INDUSTRIAL INSTRUMENTATION

&

CONTROL LAB

Submitted to:
Sir Usman

Submitted by:
Wajeeha Kiran 2008-chem-51 A1

LAYOUT OF INSTRUMENTATION & CONTROL LAB

1: pH PROCESS RIG The pH Process Rig is the main component part of the complete trainer. A self-contained educational platform for teaching pH level control and effluent treatment methods. The Rig comprises two independently pumped fluid circuits mounted on a robust bench-top panel which allows, the study of the principles of process control using the pH of the mixed effluent and reagent, fluids as the process variable. Effluent and reagent are contained in separate holding tanks prior to being pumped into the reaction tank where mixing is carried out.

2: BASIC PROCESS RIG The Basic Process Rig is the main component part of the complete trainer. A single loop system allowing the study of the principles of process control, using liquid level and flow rates as the measured process variables. The system is a completely self-contained, low pressure flowing water circuit supported on a bench-mounted panel, making it suitable for individual student work or for group demonstrations.

3: TEMPERATURE PROCESS RIG The Temperature Process Rig is the main component part of the complete trainer. A two loop system using water as the process fluid which allows the study of the principles of process control using primary and secondary circuit temperatures as the process variables to be controlled. A Forced Air Cooler 38-610 is also available. It accelerates the process dynamics using a constant input temperature, allowing a high temperature differential to be monitored for longer periods.

4: DEAD WEIGHT CALIBRATOR They are ideal in use of calibrating, setting, testing, and repairing pressure measurement and control devices. Traceable to National Standards assuring instrument accuracy. Dead weight testers have been used for many years and are the accepted industry standard for providing high accuracy pressure calibration. Available in all operating ranges our DWT's provide an easy means of precisely generating pressure to an accuracy of 0.1% of reading.

5: AIR PREPARATION UNIT In the industry signals are usually carried with the help of electricity and instrumental air. Instrumental air is moisture free and duct free air. This unit is used to prepare the instrumental air at a regulated pressure. For these purposes adsorption columns, filter and pressure control valves are provided.

6: TEMPERATURE CONTROL APPARATUS Temperature control apparatus comprises of plate and fin heat exchanger. This apparatus uses water as a process fluid.

7: PRESSURE PROCESS RIG The Pressure Training Rig is the main component part of the complete trainer. A single loop pneumatic control rig, it enables the study of the principles of both pressure regulation of a process and the control of flow in a pressurized system. The System comprises a low pressure air circuit supported on a bench-mounted panel, making it suitable for individual student work or for group demonstration.

IRON- CONSTANTAN THERMOCOUPLE

Iron- constantan Thermocouple are the low cost devices used to measure the temperature up to 800OC. This is j-type thermocouple. Temperature at a specific interval of time is determined and the graph between time and temperature helps us to obtain the time constant.

9. PROCESS CONTROL TRAINER The Armfield Process Plant Trainer can be used to demonstrate a complete range of process control methods and strategies. Manual control, single feedback loops, through to sophisticated cascade loops and distributed supervisory control of the whole process by a remotely located computer can be demonstrated. The system is a miniature replication of a true production process. The student is presented with real process control problems, with realistic dynamic behaviour and instabilities in an easy to use Process control Trainer.

EXPERIMENT # 1
JOB Demonstrate the pH process rig. OBJECTIVE The object of the experimental rig is to control a chemical reaction so that the products of the reaction form a pH neutral liquid. Effectively an alkaline effluent is treated with an acid to give a resultant neutral solution.

THEORY The effluent to be treated is stored in the effluent tank & fed via a filter to a constant speed high pressure circulating pump. The effluent passes through a flow meter/manual needle-valve combination & a manual electric on-off solenoid valve (sv1) before entering the reaction vessel. After being mixed with the reagent, the treated effluent exits through manual drain valve &/or an overflow to the treated fluid tank. The pH of the liquid in the reaction vessel is monitored using the pH probe. The reagent is stored in the reagent tank & fed via a filter to a second pump. The liquid passes through a flow meter/manual needle-type servo control valve before entering the reaction vessel. The treated fluid tank can be drained via a manual valve & associated pipe work.

INSTRUMENTS DESCRIPTION 1.pH METER A pH meter is an electronic instrument used for measuring the pH (acidity or alkalinity) of a liquid (though special probes are sometimes used to measure the pH of semi-solid substances). A typical pH meter consists of a special

measuring probe (a glass electrode) connected to an electronic meter that measures and displays the pH reading. They are used in the process industry even in the laboratories to measure the pH of the process.

2.ROTAMETER A rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It belongs to a class of meters called variable area meters, which measure flow rate by allowing the cross-sectional area the fluid travels through to vary, causing some measurable effect. The wide use of the rotameter is in the process industries to measure the flow rate of the different streams.

