NATIONAL UNIVERSITY OF SCIENCES
AND TECHNOLOGY, ISLAMABAD
CONTROLS ENGINEERING LAB
5th SEMESTER
NAME: MUHAMMAD ABDULLAH FAHEEM
CMS ID: 411819
SECTION: ME-14(A)
LAB INSTRUCTOR: LE USMAN GHANI
SCHOOL OF MECHANICAL AND MANUFACTURING
ENGINEERING
Contents
Objectives .............................................................................................................................................. 3
Equipment.............................................................................................................................................. 3
Theory .................................................................................................................................................... 3
Pressure Control Trainer ............................................................................ 3
Water Pump Driver: ....................................................................................................................... 3
Solenoid Valve Driver: ................................................................................................................... 3
ON-OFF Controller: ...................................................................................................................... 4
PID Controller:............................................................................................................................... 4
Rotameter: .................................................................................................................................... 4
Process Tank: ................................................................................................................................ 4
Sump Tank: .................................................................................................................................... 4
Water Pump .................................................................................................................................... 4
Flow Control Trainer ................................................................................. 4
Liquid Level Control Trainer ......................................................................... 5
Temperature Control Trainer ........................................................................ 6
Conclusion .............................................................................................................................................. 7
Safety precautions............................................................................................................................. 7
LAB #2
Introduction & component description of (Level, Flow,
Pressure and Temperature) trainers and modules
Objectives
Acquire a comprehensive understanding of fundamental control engineering concepts,
particularly in relation to level, flow, pressure, and temperature measurement systems.
Investigate the Hall Effect and its applications in flow measurement technologies.
Understand the operating principles of a rotameter as a device for flow measurement.
Examine the operation and significance of motorized valves in regulating fluid flow
within various processes.
Explore the concept of tuning in control systems to optimize performance.
Equipment
Pressure Control Trainer
Flow Control Trainer
Liquid Level Control Trainer
Temperature Control Trainer
Theory
Pressure Control Trainer
Pressure control is an art that deals with the regulation of force of gases
or liquids within a system to keep them within a set desired level to uphold optimal safety,
consistent performance, and reliability in several industrial applications. A typical pressure
control trainer shall be constituted of the following components:
1. Flow Sensor/Hall Effect Sensor: This sensor measures flow rate by detecting changes in
the magnetic field caused by a rotating magnet within the flow meter. It converts these
magnetic changes into electrical signals, enabling precise monitoring and control of the
flow rate.
2. Water Pump Driver: Controls the operation of the water pump, regulating flow rates and
pressure within the system.
3. ON-OFF Controller: Simple control mechanism that switches devices on or off based on
set conditions, used for basic automation.
4. Process Tank: A container where the process fluid is held and managed, allowing for
various operations such as mixing or reaction.
5. Sump Tank: A storage tank that collects excess fluid, typically for drainage or
further processing.
6. Solenoid Valve Driver: Activates or deactivates solenoid valves to control fluid flow in
the system.
7. PID Controller: A more sophisticated control system that uses proportional, integral, and
derivative calculations to maintain desired process conditions with high precision.
8. Rotameter: A flow measurement device that indicates the flow rate of a liquid or gas
through a transparent tube.
9. Water Pump: A device that moves water through the system, ensuring adequate flow
and pressure for operations.
Figure 1 Pressure control trainer
Flow Control Trainer
Flow control refers to the process of managing the flow of a fluid or gas
within a system to maintain a set flow rate or quantity in order to achieve precision and
efficiency in material transportation during industrial processes. The flow control trainer
usually includes:
1. Water Pump Driver: Controls the operation of the water pump, managing flow rates
and pressure based on system requirements.
2. ON-OFF Controller: A basic control mechanism that turns devices on or off to
maintain desired conditions in the system.
[Link] Controller: A sophisticated control system that uses proportional, integral, and
derivative actions to maintain process variables at set points with high accuracy.
4. Process Tank: A container where fluids are processed, allowing for activities such as
mixing, heating, or reaction.
5. Flow Sensor: Measures the flow rate of liquids or gases, providing essential data
for monitoring and control.
