Description

IES-PCI-414

Heat Exchanger Control Trainer is an advanced industrial training system designed to demonstrate heat transfer processes and PID-based temperature control in real-time.

This trainer enables students to study thermal dynamics, process control, and industrial heat exchange systems, making it ideal for engineering colleges, process control laboratories, and industrial training institutes.

Technical Specifications

• Hot Water Tank (HWT) – Polypropylene tank with 30–50 liter capacity and 3–5 mm wall thickness, designed for heating and hot water circulation experiments.
• Cold Water Tank (CWT) – Stainless steel tank with 50 liter capacity and 2–3 mm thickness, used for cold water storage and circulation in heat exchange experiments.
• Centrifugal Pump System – Two ½ HP centrifugal pumps operating on single-phase 230 V AC supply, dedicated for hot water and cold water circulation.
• Heating System – Circular heater coil (1″ diameter) with side-mounted 1½″ connection, rated 3–4 kW, operating on 230 V AC, used for generating controlled hot water supply.
• Process Piping Network – Industrial ¾″ CPVC / ½″ stainless steel piping system with ball valves and leak-proof fittings for safe water circulation between tanks and heat exchanger.
• Flow Measurement Units – Two rotameter flow meters with 100–1000 LPH measurement range, glass tube or acrylic body construction, and ½″ process connections.
• Heat Exchange System – Shell-and-tube or plate type heat exchanger with copper tubes capable of handling temperatures up to 100 °C for heat transfer studies.
• Temperature Measurement and Monitoring – Pt100 RTD temperature sensors (4 Nos.) with ½″ BSP connection, along with a four-point temperature indicator displaying temperature range 0–100 °C.
• Control and Pneumatic System – Includes pneumatic control valve (½″ equal-percentage type, Cv 5 US GPM), electro-pneumatic (E/P) converter converting 4–20 mA to 3–15 psi, FRL unit, bi-metallic thermostat, and PID controller with 4–20 mA I/O and PV/SP display.
• Electrical, Air Supply, and Mechanical Structure – MS powder-coated electrical control panel with switches, indicators, DIN-rail terminals, and organized wiring; 50 L air compressor (1–2 HP) providing 5–6 kg/cm² working pressure; all mounted on a rigid MS skid frame with caster wheels for mobility.

KEY FEATURES

• Demonstration of single-loop P, PI, PD and PID temperature control
• Step response & transient behaviour analysis
• Manual & Auto tuning for controller dynamics understanding
• External PLC/DCS integration capability
• Safe, mobile design with MS powder-coated frame and caster wheels
• Industrial-grade components for realistic training
• Emphasis on industrial safety practice

MECHANICAL CONSTRUCTION & DIMENSIONS

• Type: Floor-mounted trainer kit with four heavy-duty caster wheels (locking/brake)
• Overall Dimensions (Approx.): 6 ft (L) × 2.5 ft (W) × 5.5 ft (H)
• Construction: Rigid industrial structure suitable for continuous laboratory use

RANGE OF EXPERIMENTS

• Heat exchanger temperature dynamics study
• Single-loop P, PI, PD and PID temperature control
• Manual vs auto tuning of PID controller
• Step response and transient behavior analysis
• Effect of flow rate on heat transfer
• Pneumatic control valve behavior in temperature regulation
• Integration with PLC/DCS/SCADA systems

GENERAL

• • Application: Heat Exchanger & Temperature Control Training
  • Mounting: Floor-mounted mobile trainer
  • Safety: Thermostat protection, regulated air supply, proper earthing, and electrical protection