Process Plant Trainer | ProzessiX PX-03

The Process Plant Trainer, ProzessiX PX-03, is a miniature industrial process system designed for advanced study of measurement, dynamics, and process control strategies. It supports manual, single-loop, cascade, multi-loop, and PC-based PID control experiments.

Equipped with plate heat exchanger, heating and cooling systems, peristaltic pumps, multi-parameter sensors, and integrated DAQ software, the system enables realistic training in industrial automation and process control. Manufactured by SCIENTICO, it is suitable for engineering institutions and export-oriented technical training centers.

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Category Process Engineering Technology

The Process Plant Trainer is a fully integrated miniature industrial process system designed to study measurement, dynamics, and advanced process control strategies. It replicates real plant behavior, including multivariable interactions, dead time effects, and stability challenges.

Manufactured by SCIENTICO under the ProzessiX series, Model PX-03 is developed for engineering colleges, technical universities, pilot plants, and industrial training centers requiring hands-on training in process control, instrumentation, and distributed supervisory control systems.

PRODUCT OVERVIEW

The Process Plant Trainer represents a scaled-down industrial process incorporating level, flow, temperature, conductivity, and pH control using water as the working medium. The system enables users to investigate control techniques ranging from manual operation to cascade control and PC-based distributed supervisory control.

The trainer supports:

Manual control
Single-loop feedback control
Multi-loop and cascade control strategies
Direct digital control (DDC) using a PC
Industrial PID controller implementation
Data acquisition and monitoring via software

Users can study the interaction between process variables such as flow rate, temperature, and level, while observing real-time responses to disturbances and step changes. The system also enables investigation of recycle effects, operational sequencing (startup and shutdown), and alarm-based control actions.

The integrated DAQ software allows signal acquisition, monitoring, and control through a USB interface, supporting advanced control experimentation in a safe laboratory environment.

General Process Capabilities

Parameter	Specification
Control Variables	Level, Flow Rate, Temperature, pH, Conductivity
Control Strategies	Manual, Single-loop, Cascade, Multi-loop, PID, PC-based DDC
Working Medium	Water
PC Interface	USB connection for simultaneous signal monitoring

Mechanical & Process Components

Component	Specification
Feed System	Peristaltic pump
Water Heating Unit	Peristaltic pump with heater
Water Cooling System	Integrated cooling arrangement
Heat Exchanger	Plate type with holding tube
Heating Vessel Capacity	5 liters
Process Vessel Capacity	5 liters
Product Feed Pump Speed	Variable control
Heating Fluid Pump Speed	Variable control
Heater Element	Coil type, 1000 W, 220 V AC
Solenoid Valves	24 V DC
Float Switch	Drum type

Instrumentation

Sensor	Specification
Temperature Sensors	4 × K-type thermocouples
Flow Sensor	Turbine type, Max 1200 mL/min
Conductivity Sensor	0–20 mS/cm
Level Sensor	0–200 mm
Pump Max Rate	2200 mL/min

Electrical & Control

Feature	Specification
Heater Power	Measurement and control available
Digital Inputs/Outputs	From switches and to solenoid valves
Electrical Console	Built-in display for sensor outputs and signal conditioning
Software	IT-5208SW DAQ software
Software Platform	National Instruments™ LabVIEW™ environment
OS Compatibility	Windows™

Scope of Delivery

1 Experimental module
1 Instruction manual

Key Features

Miniature industrial process plant for control engineering training
Study of single-loop, cascade, and multi-loop control strategies
PC-based data acquisition and direct digital control capability
Industrial PID controller implementation
Plate heat exchanger with integrated heating and cooling
Four temperature measurement points for thermal profiling
Level, flow, conductivity, and pH control capability
Alarm-activated diverter valve for disturbance studies
Investigation of dead time and dynamic process behavior
Screen-based mimic diagrams for process visualization
Simultaneous signal monitoring via USB interface

Applications

Chemical engineering control laboratories
Process instrumentation and automation training
Industrial control strategy development
Study of cascade level and temperature control
Verification of PID tuning techniques
Process dynamics and stability analysis
Pilot plant control simulation and supervisory control training

Construction & System Design

The Process Plant Trainer is designed as a compact, bench-mounted pilot plant system integrating process vessels, heating and cooling units, instrumentation, and a centralized electrical console.

The plate heat exchanger with holding tube enables realistic heat transfer studies. Peristaltic pumps provide controlled feed and heating fluid circulation. The heating element is coil-type with controlled power input, enabling temperature regulation experiments.

