Computer Controlled Two-Stage Compressor Test Unit

The Computer Controlled Two-Stage Compressor Test Unit, is a unit that allows for studying single-stage compression and two-stage compression (compression work, efficiency, P-V curves and thermodynamic properties among others). Besides, it allows for studying compression with and without refrigeration in the intermediate stage.

ATENG 11876 — Computer Controlled Two-Stage Compressor Test 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, 10 and 11.
• Let us describe first the main items (1 to 6):
• 1HCDEC. 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.
• Priming tank: Volume: 5 l.
• Two-stage compressor:
• Power: 4 HP.
• Flow: 300 l/min.
• Maximum pressure: 14 bar.
  Four two-ways solenoid valves computer controlled.
• Maximum pressure: 12 bar.
  Two pressure tanks of 750 ml and 20 l.
  Three three-ways valves to make the circuit selection.
• Concentric tube heat exchanger. Cooling capacity:
  1580 W.
• Three relief valves. Maximum pressure: 10 bar.
• Four check valves. Maximum pressure: 10 bar.
  Two manual regulation ball valves to drain the
  condensates.
  Ball valve to drain the air.
  Ball valve to supply the water refrigeration to the heat
• exchanger. Unit: ATENG 11876
  Two pressure switches (high and low pressure).
• Instrumentation:
• Inlet lines to the compressor:
  Two “J” type temperature sensors at the inlet of the compressing cylinders.
• Two pressure sensors at the inlet of the compressing cylinders, range: 0 – 10 bar.
• Pressure manometer at the inlet of the high pressure compressing cylinder, range: 0 – 16 bar.
• Pressure manometer at the inlet of the low pressure compressing cylinder, range: -1 – 1 bar.
• Two flow sensors at the inlet of the compressing cylinders, range: 500 l/min.
• Working circuits:
  Three “J” type temperature sensors at the outlet of the compressing cylinders and in the tank.
• Three pressure sensors at the outlet of the compressing cylinders and in the tank, range: 0 – 10 bar.
• Pressure manometer in the tank, range: 0 – 16 bar.
• Cooling water circuit:
  Two “J” type temperature sensors at the inlet and outlet of the heat exchanger.
• Flow sensor at the inlet and outlet of the heat exchanger, range: 0.25 – 6.5 l/min.
• The unit is supplied with the required safety devices: safety googles.
• The complete unit includes as well:
  Advanced Real-Time SCADA.
  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.
  4

Complete Technical Specifications (for main items)

• HCDEC/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 computer control with flexibility of modifications from the computer keyboard
  of the parameters, at any moment during the process. HCDEC/CIB
  Real time computer control for pumps, compressors, heating elements, control valves, etc.
  Real time computer control for parameters involved in the process simultaneously.
  Open control allowing modifications, at any moment and in real time, of parameters involved in the
  process simultaneously.
  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 HCDEC/CCSOF. 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.
  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 passwords to facilitate the teacher’s control on the student, and allowing the access
  to different work levels. HCDEC/CCSOF
  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 11876 + HCDEC/CIB + DAB + HCDEC/CCSOF + Cables and Accessories + Manuals are
  included in the minimum supply for enabling normal and full operation.
  5