gives the corrective output signal which is fed to I/P Converter for driving Pneumatic
Control Valve (PCV). By the % opening of PCV the pressure varies. There is Remote/ Local switch available on the
Local Panel by which Control through PIC or DCS can be selected.
Apparatus Table:
SL NO. NAME SPECIFICATION MAKER’S NAME
PROCEDURE:
1) The process fluid is flowed in the pipeline using a pump.
2) The process fluid passes through two different pipes, one flows back to the tank via a valve.
3) The pressure transmitter provides an electrical I/P to the process value of the PID Controller. It also shows the % of
opening or closing of the valve.
4) The set point of the Controller can be given manually or through DCS.
5) The error signal generated due to the difference between PV and SP value is fed to the I/P Converter which
generates a pneumatic signal.
6) The pneumatic signal and the pneumatic supply of the air regulator is fed to the signal of the actuator.
7) The actuator controls the valve. Thus the flow of the fluid is also controlled and the pressure is also controlled.
3

OBSERVATION TABLE:
SL
NO.
SP PV SMART
PRESSURE
TRANSMITTE
R READING
STEM
LENGT
H (mm)
SETTLING
TIME (s)
POSITIONER
I/P SIGNAL
(Kg/ Cm2
)
O/P (Kg/
Cm2
)
CONCLUSION:
4

EXPERIMENT
NO.
04
TITLE:
Study of a Flow Control Loop having suitable Flow meter, Pneumatic
control valve, and conventional PID controller/Control System
DATE OF
EXPERIMENT
OBJECTIVE :
(I) To study the changing pattern of flow rate characteristics of process fluid
(II) To study different elements of Flow Control loop
THEORY: The water is flowing from the overhead Tank through 1 inch Pipe. The flow of water is measured by
Honeywell make Magnetic flow meter, it gives 4-20 mA DC output (PV) proportional to water flow rate (0-16 LPM).
This 4-20mA DC output is fed to the Honeywell make Microprocessor based Single Loop PID Controller (local panel)
as well as to DCS panel. The controller processes the PV input w.r.t SP and giving the corrective output signal, it is
fed to I/P Converter where 4-20 mA DC current signal has been converted to 0.2 to 1 Kg/cm2
and is fed to the
Pneumatic Control Valve located on the flow line to control the desired flow rate as per the Set Point generated from
SLC as well as Honeywell make DCS. There is Remote/Local switch available on the Local Panel by which Control
through SLC or DCS can be selected. We can include variable area flow meter (Rotameter) on the same to check the
flow rate.
Apparatus Table:
SL. No. NAME OF APPARATUS RANGE/SPECIFICATION MAKER’S NAME
5

PROCEDURE:
1) Process fluid is at first stored in the tank kept at ground level. Then the pump draws the process fluid from the
lower tank towards the pipelines and then via the pipelines it flows towards the tank kept at the higher level. The fluid
from the higher tanker flows back to the ground level tanker via a flow-transmitter and a Pneumatic Valve kept in
series.
2) The flow transmitter provides an electrical i/p to the process value field of the controller. The controller compares
this i/p value with the value that is provided in the Set Point field of the controller either through mode or through
DCS based system and thus generates an electrical o/p signal which can be called an Error signal.
3) This, fed into the I/P Converter, obtains the signal from the supply of Air Regulator and thus converts the o/p signal
into pneumatic signal which in turn is fed into the positioner.
4) Air Regulator also provides pneumatic supply to the positioner. The positioner compares the signals obtained from
I/P Converter and air regulator and generates an error o/p in the form of pneumatic signal and this is provided to the
actuator to control the valve action.
5) By valve action, water in the ground level tank will increase (or decrease). Difference in pressure between the two
tanks gives the flow rate a positive value.
OBSERVATION TABLE :
SL. No. CONTROLLER READING
PV SP
SMART TXO
READING (%)
ROTAMETER
READING
CONCLUSION :
6

