Dept.

of Electronics & Instrumentation EI 707: Process Control Laboratory

Experiment No: 1
Date

FAMILIARIZATION OF LEVEL PROCESS STATION

Aim:
To familiarize with the level process station.

System Overview:
The Level process station can be invariably classified under three heads i.e.,
I. The Level Process Mainframe
II. The PID controller
III. Process Control Software

The Level Process Mainframe

The mainframe is a metallic structure mounted on open platform. It consist of a bottom
plate houses the reservoir tank, motor and piping. A frame contains orifice plate, flow
transmitter. I/P convertor, control valve, process tank and a cabinet. The cabinet accommodates
the multi-output DC power supply, over range detection and cut off system and inlet socket for
AC mains.

Components Identification:

Sl. No: Component Name

1. Pressure Regulator
2. Pneumatic Control Valve
3. Rotameter
4. Centrifugal Pump
5. Hand Valve (Hv3)
6. Electro Pneumatic Converter
7. Process Tank
8. Reservoir Tank
9. Over Flow Tank
10. Multi Output Dc Power Supply
11. Panel Meter
12. Level Transmitter
13. Hand Valve Hv3
14. Control Panel

Pressure Regulator:
Source : PLACKA Instruments & Controls.
Maximum Input : 18kg/𝑐𝑚2 .

College of Engineering Kidangoor

Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory

Input Signal : for PRI: 0 to 2.5 Kg/𝑐𝑚2 .

Output : 0-2.1Kg/𝑐𝑚2 .
Special Features : Air Regulation, Air Filtering.

Pneumatic Control Valve :

Make : RK Valve (Globe)
Type : Air to open
Flow Rate : 500/1000LPH (Max.)
Trim Mat. : SS316
Characteristics : Equal %
Body Mat : CS Body
Spring Range : 0.2 – 1Kg/cm
End Conn. : ¾” Flanged.
Medium : Water/Air.
Valve Action : Air to open.

Rotameter:
Source : TELELIN
Range : (100-1000)LP
End Conn. : ¾” Flanged.

Pump:
Source : U.P.National Manufacturers Ltd.
Model : TULLU-80?TUF3
RPM : 6500
Voltage : 220/230 Volts AD/DC
Discharge : 800 (L.P.H)

Electro Pneumatic Convertor:

Source : WATSON SMITH/ELECTROTECH
Model : I/P 315 TD-12
Inputs Air : 20 PSI constant pressure.
Current Signal : 4 to 20mA at +24V DC
Output : Pneumatic Signal 3 to 15 psi.

Process Tank:
Source : Self Max. Water
Capacity : 35 litres
Body Mat : Fibre

College of Engineering Kidangoor

Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory

Reservoir Tank:
Source : Self
Capacity : 45 liters
Body : MS with fiber coating

Over Range Detection System:

Source : Self
Modules Used : Loop ALM
Input : 0–5V

Multi Output DC Power Supply:

Input : 230 VAC / 50 Hz
Outputs : +24 V DC, 2 A
+5 V DC, 3 A
+12 V DC, 200 mA
-12 V DC, 200 mA

Panel Meter:
Source : MECO
Inputs : 0 – 20 mA
0 – 200 mA
Level Transmitter:
Make : Switzer / Encardio Rite / ABB
Range : 0 – 800 mmwc
Output : 4 – 20 mA, 2 – wire system
Type : RF Capacitance

PID Controller
When all three control effects proportional, integral and differential are combined
together, we obtain the benefits of each control action and more nearly, duplicate action of a
good human operator on a control application. A three mode controller contains the “stability” of
proportional control and the “ability” to provide an immediate correction for the magnitude of a
disturbance because of rate control. In this trainer, computer acts as a PID controller. PID
controller is comprised of two units.
i. IBM PC
ii. VAD-103 / VAD-104 (Add-o AD/DA converter board)

VAD-104 Data Acquisition Board :

VAD-104 is a high performance ADD-ON Data Acquisition board for the IBM
Compatible PC/XT/AT pluggable onto printer port in the PC.

College of Engineering Kidangoor

Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory

The boars incorporates with 8 single ended analog inputs through 12 bit ADC, two
channels I to V converter and single channel of V to I converter. The SPP consist of control port,
Data port and Status port.

Analog Input Features :

There are two modes
• External Mode
• Internal Mode

The following details are suitable for both mode of operation.

