Description

IES-PCI-403

Single Loop Flow Control Trainer is an advanced industrial training system designed to demonstrate closed-loop flow control using PID controllers and industrial instrumentation.

This system enables students to learn flow measurement, control loop dynamics, tuning techniques, and process automation concepts, making it ideal for engineering colleges, process control laboratories, and industrial training institutes.

Technical Specifications

• Flow Measurement System – Industrial flow transmitter / flow meter with measurement range 0–1000 LPH, providing 4–20 mA output signal and operating on 24 V DC supply for continuous flow monitoring.
• Process Piping Network – Industrial ¾″ CPVC / ½″ stainless steel piping system equipped with ball valves and leak-proof fittings for realistic process flow experimentation.
• Centrifugal Pump Unit – ½ HP centrifugal pump operating on single-phase 230 V AC supply, designed for continuous liquid circulation within the process system.
• Process Reservoir (Sump Tank) – Storage tank constructed from stainless steel (1.5 mm) or polypropylene (5 mm) with 30-liter capacity for fluid storage and recirculation.
• Electro-Pneumatic Conversion System – E/P converter capable of converting 4–20 mA electrical signal into pneumatic output of 3–15 psi for pneumatic valve actuation.
• Air Supply System – Air compressor with 50 L tank capacity, discharge approximately 2 CFM, powered by 1–2 HP motor, operating on 230 V AC supply with working pressure 5–6 kg/cm².
• Electrical Power Supply – Industrial SMPS power supply converting 230 V AC input to 24 V DC output (4.5 A) for powering transmitters and control instruments.
• Air Preparation Unit – Filter–Regulator–Lubricator (AFR/FRL) assembly with pressure gauge and operating range 0–10 kg/cm² to ensure clean and regulated compressed air supply.
• Flow Monitoring and Control Instruments – Rotameter flow indicator (100–1000 LPH range) combined with PID controller supporting universal / 4–20 mA input and 4–20 mA output, displaying Process Value (PV) and Set Point (SP) for closed-loop control.
• Control Panel and Mechanical Structure – MS powder-coated electrical control panel with switches, indicators, DIN-rail terminals, organized cable tray wiring, and ½″ pneumatic control valve with equal percentage characteristic, mounted on a rigid MS floor-standing structure with heavy-duty caster wheels and locking brakes.

KEY FEATURES

• Hands-on training for P, PI, PD and PID loop control with real-time observation
• 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 practices

RANGE OF EXPERIMENTS

• ON–OFF flow control
• Closed-loop flow control using P, PI, PD and PID modes
• Manual vs auto tuning of PID controller
• Open-loop and closed-loop response comparison
• Transient response and stability analysis
• Pneumatic control valve behavior in flow regulation
• Integration with external PLC/DCS systems

GENERAL

• • Application: Flow Control Training for Process Control & Automation
  • Mounting: Floor-mounted mobile trainer
  • Safety: Proper earthing, regulated air supply, overflow protection, and electrical safety measures