BOILER HEATING BATCHING

CONTROL TRAINERMODEL: SE 107

SOLTEQ®Equipment for Engineering Education & Research

HE Boiler Heating Batching Control Trainer (Model: SE107) consists of a liquid based process system design to

study a simulated boiler drum producing heated water to heat the product water from a batching tank via a shell and

tube heat exchanger. The system exhibits realistic response times, use standard industrial process instruments

and process equipments. On line measurements for boiler drum level, feedwater in flow, hot water outflow, drumpressure, hot and cold-water circuit temperatures for heat exchanger and other instrumentations are provided. The process

is continuous and suitable for 3-hour experiment session. The experimental capabilities are fully described in the experiment

section. Instruction manuals and courseware (in English) is provided.

Level Control Studies

For the purpose of level control studies, a simulated boiler

drum is fed with preheated feedwater via pump and

feedwater flow rate measured. Level transmitter

continuously measures the drum level. The level transmitter

is capable of measuring drum level in open or close tank

application using the differential pressure method. A heater

heats up the water in the drum and acts as an energy input

to the boiler. An ON/OFF temperature controller controls

the heater. Level switch is installed in the boiler drum to cut

off the electric heater if drum level is low. This can prevent

the heater from ‘burnt out’. Temperature and pressure

indicators are also provided for local indication. In case of

over pressure in boiler drum, air relief valve will be activated

and purge the excess pressure to atmosphere. Air regulator

provides the provision for the over pressure simulation. The

simulated output from the boiler is the heated water, which

is pumped out via pump to the heat exchanger and the

throughput measured by flow meter. Pressure transmitter

measures the pressure. Measurement of level, flow and

pressure will allow the implementation of 1, 2, 3 elements

control strategy on the simulated boiler.

T

SOLTEQ®

SOLTEQ

Equipment for Engineering Education & Research

Shell and Tube Heat Exchanger Studies

For the purpose of heat exchanger studies, the heated water

passes through the shell and tube heat exchanger tubes

while cold water is pumped through the shell and heat

transfer takes place. The product (heated cold water) is

then discharged into a batch tank.

Shell and tube heat exchanger studies, consist of 2 main

circuit, which is hot water circuit and cold water circuit.

Hot water circuit – Hot water source is provided by the

simulated boiler. A water circulation pump is used to pump

water from boiler drum into the shell and tube heat

exchanger. Hot water will enter and exit through the tube

side of the heat exchanger. Hot water is then flow back to

the pre-heater tank and re-cycle again using feedwater pump

into the boiler.

Cold-water circuit – Cold water in the cold-water tank is pump

using water circulation pump into the shell and tube heat

exchanger. Cold water enters and exit through the shell

side. A rotameter is installed to measure the water flow rate

before it is flow to the product tank. Water in the product

tank will either be used back or discharge to the drain. To

use back, the water in the product tank is pump to the cold-

water tank-using pump. To discharge a pump is used to

pump water into the drain. For load changes and

disturbances, various hand valves and solenoid valves are

installed to simulate a process plant environment. Local

instrumentation such as pressure and temperature gauges

is also supplied. Fault simulation capability is also included.

PROCESS DESCRIPTION

Boiler feed water is preheated in a water tank and pumped

through the feedwater circuit into a boiler drum. The water

is further boiled to produce “steam” which is then used as

the heating medium or the tube side of shell and tube heat

exchanger. The “steam condensate” flows backs to the

feedwater tank which also has a effect of raising the

feedwater temperature. This method of energy recycling

reduces the heating requirements of the preheater. Cold

water from a tank passes through the shell side and the

resultant heated product is collected in a batch tank. The

product can also be cooled down by circulating it through

an air cooled radiator which can then be reused as cold

water.

EXPERIMENTAL CAPABILITIES

Drum Level Control Studies

a) Single element drum level control - single loop PID

control

b) Two element drum level control - cascade PID loop

control

c) Three element drum level control - cascade and feed

forward PID loop control

Heat Exchanger Control Studies

a) Temperature control loop - single loop PID control

b) Hot water flow rate control loop – single loop PID control

c) Temperature and flow control loop - cascade loop PID

control

Batch Tank Temperature Control

a) Batch tank temperature control

b) Level control

Fault Simulations

SPECIFICATIONS

a) Drum Level Controller:

Type : Microprocessor based

Input : 4 to 20 mA

Output : 4 to 20 mA

Controls : PID and “Self tuning”

b) Product Temperature Controller:

Type : Microprocessor based

Input : 4 to 20 mA

Output : 4 to 20 mA

Controls : PID and “Self tuning”

c) ON/OFF Controller:

