PADC — Computer Controlled Teaching Autonomous Pasteurization Unit
(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 and 10.
- Let us describe first the main items (1 to 6):
- 1 PADC. Unit:
Stainless steel frame.
Main metallic elements made of stainless steel.
Diagram in the front panel with distribution of the elements similar to the real one.
- Characteristics of the pasteurization process:
- Pasteurization capacity: 250 l/h.
- Water flow in the heat exchanger: 750 l/h.
- Thermal cycle: 4-75-30°C.
- Retention time: 20 seconds to 250 l/h of milk.
- Water temperature in the heat exchanger: 78°C.
- Power: 10 kW.
Start tank to introduce water in the beginning of the process and to clean the unit.
- Heat exchanger:
- Number of plates in the regeneration section: 11.
- Number of plates in the pasteurization process: 13.
- Type of plates (heat exchanger): CT-95.
- Surface of each plate: 0.032 m².
Computer controlled milk pump.
- Hot water circuit. It includes:
- Water tank with computer controlled heating element to heat the milk, power: 9 kW.
Computer controlled water pump.
Manometer.
- Security valve. Unit: PADC
Expansion vessel.
Purge valve.
Pressure regulator.
Retention tank to keep milk to the pasteurization temperature during a certain time.
Computer controlled pneumatic valve to recirculate milk if its temperature does not reach the
pasteurization temperature or to extract milk if its temperature reaches the pasteurization temperature
(automatic control (PID)).
- Flow sensor to measure the milk flow at the pump outlet, range: 0.21 – 50 l/min.
- Two “J” type temperature sensors: one is situated at the pneumatic valve inlet and the other is situated
at the retention tank outlet.
Six valves to direct the milk flow during the different steps of the pasteurization process.
Controller situated in the front panel allows a manual control of the unit.
Printer situated in the front panel allows to show a history with the start date and time, end date and time
and minimum and maximum pasteurization temperatures reached during the process.
- 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 and remote control for 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.
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Complete Technical Specifications (for main items)
- PADC/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
the PID parameters, at any moment during the process. PADC/CIB
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.
- Output range (V)=±10 V. Data transfers=DMA, interrupts, programmed I/0. DAB
- 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.
4 PADC/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.
PADC/CCSOF
Open software, allowing the teacher to modify texts, instructions. Teacher’s and student’s
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: PADC + PADC/CIB + DAB + PADC/CCSOF + Cables and Accessories + Manuals are included
in the minimum supply for enabling normal and full operation.
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