Instrumentation includes four K-type thermocouples, turbine flow sensor, conductivity sensor, and level measurement devices. Solenoid valves and digital I/O facilitate automated control and sequencing experiments.

All signals are routed through a control console providing electrical interfacing and signal conditioning. A built-in display shows sensor outputs, and signals are available for external monitoring and PC-based control. The system supports advanced DAQ software integration for data logging, monitoring, and closed-loop control implementation.

The trainer is engineered for repeated academic use, ensuring durability, operational safety, and clear demonstration of industrial control principles.

Export & Supply Capability

The ProzessiX PX-03 Process Plant Trainer is manufactured by SCIENTICO for domestic and international supply. The system is suitable for export to engineering universities, R&D laboratories, technical institutions, and industrial training centers.

Standard delivery includes the experimental module and detailed instruction manual. The unit is prepared for secure packaging and international transportation. Documentation support is provided for installation, commissioning, and academic integration.

Q1. What is the main purpose of the Process Plant Trainer?
The trainer is designed to simulate a real industrial process plant, enabling study of process dynamics, measurement systems, and advanced control strategies including PID and cascade control.

Q2. What control strategies can be implemented on this system?
Users can implement manual control, single-loop feedback control, cascade control, multi-loop control, direct digital control via PC, and industrial PID control strategies.

Q3. How does the system support cascade control experiments?
Cascade control can be implemented for level and temperature loops, where a primary controller adjusts the setpoint of a secondary controller, allowing study of improved disturbance rejection.

Q4. Can students analyze process dynamics and dead time?
Yes. The system allows measurement of step responses, study of dead time effects, and analysis of variable interactions such as flow affecting temperature.

Q5. Is the trainer suitable for industrial automation training?
Yes. With digital inputs/outputs, solenoid valves, PID control capability, and PC-based supervisory control, the system is suitable for advanced industrial control training.

Q6. What software is used for data acquisition and control?
The trainer uses IT-5208SW DAQ software developed in the National Instruments™ LabVIEW™ environment and is compatible with Windows™ operating systems.

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Process Plant Trainer | ProzessiX PX-03

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The Venturi Meter Apparatus FluidoSurge-X 176 is designed for measuring flow rate in pipes using the Venturi principle. It features a transparent acrylic Venturi tube with multiple pressure tapping points and a manometer bank. The setup enables study of pressure drop, pressure recovery, and discharge coefficient. It is suitable for fluid mechanics laboratory teaching and experimental analysis.

Advance Dead Weight Apparatus | FluidoSurge-X 173

The Advance Dead Weight Apparatus FluidoSurge-X 173 is designed for high accuracy pressure calibration in laboratories. It uses a precision piston manometer with calibrated dead weights to generate known pressures. The setup supports calibration of Bourdon tube pressure gauges and systematic error analysis. It is suitable for advanced fluid mechanics and instrumentation laboratory experiments.

Dead Weight Apparatus | FluidoSurge-X 172

The Dead Weight Apparatus FluidoSurge-X 172 is designed for calibration of pressure gauges in laboratory environments. It generates accurate pressure using a precision piston and calibrated dead weights. The setup enables comparison between applied pressure and Bourdon gauge readings. It is suitable for fluid mechanics and instrumentation laboratory experiments.

Pipe Friction Apparatus | FluidoSurge-X 168

The Pipe Friction Apparatus FluidoSurge-X 168 is designed for studying friction losses in pipe flow. It supports experiments under laminar and turbulent conditions using controlled water supply. The setup includes an elevated head tank, test pipe, and manometers for head loss measurement. It is suitable for fluid mechanics laboratory teaching and experimental analysis.

Hydraulic Ram Pump Apparatus | FluidoSurge-X 164

The Hydraulic Ram Pump Apparatus FluidoSurge-X 164 is designed to demonstrate water hammer and hydraulic ram pumping principles. It operates without external power and uses pressure surges to lift water to a higher level. The setup features transparent tanks, adjustable valves, and a visible air vessel for clear observation. It is suitable for fluid mechanics and hydraulic machinery laboratory experiments.

Francis Turbine Apparatus | FluidoSurge-X 160

The Francis Turbine Apparatus FluidoSurge-X 160 is designed for studying reaction turbine principles in fluid mechanics laboratories. It enables measurement of torque, power output, and efficiency of a Francis turbine. The setup features adjustable guide vanes, a band brake loading system, and transparent casing.It operates with a hydraulic bench or laboratory water supply and supports characteristic curve analysis.