Type : Microprocessor based

Input : 4 to 20 mA

Controls : On/Off

d) Batch Controller:

Type : Microprocessor based

Input : 4 to 20 mA

Controls : On/Off

e) Recorder:

Type : Continuous pen

No of pen : 4

Chart : Z-fold

Chart speed : 3600 m/hr, Stepped

f) Level Control Valve:

Type : Globe

Actuator : Diaphragm

Size : 1"

Range : 0-100%

g) Temperature Control Valve:

Type : Globe

Actuator : Diaphragm

Size : 1"

Range : 0-100%

SOLTEQ

h) I/P Converter/Positioner:

Input : 4 to 20 mA

Output : 3 to 15 psig

i) Pressure Transmitter:

Range : 0 to 30 Psig

Output : 4 to 20 mA

j) Level Transmitter:

Range : 0 to 1000 mm

Output : 4 to 20 mA

k) Orifice D/P Transmitter:

Range : 0 to 60 LPM

Output : 4 to 20 mA

l) RTD Temperature Transmitter:

Range : 0 to 100oC

Output : 4 to 20 mA

m) T/C Temperature Transmitter:

Range : 0 to 100oC

Output : 4 to 20 mA

n) Hand Valve:

Type : Ball/globe

Material : Brass/Stainless Steel

o) Process Tank:

Range : a) Preheater : 120 L

b) Product : 120 L

c) Cold Water : 120 L

d) Boiler drum : 140 L

p) Relief Valve:

Type : Spring Loaded

Material : Brass/Bronze

q) Process Pump:

Range : a) Feedwater : 60 LPM

b) Steam circulation : 60 LPM

c) Product circulation : 40 LPM

d) Product cooling : 40 LPM

r) Vortex Flowmeter:

Range : 0 to 60 LPM

Output : 4 to 20 mA

s) Shell and Tube Exchanger:

Shell : 1

Tube : 2

Heat transfer area : 1.5 m2

Duty : 25 kW

t) Pressure Gauge:

Type : Bourdon Tube

Dial size : 100 mm

Range : a) 0 to 100 psig

b) 0 to 60 psig

u) Temperature gauge:

Type : Bimetallic

Size : a) 100 mm

b) 75 mm

Range : a) 0 to 120°C

b) 0 to 100°C

Material : Stainless Steel

v) Alarm Annunciator

No of points : 4

w) Fault Simulation Switch:

No of points : 5

OPTIONAL ITEMS

- RA

RADIATOR

Air cooled radiator

- DAS

SOLDAS DATA ACQUISITION SYSTEM

i) A PC with latest Pentium Processor

ii) An electronic signal conditioning system

iii) Stand alone data acquisition modules

iv) Windows based software

♦ Data Logging

♦ Signal Analysis

♦ Process Control

♦ Real-Time Display

♦ Tabulated Results

♦ Graph of Experimental Results

- CAL

SOLCAL COMPUTER AIDED LEARNING SOFTWARE

i) Interactive multimedia features

ii) Graphical simulation

iii) Experiment results samples

iv) Full experiment manuals

UTILITIES REQUIREMENTS

Electricity : 415VAC/3-phase/50Hz/

60Amps

Water Supply : 20 L @ 5m Head

OVERAL DIMENSIONS

Height : 1.83m

Depth : 3.05m

Width : 1.52m

SOLTEQ®Equipment for Engineering Education & Research

Our range of teaching equipment can be complemented with our

SOLDAS and SOLCAL software.

SOFTWARE & E - LEARNING

SOLDAS - Supervisory Control & Data Acquisition

- Data Logging

- Signal Analysis

- Process Control

- Real-Time Display

- Tabulated Results

- Graph of Experimental Results

SOLCAL - Computer Aided Learning

- Multimedia Features

- Interactive

- Graphic Simulation

- Experiment Result Samples

- Full Experiment Manuals

SOLTEQ®

Contact us for a catalog CD

SOLUTION ENGINEERING SDN. BHD.(Co. No. 174876-M)

Sales Office :

No.3, Jalan TPK 2/4, Taman Perindustrian Kinrara,47100 Puchong, Selangor Darul Ehsan, Malaysia.Tel. No. : +(603) 80758000Fax. No. : +(603) 80755784

R&D Office :

G-2A, Incubator 3, Technology Park Malaysia,Bukit Jalil, 57000 Kuala Lumpur, Malaysia.Tel. No. : +(603) 8996 0023

Email : solution@solution.com.myWeb site : http//www.solution.com.my/

AGENT:

Equipment for Engineering Education & Research

BUATAN MALAYSIA

MSC- StatusCompany

®

®