Controls Lab

Lab Report Number: 06

Study and plotting Characteristic Curve for Level

Control Training System
Section: ME-14 (C)

Name CMS ID
Muhammad Ahmad Nadeem 416175
Objectives: -

• To study the relationship between fluid level and Sensor Voltage (signal) reading.

• To plot the characteristic curve between the Fluid level and Sensor Voltage.

• To learn about the various reasons for error between fluid level increasing and decreasing
values.

• To learn about LVDT (Linear Variable Differential Transformer).

Apparatus: -

Level control training system

Procedure: -

1) First, the circuit was constructed, and the control system was powered.

2) Any excess water in the process tank was removed firsthand before starting the experiment by
opening the drain valve.

3) Then the voltage was applied to the water pump driver to turn on the water pump.

4) Every value of the voltage, after an increasing interval of 2cm rise in water level, was measured
through the sensor by connecting the multimeter to the output of the level sensor interface.

5) After that, the same process was done but in the reverse direction ie decreasing the water level.

6) Finally, a graph was made between the Sensor Voltage and the level readings for both rise and
fall in the water level.

Circuit Representation: -

Circuit diagram for Level control training system

 Readings:
For Increasing Temperature: -
Voltage data for increasing and decreasing flowrate

S# Water level (cm) Voltage forward (v) Voltage backward (v)

1 2 -1.081 -0.786
2 4 -1. 085 -0.780
3 6 1.162 1.467
4 8 3.3 4.081
5 10 5.69 6.436
6 12 8.367 8.98
7 14 8.841 9.61

Graph: -
Graph for increasing and Decreasing Voltage
12
Voltage (V)

10

0 2 4 6 8 10 12 14 16
-2
Water level (cm)

Forward Voltage Backward Voltage

Graph for increasing and decreasing voltage

Applications

A LVDT training system has several real-world applications across industries.

• Chemical Processing: Controls and monitors fluid levels in reactors and mixing tanks to
ensure safe and efficient chemical reactions.
 • Food and Beverage Manufacturing: Maintains levels in mixing and fermentation tanks to
ensure consistent product quality and efficient production processes.

• Pharmaceutical Manufacturing: Controls liquid levels in reactors and formulation tanks to

ensure precise ingredient proportions, which is crucial for product consistency and regulatory
compliance.

• Power Generation: Regulates water levels in boilers and cooling systems, which is essential for
stable operation and safety in power plants.

Discussion:
In this lab experiment, we observed the behavior of an LVDT (Linear Variable Differential
Transformer) concerning changes in liquid level. As the liquid level increased, a corresponding rise in
voltage was detected by the Digital Multimeter. This indicated a clear relationship between the fluid
level and the output voltage signal. However, when the liquid level decreased back to the setpoint,
hysteresis was observed, resulting in a delayed or non-linear response from the LVDT system.

This hysteresis effect can be attributed to mechanical factors such as elastic deformation, system
inertia, and internal friction within the system. Additionally, other factors like temperature
variations, sensor calibration errors, and non-linearities in the voltage response may have
contributed to the discrepancies. These factors highlight the system's sensitivity to external
conditions and mechanical limitations.

The experiment also demonstrated that while the LVDT provides reliable measurements for
increasing fluid levels, the slight delay during level reduction emphasizes the importance of
accounting for hysteresis when designing or implementing fluid-level control systems.

Conclusion
In conclusion, the experiment successfully demonstrated the relationship between fluid level and
output voltage in a fluid-level control system. As the fluid level increased, a corresponding rise in
voltage was observed, confirming a generally linear correlation between these two quantities.
However, some errors, such as hysteresis and mechanical inertia, were noted, causing the system to
lag behind the input changes during level reduction.

Despite these limitations, the experiment provided valuable insights into the performance of LVDT
sensors in fluid-level measurement. Understanding these factors can help in optimizing fluid-level
control systems for better accuracy and efficiency in practical applications.
Safety Precautions
• Personal Protective Equipment (PPE): Ensure that all lab personnel wear appropriate PPE, including
safety goggles, lab coats, gloves, and closed-toe shoes to protect against chemical splashes, electrical
hazards, or mechanical injuries.
• Equipment Inspection: Regularly inspect all lab equipment and apparatus for any signs of damage or
wear. Report any defects immediately and ensure that faulty equipment is taken out of service until
repaired or replaced.
• Emergency Procedures: Familiarize all lab members with emergency procedures, including the location
of fire extinguishers, eyewash stations, safety showers, and emergency exits. Conduct regular safety
drills.
• Hazardous Materials Handling: Follow proper procedures for handling, storing, and disposing of
hazardous materials, such as chemicals and solvents. Use fume hoods and ventilation systems as
needed.
• Electrical Safety: When working with electrical circuits and equipment, ensure that power sources are
disconnected before making connections or adjustments. Avoid contact with exposed wires and use
insulated tools.
• First Aid Kit: Maintain a well-equipped kit in the lab and ensure lab personnel are trained in basic first
aid procedures. Display emergency contact numbers and locations prominently.
• Equipment Safety: Follow the manufacturer's guidelines and instructions for operating lab equipment
and machinery. Ensure that the equipment is properly grounded and that safety interlocks are
functional.
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