Instrumentation & Control Lab

Flow Control Training System

Objective:
 To study the effect of flow rate on voltages by flow control training system.

Introduction:
Flow control training system can be used to study the change in induced voltage by changing the
flow rate of liquid. The flow control training system is basically a system consisting of single loop
which allows the study of process control principles using a liquid flow rates as the measured process
variables. Low pressure flowing water circuit mounted on a benchtop make it suitable to work within
the laboratory premises to study the effect of liquid flow rate on the induced voltage values [1]. Flow
control serves to demonstrate and teach the measurements and control of liquid flow processes. Flow
Process Control course gives students hands-on experience raising and lowering water flow rates to
preset levels using manual control and auto-tuning methods. The process setup consists of supply
water tank fitted with pump for water circulation [2]. Flow sensors are used to accurately determine
the mass, pressure and volume flow rates of fluids. The basic principle behind this is that the potential
difference is sensed by electrodes aligned perpendicular to the flow and the applied magnetic field.
The physical principle at work is Faraday's law of electromagnetic induction.

Figure 2: Flow control Training System Schematic

Figure 1: Flow control Training System

Working Principle:
The simple working is that the impeller in the flow sensor, placed in system, rotates as the fluid passes
through it and the voltage produces as impeller moves. The increase in the water flow rate tends to
increase the rotation of impeller which results in the increase in the voltage produced.

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Parts and Function:
A laboratory scale flow control training system has the following parts.
Voltage Meter: Voltage meter is used to detect the voltage changes produced due to change in flow
rate of water.

Straine : Strainer stains the water before letting it to pass through the non-return valve.

Non-Return Valve: Non-return valve resists the backward flow of water once it passes through the
valve.

Pump: Pump is used for the circulation of water throughout the system.

Flow Meter: Flow meter provides the value of flow rate in Liter per minute units.

Motorized Valve: Motorized valve connected with motor, as name suggests, is used to control the
flow the water using motor connected with system.

Manual Valve: Manual valve, as name suggests, is used to control the flow manually by opening and
closing of valve.
Flow Sensor: Fluid passes through the flow sensor and the impeller inside the flow sensor rotates
and as a result voltage is produced.

Figure 2: Flow control Training System Schematic

Procedure:
 Connect the leads of the pin No. 8 of the pump driver to the bush off the set point 1, pin No. 9
to adjacent bush and pin No. 10 to its adjacent bush.
 Start the pump regulating the voltage on set point 1 at 10V.
 Regulate the valve MANUAL VALVE to read on the FLOW METER 6 lt/min. if the flow is
slightly lower, regulate MANUAL VALVE to reach the value closely higher.
 Regulate the voltage on SET POINT 1 at 0V.
 Connect pins No.1 and 2 of the flow sensor FLOW to its adjacent pins of the relevant
interface.
 Insert one terminal of the digital voltmeter, set in dc, in pin No.3 and the other one in the
earth bush.

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 Regulate the trimmer OFFSET to read the value 0V on the multi-meter.
 Start the pump regulating the voltage on SET POINT 1 at 10V.
 Regulate the trimmer GAIN to read on the multi-meter the value 9V, in case the flow read
and calculated is 6 lt/min.
 Regulate the valve MANUAL VALVE for all the value of flow listed in table 2.1 and write
down the voltage values read on the voltmeter.
 Put OFF the main switch.
 Remove all the connections.
 Draw the diagram of the voltage as a function of the flow.

Results and Discussion:

Experiment was done to get the voltage values at various liquid flow rates. The flow rates were
adjusted manually using probe adjusted on control panel and the variation in the voltage, measured
through voltmeter, was observed in mV. Table 1 shows the voltage values at corresponding flow rates
of water in litre per minute. The increasing trend was observed in the voltage values as the flow rate
of water was increased. The curve showing relation between flow rate L/min and measured voltage is
shown in graph 1. Motorized valve or solenoid valve contains coil inside it and the movement of coil
in upward and downward direction results in the production of voltage which is detected through
voltmeter.

Table 1: voltage at various flow rates

No of Obs. Flow Rate Voltages

(L/min) (mV)
1. 1 2.75
2. 2 9.29
3. 3 13.79
4. 4 15.20
5. 5 15.21
6. 6 15.23

Flow Rate vs Voltage

20
18 y = 2.330x + 3.754
16
14
Voltage (mV)

12
10
8 Series1
6
Linear (Series1)
4
2
0
0 2 4 6 8
Flow Rate (L/Min)

Graph 1: Relation between Flow rate and Voltage

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Applications:
 Flow Trainer simulates industrial plant systems found in oil & gas, chemical and food
production plants around the world.
 Training system Process Plant makes an excellent platform for training in all aspects of liquid
flow instrumentation and engineering.

References:
[1] https://www.intelitek.com/process-control-learning-systems/flow-process-control-trainer/

[2] Flow Process Control Trainer. InteliStaf. Retrieved from https://www.intelitek.com/process-

control-learning-systems/flow-process-control-trainer/
[3] Hands-On Level and Flow Process Control Skills, Process Control Training. AMATROL. Retrieved
from https://amatrol.com/coursepage/process-control-training/

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