3.LEVEL SENSOR Level sensors detect the level of substances that flow, including liquids, slurries, granular materials, and powders. Fluids and fluidized solids flow to become essentially level in their containers (or other physical boundaries) because of gravity whereas most bulk solids pile at an angle of repose to a peak. The level measurement can be either continuous or point values. Continuous level sensors measure level within a specified range and determine the exact amount of substance in a certain place, while point-level sensors only indicate whether the substance is above or below the sensing point.

EXPERIMENT # 2
JOB Demonstrate the process control trainer. OBJECTIVE The object of the trainer is in the continuous, high temperature-short time pasteurization, where the process fluid is in reality milk, juice, or other liquid food product requiring heat treatment for biological purposes. It involves indirect heating & sudden cooling of the process liquid.

THEORY The process liquid is pumped at a preset flow rate from one of the two storage tanks to an indirect plate heat exchanger, the purpose of which is to raise the temperature of the process liquid to a predetermined value. The process requires the liquid stream to be maintained at this temperature for a given period of the time. This is achieved by use of a holding tube, followed by a temperature activated diverter valve which allows only fluid of the correct temperature to progress through the process. The process fluid is then cooled to the lowest possible temperature by firstly exchanging otherwise wasted heat with incoming feed generation & subsequently by the use of externally supplied cooling water. INSTRUMENTS DESCRIPTION 1.ROTAMETER A rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It belongs to a class of meters called variable area meters, which measure flow rate by allowing the cross-sectional area the fluid travels through to vary, causing some measurable effect.

2.MEASURING TAPE A tape measure or measuring tape is a flexible form of ruler. It consists of a ribbon of cloth, plastic, fiber glass, or metal strip with linearmeasurement markings. It is a common measuring tool. It is used in the laboratories & process industries for measuring the level of liquid in the vessels, tanks etc.

3.THERMOCOUPLE A thermocouple is a device consisting of two different conductors (usually metal alloys) that produce a voltage proportional to a temperature difference between either ends of the pair of conductors. Any junction of dissimilar metals will produce an electric potential related to temperature. Thermocouples for practical measurement of temperature are junctions of specific alloys which have a predictable and repeatable relationship between temperature and voltage. Thermocouples are widely used in science and industry; applications include temperature measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes. 4.PRESSURE TRANSDUCER A pressure transducer is a transducer that converts pressure into an analog electrical signal. Although there are various types of pressure transducers, one of the most common is the strain-gage base transducer. The conversion of pressure into an electrical signal is achieved by the physical deformation of strain gages which are bonded into the diaphragm of the pressure transducer and wired into a Wheatstone bridge configuration. Pressure applied to the pressure transducer produces a deflection of the diaphragm which introduces strain to the gages. The strain will

produce

an

electrical

resistance

change

proportional

to

the

pressure.

EXPERIMENT # 3
JOB Calibration of pressure gauge using a dead weight tester. OBJECTIVE The object of Dead weight calibrator or tester is the calibration & recalibration of the high pressure instruments use for pressure measurements. PROCEDURE 1. Close the needle valves 5, 6, 6 while the valve (2) is kept open. Pour the hydraulic oil through the cup (3) into the tester to fill it. 2. Rotate the piston outwards to suck the oil in it. 3. Close the valve (2) & open valve (5) & (6) after mounting the gauge to be tested on nipple provided for the gauge pressure. In case a precision gauge is available mount it on the other position & open valve (6) as well. 4. Put the standard weights available on the pan (7). 5. While rotating slowly the weight pan, turn the handle of the cylinder piston to transmit the pressure towards the weight & pressure gauge/s. 6. When the fluid pressure is equal to the pan it is lifted as well as the gauge indicates the corresponding pressure. Note that the weight should be lifted to red line only. Beyond white line it would be in effective. 7. Marks the point on the gauge, release the pressure, put the next weight & repeat the above experiment for the next calibration. INSTRUMENTS DESCRIPTION 1. PRESSURE GUAGE The Bourdon pressure gauge uses the principle that a flattened tube tends to change to a more circular cross-section when pressurized. Although this change in cross-section may be hardly noticeable, and thus involving moderate stresses within the elastic range of easily workable materials, the strain of the material of the tube is

magnified by forming the tube into a C shape or even a helix, such that the entire tube tends to straighten out or uncoil, elastically, as it is pressurized.

OBSERVATIONS & CALCULATIONS

Ascending readings
Weight loaded(pressure applied) atm. 2 4 6 8 13 23 Gauge reading (atm.) 0.774 2.219 4.065 7.549 11.614 23.023

Descending readings
Weight loaded(pressure applied) atm. 13 8 7 6 5 4 Gauge reading (atm.) 11.711 5.710 4.355 3.968 2.904 0.968

Graph b/w applied & gauge pressure

(Descending readings)
16 14 12 Fauge pressure (atm.) 10 8 6 4 2 0 0 2 4 6 8 10 weight applied(pressure applied) atm. 12 14 16

Graph b/w applied & gauge pressure

(Descending readings)
16 14 12 Gauge pressure (atm.) 10 8 6 4 2 0 0 2 4 6 8 10 weight applied(pressure applied) atm. 12 14 16