6. Motorized Valve Control: Regulates the position of motorized valves to control fluid
flow precisely within the system.
7. Rotameter: A flow measurement device that visually indicates the flow rate of a liquid
or gas through a tapered tube.
8. Water Pump: A device that moves water through the system, ensuring consistent flow
and pressure for various operations.
9. Sump Tank: A reservoir that collects excess fluids, often used for drainage or
further treatment in the system.
Figure 2 flow control trainer
Liquid Level Control Trainer
Level control can refer to a regulation scheme of height or volume
of a liquid or granular material within a container or a system. Regulation helps in preventing
overflows or spills and underflows, which may be the causes of industrial process disruptions
or equipment damage. Level control ensures smooth operation, improves safety, and creates
efficiency for many industrial applications.
Level Sensor Solenoid valve control
Water pump driver ON-OFF controller
PID Controllers Rotameter
Water pump Process Tank
Sump Tank
Figure 3 level control
1. Level Sensor: Measures the liquid level or material height in a container for precise
monitoring.
2. Solenoid Valve Control: Regulates the opening and closing of valves using
electromagnetic mechanisms.
3. Water Pump Driver: Manages the operation of water pumps to control flow and
pressure.
4. ON-OFF Controller: A basic mechanism that toggles systems between operational and
non-operational states.
5. PID Controllers: Advanced controllers that optimize system performance using
proportional, integral, and derivative actions.
6. Rotameter: A device that visually indicates the flow rate of liquids or gases through a
tapered tube.
7. Water Pump: Facilitates the movement of water within the system to ensure consistent
operation.
8. Process Tank: Holds and processes fluids for mixing, heating, or chemical reactions.
9. Sump Tank: Collects excess fluid for drainage or further treatment.
Temperature Control Trainer
Temperature control in such systems involves the maintenance of heat either by initiating
heating or cooling; the aim is usually to achieve and maintain a set particular temperature. It
is crucial in many industries to ensure product quality and operational efficiency and safety
where close, precession temperature management prevents overheating, spoilage, or
degradation of performance.
1. Temperature Sensor: Detects and measures temperature changes for system
monitoring and control.
2. Solenoid Valve Control: Controls valve operations to regulate fluid or gas flow
based on temperature needs.
3. Heater: Generates heat to maintain or raise the temperature of the system.
4. ON-OFF Controller: Switches the heating or cooling system on or off based on
predefined temperature thresholds.
5. PID Controllers: Maintains precise temperature control by using proportional,
integral, and derivative mechanisms.
6. Rotameter: Measures and visually indicates the flow rate of liquid or gas in the
system.
7. Water Pump: Circulates water to aid in heating or cooling processes within the
system.
8. Process Tank: Holds fluid for thermal processing, such as heating or cooling
operations.
9. Sump Tank: Stores excess fluid from the system, often used for drainage or
recirculation.
Figure 4 temperature control trainer
Temperature Sensor Solenoid valve control
Heater ON-OFF controller
PID Controllers Rotameter
Water pump Process Tank
Sump Tank
Conclusion:
This lab provided an excellent background in instrumentation for measuring
several key process variables including level, flow, pressure, and temperature. We have gained
valuable insights into the application of the Hall Effect in flow measurement, as well as the
operating principles of a rotameter for effective flow monitoring. We have investigated the
operation of motorized valves and their essential function in controlling fluid flow in processes.
We finally addressed tuning in control systems, which is one of the crucial tasks in ensuring
that performance is indeed optimized to guarantee efficiency in operations.
Safety precautions
Regularly check lab equipment for damage; report defects immediately and remove
faulty items from service.
Follow proper procedures for the handling, storage, and disposal of hazardous
materials, using fume hoods and ventilation as necessary.
Ensure power sources are disconnected before working with electrical equipment,
avoiding contact with exposed wires and using insulated tools.
Maintain a stocked first aid kit and ensure personnel are trained in basic first aid.
Display emergency contact information prominently.
Adhere to manufacturer guidelines for operating equipment, ensuring proper grounding
and functional safety interlocks