LEVEL CONTROL SYSTEM

Objective:
To study the level process control system

Block Diagram:

1. Front Panel

7. Control Valve

2. Rotameter

8. Drain Valve

3. Level Transmitter

9. Motor

4. I to P Converter

10. By Pass Valve

5. Air Regulator

11. Reservoir

6. Process Tank

Specifications:
Technical Data 0f I/P converter:
RANGES

INPUT

OUTPUT

Standard
Input Resistance

420mA
Ri = 260 20 ohms

(3-15psi/0.2-1.0kg\cm2)

Capacitance

Negligible

Characteristic

linear, direct action

Transmission Behavior of I/P converter:

Linearity error
Hysteresis

<=0.5%
<=0.3% (with temperature
<=-20C (-4.0F) error may Increase)
<=0.1%
<=0.5%\10k zero & span
<=0.3% \0.1 bar (1.5 psi)
<0.5% for zero & span (in case of change from.
Vertical to Horizontal position)
<1% up to 10g & frequency 10150 Hz and
max. amplitude 0.5mm.

Response threshold
Ambient temperature
Air supply Influence
Mounting Position
Vibration Influence

General Specifications of actuator:

Type

Pneumatically actuated single sealed globe control valve

Size
Actuator
Valve action
Body gasket

1\2
pneumatic 0.2-1bar
signal fail to close
Grafoil

General Specification of rotameter:

1. Maximum range : 1200 LPH
2. A calibration scale is printed on the front size of the rotameter to indicate the rate of flow.
3. Made see through acrylic sheet.

General Specifications of motor and pump:

1.
2.
3.
4.
5.
6.
7.

Self starting mono block motor.

Capacitor start & Run type
Horse power - 0.5HP
RPM - 2800RPM
Input voltage - 1 230V 50Hz
Head range 6m/30m
Pump size - 25*25 mm (1 * 1)

Specifications of process tank:

Height of the tank
= 65cm approximately
Diameter of the tank = 20cm approximately
Capacity of the tank = 22cm3 approximately
Specifications of reservoir:
Height of the tank
Length of the tank
Breadth of the tank
Capacity of reservoir

= 25cm
= 76 cm
= 40 cm
= 76L

Level transmitter:
The capacitance type Level transmitter provides a reliable and relatively low cost solution to
continuous level measurements. The change in level is recognized and converted to an analog output
signal (4-20mA DC or 1-5VDC). The system will operate with standard 4-20mA DC or 1-5V DC indicators.
Power supply
Ambient temperature
Response time
Accuracy
Permissible load
Output
Probe length
Zero and span adjustment
Capacitance range
Wiring
Probe orientations

24v dc
0-60c
100 milli sec
1 of the operation span of the
probe including linearity
600E max for 4-20mA DC o/p
4-20 mA (or) 1-5 b DC
60cm
Non interacting and Independent
adjustment with 20 turn Potentiometer
pF (min) to 5000pF (Max).
Two wire systems.
Vertical

Theory:
In many processes involving Liquids contained in vessels Such as distillation Columns, reboilers,
evaporators, Crystallizers and mixing tanks the particular Level of liquid in each vessel can be of great
importance in process operation. A Level, which is too high, for example, may upset reaction equilibria,
cause damage to equipment, or result in spillage of valuable (or) hazardous material. A level that is too
low may have equally bad consequences. Combined with such basic Considerations, there is the
advantage in continuous processing of reducing storage capacity throughout the process.
In this experiment, the level is controlled by manipulating the fluid flow rate. There are two ways
to control the level. One is in manual mode and the other one is by using LABVIEW. Here, we use
LABVIEW for controlling the level.

Experiment 1
Aim:
To study the current to pressure (I/P) converter

Connection Details:
1. Connect the Air Source from the compressor to the Air In Port.
2. Connect output of PID controller to input of the I/P converter.
3. Set the pressure at air regulator for 20psi.
4. Connect the process variable to the input of the I/P converter.

Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Verify the input pressure at 20 psi.

Close the Drain Valve.
Ensure the Bypass valve which should be open .
Change the selector switch to manual mode.
Connect the trainer to Single phase AC mains.
Switch ON the MSB and start the motor using start button.
Allow the Process Tank to fill up the water at max of 35cm.
Switch off the Motor.
To give the (20mA to 4 mA) input drain the water 35cm to 0cm.Take down the reading current
versus pressure.

Observations:
Current
(in mA)

Pressure
(in Kg/cm2)

Model graph:

P
(psi)

I(mA)

Summary and Conclusions:

The experiment for current to pressure (I/P) converter was studied and plotted the characteristic
curve. It is observed that the bahaviour is linear.

Experiment 2
Aim:
To study the level trainer

Connection Details:
1. Connect the Air Source from the compressor to the Air In Port.
2. Set the pressure at air regulator for 20psi.
3. Connect the process variable output to the input of the I/P converter.

Procedure:
1.
2.
3.
4.
5.
6.
7.
8.

Verify the input pressure at 20 psi.

Close the Drain Valve.
Ensure the Bypass valve which should be open for 50% to protect the motor.
Switch ON motor using start button.
Allow the Process Tank to fill up the water at max of 35cm.
Switch of the Motor.
Connect the Ammeter (mA) in the Process Variable terminal at the control panel.
Open the drain valve and note down the readings with the interval of 5cm.

Observations:

Current level ( in cm)

Process variable (in volts)

Model graph:

L
(cm)

V(Volts)
Summary and Conclusions:
The experiment for level trainer was studied and observed that the behaviour is linear.

Experiment 3
Aim:
To study the Level Process under closed loop conditions

Procedure:
1.
2.
3.
4.
5.
6.

To interconnect the Level Process Station circuits as per the patching diagram.
Connect the trainer to Single phase AC mains.
Switch ON the key lock and change the selector switch to auto mode.
Ensure the Bypass valve which should be open 25%.
Ensure the outlet valve it should be 50% open.
Given the pressure signal to the input of air regulator and observes the I to P input pressure
which should in 1.2 kg per cm2 otherwise adjust the air regulator.
7. Connect the LEVEL PROCESS STATION to the PC through USB cable. It is done by connecting
USB port (SERIAL INTERFACE) of LEVEL PROCESS STATION to any USB port of PC.
8. Give the 20-30% of change in the manipulated variable.
9. Observe the level readings w.r.to time.
10. Plot the graph and calculate the gain, time constant and time delay values.
11. Put the process under closed loop
12. Enter the set level of the tank in the front panel of the software program.
13. Enter proportional, integral and derivative gains manually for PID control. For PI control, put
derivative gain = 1.4, integral gain = 0.6(minutes) and derivative gain=0.

Observations:

Current level ( in cm)

Time (in millisecond)

Summary and Conclusions:

The experiment for level process station under closed loop was studied and it is observed that the set
point is followed in closed loop with the given controller.