Description

IES-PCI-404

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

This trainer enables students to learn liquid level 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

• Centrifugal Pump System – Surface-mounted centrifugal pump rated at ½ HP, operating on single-phase 230 V AC supply, used for continuous liquid circulation in the level control process setup.
• Level Measurement Tank – Transparent acrylic level tank with 10–15 liter capacity, designed for visual observation and study of liquid level variation.
• Process Piping Network – Industrial ¾″ CPVC / ½″ stainless steel piping system with ball valves and leak-proof fittings for reliable fluid flow and process simulation.
• Pneumatic Control Valve – ½″ industrial control valve with equal percentage flow characteristic, designed for precise level control using pneumatic actuation.
• Level Measurement Instrumentation – Level transmitter with measurement range 0–500 mm, providing 4–20 mA output signal and operating on 24 V DC supply (~100 mA) for continuous level monitoring.
• Flow Measurement Unit – Rotameter flow meter with measurement range 100–1000 LPH, glass tube or acrylic body construction with ½″ process connection.
• Air Preparation System – Filter–Regulator–Lubricator (FRL) unit with pressure gauge, operating range 0–10 kg/cm², ensuring clean and regulated compressed air supply.
• Level Switching and Signal Conversion System – Float-operated ON–OFF level switch for level detection and Electro-Pneumatic (E/P) converter converting 4–20 mA input signal to 3–15 psi pneumatic output.
• Electrical Power and Control System – 230 V AC to 24 V DC power supply (4.5 A) along with MS powder-coated electrical control panel equipped with switches, indicators, test points, PID controller on front fascia, and organized cable tray wiring.
• Air Supply and Mechanical Structure – Air compressor with 50 L tank capacity, 1–2 HP motor, operating on 230 V AC supply with working pressure 5–6 kg/cm², mounted on a floor-standing rigid MS structure with heavy-duty caster wheels and locking brakes.

KEY FEATURES

• Training on single-loop P, PI, and PID level control with real-time observation
• ON–OFF level control using float level switch
• Manual & Auto tuning for controller performance evaluation
• External PLC/DCS integration capability
• Robust MS frame with mobile design for laboratory flexibility
• Industrial-grade components ensuring realistic training

RANGE OF EXPERIMENTS

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

GENERAL

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