PROCESS PLANT TRAINER

Submitted by:
Shahbano Hashmi 2013-PE-07
Bushra Ameer 2013-PE-08
Alvia Asif 2013-PE-14
Natashah Ashraf 2013-PE-15
Hira Ehsan 2013-PE-26
Aqsa Aslam 2013-PE-27

Submitted to:
Mam Zoobia

Polymer department
Instrumentation and control lab
Contents
Process Plant Trainer ...................................................................................................................... 2
Working principle ........................................................................................................................... 2
Features ........................................................................................................................................... 3
Instrumentation ............................................................................................................................... 3
3/2 way solenoid valve ............................................................................................................... 4
Peristaltic pump......................................................................................................................... 4
Plate heat exchanger ................................................................................................................. 4
Control objective............................................................................................................................. 4
Control (Manipulated Variables) .................................................................................................... 4
Possible loops.................................................................................................................................. 5
Level Control loop: ..................................................................................................................... 5
Product-Diverted valve loop: ...................................................................................................... 5
References ....................................................................................................................................... 6
 Process Plant Trainer
The PCT23-A is a bench top process control system, comprising a process unit mounted on an
ABS plinth, an electrical control console, and control software, which can be run on any Windows
PC with a spare USB port.
Diverted
product

Holding Plate type heat

tube
Exchanger

Heated vessel Feed tanks

Valves

Peristaltic pump

Process Unit:
Figure 1. Process plant trainer

Working principle
The process is modelled on an industrial high-temperature/short-time (HTST) pasteurization
process. In this process the product stream has to be kept at a predetermined temperature for a
minimum time, usually for bacteriological purposes. This is effected by the use of a holding tube,
which delays the product stream, thus posing particular process control problems and introducing
the concept of dead time.
 Solenoid-driven valves control the filling and emptying of these tanks. These enable different level
control strategies to be developed and provide startup and shutdown operational sequencing
capability. [1]

Features
Multiple inputs, multiple sensors, multiple control strategies.
Manual control, single feedback loops, through to sophisticated cascade loops
Temperature, level, flow control loops can be implemented
Effects of dead time
Operational sequencing, including startup and shutdown
Recycle implications on process control.

Instrumentation
2 way solenoid valve
3 way solenoid valve
Peristaltic pump
Plate heat exchanger
Flow sensor
Temperature sensor
Level sensor

Figure 2. Schematic of process plant trainer

 3/2 way solenoid valve
A 3/2 way solenoid valve has three ports and two switching states. In each switching state, two
of the three ports are connected. By activating the solenoid, the valve switches state and a different
connection between the valve ports is established. In the de-energized state, the medium can flow
between from the port on the right side to the top port. In the energized state, the medium can
flow from the left port to the right port. This is a called a normally closed 3/2-way valve. [2]

Peristaltic pump
The peristaltic pump is based on alternating compression and relaxation of the hose or tube
drawing the contents into the hose or tube, operating in a similar way to our throat and intestines.
A rotating shoe or roller passes along the length of the hose or tube totally compressing it and
creating a seal between suction & discharge side of the pump, eliminating product slip. Upon
restitution of the hose or tube a strong vacuum is formed drawing product into the pump. [3]

Plate heat exchanger

The plate type heat exchanger is the most efficient type of heat exchanger with its low cost,
flexibility, easy maintenance, and high thermal transfer. WCR plate corrugations are designed to
achieve turbulence across the entire heat transfer area. This produces the highest possible heat
transfer coefficients with the lowest possible pressure drop, allowing for close
temperature approaches. Subsequently, this leads to a smaller heat transfer area, smaller units and
in some cases, fewer heat exchangers. [4]

Control objective
The product stream must be kept at a predetermined temperature for a minimum time.

Control (Manipulated Variables)

Product feed pump speed
Heating fluid pump speed
Heater power
Temperature, flow, level measurement
Possible loops
Level Control loop:

Product-Diverted valve loop:

References
1. http://discoverarmfield.com/en/products/view/pct23/process-plant-trainer-process-
control-trainer
2. https://tameson.com/solenoid-valve-types.html
3. http://www.verderflex.com/en/how-do-peristaltic-pumps-work/
4. http://www.wcrhx.com/plate-heat-exchangers