2016-CH-420

Submitted To: Dr.Khalid Mehmood

INSTRUMENTATIO
N & CONTROL
LAB REPORT
 Lab Report

LAB LAYOUT

Fluid Mixing Temperature Flow

Continous
Study Instrumentation Instrumentation
Stirred Tank
Apparatus Bench Bench
Reactor

Batch
Polymerization
Reactor Pressure
Instrumentation
Bench

Batch
Polymerization
Bench
Level Instrumentation
Bench

Notice Board
Exit Entrance
n

1
Lab Report

Pressure Control Trainer

Pressure Control:
Pressure control (PC) is mode of mechanical ventilation alone and a variable within other
modes of mechanical ventilation. Pressure control is used to regulate pressures applied
ventilation.

Objective:
 To understand fundamentals of control engineering
 Optimization and Parametrization of local industrial controller
 Investigate disturbance and response system in 2nd order Controller

Pressure Control trainer:

This trainer has been designed to demonstrate and provide students a hand on experience on
how a pressure loop can be controlled using a microprocessor-based controller, The equipment
consists of industrial grade instrumentation to exhibit a realistic working environment of
standard industrial pressure control loop.

2
Lab Report

Description:
Pressure control trainer is designed for understanding the basic principles of pressure control.
The process set up consists of pressure vessel fitted with pneumatic control valve. Pressure
transmitter is used for pressure sensing. The process parameter (Pressure) is controlled by
microprocessor based digital indicating controller which manipulates pneumatic control valve
fitted at outlet of pressure tank outlet through I/P converter. These units along with necessary
piping are fitted on support housing designed for tabletop mounting. The controller can be
connected through Ethernet Port for monitoring process in SCADA mode.

Panel Components:
Pressure Instrumentation Bench can be divided to following components
1. Low Pressure Tank
2. High Pressure Tank
3. Pressure Sensor
4. Digital Controller
5. Line Recorder
6. Switch Bench
7. Manometer
8. Pneumatically Operated Control Valve

3
Lab Report

Installation requirements
Electric supply:
Provide 230 VAC single phase electric supply with proper earthing. (Neutral – Earth voltage less
than 5 VAC
5A, three pin socket with switch (1 No.)

Air supply:
Clean, oil and moisture free air, pressure 3 Bar, Air consumption 7.0 m 3/hr.
Computer:
Computer with standard configuration
Support table:
Size: 800Wx800Dx750H in mm

Process Description:
Pressure Control Trainer (Model: SE101) has been designed for student experiments on the
measurement and control of air pressure in a vessel. It is constructed on an epoxy coated steel
frame with lockable castor wheel. The air is contained in an air receiver tank before entering
the air pressure control tank. A pressure transmitter is installed to measure the air pressure and
is linked to the microprocessor-based Controller. The output of the controller is linked to the
pneumatic control valve to manipulate the airflow rate and hence the pressure in the control
tank. The unit is supplied with 3 chart recorders. All instrumentation supplied are of industry
standard and all electrical wires are numbered for identification. All electrical wiring is laid in
flexible PVC conduit and all instrument wirings are screened. The Control panel is safely
protected against water splashes.

Experimental Capabilities:
 Close loop with Proportional band only control
 Close loop with P plus Integral time control
 Close loop with Pl plus Derivative control
 PID Loop tuning for optimum control
 Self-tuning
 Control valve sizing calculation
 Demonstration of a pressure relief valve for overpressure protection

Specifications:
a) Pressure Controller:
 Type: Microprocessor based
 Input: 4 to 20 mA
 Output: 4 to 20mA

4
Lab Report

 Controls: P, Pl, PD, PID and “Self-Tuning”

b) Pressure Recorder:
 Type: Continuous pen
 No of pen: 2
 Chart: 2-fold
 Chart speed: 0 to 3600 mm/hr., Stepped

c) Control Valve:
 Type: Globe Actuator: Diaphragm
 Input: 3 to 15 psig

d) 1/P Converter/Positioner:
 Input: 4 to 20 mA
 Output: 3 to 15 psig

e) Pressure Transmitter:
 Range: 0 to 30 psig
 Output: 4 to 20 mA

f) Air Regulator:
 Air supply: 100 psig
 Output: a) 0 to 60 psig “
 b) 0 to 30 psig 4 °

g) Air Receiver Tank:

 Capacity: 50 liters
 Material: Mild Steel

h) Pressure Gauge:
 Type: Bourdon Tube
 Dial size: 100 mm
 Range: a) 0 to 100 psig
 b) 0 to 60 psig

5
Lab Report

Troubleshooting:
Problems
Control valve does not operate
I/P converter does not work
No communication with computer
Possible causes / remedies
Faulty I/P converter
No output from Controller
Insufficient supply air pressure
Faulty electrical input signal
Check communication settings for IP
addresses of computer and controller.
Default setting computer 192.168.1.2 and
controller
192.168.1.14

6
Lab Report

Flow Instrumentation Bench

Flow Instrumentation:
Automatic and continuous controlling of flow in any process is known as Flow
Instrumentation.
Objective:
 calibration of different flow meters

 position dependency of flow meters

 Investigation of properties of open and controlled loop system

 plotting and comparison of pressure loss curves

Flow Instrumentation Bench:

7
Lab Report

Description:
This trainer provides the comprehensive experimental introduction to fundamental of control
engineering using an example of Pressure Control. The air pressure control is a 2nd order
system. It comprises two in-line Pressure tanks interconnected by a flow valve. An additional
valve on the second tanks makes air tapping possible and so can be used to simulate a
disturbance variable. A pressure sensor measures the Pressure in the second vessel. The
actuator used in the loop is pneumatically controlled valve with a standardized current signal
input unit. The controlled signal X and manipulated variables Y are plotted directly on 2-channel
line recorder. Alternatively, the variables can be tapped as analogue signals at lab jacks on the
switch cabinet.

Components of Trainer:
The flow instrumentation trainer contains following components:

1. Submerged Pump:
Submersible Pump is a device with hermitically sealed motor close-coupled to the pump body.
The whole body submerged in the fluid is to be pumped. It is represented by cavitation.

2. Rotameter:
Rotameter is device which measures the volumetric flowrate of fluid in a closed tube. It is a
variable area flowmeter which measures flow by allowing cross sectional area of fluid to vary.
8
Lab Report

3. Sensor:
Sensor is a device that measures a physical quantity and converts it into signals.

4. Controller:
Controller receives the signals from sensor and match with the standard value assigned to it
and if there is a fluctuation, then it decides which variables (Temperature, Pressure, and
Flowrate) should be controlled.

5. Electromagnetic Sensor:
The device to measure physical quantity such as pressure and convert it into signals.

Procedure:
1. Firstly, switch on the system and fill the tank with water.
2. Flow will be measured using Rotameter and controlled by Controller.
3. When the flowmeter is calibrated, the software will show X variation against Y.

Applications:
Flow Instrumentation Trainer can be used for:

 Controlling flow of Natural Gas

 Measurement of Compressed Air Flow
 Controlling Burner
 Measuring Steam Flow

Troubleshooting:
Problems
Control valve does not operate
I/P converter does not work
No communication with computer
Possible causes / remedies
Faulty I/P converter
No output from Controller
Insufficient supply air pressure
Faulty electrical input signal
Check communication settings for IP
addresses of computer and controller.
Default setting computer 192.168.1.2 and
controller
192.168.1.14