Controls Engineering Lab

Lab Report – 02

Introduction to
Level, Flow, Pressure and Temperature
Trainers & Modules

Submitted to
LE. Usman Ghani

Submitted by

Name Waleed Nasir

CMS ID 394281
Semester 5th
Section ME-13-C

School of Mechanical & Manufacturing Engineering

National University of Science and Technology – Islamabad
 Control Engineering Lab
• Objectives
1. To briefly introduce and explain different control system training apparatus.
2. Learn different components and equipment in control systems.
3. Interaction with pressure, temperature, flow and level control training systems

• Equipment
1. Pressure control training system
2. Flow control training system
3. Temperature control training system
4. Level control training system

• Theoretical Background

1- Pressure Control Trainer:

Pressure
Sensor
PID Controller Control Panel

Pressure
Gauge

Pump Driver

ON OFF
Float Switch
Controller

Process Tank Voltage

regulator

Rotameter

Sump Tank

Pump
Fig.1.1. Pressure Control Trainer

Components of Flow Control Trainer

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Pressure sensor interface
The pressure sensor is used to determine the pressure of the fluid in terms of the voltage
produced. The voltage is mapped to the change in pressure of the container. The voltage is
amplified and converted into the pressure reading.
Solenoid valve
The solenoid valve is used to electronically control the flow valve using a solenoid. It is a
precise and a fast way of controlling the flow/drain electrically/electronically.
Pressure gauge
Pressure gauge is a device used to measure pressure of a liquid inside a room or container.

2. Flow Control Training System

Components of Flow Control Trainer
Water Pump Driver
The water pump is used to transport water to the observation tank. The pump is switched
on using the pump interface on the controller by connecting it to the 10V DC power supply.
The drain valve is then used to move water from the observation tank back to the reservoir
tank.
Gate Valve:
The gate valve is used to control the flow of water/fluid in the pipe. It has a flat gate or wedge-
shaped disc in it that blocks or allows the flow of water across the valve, hence the name “Gate
Valve”.

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 Control Engineering Lab

Flow Control
PID Controller Sensor Panel
Float Switch

Pump Driver

Process Tank

ON OFF
Controller

Voltage
Motorized Valve regulator

Rotameter

Sump Tank

Pump

Fig.1.2. Flow Control

Trainer
Process Tank
A process tank, also known as a processing tank or observation tank, is a large container
or vessel used to store, mix, blend, react, or otherwise handle liquids, gases, or solids.

Hall Sensor
The effect of generation of an induced voltage within a conducting coil in the presence of a
changing magnetic field is known as “Hall Effect”. The magnitude of the induced voltage is
directly proportional to the strength of the magnetic field.
PID Controller
In open loop control systems, we need feedback from the control system and the PID
controller is one of the most widely and commonly used feedback controller. The term "PID"
stands for Proportional-Integral-Derivative, which are the three primary control actions or
terms that the controller uses to maintain a desired setpoint and regulate a process or system.
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 Control Engineering Lab
Flow Sensor
To measure the flow rate of a fluid in a pipe system, we use a flow sensor. It works on the
“Hall Effect”, a magnetic turbine rotates as the fluid flows across it and generates a changing
magnetic field which is detected by a conducting coil. The induced emf if mapped to the flow
rate in the pipe.
Float Switch
A float switch is a device used to detect the level of a liquid within a container or reservoir.
It consists of a buoyant float attached to an actuating mechanism. It is basically a digital signal
output. It moves up and down and when the water level is high, it becomes short (Lever Ball
Mechanism).
Rotameter
The rotameter is a device that is used to measure the flow rate of a fluid (especially liquid)
in a pipe system. It uses a variable cross section pipe in which the area gradually increases as
its length increases. It consists of a float which floats on the water as water hits it from below.
As the flow rate increases the height of the float in the rotameter increases and the graduation
on the rotameter gives the flow rate.

Fig. 1.5. Rotameter

Storage Tank
A storage tank (also known as sump tank) is a container designed for the purpose of storing
liquids or gases in a safe and secure manner. The liquid/gases stored in the sump tank is used
In the process for observation. It is moved to the process tank using a pump.

3. Level Control Training System

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 Control Engineering Lab

Fig.1.6. Level Control Trainer

Fig.1.7. Control Panel & CRO

CRO

Pump Driver

Solenoid
Valve Driver

ON OFF
Controller
Components of Flow Control Training System
Level Sensor
PID Controller
LVDT (Linear Variable Differential Transformer)

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 Control Engineering Lab
An LVDT (Linear Variable Differential Transformer) is a sensor that works in the
principle of mutual induction. It has a long tube consisting of a primary and two secondary
coils. The primary coil is wound on a bar connected to a float that rises in height as the
level of the water/fluid increases. The primary coil moves inside the tube and thus moves
between the secondary coils generating an induces voltage which is amplified and mapped
to the level of the liquid in the tank.

Fig. 1.8. Linear Variable Differential Transformer

Float Switch:

A float switch uses a float which when the level of the fluid reaches the top of the tank or the
set level, the float rises and closes the circuit. It is used to turn off the pump when the
maximum level is reached.
Non-Return Valve:

It is a one-way valve that allows water/fluid to flow only in one direction.

Strainer:

It is a sort of filter to filter out the unwanted particles to protect the pump from damage.
Solenoid Valve Driver
A solenoid valve driver, often referred to as a solenoid driver or solenoid controller, is an
electronic or electromechanical device used to control and manage the operation of solenoid
valves. Solenoid valves are electromechanical devices that control the flow of fluids or gases
by opening or closing a valve when an electric current is applied to a coil (solenoid).

4. Temperature Control Training System

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 Control Engineering Lab

Condenser

Heater

Pump

In Out Valve

Process Tank

Fig. 1.9. Temperature Control Trainer

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 Control Engineering Lab
Temperature
Sensor

Digital PID
Controller

Pump Driver

Heater Driver

Auxiliary Driver
ON OFF
Controller

Fig. 1.10. Control Panel

PID Controller

Components of Temperature Control Training System

Condenser:
A condenser is a device used in various applications to condense or change the physical state
of a substance, typically a gas, into its liquid state by removing heat from it. Condenser is used
here to cool the water.
Heater:
A heater is a device used to produce heat to raise the temperature of room, liquid etc.
Temperature Sensor:
Temperature sensor is an instrument designed to measure temperature and convert the
temperature information into a usable electrical signal or digital output. Temperature sensors
are used in a wide range of applications, from monitoring and controlling industrial processes
to measuring environmental conditions, ensuring food safety, and regulating the temperature
in electronic devices.

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 Control Engineering Lab
Auxiliary Control Driver:
An auxiliary control driver typically refers to a component or device used in control systems
and electronics to manage auxiliary or secondary functions within a larger system. It is not a
standardized term, and its specific meaning can vary depending on the context and the industry
in which it is used.
Heater Driver:
A heater driver is a component or device used to control and manage electric heaters. Electric
heaters are used in various applications to generate heat, and a heater driver is responsible for
controlling the power supplied to the heater elements to achieve the desired temperature or
heating level.
• On off controller
• PID sensor
• Non return valve
• Water pump driver
• Process Tank

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