Pelton Turbine Apparatus | FluidoSurge-X 156

The Pelton Turbine Apparatus FluidoSurge-X 156 is designed for studying impulse turbine performance in fluid mechanics laboratories. It features a transparent housing with adjustable spear valve and miniature Pelton wheel. The setup enables measurement of speed, torque, power, and efficiency under constant head conditions. It operates with a hydraulic bench or laboratory water supply and supports comprehensive turbine experiments.

Energy Losses in Pipe Apparatus | FluidoSurge-X 148

The Energy Losses in Pipe Apparatus FluidoSurge-X 148 is designed for studying friction and local losses in pipe flow. It enables measurement of pressure losses for laminar and turbulent conditions. The setup includes multiple pipe fittings and a manometer bank for detailed analysis. It operates with a hydraulic bench or laboratory water supply and is suitable for fluid mechanics laboratories.

Inclined Pitot Tube Apparatus | FluidoSurge-X 152

The Inclined Pitot Tube Apparatus FluidoSurge-X 152 is designed for precise velocity and pressure measurement in fluid mechanics laboratories. It uses an inclined manometer for enhanced sensitivity at low pressure differences. The setup supports static and dynamic pressure measurement and velocity profile studies. It is compatible with hydraulic benches and standard laboratory water supplies.

Pitot Tube | FluidoSurge-X 144

The Pitot Tube FluidoSurge-X 144 is designed for velocity and pressure measurement in fluid mechanics laboratories. It enables determination of static and dynamic pressure using a Pitot static tube and manometer. The setup supports velocity profile studies in pipe flow with a transparent acrylic section. It is compatible with hydraulic benches and standard laboratory water supplies.

Free and Forced Vortex Apparatus | FluidoSurge-X 140

The Free and Forced Vortex Apparatus FluidoSurge-X 140 is designed for studying vortex motion in fluid mechanics laboratories. It enables generation and measurement of both free and forced vortices using a transparent acrylic vessel. The setup supports surface profile plotting and velocity measurement with interchangeable orifices and a Pitot tube. It is suitable for academic experiments and verification of vortex flow theory.

Flowmeter Measurement Apparatus | FluidoSurge-X 136

The Flowmeter Measurement Apparatus FluidoSurge-X 136 is designed for comparative study of flow measurement techniques. It integrates a Venturi meter, orifice meter, and rotameter in one laboratory setup. The system allows comparison of flow readings and pressure drops for incompressible fluids. It operates with a hydraulic bench or laboratory water supply and is suitable for fluid mechanics teaching laboratories.

Osborne Reynold’s Apparatus with Manometer | FluidoSurge-X 133

The Osborne Reynold’s Apparatus with Manometer FluidoSurge-X 133 is designed for studying flow regimes in fluid mechanics laboratories. It enables visualization of laminar, transitional, and turbulent flow using dye injection. The system includes U tube and inverted U tube manometers for pressure measurement. It supports Reynolds number determination through volumetric flow analysis and controlled experimentation.

Osborne Reynold’s Apparatus | FluidoSurge-X 132

The Osborne Reynold’s Apparatus FluidoSurge-X 132 is designed to visualize flow regimes in fluid mechanics laboratories. It enables observation of laminar, transitional, and turbulent flow using dye injection. The setup supports Reynolds number determination through volumetric flow measurement. It is suitable for engineering education and demonstration of classical flow behavior.

Orifice Discharge Apparatus | FluidoSurge-X 128

The Orifice Discharge Apparatus FluidoSurge-X 128 is designed for studying discharge characteristics through orifices. It features a transparent Plexiglass tank with adjustable overflow and interchangeable nozzles. The setup enables measurement of jet velocity, diameter, and flow rate using standard instruments. It is suitable for fluid mechanics laboratory teaching and experimental analysis.

Bernoulli’s Theorem Apparatus | FluidoSurge-X 120

The Bernoulli’s Theorem Apparatus FluidoSurge-X 120 is designed for studying pressure and energy variation in flowing fluids. It uses a transparent Venturi with multiple pressure tapping points and a manometer bank. The setup supports converging and diverging flow experiments and discharge coefficient determination. It is suitable for fluid mechanics laboratory teaching and experimental verification of Bernoulli’s principle.

Impact of Jet Apparatus | FluidoSurge-X 124

The Impact of Jet Apparatus FluidoSurge-X 124 is designed for studying jet impact forces in fluid mechanics laboratories. It enables direct measurement of force due to change in momentum of a water jet. The unit includes four interchangeable deflectors with different deflection angles. It operates with a hydraulic bench or standard laboratory water supply for flexible installation.