EXPERIMENT
NO.
05
TITLE:
Study of a typical Level Control Loop having Level Transmitter,
Motorized control valve, and conventional PID controller/Control System
DATE OF
EXPERIMENT
Objective:
I) To Study the level characteristics when it is controlled by PID controller.
II) To study different elements of Level Control loop
Theory:
The water is flowing from the bottom tank through 1 inch pipe to top tank where level of water is maintained. The
water level is measured by Honeywell made Ultrasonic level transmitter giving 4- 20 amp DC output (PV)proportional
to water level .This 4- 20 amp DC output is fed to PID controller as well as to DCS panel. The controller processes the
PV input with respect to SP and giving the corrective output signal , which is fed to Honeywell made electrically
operated linear control valve located on the incoming flow line to control the desired level as per the set point
generated from PID as well as DCS.There is remote / local switch available on the local panel by which control
through PID or DCS can be selected.
Apparatus Table:
SI no. Name of the
apparatus
Quantity Specification Maker’s name
Procedure :
1. Power is supplied to the system.
7

2. Local mode control is selected in the PID controller.
3. A set point is provided and the pump is turned on.
4. The electronic actuator is controlled by the PID controller to obtain the set point value .
5. The Process Variable (PV) value is shown on the display of PID controller. The ultrasonic level sensor sends
the signal which corresponds to the level of the tank in terms of current signal to the PID controller.
6. PID controller transforms it into PV value The valve actuator control depends on this PV value.
7. The maximum overshoot and undershoot PV value, and the position of valve stem and settling time is also
measured.
Observation Table :
SI no. Set Point(SP) Process
variable(PV)
Max.
overshoot
Max.
undershoot
Valve stem
length
Settling time
Conclusion :
8

EXPERIMENT
NO.
06
TITLE:
Study of a Air Duct Flow Monitoring and Control
DATE OF
EXPERIMENT
OBJECTIVE:
TO STUDY THE MONITORING OF AIR DUCT FLOW BY
I) POT CONTROL MODE
II) AUTO CONTROL MODE
THEORY :
There is a fan blower which is mechanically connected to a1 horse power 1400rpm 1 phase motor. Once
the motor gets powered the fan blower sucks the air from the atmosphere and delivers through a tunnel where the flow
of air is measured continuously by an orifice plate with the help of a flow transmitter. The DP across the orifice plate
is measured by flow transmitter giving 4- 20 m Amp DC output proportional to the square root of air flow rate. This 4
– 20 m amp Dc(PV)is fed to the PID controller. The controller processes the PV input with respect to SP and giving
the corrective output signal 0-10 V DC to a VFD drive and a electrical actuator mounted on the inlet of the
pipeline. There is a change over switch is available on the local panel by which control can be done by either
VFD /Electrical Actuator.
9

PROCEDURE:
(1) Power supplied to the system.
(2) POT control mode is selected.
(3) RPM of the pump is controlled from RPM controller.
(4) PV value is noted by changing SP.
(5) Auto control mode is selected.
(6) SP is set ,RPM of pump is auto adjusted.
APPARATUS TABLE:
SL NO. NAME OF THE APPARATUS SPECIFICATION QUANTITY
OBSERVATION TABLE:
FOR POT CONTROL:
SL NO. CONTROLLER
SP PV
DPT
O/P
REMARK
10

FOR AUTO CONTROL:
SL NO. CONTROLLER
READING
SP PV
DPT
O/P
REMARK
CONCLUSION:
EXPERIMENT
NO.
07
TITLE:
PLC Programming through PC
DATE OF
EXPERIMENT
Objective:
I)To study PLC and design the digital logic circuits using ladder logic programming
II) Design PLC based instrumentation experiments
Theory:
A programmable logic controller, PLC is a digital computer used for automation of typically industrial
electromechanical process such as control of machinery on factory usually lines etc. PLC’s are designed for multiple
arrangements of digital and analog inputs and outputs executed temperature ranges immunity to electrical noises and
resistance to vibration and impact. Programs to control machine operation are typically stored in battery backup or
non- volatile memory.
Most recently PLC are programmed using application software a personal computer. PC is connected to PLC through
RS-232 protocol. The programming software allows entry and editing of ladder logic.
11

