IMI 117 UNIVERSAL PROCESS CONTROL TRAINER

OBJECTIVE

To demonstrate wide range of experiments, applications and advanced control techniques using industry standard instrumentation and controls.

 

FEATURES

  • DCS control
  • MODBUS communication
  • SCADA software
  • Manual tuning and Auto tuning
  • Patch board configurable experiments
  • Facility to introduce external controller
  • SS wetted parts
  • Inbuilt compressor and plunger pump with VFD
  • Study of I/P, DPT, control valve, valve positioner
  • Study of rotameter, orificemeter, venturimeter
  • Temperature, flow, level, pressure control
  • On-off, P, PI, PID control, PLC control
  • Open loop tuning by process reaction curve
  • Closed loop tuning by Zigler Nicholas method
  • Stability analysis by Bode plot
  • Cascade, Feed-forward and Ratio control
  • Three element control and interactive control

SETUP

Universal Process Control Trainer resembles a typical small industrial process plant with different processes and parameters. The plant is controlled using DCS control (Hybrid controller) with SCADA software for supervisory control systems. A jack plug and socket patch board provided at the interface of the process facilitates configuration of different experiments and allows user to develop and test own control strategies. The patch board also allows direct access to transmitters and control elements enabling user to connect external controllers, PLCs

& DCSs. The product layout is designed to educate, train and develop the user to cover various aspects of process control. User can configure the product from study of basic components to advanced study of complex process control loops using advanced DCS control.

More than 25 different experimental configurations are incorporated to support the study. The product allows user to experience the feel of physical use of industrial components and processes, routing the flow for intended configuration and observing the process controllability.

  • Heating tank module consisting of Heating tank, Heater, RTD sensors, heating control unit and Piping.

 

  • Control panel module with DCS controller, power supply units, push buttons and patch board.

 

  • I/P converter module with I/P converters, pressure regulators and pressure gauges.

 

  • Water supply module consisting of plunger pump, centrifugal pump, water supply tank, rotameter, VFD for plunger pump, float switches, solenoid valve and piping.

 

  • Control valve module consisting of two pneumatic control valves, valve positioned and position transmitter

 

  • Process tanks module consisting of process tank (SS) with pressure transmitter, level tank with level transmitter and

interconnected piping.

 

  • Flow sensing elements consisting of orifice meter, venturimeter and DP transmitter.

 

  • Air supply module consisting air compressor These modules and components are mounted on stand-alone type structure and interconnected with valves and piping.

 

Along with MNC grade controllers and transmitters, an industrial grade SS used for wetted parts increases reliability of the product manifold

 

RANGE OF EXPERIMENT

 

Study of component basics

  1. Study of I/P : Input-output, Calibration
  2. Study of DP transmitter: Input /output
  3. Study of control valve characteristics: Valve coefficient and control valve characteristics

 

  1. Study of valve positioner: Input/output

 

Study of flow measuring devices

  1. Study of Rotameter: Calibration
  2. Study of Orifice meter: Coefficient of discharge
  3. Study of Venturi meter: Coefficient of discharge

 

Interacting and non interacting study

  1. Study of interacting system: Step response
  2. Study of non interacting system: step response

 

Single loop feedback control PID control, tuning, Stability of following processes

  1. Temperature control of direct heating process
  2. Flow control of pump outlet
  3. Flow control of process outlet
  4. Level control by inlet flow manipulation using pneumatic valve
  5. Level control by outlet flow manipulation using pneumatic valve
  6. Level control by inlet flow manipulation using Plunger pump
  7. Pressure control of closed tank (Air)
  8. Pressure control of closed tank (Water)

 

Multi-loop control

  1. Cascade control (Level + Flow)
  2. Cascade control (Temperature + Flow)
  3. Cascade control (Level + Pressure)
  4. Feed forward control (temperature)
  5. Feed forward + Feedback control (Level)
  6. Ratio control (Flow)
  7. Three element control (Level)

 

Multi input multi output control

  1. Pressure and Level control (Interactive loops)
  2. Level and Flow control (Interactive loops)

 

Study of PLC

  1. PLC Study and control

 

 

SOFTWARE

 

Set up is supplied with Hybrid control designer software and Wonderware in touch SCADA Software package (64 tags) which helps in learning basics of SCADA programming. The software can be operated in development and runtime mode. The experiments are conducted in Runtime mode and the engineering can be viewed / modified in Development mode. The software is easy to use, flexible & scalable with features like Data access, trend plots, Data logging, Printing, Data export.

UTILITIES REQUIRED

 

Electric supply Provide 230 VAC +/- 10V (16A), 1 ph, electric supply with proper earthing. (Neutral –

Earth voltage less than 5 VAC)

5A, 3pin socket with switch (3No.)

16A, 3pin socket with switch (1No.)

 

Water supply

 

Continuous, clean and soft water supply @100 LPH with suitable drain arrangement.

Computer IBM compatible, standard configuration with USB port for Hardware lock. Monitor: Screen resolution 1280×1024. Space L4000 mm x W3000 mm x H2000 mm

 

Support table

Size: 800Wx800Dx750H in mm for computer

TECHNICAL SPECIFICATIONS

Product & Code Universal Process Control Trainer & IMI 117
Type of control DCS and SCADA
Control unit Hybrid controller, Make Honey well, Model HC900, AI 8, AO 4, DI 16, DO 16, Control loops 8 with
Communication RS232, RS485, Ethernet
Software packages DCS: Hybrid Control Designer
Temperature sensor Make Radix, RTD, PT100, Range 0-100 deg.C, 2Nos
Temperature transmitter Make ABUSTEK, PT100, Type 2 wire, Range 0-100 deg.C, Output 4-20mA, 2Nos
Flow transmitter Make Yokogawa, DPT, Type 2 wire, Range 0–200 mm H2O, Output 4–20 mA, Sq. root
Level transmitter Make Yokogawa, DPT, Type 2 wire, Range 0–500 mm H2O, Output 4–20 mA, Linear
Level transmitter Make Wika, GPT, Type 2 wire, Range 0–600 mm H2O, Output 4–20 mA
Pressure transmitter Make Wika, GPT, Type 2 wire, Range 0–2.5 bar, Output 4–20 mA
Position transmitter Type Electronic, 2 wire, O/P 4–20mA
I/P converter Make Control Air Inc., Input 4-20mA, Output 3-15 psig (2Nos)
Heating control Proportional power controller (SSR), Input 4-20 mA
Heater Type Electrical 2 coil, Capacity 3 KW
Rotameter Make Eureka, 40-400LPH
Solenoid valves Make Avcon Controls, Type 2/2way normally closed, 1/4"BSP, water(2Nos)
Control valve Make Pneucon Valve, Type: Pneumatic, Size:1/2", Input: 3–15psig, Linear & Equal % (2Nos)
VFD Input single phase 200VAC, 1.1A, output AC3 phase
Pump Make Kirloskar, Fractional horse power, type centrifugal
Diaphram pump Make SITC Spanish, Positive displacement Diaphram pump, Cap 200Lph
Compressor Make ELGI, 1 Hp,3.8CFM, 10 kg/cm^2 with 45 lit inbuilt tank receiver
Overall dimensions 1150mmL x 800mmW x 1900mmh

The whole setup is well designed and arranged in a good quality painted structure.

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