Process Automation Training Kit (PID2601)

Process Automation Training Kit

The Process Automation Training Kit from Hytech Automation is an Industry 4.0-ready training platform designed to provide comprehensive hands-on learning in industrial process control and automation. Developed using real industrial instruments, pumps, control valves, transmitters, sensors, PLCs, HMI, SCADA, and Industrial IoT technologies, the system bridges the gap between classroom learning and modern process industry requirements.

The training system simulates a small-scale process plant and enables learners to understand, operate, monitor, and optimize the four most important process variables used across industrial sectors: Level, Flow, Temperature, and Pressure. Through real-time process loops, continuous operation, industrial instrumentation, and advanced control strategies, participants gain practical exposure to industrial automation concepts used in chemical, pharmaceutical, food processing, water treatment, energy, and manufacturing industries.

The modular architecture allows users to study both basic and advanced process control techniques including On/Off control, PID control, feedforward control, permissive logic, alarm management, process interlocks, disturbance handling, and process optimization.

Designed using industrial-grade aluminum extrusion structures and process components, the system provides a safe, reliable, and repeatable platform for engineering colleges, technical institutions, vocational training centers, industrial training departments, and Industry 4.0 laboratories.

Key Features & Benefits

• Industry-oriented process automation training platform
• Real industrial Level, Flow, Temperature, and Pressure control loops
• PLC-based automation using Siemens S7-1500 controller
• Siemens Unified HMI for process visualization and control
• Supports On/Off and PID control strategies
• Industrial transmitters, sensors, pumps, and pneumatic control valves
• Closed-loop process control with real-time feedback
• Industrial IoT (IIoT) integration using Siemens Industrial Edge
• SCADA-ready architecture for monitoring and diagnostics
• Learning Management System (LMS) with structured training modules
• Supports Industry 4.0 concepts including data acquisition, analytics, and remote monitoring
• Modular and expandable design for future upgrades

Integrated Training Modules

• Level Control Module
• Flow Control Module
• Temperature Control Module
• Pressure Control Module
• PLC and HMI Integration Module
• Industrial IoT (IIoT) Module
• Learning Management System (LMS)
• Workstation with PLC, HMI, and SCADA Software

Level Control Training

• On/Off level control using solenoid valves
• Continuous PID level control using pneumatic control valves
• Level sensor integration and feedback control
• Process stability and disturbance analysis
• Industrial tank-based level control applications

Flow Control Training

• Ultrasonic flow measurement
• Differential Pressure (DP) flow measurement
• Flow control using pneumatic control valves
• PID-based flow regulation
• Flow verification using manual indicators

Temperature Control Training

• Heat exchanger-based process temperature control
• RTD sensor integration
• Feedforward and permissive control logic
• Closed-loop PID temperature control
• Thermal process optimization and disturbance handling

Pressure Control Training

• Pressure measurement using industrial pressure transmitters
• Differential pressure sensing applications
• Pneumatic pressure control valves
• PID pressure control loops
• Industrial pressure regulation concepts

Industrial IoT & Industry 4.0 Integration

• Siemens Industrial Edge integration
• Real-time data acquisition and analytics
• Edge-to-cloud connectivity
• Dashboard-based visualization
• MQTT and OPC UA communication concepts
• Condition monitoring and smart manufacturing applications

Learning Outcomes

• Understand industrial process automation architecture
• Learn operation and tuning of Level, Flow, Temperature, and Pressure loops
• Develop PLC programming skills for process control applications
• Create HMI screens for monitoring and operation
• Implement PID control and process optimization techniques
• Integrate industrial instrumentation with PLC systems
• Configure alarms, interlocks, and safety functions
• Apply SCADA concepts for industrial process visualization
• Understand Industrial IoT and Industry 4.0 technologies
• Gain practical skills directly applicable to process industries

Mechanical Specifications

• Industrial aluminum extrusion structure
• Heavy-duty powder-coated steel frame
• Castor wheels with brakes
• Overall Dimensions: 2080 mm × 1000 mm × 1820 mm (L × W × H)
• Work Surface Dimensions: 2080 mm × 1600 mm

Software & Workstation

• Siemens STEP 7 (TIA Portal)
• WinCC Advanced SCADA Software
• Industrial process visualization and diagnostics
• PLC-HMI-SCADA integration platform
• Preconfigured workstation for programming and experimentation