ME-339 Control Engineering Lab

Lab Report – 02

Introduction to
Level, Flow, Pressure and Temperature
Trainers & Modules

Submitted to
LE. Usman Ghani

Submitted by

Name Muhammad Talha Nouman

CMS ID 366197
Semester 5th
Section ME-13-C
Group

School of Mechanical & Manufacturing Engineering

National University of Science and Technology – Islamabad
 Control Engineering Lab

 Objectives
1. To introduce the different types of control training systems briefly
2. To learn about different components used in control systems
3. Interaction with pressure, temperature, flow and level control training systems

 Equipment
1. Pressure control training system
2. Flow control training system
3. Temperature control training system
4. Level control training system

 Theoretical Background

1- Pressure Control Trainer:

Pressure
PID Controller Control Panel
Sensor

Pressure
Gauge

Pump Driver

ON OFF
Float Switch
Controller

Process Tank Voltage

regulator

Rotameter

Sump Tank

Pump

Fig.1.1. Pressure Control Trainer

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Components of Flow Control Trainer

Pressure sensor interface
The output signals from pressure sensors are interfaced, amplified, conditioned, and converted
into useful data for monitoring, control, or data gathering systems using a pressure sensor
interface, which is a circuit or device.
Solenoid valve
A solenoid valve is an electromechanical device used to control the flow of various fluids,
such as liquids and gases, through a pipe or tubing system. It operates by using an
electromagnetic coil to generate a magnetic field, which, in turn, controls the movement of a
plunger or piston inside the valve.
Pressure gauge
Pressure gauge is a device used to measure pressure of a liquid inside a room or container.
1. On off controller
2. PIDsensor
3. Rotameter
4. Nonreturn valve
5. Float switch
6. Solenoid valve
7. Water pump driver
8. Process Tank

2. Flow Control Training System

Components of Flow Control Trainer
Water Pump Driver
A water pump driver is typically a component or device used to power and control a water
pump. Water pumps are mechanical devices designed to move water from one place to another,
such as from a well to a storage tank, or from a reservoir to a distribution system.
Motorized Valve
A motorized valve is a type of valve that uses an electric motor or actuator to control the
opening and closing of the valve. These valves are used in various applications across
industries to regulate the flow of liquids, gases, or other fluids through pipelines, ducts, or
systems.
Gate Valve: A gate valve is a type of valve used to control the flow of fluid through a pipeline.
It gets its name from the flat gate or wedge-shaped disc that is used to block or allow the flow
of the fluid.

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 Control Engineering Lab

Flow Control
PID Controller Sensor Panel

Float Switch

Pump Driver

Process Tank

ON OFF
Controller

Voltage
regulator

Motorized Valve

Rotameter

Sump Tank

Pump

Fig.1.2. Flow Control Trainer

ON OFF Controller
An On/Off controller is a simple type of control system used to regulate a process or a
system by turning a device, such as a valve or a pump, fully on or fully off based on a specific
setpoint or reference value. This type of controller operates in a binary manner, meaning it has
only two states: fully open or fully closed.
Process Tank
A process tank, also known as a processing tank or simply a tank, is a large container or
vessel used in industrial processes to store, mix, blend, react, or otherwise handle liquids,
gases, or solids.

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Hall Sensor
The Hall Effect refers to the generation of a voltage difference (Hall voltage) across a
conductor or semiconductor when it is subjected to a perpendicular magnetic field and an
electric current flow through it. This voltage is directly proportional to the strength of the
magnetic field.

Fig.1.3. Hall Effect Fig.1.4. Circuit Diagram

Graph. 1.1. Graph 1.2.

PID Controller
A PID controller is a widely used type of feedback control system in industrial and
automation applications. The term "PID" stands for Proportional-Integral-Derivative, which
are the three primary control actions or terms that the controller uses to maintain a desired
setpoint and regulate a process or system.
Proportional (P) Control: The proportional component of the controller responds to the
current error, which is the difference between the desired set point and the actual process
variable, proportional control alone can lead to oscillations and instability.
Integral (I) Control: The integral component takes into account the accumulated past errors.
It continuously sums the errors over time and multiplies them by a constant (the integral gain).

