2019

Temperature Control Trainer

INSTRUMENTATION & CONTROL LAB
2016-CH-454
Objectives:
The temperature control trainer has the following objectives:
1. To study the fundamentals of control engineering
2. To study the real industrial control engineering components:
 Controllers
 Transducers
 Actuators
3. To study the operation, configuration and parameterization of the local industrial
controller manually and by using the process control software
4. To study the control response to:
 Switching control (2-point and 3-point controller)
 Continuous control
 Dead times
5. For investigation of any disturbance and control response on it
6. For investigation of the properties of the open and closed control loops and control
optimization
7. For processing of process variables using external equipment such as computer
plotter
Line Diagram:
Description: -
Temperature control trainer consists of a heat exchanger with two input and output
ports with hot and cold water as the medium of exchange. Hot water is heated by
submersion heater in the hot water and is circulated in the system by the circulation
pump. Cold water is supplies b the cold water tank which connected to tap water and
circulated by circulation pump. Temperature at inlet and outlet of heat exchanger for
both hot and cold water circuit is indicated by temperature gauges. Temperature
transmitter is used to measure the cold water outlet temperature. This linked to a
microprocessor based controller. The output of controller is connected to a pneumatic
based control valve to manipulate the hot flow rate which will affect the cold water
outlet temperature. The unit is supplied with chat recorder. The control and patch panel
are safely protected against water splashes.
A circulating pump delivers water within a closed circuit. The flow rate of water can be
adjusted by a hand-operated valve. The loop also contains a screw-in heater, a heat
exchanger with fan, and three integrated thermocouples for temperature measurement.
Dead times can be represented by the use of different lengths of process delay. A thyristor
power controller is used as the actuator. The controller used is a state-of-the-art digital
industrial controller. It can be configured as a continuous or a switching device, and can
activate the heater via the actuator and/or the fan. The controlled variable X and the
manipulating variable Y are plotted directly on an integrated 2-channel line recorder.
Alternatively, the variables can be tapped as analogue signals at lab jacks on the switch
cabinet. This enables external recording equipment such as an oscilloscope or a flatbed
plotter, to be connected.

Components of equipment and their function:

1. Screw-In Heater
2. Switch Cabinet
3. Line Recorder
4. PID Controller
5. Process Delays
6. Fan
7. Heat Exchanger
8. Ball Valve with Scale
9. Pump
10. Thermocouples

Switch cabinets:
Switch cabinets/switchgear contain sensitive electrical, electronic and
mechanical components to perform control, drive, power supply and safety functions.

PID Controller:
A proportional integral derivative (PID) controller can be used as a means of
controlling temperature, pressure, flow and other process variables. As its name implies,
a PID controller combines proportional control with additional integral and derivative
adjustments which help the unit automatically compensate for changes in the system .
Heat Exchanger/Condenser:
Use to transfer heat from high temperature source to surrounding using air that
comes from the blower/fan.

Thermocouple:
A Thermocouple is a sensor used to measure temperature. Thermocouples consist
of two wire legs made from different metals. The wires legs are welded together at one
end, creating a junction. This junction is where the temperature is measured. When the
junction experiences a change in temperature, a voltage is created.

Ball Valve:
Ball valve is the most used fluid shutoff valve in upstream oil and gas production
facilities, both onshore and offshore.

Fan:
The purpose of the fan to provide the air to exchanger for exchanging heat.

Procedure: -
 Enter the process parameters into the data entry menu.
 Check whether the control output is 100 % before switch on the motor.
 Switch on the pump and select the desired speed by varying the speed control
knob.
 Tune the parameters gain to maintain the controlled variable almost at the set
point.
 The readings are noted for 15 minutes’ increase or decrease in flow output and a
graph is drawn for the time vs flow.
 View the response for different set points.
Time(sec) Flow Controller position
Result: -
All the characteristics of controller for the given set point is obtained.

Conclusions: -
1. I studied the fundamentals of control engineering and real industrial control
engineering components.
2. I studied the operation, configuration and parameterization of the local industrial
controller manually by using the process control software and studied the control
response to:
 Switching control (2-point and 3-point controller)
 Continuous control
 Dead times

3. I investigated the properties of the open and closed control loops and control
optimization.

References: -
http://www.usdidactic.com/html/p3591.htm
https://www.gunt.de/en/products/mechatronics/automation-and-process-control-
engineering/simple-process-engineering-control-systems/temperature-control-
trainer/080.54200/rt542/glct-1:pa-148:ca-83:pr-1191