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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Control Engineering Lab
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”.
Flow Control
PID Controller Sensor Panel
Float Switch
Pump Driver
Process Tank
ON OFF
Controller
Voltage
regulator
Control Engineering Lab
Motorized Valve
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.
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).
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Control Engineering Lab
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
Components of Flow Control Training System
Controller
Level Sensor
LVDT (Linear Variable Differential Transformer)
PID Controller
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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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