PLC Module-Master Logic 50:
It is Honeywell’s ML50 compact PLC with high performance and functionality, which can be used as I/O and as a
stand Alone PLC or as a distributed control.
Features: The system has following high performances-
i) CPU processing speed (bit):160 ns/step.
ii) Max 480 I/O control supporting small and mid-sized system instrumentation.
iii) Max 10K steps of large program capacity.
iv) Expanded application with the support of floating print.
Soft master:
It is a software used for interfacing Honeywell ML50 PLC module to PC and the software also provides the platform
for PLC programming and uploading it to PLC module.
Communication-FAST ETHERNET:
Here fast Ethernet is used which is much more faster than RS-232 protocol. Features are-
• Model: MLL-EMTA.
• Communication spec: 10/100 Base-TK.
• Protocol: TCP/IP, UDP/IP.
• HS Link Sending/Recording: 200 words/Block.
• No. of channels connectable to upper stage: 8 channels.
Apparatus Table:
SI. no. Name of the apparatus Quantity Specification Maker’s Name
Procedure:
i) Turn on the PLC module.
ii) Program is written on software.
iii) Then connect it to PLC module and click on RUN.
12

iv) According to the program, i/p is given and corresponding o/p is observed.
Observation table:
Programs:
(1) NOT GATE:
Boolean Expression Q= NOT A or
Truth table:
Input(A) Output(Q)
(2) OR GATE:
Boolean Expression Q= A+B
Truth table:
Input(A) Input(B) Output(Q)
(3) AND GATE:
Boolean Expression Q= A.B
Truth table:
(4) NAND GATE:
Boolean Expression Q=
Truth table:
13

(5) NOR GATE:
Truth table:
(6) XOR GATE
Truth table:
(7) XNOR GATE
Truth table:
(8) HALF ADDER CIRCUIT
Boolean Expression Q =
14

Truth tab
Input(A) Input(B) SUM (S) CARRY(C)
le:
(9) FULL ADDER CIRCUIT
Boolean Expression Q =
Truth table:
Input(A) Input(B) Input (C) SUM (S) CARRY(C)
10) HALF SUBTRACTOR CIRCUIT
Truth table:
Input(A) Input(B) DIFFERENCE(D) BORROW(B)
11) FULL SUBTRACTOR CIRCUIT
15

Truth table:
Input(A) Input(B) Input (C) DIFFERENCE
(D)
BORROW(B)
12) 4:1 MULTIPLEXER CIRCUIT
Truth table:
Selection Line 1 Selection Line 2 Output(Q)
Conclusion:
EXPERIMENT
NO.
08
TITLE:
DCS based Instrumentation Experiments
DATE OF
EXPERIMENT
16

Objective:
I) Introduction to DCS system and its Architecture, Operation, Applications
II) To operate and study the behaviour of Pressure Control Loop , Flow Control Loop , Level Control Loop
and
Tempareture Control Loop in DCS mode
Theory:
A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind
of dynamic system, in which the controller elements are not central in location but are distributed throughout the
system with each component sub system controlled by networks for communication and monitoring .DCS is a very
broad term used in variety of industries, to monitor & control distributed components.
CENTUM is the generic name of distributed control system for small and medium scale plants (CENTUM CS1000),
and for large scale plants (CENTUM CS3000).
Block diagram:
17

(Diagram of the hardware architecture CENTUM CS 1000)
Architecture:
The CENTUM CS 1000 architecture can be subdivided into several units namely CPU, Battery units, I/O Modules,
communication cards, Human Interface System(HTS).
i)CPU : There are two models of CPU card. The CP701 for basic systems and CP703 for enhanced systems. CP701
model has 8MB memory but CP703 model has 16 MB memory. The model chosen depends on the type of system
software used. The main memory is ensured of the high reliability by error correction code(ECC).
ii)Power supply cord: The power supply cord is designed to supply power to the common nets such as the as CPU
cards, and up to five I/O modules nests. Standardizing the output voltages to +5v DC has simplified the circuit and
structure and reduced the no of parts.
iii)Input and Output modules: The I/O modules convert the analog or digital signals from the field equipment
then pass to field control stations or vice versa to convert the signals from field control stations for the field
equipments.
iv)Communication cards: The communication cards are used to realize the general purpose communication of
field control station and subsystems via serial links, so that the subsystem may be controlled or monitored .
18

