PLC Based Process Control Trainer
(MPC106)

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
  • Investigating different methods to control system parameters including:
    • Level control
    • Temperature control
    • Pressure control
    • Flow control
  • Writing a PLC program to control an idustrial 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 = 370 mm
    • Middle tank
      • Inner diameter = 190 mm
      • Effective height = 245 mm
  • Pump
    • Max. Head = 20
    • Flow Rate = 90 L/M
    • Voltage : 230V - 50HZ.
  • Valves
    • Solenoid valve
      • Max. Allowable pressure: 16 bar
    • Needle valve
      • Multistep
      • Diameter: ½ inch
    • Relief valve
      • Pressure: 0 to 5 bar.
      • Diameter: ½ inch
  • Electric heater
    • Voltage: 220-volt.
    • Power: 400 watts.
  • Sensors
    • Pressure sensor
      • Range: 6.0 bar.
    • Level sensor
      • Range: 800 mm.
      • Supply voltage: 24 VDC (loop).
    • Flow sensor
      • Range : 25 L/m.
  • PLC based process control trainer (MPC106)
  • Hard copy user manual
  • BEDO Software
  • Tia portal v17 license.

PLC – based process control trainer is designed to provide a practical training on controling an industrial process using PLC with HMI, with the using of BEDO software where the user can monitor the process. the trainer is capable of presenting real process control 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
    • Main control board
    • HMI touch screen
  • At the begining 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 then select the required flow set point.
      • When the process is started the system will control the process using PID control.
      • The user can also make a disturbance to the system through the HMI and observe the behavior of the system to try to maintain the flow set point.
    • Level Control Mode :
      • The user can select this mode from the HMI then select the required level set point.
      • When the process is started the system will control the process using PID control.
      • The user can also make a disturbance to the system through the HMI and observe the behavior of the system to try to maintain the level set point.
    • Pressure Control Mode :
      • The user can select this mode from the HMI then select the required pressure set point.
      • When the process is started the system will control the process using PID control.
      • The user can also make a disturbance to the system through the HMI and observe the behavior of the system try to maintain the pressure set point.
    • Temperature Control Mode :
      • The user can select this mode from the HMI then select the required temperature set point.
      • When the process is started the system will control the process using PID control.
      • The user can also make a disturbance to the system through the HMI and observe the behavior of the system to try 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 pressure and flow sensors to measure the tank parameters and display it on HMI touch screen and Bedo Software
  • Upper tank is equipped with a releif 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 sensor is attached to the middle tank to measure water temperature inside the tank and these values are displayed on HMI and Bedo Software.
  • A needle valve is used to transfer water from the upper to the middle tank manually while controlling the pressure.
  • In the mixing process: there is a cooling sequence not a certain valve.
  • Process parameters are displayed on HMI 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 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.