Orifice Discharge & Free Jet Flow Apparatus | FluidoSurge-X 116

The FluidoSurge-X 116 Orifice Discharge and Free Jet Flow Apparatus is designed for experimental study of jet flow and discharge through orifices. It features a constant head Plexiglas cylinder with interchangeable nozzles. The setup enables measurement of jet velocity, diameter, and trajectory using standard laboratory instruments. It is suitable for fluid mechanics teaching and verification of theoretical flow principles.

Hydrostatic Pressure Apparatus | FluidoSurgeX 112

The FluidoSurgeX 112 Hydrostatic Pressure Apparatus is designed for studying hydrostatic thrust on submerged plane surfaces. It allows measurement of force and moment for vertical and inclined planes. The setup uses a transparent quadrant tank with lever arm and calibrated weights. It supports accurate comparison between experimental results and theoretical hydrostatic analysis.

Metacentric Height Apparatus | FluidoSurgeX 108

The FluidoSurgeX 108 Metacentric Height Apparatus is designed for studying the stability of floating bodies in fluid mechanics laboratories. It allows determination of metacentric height by varying the center of gravity of a floating pontoon. The setup includes a water tank, adjustable sail weight, plumb bob, and tilt indicator. It is suitable for marine engineering and buoyancy related laboratory experiments.

Flow Over Weirs Apparatus with Weir Tank | FluidoSurgeX 107

The FluidoSurgeX 107 Flow Over Weirs Apparatus with Weir Tank is designed for open channel flow experiments in fluid mechanics laboratories. It allows investigation of discharge characteristics over rectangular and V notch weirs. The system includes a corrosion resistant weir tank, stainless steel weir plates, and an adjustable depth gauge. It can be operated using a hydraulic bench or a standard laboratory water supply for flexible installation.

Flow Over Weirs | FluidoSurgeX 104

The FluidoSurgeX 104 Flow Over Weirs apparatus is designed for open channel flow experiments in fluid mechanics laboratories. It is used with a hydraulic bench to study flow over V notch and rectangular weirs. The unit includes stainless steel weir plates and a level gauge for head measurement. It supports accurate determination of flow rate and discharge characteristics during laboratory experiments.

Hydraulic Bench Apparatus with Flowmeter | FluidoSurgeX 105

The SCIENTICO FluidoSurgeX 105 Hydraulic Bench Apparatus with Flowmeter is designed for fundamental fluid mechanics experiments.
It operates on a closed water circuit with a centrifugal pump and stepped measuring tank.
Integrated flowmeters provide direct flow measurement, supported by manual volumetric methods.
An integrated flume and GRP construction make it suitable for routine laboratory teaching and experimentation.

Hydraulic Bench with Series and Parallel Pumps | FluidoSurgeX 104

The SCIENTICO FluidoSurgeX 104 Hydraulic Bench is designed for studying centrifugal pump performance in fluid mechanics laboratories.
It features two centrifugal pumps configurable in single, series, or parallel operation within a closed water circuit.
The system supports volumetric flow measurement, pressure monitoring, and weir experiments.
GRP construction, industrial piping, and integrated instrumentation make it suitable for comprehensive hydraulic studies.

Gravimetric Hydraulic Bench | FluidoSurgeX 103

The SCIENTICO FluidoSurgeX 103 Gravimetric Hydraulic Bench is designed for accurate flow measurement in fluid mechanics laboratories.
It uses a closed water circuit with a centrifugal pump and gravimetric measurement system.
Flow rates are determined using lever based weights or optional digital load cells.
An integrated flow channel supports weir experiments, while reinforced fiberglass construction ensures long term laboratory use.

Digital Hydraulic Bench Apparatus | FluidoSurgeX 102

The SCIENTICO FluidoSurgeX 102 Digital Hydraulic Bench is designed for fundamental fluid mechanics laboratory experiments.
It features a closed water circuit with a centrifugal pump, stepped measuring tank, and digital flowmeter.
The system supports accurate volumetric flow measurement using both manual and digital methods.
An integrated flume enables weir experiments, while GRP construction ensures reliable laboratory performance.

Hydraulic Bench Apparatus | FluidoSurgeX 101

The SCIENTICO FluidoSurgeX 101 Hydraulic Bench Apparatus is a basic laboratory unit for fluid mechanics experiments.
It features a closed water circuit with storage tank, centrifugal pump, and stepped measuring tank.
The system enables accurate volumetric flow rate measurement using tanks and a measuring beaker.
An integrated flume supports weir experiments, while the GRP construction ensures long-term laboratory use.

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