Computer Controlled Industrial Process Control Plant Deluxe

The The Computer Controlled Industrial Process Control Plant, allows users to understand the complexity of industrial automation, observe the interaction between different variables, and analyze how changing a setpoint affects process stability, bringing them closer to the reality of industrial plants.

ATENG 12668 — Computer Controlled Industrial Process Control Plant

(for main items)

• With this unit there are several options and possibilities:
• Main items: 1, 2, 3, 4, 5 and 6.
• Optional items: 7, 8, 9, 10 and 11.
• Let us describe first the main items (1 to 6):
• 1 ATENG 12668. Unit:
  Anodized aluminum frame and panels made of
  painted steel.
  The unit includes wheels to facilitate its mobility.
  Main metallic elements made of stainless steel.
  Diagram in the front panel with distribution of the
  elements similar to the real one.
• Main unit contains the following elements:
• Two pneumatic valves with Cv: 0.25. Actuator (I/P)
• from 0.2 to 1.0 bar for electric signal from 4 to
  20 mA.
  Two electronic valves for electric signal from 4 to
  20mA.
  Twelve solenoid valves, normally closed.
  Two solenoid valves, normally open, placed at the
  air loop and flow loop.
  Three differential pressure sensors. They have a
  range from -100 to 100 psi.
  Five temperature sensors, “J” type. These sensors
  are placed along the unit to control the temperature
  in different lines.
• Level sensor (effective length: 300 mm).
  Four level switches.
• Water pump: maximum water flow: 106 l/min and maximum pressure: 7 bar.
• Stainless steel water tank: maximum capacity: 100 l. It has five drains at its lower
  part. Two of them are placed at different height, middle and top of the tank.
• Stainless steel tank: Unit: ATENG 12668
• Maximum capacity: 200 l.
• Maximum pressure:16 bar.
  It has eight takings, but only six are used in this unit.
• In the upper part, there is a safety valve that opens when the pressure exceeds 4 bar.
  Two takings are used to measure the water height by the means of a differential pressure sensor.
  Other differential pressure sensor gives us the inner pressure.
• Service module contains the following elements:
• Heater unit:
• A tank with a maximum capacity of 80 l and an electrical resistance of 1.2 kW as maximum
  electrical power. The temperature control is placed in the electrical resistance.
  It has a safety valve and purge valve.
  The lower part of the unit has an inlet pipe (cold water) and an outlet pipe (hot water).
• Compressor unit:
• Maximum pressure: 10 bar.
  This unit has a regulating valve with a manometer to fix the outlet maximum pressure.
• Water system:
• Water tank, capacity: 400 l.
• Water pump: 3.0 bar and 2500 l/h.
  The inlet pipe of the tank has an automatic filling system.
  Drain valve in the water tank.
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Complete Technical Specifications (for main items)