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Derivative (D) Control: The derivative component predicts future error by calculating the rate
of change of the error over time. It multiplies this rate of change by a constant (the derivative
gain). This component helps dampen the control system's response to sudden changes and
reduce overshoot, thus improving system stability.
Flow Sensor
A flow sensor is a device used to measure the rate of flow of a fluid, typically a liquid or
gas, as it passes through a specific point in a system or process. In this apparatus flow moves
a wheel placed in a magnetic field which produces an emf through which flow is control.
Float Switch
A float switch is a device used to detect the level of a liquid within a container or reservoir.
It consists of a buoyant float attached to an actuating mechanism. It is basically a digital signal
output. It moves up and down and when water level is high, it becomes short (Lever Ball
Mechanism).
Rotameter
A rotameter, also known as a variable-area flowmeter, is a device used to measure the flow
rate of a fluid within a closed system, such as a pipeline or tubing. It operates on the principle
of variable flow area, where the flow rate is directly proportional to the area of an internal
orifice through which the fluid passes. Rotameters are commonly used to measure the flow of
gases and liquids in a wide range of industrial, laboratory, and process control applications.

Fig. 1.5. Rotameter

Storage Tank
A storage tank (also known as sump tank) is a container designed for the purpose of storing
liquids or gases in a safe and secure manner. These tanks are used in various industries and
applications to store materials such as water, chemicals, petroleum products, liquefied gases,
and more.

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3. Level Control Training System

Fig.1.6. Level Control Trainer

Fig.1.7. Control Panel & CRO

CRO

Pump Driver

Solenoid
Valve Driver

ON OFF
Controller
Level Sensor
PID Controller 7
 Control Engineering Lab

Components of Flow Control Training System

LVDT (Linear Variable Differential Transformer)
An LVDT, or Linear Variable Differential Transformer, is a type of
electromechanical sensor used to measure linear displacement or position. It is commonly
employed in a wide range of industrial and scientific applications where precise and
accurate measurement of linear movement is required. LVDTs are known for their high
accuracy, reliability, and durability.

Fig. 1.8. Linear Variable Differential Transformer

Gear Pump: It is used to pump water into the graduated water tank.
2 Needle Valve: It is used to drain water in a slow manner and regulate it to achieve the
required level.
Drain Valve: It is used to drain water from the tank during emptying it or to get a specific
level.
Process Tank: It is a transparent tank having markings on it which is used to manually
measure the water level pumped into it.
Float Switch: It is a level sensor which detects the level of liquid in the tank acting as a
mechanical switch as the water level moves up and down.
Non-Return Valve: It is used to restrict water motion such that it allows water to move in only
one direction.
Strainer: It is used to filter out the larger unwanted suspended particles from water primarily
to protect the pump from any damage.
Level Sensor
A level sensor is a device used to measure and monitor the level of liquids, solids, or
granular materials in a container or a reservoir. Level sensors are employed in various
industrial, commercial, and consumer applications to ensure accurate and reliable control of

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liquid levels or material levels. They help prevent overflows, monitor inventory, automate
processes, and maintain safety in various systems.
Solenoid Valve Driver
A solenoid valve driver, often referred to as a solenoid driver or solenoid controller, is an
electronic or electromechanical device used to control and manage the operation of solenoid
valves. Solenoid valves are electromechanical devices that control the flow of fluids or gases
by opening or closing a valve when an electric current is applied to a coil (solenoid).
CRO (Cathode Ray Oscilloscope)
CRO stands for "Cathode Ray Oscilloscope." It is a widely used electronic test instrument
in various fields, including electronics, telecommunications, physics, and engineering. A CRO
is primarily used for visualizing and analyzing electrical signals and waveforms.

4. Temperature Control Training System

Condenser

Heater

Pump

In Out Valve

Process Tank

Fig. 1.9. Temperature Control Trainer

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 Control Engineering Lab

Temperature
Sensor

Digital PID
Controller

Pump Driver

Heater Driver

Auxiliary Driver
ON OFF
Controller

Fig. 1.10. Control Panel

PID Controller

Components of Temperature Control Training System

Condenser:
A condenser is a device used in various applications to condense or change the physical state
of a substance, typically a gas, into its liquid state by removing heat from it. Condenser is used
here to cool the water.
Heater:
A heater is a device used to produce heat to raise the temperature of room, liquid etc.
Temperature Sensor:
Temperature sensor is an instrument designed to measure temperature and convert the
temperature information into a usable electrical signal or digital output. Temperature sensors
are used in a wide range of applications, from monitoring and controlling industrial processes

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to measuring environmental conditions, ensuring food safety, and regulating the temperature
in electronic devices.
Auxiliary Control Driver:
An auxiliary control driver typically refers to a component or device used in control systems
and electronics to manage auxiliary or secondary functions within a larger system. It is not a
standardized term, and its specific meaning can vary depending on the context and the industry
in which it is used.
Heater Driver:
A heater driver is a component or device used to control and manage electric heaters. Electric
heaters are used in various applications to generate heat, and a heater driver is responsible for
controlling the power supplied to the heater elements to achieve the desired temperature or
heating level.
 On off controller
 PID sensor
 Non return valve
 Water pump driver
 Process Tank

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