v)Human Interface System(HTS): These are different operational and monitoring windows, which have to
define during designing the HTS. The human interface system programmed for a project or plan is designed in such a
way that it would be easy for the operator to understand all the operations occurring in the plant.
RS 232: RS 232 is a standard communication protocol for linking computer and its peripheral devices to allow serial
data exchange. In simple terms RS 232 defines the voltage for the path used for data exchange between the devices. It
specifies common voltage and signal level, common pin wire configuration and minimum, amount of control signals.
Hart Protocol: HART ("Highway Addressable Remote Transducer") is a communication protocol designed for
industrial process measurement and control applications. It's called a hybrid protocol because it combines analog and
digital communication. It can communicate a single variable using a 4-20 ma analog signal, while also communicating
added information on a digital signal. The digital information is carried by a low-level modulation superimposed on
the standard 4-to-20 mA current loop.
The digital signal does not affect the analog reading because it's removed from the analog signal by standard filtering
techniques.
The ability to carry this added digital information is the basis for HART's key benefits.
Advantage: Traditional analog and discrete devices communicate only a single process variable — and you typically
have no easy way to tell if the information they're sending is valid.
With HART, you still get the process variable — but other types of information, too. Examples include
• Device Status & Diagnostic Alerts
• Process Variables & Units
• Loop Current & % Range
• Basic Configuration Parameters
• Manufacturer & Device Tag
HART devices that are digitally polled by a host can tell you if they're correctly configured and operating correctly.
This eliminates the need for most routine checks — and helps you detect failure conditions before they cause a major
process problem.
Hart protocol specification:
The HART Protocol implements layers 1,2, 3, 4 and 7 of the Open System Interconnection (OSI) 7-layer protocol
model:
The HART Physical Layer is based on the Bell 202 standard, using frequency shift keying (FSK) to communicate at
1200 bps. The signal frequencies representing bit values of 0 and 1 are 2200 and 1200Hz respectively. This signal is
superimposed at a low level on the 4-to-20mA analog measurement signal without causing any interference with the
analog signal.
The HART Data Link Layer defines a master-slave protocol - in normal use, a field device only replies when it is
spoken to. There can be two masters, for example, a control system as a primary master and a handheld HART
communicator as a secodary master. Timing rules define when each master may initiate a communication transaction.
Up to 15 or more slave devices can be connected to a single multidrop cable pair.
The Network Layer provides routing, end-to-end security, and transport services. It manages "sessions" for end-to-
end communication with correspondent devices.
The Transport Layer: The Data-Link Layer ensures communications are successfully propagated from one device to
another. The Transport Layer can be used to ensure end-end communication is successful.
The Application Layer defines the commands, responses, data types and status reporting supported by the Protocol.
In the Application Layer, the public commands of the protocol are divided into four major groups:
1. Universal Commands - provide functions which must be implemented in all field devices
19

2. Common Practice Commands - provide functions common to many, but not all field devices
3. Device Specific Commands - provide functions that are unique to a particular field device and are specified
by the device manufacturer
4. Device Family Commands - provide a set of standardized functions for instruments with particular
measurement types, allowing full generic access without using device-specific commands.
SCADA(Supervisory Control and Data Acquisition): SCADA (supervisory control and data acquisition) is a
category of software application program for process control, the gathering of data in real time from remote locations
in order to control equipment and conditions. SCADA is used in power plants as well as in oil and gas refining,
telecommunications, transportation, and water and waste control.
SCADA systems include hardware and software components. The hardware gathers and feeds data into a computer
that has SCADA software installed. The computer then processes this data and presents it in a timely manner. SCADA
also records and logs all events into a file stored on a hard disk or sends them to a printer. SCADA applications warn
when conditions become hazardous by sounding alarms.
SCADA diagram:
Application of DCS: Today’s controllers have extensive computational capabilities and in additional to proportional,
integral and derivative (PID) control, can generally perform logic and sequential control. Modern DCS also support
neural networks and fuzzy applications.
DCSs are dedicated systems used to control manufacturing processes that are continuous ar batch oriented such as:-
 Electrical power grids and electrical generation plants.
 Environmental control systems.
 Traffic signals.
 Radio signals.
 Water management systems.
20

 Oil refining plants.
 Metallurgical process plants.
 Chemical plants.
 Pharmaceutical manufacturing.
 Sensor networks.
Conclusion:
21

Process control lab manual

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Process control lab manual