• The complete unit includes as well:
  Advanced Real-Time SCADA and PID Control.
  Open Control + Multicontrol + Real-Time Control.
  Specialized Control Software based on LabVIEW.
  National Instruments Data Acquisition board (250 KS/s, kilo samples per second).
  Calibration exercises, which are included, teach the user how to calibrate a sensor and the
  importance of checking the accuracy of the sensors before taking measurements.
  Projector and/or electronic whiteboard compatibility allows the unit to be explained and
  demonstrated to an entire class at one time.
  Capable of doing applied research, real industrial simulation, training courses, etc.
  Remote operation and control by the user, as well as remote support from technical
  support, are always included.
  Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic & Software).
  Designed and manufactured under several quality standards.
  Optional ICAI software to create, edit and carry out practical exercises, tests, exams,
  calculations, etc. Apart from monitoring user's knowledge and progress reached.
  This unit has been designed for future expansion and integration. A common expansion is
  the Scada-Net (ESN) System which enables multiple students to simultaneously
  operate many units in a network.
• CPIC/CIB. Control Interface Box:
  The Control Interface Box is part of the SCADA system.
  Control interface box with process diagram in the front panel and with the same distribution that
  the different elements located in the unit, for an easy understanding by the student.
• All sensors, with their respective signals, are properly manipulated from -10V. to +10V. computer output.
  Sensors connectors in the interface have different pines numbers (from 2 to 16), to avoid
  connection errors.
  Single cable between the control interface box and computer.
  The unit control elements are permanently computer controlled, without necessity of
  changes or connections during the whole process test procedure.
  Simultaneous visualization in the computer of all parameters involved in the process.
  Calibration of all sensors involved in the process.
  Real time curves representation about system responses.
  Storage of all the process data and results in a file.
  Graphic representation, in real time, of all the process/system responses.
  All the actuators’ values can be changed at any time from the keyboard allowing the
  analysis about curves and responses of the whole process.
  All the actuators and sensors values and their responses are displayed on only one screen in the
  computer.
  Shield and filtered signals to avoid external interferences.
  Real time PID control with flexibility of modifications from the computer keyboard of CPIC/CIB
  the PID parameters, at any moment during the process.
  Real time PID and on/off control for pumps, compressors, heating elements, control valves, etc.
  Real time PID control for parameters involved in the process simultaneously.
  Proportional control, integral control and derivative control, based on the real PID mathematical
  formula, by changing the values, at any time, of the three control constants (proportional, integral
  and derivative constants).
  Open control allowing modifications, at any moment and in real time, of parameters involved in the
  process simultaneously.
  Possibility of automatization of the actuators involved in the process.
  Three safety levels, one mechanical in the unit, another electronic in the control interface and
  the third one in the control software.
• 3 DAB. Data Acquisition Board:
  The Data Acquisition board is part of the SCADA system.
  PCI Express Data acquisition board (National Instruments) to be placed in a computer slot. Bus
  PCI Express.
• Analog input:
  Number of channels= 16 single-ended or 8 differential. Resolution=16 bits, 1 in 65536.
• Sampling rate up to: 250 KS/s (kilo samples per second).
• Input range (V)=±10 V. Data transfers=DMA, interrupts, programmed I/0. DMA channels=6.
• Analog output:
  Number of channels=2. Resolution=16 bits, 1 in 65536.
• Maximum output rate up to: 900 KS/s.
  DAB
• Output range (V)=±10 V. Data transfers=DMA, interrupts, programmed I/0.
• Digital Input/Output:
• Number of channels=24 inputs/outputs. D0 or DI Sample Clock frequency: 0 to 100 MHz.
• Timing: Number of Counter/timers=4. Resolution: Counter/timers: 32 bits.
  The Data Acquisition board model may change at any moment, providing the same or better
  features than those required for the unit.
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Complete Technical Specifications (for main items)

• 4 CPIC/CCSOF. PID Computer Control + Data Acquisition + Data Management Software:
  The three softwares are part of the SCADA system.
  Compatible with actual Windows operating systems. Graphic and intuitive simulation of the
  process in screen. Compatible with the industry standards.
  Registration and visualization of all process variables in an automatic and simultaneous way.
  Flexible, open and multicontrol software, developed with actual windows graphic systems,
  acting simultaneously on all process parameters.
  Analog and digital PID control.
  PID menu and set point selection required in the whole work range.
  Management, processing, comparison and storage of data.
  Sampling velocity up to 250 KS/s (kilo samples per second).
  Calibration system for the sensors involved in the process.
  It allows the registration of the alarms state and the graphic representation in real time.
  Comparative analysis of the obtained data, after the process and modification of the conditions
  during the process.
  Open software, allowing the teacher to modify texts, instructions. Teacher’s and student’s CPIC/CCSOF
  passwords to facilitate the teacher’s control on the student, and allowing the access to different work
  levels.
  This unit allows the 30 students of the classroom to visualize simultaneously all the results
  and the manipulation of the unit, during the process, by using a projector or an electronic
  whiteboard.
  5 Cables and Accessories, for normal operation.
• 6Manuals:
• This unit is supplied with 8 manuals: Required services, Assembly and Installation, Interface and
  Control software, Starting-up, Safety, Maintenance, Calibration & Practices manuals.
• References 1 to 6 are the main items: ATENG 12668 + CPIC/CIB + DAB + CPIC/CCSOF + Cables and Accessories + Manuals are included in
  the minimum supply for enabling normal and full operation.
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