EL – 426

INDUSTRIAL PROCESS
CONTROL LAB

Student’s Lab Report

Name: _______________________________________________

Roll no: ___________________________ Group: _____________

Department of Electrical Engineering

FAST – NU Peshawar Campus
EL - 426 Industrial Process Control Lab Safety Measures

Safety Measures
Industrial Process Control lab usually deals with Programmable Logic Controller (PLC),
HMI, Relays, PID controller, Sensors, Buzzers, switches & VFD’s. Be careful when working
with spinning motors and movable parts that can become hot. Most of our equipment is
rugged, but some delicate instruments are also used for measuring purposes, even rugged
instruments can be damaged when mishandled or driven beyond ratings, specifically using 3-ϕ
machines. Please follow the safety precautions to avoid injury, discomfort, lost lab time, and
expensive repairs.

MAKING CONNECTIONS:

 Get circuit diagram approval from your staff in charge.

 Go to the respective worktable and start to give connection as per the circuit diagram
from source side.
 Make series circuit connections before the parallel circuits like voltmeter connections.
 Before switch on the power, get circuit connection approval from the staff in charge.
 In case of any wrong observations, you have to SWITCH OFF the power supply of
trainer related with it.

DOING EXPERIMENT:

 Start the experiment in the presence of an instructor / staff in-charge and do the same
by proper procedure.
 If staff permits you then precede your experiment.

OBSERVATION:

 Before take the output, do check the PLC connections.

 Observe all the required power (24V) Input & Output connectivity for relevant devices.
 Note all the devices run according to desired need.

CALCULATION:

 Calculate the required quantities by suitable formulae and tabulate them with units.
 Draw the necessary graphs and write the result with reference.
 Get verification of observation and calculation from your staff in charge.

RECORD:

 Shows the performance of equipment and yourself. It will be very useful for future
reference. So keep it as follows.
 Neatly enter the readings in the record notebook that are taken during observation.
 Units should be written for all quantities.
 Draw necessary graphs and complete the record before coming to the next lab class.

National University of Computer and Emerging Sciences, FAST – NU, Peshawar Campus ii
EL - 426 Industrial Process Control Lab Safety Measures

PREVENT ACCIDENTS: FOLLOW THIS ADVICE

 Never hurry. Work deliberately and carefully.

 Connect to the power source LAST.
 If you are working with a lab kit that has internal power supplies, turn the main
power switch OFF before you begin work on the circuits. Wait a few seconds for
power supply capacitors to discharge. These steps will also help prevent damage to
circuits. If you are working with a circuit that will be connected to an external power
supply, turn the power switch of the external supply OFF before you begin work
on the circuit.
 Check circuit power supply voltages for proper value and for type (DC, AC, frequency)
before energizing the circuit.
 Do not run wires over moving or rotating equipment, or on the floor, or string them
across walkways from bench-to-bench.
 When using large electrolytic capacitors be sure to wait long enough (approximately five
time constants) for the capacitors to discharge before working on the circuit.
 All conducting surfaces intended to be at ground potential should be connected
together.

BASIC ELECTRICAL SAFETY PRACTICES

The Institute requires everyone who uses electrical equipment to understand these safety
precautions.

A. Safe Work Practices:

 Don’t remove the protective cover of an equipment to replace a part, adjust or

troubleshoot. Ask a qualified person to do the work
 Don't use an electrical outlet or switch if the protective cover is ajar, cracked or
missing.
 Only use DRY hands and tools and stand on a DRY surface when using electrical
equipment, plugging in an electric cord, etc.
 Never put conductive metal objects into energized equipment.
 Always pick up and carry portable equipment by the handle and/or base. Carrying
equipment by the cord damages the cord's insulation.
 Unplug cords from electrical outlets by pulling on the plug instead of pulling on the
cord.
 Use extension cords temporarily. The cord should be appropriately rated for the job.
 Use extension cords with 3 prong plugs to ensure that equipment is grounded.
 Never remove the grounding post from a 3 prong plug so you can plug it into a 2 prong,
wall outlet or extension cord.
 Re-route electrical cords or extension cords so they aren't run across the floor, under
rugs or through doorways, etc. Stepping on, pinching or rolling over a cord will break
down the insulation and will create shock and fire hazards.
 Don't overload extension cords, multi-outlet strips and wall outlets.
 Heed the warning signs, barricades and/or guards that are posted when equipment or
wiring is being repaired or installed or if electrical components are exposed.
 Use isolated supply for the CRO or other interconnecting devices.

National University of Computer and Emerging Sciences, FAST – NU, Peshawar Campus iii
EL - 426 Industrial Process Control Lab Safety Measures

B. Check for Unsafe Conditions (either before or while you're using equipment)

 Is the cord's insulation frayed, cracked or damaged, exposing the internal wiring?
 Are the plug's prongs bent, broken or missing, especially the third prong?
 Is the plug or outlet blackened by arcing?
 Was liquid spilled on or around the equipment?
 Are any protective parts (or covers) broken, cracked or missing?
 Do you feel a slight shock when you use the equipment?
 Does the equipment or the cord overheat when it is running?
 Does the equipment spark when it is plugged in or when switches or controls are used?

C. If you observe any of these unsafe conditions:

 Don't use (or stop using) the equipment.

 Immediately report the problem to the Lab Instructor or person In-charge of lab.

I have read and understood the safety practices. I will

observe and follow the safety practices and perform lab
experiments without compromising my or others safety.

Name: ___________________________________________

Date: __________________ Signature: ___________________

National University of Computer and Emerging Sciences, FAST – NU, Peshawar Campus iv
 Hardware Requirements
Industrial Process Control lab is facilitated with Industrial Process Control trainers Model
EM–CN–IST–100. It is fabricated with the following necessary components.

.No. Equipment Description

1 Breaker Manually operated Breaker serving as input supply switch to power trainer.

Programmable A digital computer used for automation of typically industrial

2
Logic Controller (PLC) electromechanical processes.

A user interface in process control system to provide a graphics-based

3 HMI
visualization of an industrial control and monitoring system.

Variable
A type of motor controller that drives induction motors by varying the
4 Frequency Drive
frequency and voltage supplied to them.
(VFD)

Used to measure rotation speed of rotating machines. Commonly called

5 RPM Sensor "tachometer”. The information retrieved is usually conveyed to the operator
through a gauge/meter.

A sensor that is able to detect the presence of nearby objects without any
6 Proximity Sensor
physical contact by emitting a beam of EM wave.

Temperature
7 Resistive temperature detectors PT-100 using PID controller guages.
Controller

A manually adjustable variable resistor with 3 terminals. Two terminals are

8 Potentiometer connected to both ends of a resistive element, and the third one called a
wiper, slides over the resistive element.

Usually a lever that allows a circuit to be powered or depowered by throwing

9 Toggle Switches
the switch from the open to closed position.

Available in the trainer to operate 3-ϕ squirrel cage induction motor &
10 AC input relevant loads as per requirement. Normally VFD’s are used to operate such
loads using 220 V AC input.

Available in the trainer to operate PLC & relevant loads as per requirement.
11 DC input
A constant supply of 24V is available for feeding.

12 Switches Flow switches- Paddle type, Spring type

13 Buzzer/Fan Interconnecting output loads.

14 Jumper Wires Used for Connecting purpose.

National University of Computer and Emerging Sciences, FAST – NU, Peshawar Campus v