PLC Based Process Control Trainer
(CT-023)

1.Main tank, 2.Middle tank, 3.Upper tank, 4.Electric heater, 5.Solenoid valves, 6.Flowmeter, 7.Forced air water cooler, 8.Needle valve, 9.Main control and display board, 10.Pressure and level sensors, 11.Temperature sensor

  • Familiarization with the operation and function of different instrumentation
    (including sensors and valves) through a real industrial process.
  • Methods of industrial process control using PLC or integrated software.
  • Investigating different methods to control system parameters including:
    • Level control
    • Temperature control
    • Pressure control
    • Flow control
  • Writing a PLC program to control an industrial process.
  • Manipulating system conditions and parameters using control devices. and disturbances.
  • Learning about the difference between open loop control system and closed loop control system.
  • Tanks
    • Main tank
      • Length x Width = 800 x 294 mm
      • Effective height =160 mm
    • Upper tank
      • Inner diameter = 154 mm
      • Effective height = 415 mm
    •  Middle tank
      • Inner diameter = 190 mm
      • Effective height = 245 mm
  • Pump
    • Operating range: 5-50 L/min
    • Operating pressure: 10 bar
    • Voltage: single-phase 1 x 230 V / 50 Hz,
  • Valves
    • Solenoid valve
      • Max. Allowable pressure: 16 bar
    • Needle valve
      • Multistep
      • Diameter: ½ inch
    • Ball valve
      • Diameter: ½ inch.
    •  Relief valve
      • Pressure: 0 to 5 bar.
      • Diameter: ½ inch
  • Electric heater
    • Voltage: 220-volt.
    • Power: 400 watts.
  •  Sensors
    • Pressure sensor
      • input Pressure gauge: 6.0 bar.
      • Nominal pressure abs.: 6.0 bar.
    • Level sensor
      • Range: 49.2” (1.25m).
      • Supply voltage: 24 VDC (loop).
      • Consumption: 0.5W.
    • • Temperature sensor (PT100)
      • Probe Length: 2-6 inch.
    • Flow sensor
      • range : 50 L/m.
  • PLC based process control trainer- (CT - 023).
  • BEDO Software + USB cable.
  • Hard copy user manual
  • Laboratory PC.

PLC – based process control trainer is designed to provide a practical training on controlling an industrial process using two methods either through BEDO software or using PLC unit. The trainer is capable of presenting process control real malfunctions, with realistic dynamic behavior and instabilities. The trainer demonstrates the methods of controlling the four main parameters found in any industrial process namely, pressure, temperature, flow and level.

                                     
  • The trainer is a stand-alone unit which features a system setup for an industrial process and the trainees can observe and monitor the system operation and behavior during the training.
  • The system setup consists of:
    • 3 tanks (lower , middle , upper)
    • Water pump
    • solenoid valves
    • Forced air cooler
    • Temperature sensors
    • Level transducer
    • Relief valve
    • Electric heater
    • Pressure transducer
    • Needle valve
    • Ball valve
    • Main control board
    • HMI touch screen
  • At the beginning of the process the user should select between 5 operation modes using HMI touch screen.
  • There are 5 modes of operation:
    • Manual Mode :
      • In this mode the user can change the statues of all of the actuators (ON/OFF) through the HMI touch screen , and also observe the sensors readings from BEDO Software.
      • the system is fully protected against any error to protect the main component of the system
    • Flow Control Mode :
      • The user can select this mode from the HMI touch, then select the required flow set point.
      • The system is automatically start the process cycle using PID control.
      • The user can also make a disturbances to the system through the hmi touch screen and observe the behavior of the system to maintain the flow set point.
    • Level Control Mode :
      • The user can select this mode from the HMI touch, then select the required level set point.
      • The system is automatically start the process cycle using PID control.
      • The user can also make a disturbances to the system through the HMI touch screen and observe the behavior of the system to maintain the level set point.
    •  Pressure Control Mode :
      • The user can select this mode from the HMI touch, then select the required pressure set point.
      • The system is automatically start the process cycle using PID control.
      • The user can also make a disturbances to the system through the HMI touch screen and observe the behavior of the system to maintain the pressure set point.
    •  Temperature Control Mode :
      • The user can select this mode from the HMI touch, then select the required temperature set point.
      • The system is automatically start the process cycle using PID control.
      • The user can also make a disturbances to the system through the hmi touch screen and observe the behavior of the system to maintain the temperature set point.
  •  The pump is operated and the water is pumped from the lower tank to the upper tank up to a certain level.
  • Pump is connected to an inverter which used to control the pump speed, while pump feed rate can be monitored and controlled using a flowmeter.
  • The upper tank is provided with a built-in electric heater to start heating the water to a pre-set temperature value.
  • Upper tank is equipped with temperature , level and pressures sensors to measure the tank parameters and display it on HMI touch screen and Bedo Software
  • Upper tank is equipped with a relief valve to release the excess pressure to the outside ambient air.
  • Opening the solenoid valve between the upper and middle tanks , the water will flow down to the middle tank passing through the cooler to be cooled.
  • Temperature and flow sensors are attached to the middle tank to measure level and temperature of the water inside the tank and these values are displayed on HMI touch screen and Bedo Software.
  • A needle valve is used to transfer water from the upper to the middle tank manually while controlling the water flow rate.
  • If the temperature inside the middle tank is not equal to a pre-set value ; an electrical signal is sent to certain solenoid valves in the system to allow water to return back to the cooler to be cooled again until the required temperature is reached.
  • A ball valve is used to transfer the water from the middle to the lower tank.
  • Process parameters are displayed on HMI touch screen and Bedo Software
  • A schematic diagram of the system process is printed on the front panel for better understanding of the system operation and sequence.
  • All tanks and piping elements are made of transparent material to provide better observation of the liquid inside.
  • The system is equipped with solenoid valves for a precise control of water flow according to the system requirements.
  • Software provides the ability to monitor the system and display its values.
  • An emergency switch, ON/OFF switch are included in the main control panel.