SINGLE LOOP LEVEL CONTROL TRAINER – IES-PCI-404
The Single Loop Level Control Trainer is designed for academic and industrial training to demonstrate feedback-based level control principles in process systems. The trainer enables detailed study of ON–OFF, P, PI, PD and PID control actions, along with manual and automatic tuning, open-loop and closed-loop response analysis, and transient behaviour. The system supports integration with external PID controllers, PLCs, and DCS systems, making it suitable for advanced experimentation. Mounted on a robust MS powder-coated mobile frame, the trainer ensures safety, durability, and ease of use in laboratory environments.
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
MAECENAS IACULIS
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ADIPISCING CONVALLIS BULUM
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