SOLTEQ® Equipment for Engineering Education & Research

MODEL: SE 107

HE Boiler Heating Batching Control Trainer (Model: SE107) consists of a liquid based process system design to
T 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, drum
pressure, 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.
 SOLTEQ® Equipment for Engineering Education & Research

Shell and Tube Heat Exchanger Studies Drum Level Control Studies
For the purpose of heat exchanger studies, the heated water a) Single element drum level control - single loop PID
passes through the shell and tube heat exchanger tubes control
while cold water is pumped through the shell and heat b) Two element drum level control - cascade PID loop
transfer takes place. The product (heated cold water) is control
then discharged into a batch tank. c) Three element drum level control - cascade and feed
forward PID loop control
Shell and tube heat exchanger studies, consist of 2 main Heat Exchanger Control Studies
circuit, which is hot water circuit and cold water circuit. a) Temperature control loop - single loop PID control
b) Hot water flow rate control loop – single loop PID control
Hot water circuit – Hot water source is provided by the c) Temperature and flow control loop - cascade loop PID
simulated boiler. A water circulation pump is used to pump control
water from boiler drum into the shell and tube heat Batch Tank Temperature Control
exchanger. Hot water will enter and exit through the tube a) Batch tank temperature control
side of the heat exchanger. Hot water is then flow back to b) Level control
the pre-heater tank and re-cycle again using feedwater pump Fault Simulations
into the boiler.

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

using water circulation pump into the shell and tube heat a) Drum Level Controller:
exchanger. Cold water enters and exit through the shell Type : Microprocessor based
side. A rotameter is installed to measure the water flow rate Input : 4 to 20 mA
before it is flow to the product tank. Water in the product Output : 4 to 20 mA
tank will either be used back or discharge to the drain. To Controls : PID and “Self tuning”
use back, the water in the product tank is pump to the cold- b) Product Temperature Controller:
water tank-using pump. To discharge a pump is used to Type : Microprocessor based
pump water into the drain. For load changes and Input : 4 to 20 mA
disturbances, various hand valves and solenoid valves are Output : 4 to 20 mA
installed to simulate a process plant environment. Local Controls : PID and “Self tuning”
instrumentation such as pressure and temperature gauges c) ON/OFF Controller:
is also supplied. Fault simulation capability is also included. Type : Microprocessor based
Input : 4 to 20 mA
Controls : On/Off
PROCESS DESCRIPTION d) Batch Controller:
Type : Microprocessor based
Boiler feed water is preheated in a water tank and pumped Input : 4 to 20 mA
through the feedwater circuit into a boiler drum. The water Controls : On/Off
is further boiled to produce “steam” which is then used as e) Recorder:
the heating medium or the tube side of shell and tube heat Type : Continuous pen
exchanger. The “steam condensate” flows backs to the No of pen :4
feedwater tank which also has a effect of raising the Chart : Z-fold
feedwater temperature. This method of energy recycling Chart speed : 3600 m/hr, Stepped
reduces the heating requirements of the preheater. Cold f) Level Control Valve:
water from a tank passes through the shell side and the Type : Globe
resultant heated product is collected in a batch tank. The Actuator : Diaphragm
product can also be cooled down by circulating it through Size : 1"
an air cooled radiator which can then be reused as cold Range : 0-100%
water. g) Temperature Control Valve:
Type : Globe
Actuator : Diaphragm
EXPERIMENTAL CAPABILITIES Size : 1"
Range : 0-100%
 SOLTEQ® Equipment for Engineering Education & Research

h) I/P Converter/Positioner: u) Temperature gauge:

Input : 4 to 20 mA Type : Bimetallic
Output : 3 to 15 psig Size : a) 100 mm
i) Pressure Transmitter: b) 75 mm
Range : 0 to 30 Psig Range : a) 0 to 120°C
Output : 4 to 20 mA b) 0 to 100°C
j) Level Transmitter: Material : Stainless Steel
Range : 0 to 1000 mm v) Alarm Annunciator
Output : 4 to 20 mA No of points : 4
k) Orifice D/P Transmitter: w) Fault Simulation Switch:
Range : 0 to 60 LPM No of points : 5
Output : 4 to 20 mA
l) RTD Temperature Transmitter: OPTIONAL ITEMS
Range : 0 to 100oC
Output : 4 to 20 mA - RA
m) T/C Temperature Transmitter: RADIATOR
Range : 0 to 100oC Air cooled radiator
Output : 4 to 20 mA
n) Hand Valve: - DAS
Type : Ball/globe SOLDAS DATA ACQUISITION SYSTEM
Material : Brass/Stainless Steel i) A PC with latest Pentium Processor
o) Process Tank: ii) An electronic signal conditioning system
Range : a) Preheater : 120 L iii) Stand alone data acquisition modules
b) Product : 120 L iv) Windows based software
c) Cold Water : 120 L Data Logging
d) Boiler drum : 140 L Signal Analysis
p) Relief Valve: Process Control
Type : Spring Loaded Real-Time Display
Material : Brass/Bronze Tabulated Results
q) Process Pump: Graph of Experimental Results
Range : a) Feedwater : 60 LPM
b) Steam circulation : 60 LPM - CAL
c) Product circulation : 40 LPM SOLCAL COMPUTER AIDED LEARNING SOFTWARE
d) Product cooling : 40 LPM i) Interactive multimedia features
ii) Graphical simulation
r) Vortex Flowmeter:
iii) Experiment results samples
Range : 0 to 60 LPM
iv) Full experiment manuals
Output : 4 to 20 mA
s) Shell and Tube Exchanger:
UTILITIES REQUIREMENTS
Shell :1
Electricity : 415VAC/3-phase/50Hz/
Tube :2
60Amps
Heat transfer area : 1.5 m2
Water Supply : 20 L @ 5m Head
Duty : 25 kW
t) Pressure Gauge:
OVERAL DIMENSIONS
Type : Bourdon Tube
Height : 1.83m
Dial size : 100 mm
Depth : 3.05m
Range : a) 0 to 100 psig
Width : 1.52m
b) 0 to 60 psig
 SOLTEQ® Equipment for Engineering Education & Research

SOFTWARE & E - LEARNING

Our range of teaching equipment can be complemented with our

SOLDAS and SOLCAL software.

SOLDASTM - Supervisory Control & Data Acquisition

- Data Logging
- Signal Analysis
- Process Control
- Real-Time Display
- Tabulated Results
- Graph of Experimental Results

SOLCALTM - Computer Aided Learning

- Multimedia Features
- Interactive
- Graphic Simulation
- Experiment Result Samples
- Full Experiment Manuals

Contact us for a catalog CD

SOLUTION ENGINEERING SDN. BHD. AGENT:
(Co. No. 174876-M)
Sales Office :
No.3, Jalan TPK 2/4, Taman Perindustrian Kinrara,
47100 Puchong, Selangor Darul Ehsan, Malaysia.
Tel. No. : +(603) 80758000
Fax. 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.my
BUATAN MALAYSIA
Web site : http//www.solution.com.my/