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 Component Name Identification: Sl. No: 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/2. Input Signal : for PRI: 0 to 2.5 Kg/2. Output : 0-2.1Kg/2. 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. : Flanged. Medium : Water/Air. Valve Action : Air to open. Rotameter: Source : TELELIN Range : (100-1000)LP

End Conn. : Flanged. Pump: Soure: U.P.N ationa l Manuf acture rs Ltd. Model : TULL U80?T UF3 RPM : 6500 Volta ge : 220/2 30 Volts AD/D C Disch arge : 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 Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory College of Engineering Kidangoor

Reservoir Tank: Source : Self Capacity : 45 liters Body : MS with fiber coating Over Range Detection System: Source : Self Modules Used : Loop ALM Input : 0 5 V 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. Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory College of Engineering Kidangoor

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

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 s Max Resolution : 12 bits V to I section: Input Range : 0 5 V Output : 4 20 mA Dept. of Electronics & Instrumentation EI 707: Process Control Laboratory College of Engineering Kidangoor

O/P Impedance : 500 (Max) I to V section: Input Channels : 2 (VAD-104) Input Range : 4 20 mA Output : 0 5 V 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 behaviour 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.