The standard version of the VAD-104 has one CMOS multiplexer. Together, these input
multiplexer have analog input capabilities for 8channels of single ended input. These multiplexer
can handle upto + 10V signals without any damage. However the ADC can accept voltages in
the range-5V to +5V. Voltage above these limits will have no effects and ADC will read the
maximum value for those voltages and these over voltages will be indicated by an over range
bit, which could be read. The board features a single integrating ADC with a resolution of 2 bits
providing an least significant bit values of 1.22mV.

Analog Output Features:

The board contains single Analog output voltage within a range of -5V to +5V.

Single channels of DAC with 12 bit resolution of 2ms. Settling time is incorporated in
this board. The voltage range from 0 to 5V can be given to the input of V to I converter by
strapping jumper J4 to get the current Output of 4-20mA,which is terminated at the connector.
The 12 bit resolution provides a least significant bit values of 2.44mV.

ADC:
The data should be read in at addresses 0B, 03, 0F. Data at 0b forms the first lower byte,
at 03 forms second lower byte & data at 0F forms the higher order byte. The ADC is se bipolar
operations. The polarity of the input is indicated by a polarity bit. So for an analog input of 0 to
+5V, a digital values of 0 to FFF is available at the ADC output with sign bit set to 1. an
analog output of 0 to -5V a digital value of 0 to FFFH is available at the ADC output with bit
reset to 0.
The ADC can be operated in single ended mode only. In single ended mode CH1 to CH8
be used.
The following steps should be followed to read error free data from ADC.
1. Select the channel by writing control word in MUX.
2. Read higher byte of ADC port. Check for status, if status is high repeat same step.
Otherwise go to next step.

College of Engineering Kidangoor

Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory

3. If the status is low read the status bit once again. If it is low, repeat the same step.
Otherwise go to next step.
4. If the status is high read the status bit once again. If it is high, repeat the same step
again. Otherwise go to next step.
5. If the status is low the data is valid. Now read the data check for over range bit. If
it is 1 the input is out of range and the program can be terminated displaying error
message. Otherwise go to next step.
6. Check for sin bit, if the bit is set it represents the input is negative. If the bit is
zero the input is positive.
7. Now read the higher order byte and shift it toward left through 4bit. Read second
lower byte then read first lower byte & shift towards right by 4bit then add all the
three to get 12 bit digitized value of the analog input.

Digital Output:
For 8-bit TTL output data lines, you must write 8-bit (0-FF) data in address 0X0A.

Digital Data Input:

To get 8 bit digital input you must read two ports. First port for LSB and second port for
MSB. Read second port (higher) and shift it towards left by 4 bits and read lower byte and with
higher to get 8 bit output.

Specifications:
A/D channel :
Input Range : Bipolar ±5V
Input Channels : 8 single ended
Accuracy : ±0.8% max at 25 °C
Input Impedance : > 10 mega Ohms.
Conversion time : 30 conversions per second
Resolution : 12bits

D/A channel:
Output Range : Bipolar ±5 V
Output Channels : 1
Accuracy : 0.02% max. at 25 °C
Settling time : 2 μs Max
Resolution : 12 bits

V to I section:
Input Range : 0–5V
Output : 4 – 20 mA

College of Engineering Kidangoor

Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory

O/P Impedance : 500Ω (Max)

I to V section:
Input Channels : 2 (VAD-104)
Input Range : 4 – 20 mA
Output : 0–5V
Digital Output : 8 TTL output lines
Digital Inputs : 8 TTL input lines

Process Control Software

Process control Software is an indigenous software designed by our in-house R&D for
level process station. The software package for level control application is very powerful,
general purpose packagewhich measures the process variables, displays it on the screen and
issues control action to the controller (pneumatic control valve).

The software is organised to explain all the control actions available via ON/OFF control,
proportional control (P), proportional plus integral control (PI), proportional plus derivative
control (PD) and proportional plus integral plus derivative control.

Some of the key features of the software are,

- User feedable process parameters.
- Facility to store the data being processed as a separate file on the disk which can
be used for future analysis.
- A complete display of the process flow chart with animation.
- Display all the process parameters both numerically and graphically.
- Simultaneous graphical display of both process variable and controller output.
- Magnify (zoom) and display the process variable in the proportional band or Dead
band.
- Support to take up printouts of the processed data on a centronic printer.
- Convert the stored data to “WordPad” supported format to study the behavior of
the process.
- Analyze the stored data.
- Dynamically shift set point and thereby disturb the process.
- Tune control parameters for PID.
- To perform a historical trend of the variable.
- Off-line simulation of process variable.
- Real time simulation using waveform generator.

Result:
Familiarized with the level process station.

College of Engineering Kidangoor

Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory

College of Engineering Kidangoor