IES-PCI-415

Flow and Pressure Control Trainer is an advanced industrial training system designed to provide hands-on experience in process control, flow regulation, and pressure monitoring using PLC-based automation.

This system enables students to learn multi-tank process control, sequential operations, ratio control, and industrial instrumentation, making it ideal for engineering colleges, process control laboratories, and industrial training institutes.

Technical Specifications

Process Tanks – Three industrial-grade tanks with 20 liter capacity each, designed for liquid storage and multi-tank process control experiments.
Pneumatic Control Valves – Three two-way globe type control valves (½″ size) with pneumatic actuation, operating at approximately 1.4 kg/cm² air pressure for accurate flow regulation.
Centrifugal Pump System – Two ½ HP centrifugal pumps operating on single-phase 110/230 V AC, 50/60 Hz supply, used for fluid circulation within the process system.
Process Piping Network – Industrial ¾″ CPVC / ½″ stainless steel piping system with multiple ball valves and leak-proof fittings for reliable fluid transfer between tanks.
Level Measurement System – Three industrial level sensors with measurement range up to 1 ft, designed for monitoring tank liquid levels.
Air Preparation Unit – Filter–Regulator–Lubricator (FRL) with pressure gauge and operating range 0–10 kg/cm², ensuring clean and regulated compressed air supply.
Pressure Monitoring System – Glycerin-filled pressure gauges with 50–60 mm dial size and measurement range 0–4 kg/cm² for accurate pressure indication.
Flow Measurement Units – Two rotameter flow meters with measurement range 100–1000 LPH for monitoring liquid flow within the system.
Control and Instrumentation System – Includes 4–20 mA current source/calibrator and a PLC-based or relay-based controller designed to implement sequential control and ratio control logic.
Air Supply and Mechanical Structure – Air compressor with 20 L tank capacity (~2 CFM, 1 HP motor) operating on 110/230 V AC supply, mounted on a rigid MS floor-standing structure with heavy-duty caster wheels and locking brakes.

KEY FEATURES & LEARNING OBJECTIVES

Multi-tank process simulation for batch processing and liquid transfer
Sequential control with step logic, interlocks, and safety conditions
Ratio control for proportioning multiple feeds
PLC/Relay-based automation with manual & automatic modes
Real-time monitoring and fault diagnosis
Industrial-grade construction emphasizing safety practices

RANGE OF EXPERIMENTS

Sequential filling, mixing, and transfer operations
Interlock-based step control and safety logic
Ratio control of multiple input streams
Manual vs automatic operation comparison
Flow/level deviation analysis and correction
PLC/Relay logic verification and troubleshooting

GENERAL

- Application: Sequential & Ratio Control Training for Process Automation
- Mounting: Floor-mounted mobile trainer
- Safety: Interlocks, regulated air supply, pressure-rated components, proper earthing