Process Control Trainer

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PCS- 1

INTRODUCTION

The process setup consists of supply water tank fitted with pump for water circulation .The flow sensor is fitted on the orifice meter . A pneumatic control valve adjusts the water flow in the pipeline. The process parameter is controlled through computer or up controller. These units along with necessary piping are fitted on support housing designed for tabletop mounting.

RANGE OF EXPERIMENTS

1) Models of control : Control mode counteracts deviation from set point. Feedback control models are Proportional, Derivative and studied separately.
2) PID control: Control computation is set for P, PI, and PID control. Set of PID parameters selected based on process.
3) Tuning of controller: Study of controller tuning based on quarter amplitude damping
4) Ziegler Nicholas tuning (Closed loop response) : Continuous cycling of process enables evaluation of ultimate proportional band and time.
5) Process reaction curve (Open loop response): Process reaction curve for nit step change is drawn for determining PID values.
6) Function generator: System response is studied under frequency and sinusoidal mode of controller.
7) Stability analysis ( Bode plots): Bode plot is drawn for magnitude versus frequency. Phase lag of gain from plots confirms stability.
8) Auto tuning For SCADA model.

SPECIFICATION

1) DP Transmitter Range 0-200 mm of water, output 4-20 mA.
2) Orifice meter : SS304
3) Pump: vertical - fractional horsepower.
4) ROTAMETER: range 10-100 LPH.
5) Piping ¼” size
6) Air regulator size ¼” BSP, Range 0-2.5 BAR.
7) Supply tank: FRP
8) E/P Converter input 4-20mA ,output 0.2-1BAR
9) Interfacing unit for input-output communication with auto / manual facility ( Optional ).
10) Control valve size ½”,pneumatic,Actuator 15 sq” ,stroke 9 mm.
11) µp controller with communication facility ( optional )
12) Software for experimentation, PID control, data logging, trend plot offline analysis and printing.

INSTRUCTION MANUAL

A manual is supplied which gives details of the apparatus and procedure of experiments along with sample calculations.

SERVICES REQUIRED

3 1) Air supply compressed 1 m / h at 3 bar
2) Electricity supply … 230V ,1Ph AC
3) Computer… Pentium with VGA monitor
4) Table … for setup support.

PCS- 2

INTRODUCTION

The pressure inside pressure tank is sensed by pressure sensor with transmitter. .A pneumatic control valve adjusts compressed air flow from the tank . The process parameter [ pressure ] is controlled through computer or µp controller. By manipulating the control valve.
These units along with necessary piping are fitted on support housing designed for tabletop mounting.

RANGE OF EXPERIMENTS

1) Models of control : Control mode counteracts deviation from set point. Feedback control models are Proportional, Derivative and studied separately.
2) PID control: Control computation is set for P, PI, and PID control. Set of PID parameters selected based on process.
3) Tuning of controller: Study of controller tuning based on quarter amplitude damping.
4) Ziegler Nicholas tuning ( Closed loop response): Continuous cycling of process enables evaluation of ultimate proportional band and time.
5) Process reaction curve (Open loop response): Process reaction curve for nit step change is drawn for determining PID values.
6) Function generator: System response is studied under frequency and sinusoidal mode of controller.
7) Stability analysis ( Bode plots): Bode plot is drawn for magnitude versus frequency. Phase lag of gain from plots confirms stability.
8) Auto tuning For SCADA model.

SPECIFICATION

1) Pressure Transmitter Range 0-5 bar . output 4-20 Ma..
2) Process tank : capacity 1.5 lt.
3) Piping 1/2" size
4) Air regulator size ¼” BSP, Range 0-2.5 BAR
5) E/P Converter input 4-20mA ,output 0.2-1BAR
6) Interfacing unit for input-output communication with auto / manual facility ( optional )
7) Control valve size ½”,pneumatic,Actuator 15 sq” ,stroke 10 mm.
8) µp controller with communication facility ( Optional )
9) Software for experimentation, PID control, data logging, trend plot offline analysis and printing. (
Optional )

INSTRUCTION MANUAL

A manual is supplied which gives details of the apparatus and procedure of experiments along with sample calculations.

SERVICES REQUIRED

3 1) Air supply compressed 1 m / h at 3 bar
2) Electricity supply … 230V ,1Ph AC
3) Computer… Pentium with VGA monitor
4) Table … for setup support.