Description

IES-PCI-404

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