Universal Process Control Trainer…Code 330

Objective
To demonstrate wide range of experiments, applications and
advanced control techniques using industry standard
instrumentation and controls
Features
 DCS control
 MODBUS communication
 SCADA control
 Manual tuning and Auto tuning
 Patch board configurable experiments
 Facility to introduce external controller
 SS wetted parts
 Inbuilt compressor and Diaphram pump with VFD
 Study of I/P, DPT, control valve, valve positioner
 Study of rotameter, orifice meter, 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 Code 330
resembles a typical small industrial process plant
with different processes and parameters. The plant
is controlled using DCS control (Hybrid controller)
with specially developed 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.

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Universal Process Control Trainer…Code 330
Setup subassemblies
Heating tank module Control panel & I/P converter
1) Heating tank module consisting
of Heating tank, Heater, RTD
sensors, heating control unit and
Piping.

2) Control panel module with DCS

controller, power supply units,
push buttons and patch board.

3) I/P converter module with I/P

converters, pressure regulators
and pressure gauges.

Water supply module Control valve module

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

5)Control valve module consisting

of two pneumatic control valves,
valve positioned and position
transmitter

Process tanks module VFD for plunger pump

6) Process tanks module
consisting of process tank (SS)
with pressure transmitter, level
tank with level transmitter and
interconnected piping.
7) Flow sensing elements
consisting of orifice meter,
venturimeter and DP transmitter.
8) 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.

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Universal Process Control Trainer…Code 330
Range of Experiments
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
4. Study of valve positioner: Input/output
Study of flow measuring devices
5. Study of Rotameter: Calibration
6. Study of Orifice meter: Coefficient of discharge
7. Study of Venturi meter: Coefficient of discharge
Interacting and non interacting study
8. Study of interacting system: Step response
9. Study of non interacting system: step response
Single loop feedback control
PID control, tuning, Stability of following processes
10. Temperature control of direct heating process
11. Flow control of pump outlet
12. Flow control of process outlet
13. Level control by inlet flow manipulation using
pneumatic valve
Software
Set up is supplied with Hybrid control designer
software and specially developed supervisory
control software. The hybrid control designer
software can be used for development of new FBD
as per user’s requirements and can be downloaded
for execution.
The supervisory control software is easy to use,
flexible & scalable with features like Data access,
trend plots, Data logging, Printing, Data export.
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14. Level control by outlet flow manipulation using
pneumatic valve
15. Level control by inlet flow manipulation using
Plunger pump
16. Pressure control of closed tank (Air)
17. Pressure control of closed tank (Water)
Multi-loop control
18. Cascade control (Level + Flow)
19. Cascade control (Temperature + Flow)
20. Cascade control (Level + Pressure)
21. Feed forward control (temperature)
22. Feed forward + Feedback control (Level)
23. Ratio control (Flow)
24. Three element control (Level)
Multi input multi output control
25. Pressure and Level control (Interactive loops)
26. Level and Flow control (Interactive loops)
Study of PLC
27. PLC Study and control
PSP330
Universal Process Control Trainer…Code 330
Specifications
Product Universal Process Control Trainer (Code 330)
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 package 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 Euraka, 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

Our other products

1. Temperature control trainer (SCADA) 9. First and second order system
2. Flow control trainer (SCADA) 10. Temperature measurement
3. Level control trainer (SCADA) 11. Flapper nozzle system
4. Pressure control trainer (SCADA) 12. Multi variable control trainer
5. Cascade control trainer: Level + Flow (SCADA) 13. Interacting and non interacting system
6. Multi process trainer: Level, Flow, Cascade, Ratio 14. DCS trainer (Hybrid controller)
& FF 15. Level measurement
7. Flow measurement 16. Universal process control trainer
8. Control valve characteristics

Specifications subject to change without notice

APEX INNOVATIONS PVT. LTD.
E9/1, MIDC, Kupwad, Sangli - 416436 (MS) India Telefax: +91 233 2644098/2644398
Email: support@apexinnovations.co.in Web: www.apexinnovations.co.in