607 - Process Trainer, Heat Exchanger

Product Dimensions
(L x W X H)
33.5in x 48in x 76in (860 x 1210 x 1930 mm)
425 lbs. (193 kg)

Shipping Dimensions
750 lbs. (340 kg)

A full-size, working, fluid system allowing for hands-on training in measurement and control as it relates to temperature in an industrial fluid process system. With optional instruments, the device allows control loops to be configured employing feedback and feed-forward control methods, incorporating thermocouple or RTD inputs. Variable demand and supply disturbances can be inserted using a solenoid valve in combination with a metered ball valve.

Four, industrial-quality, heat exchangers and two immersion process heaters are provided within the unit, allowing for the creation of dynamic temperature control systems. Both the hot and utility legs can be controlled using industrialquality pneumatic control valves. Common cold tap water can be used as a cooling water source and is incorporated through quick-disconnect fittings and valves at the rear of the training aid. An optional chiller can also be provided, creating greater temperature differentials, and more dynamic control experiments.

Areas within the piping system subject to elevated temperatures are CPVC, providing protection from elevated process heat levels. The balance of the system incorporates clear, PVC piping allowing the process flow to be seen directly. The device contains a 24 volt DC power supply and two air regulators with gauges creating an instrument air supply. All 24 volt power sources, air sources, and operational switches are conveniently located on the front panel face.

Additionally, the training aid can be used to study, in depth, the fundamentals of heat transfer within industrial heat exchangers. Four industrial heat exchanges are provided including a plate-type exchanger, and three varieties of shell and tube heat exchangers. The piping system includes multiple thermowells allowing for temperature measurement at inlet points and outlet points on both process sides of the exchangers. A system of solenoid valves and piping manifolds allows for selection of individual heat exchanger’s for use and study. Additionally, these same features allow for flow reversal creating both concurrent and countercurrent flow capabilities. Four, digital temperature meters are provided, allowing for direct indication and study of each exchanger using modular RTD’s in tube-side and shell-side flow as required.

A variety of optional equipment allows for complete system automation and control, using PLCs or conventional PID controllers, temperature controllers, and related instruments.

In general, the device has the look and feel of actual industrial hardware, and allows for a broad range of exercises in temperature and flow measurement and control. Additionally the training aid provides a framework for study of the heat transfer process. Through its standard features and its adaptability to optional, specialized control and measurement equipment, it can replicate many unique industrial control arrangements. Standard, user-supplied or user-specified instruments, of any brand, can be easily installed, either on a mounting stanchion or on the built-in, 19" instrument rack.
One-piece, welded, 1/8" wall, tubular steel frame. 3/16" steel mounting floor.
Four, 4" diameter casters, two with locks.
Integral, 19" x 70" high, instrument mounting rack, with silk-screened instrument and controller panels.
Front panel faces fabricated from 1/2" MDF board and covered with a high-durability, laminate.
3/4" diameter, CPVC and clear PVC piping components throughout.
Front panel-mounted, operator control panel, includes switches and pilot lights for: pumps, solenoid valves, and immersion heaters, as well as control relay connections for equipment, 24 VDC power supply terminals and electric “free line” connections. A regulator with gauge controlling a 0-60 psi air supply with associated fittings and a second instrument air gauge with associated fittings is also mounted on this panel. An operator panel is also provided allowing for manual or semi-automatic operation, via contacts, of flow control solenoid valves.
Master instrument air supply regulator.
Circuit breaker with GFI protection.
Two variable-area flow meters.
5 brass thermowells, facilitating temperature measurement at each heat exchanger.
Two orifice flow assemblies with associated flanges and tubing connections.
Power distribution panel, mounted in instrument rack, including on/off power switch, GFI receptacle, fuses for all primary circuits, and 12 electric “free line” connections to front panel.
Quick-disconnect fittings throughout, allowing for convenient attachment of instruments.
One diaphragm-type, industrial control valve.
One diaphragm-type, industrial, three-way control valve.
Multiple solenoid valves allowing for heat exchanger selection and concurrent/crosscurrent operations.
Four, thermowell-type bi-metal, thermometers.
Industrial-quality, multi-pass, shell and tube heat exchangers including: u-tube, single-pass, and multipass, straightflow varieties.
One plate-type heat exchanger.
Pipe stanchion, allowing for attachment of differential pressure transmitters and pressure transmitters at varying heights.
Primary reservoir, 20 gallon capacity, high-temperature polypropylene.
Four, on-board digital thermometers with related RTDs, allowing for measurement at any location on the device.
Centrifugal pump, ½ HP.
Two, immersion-type heaters, 4 KW each.
24 VDC Power supply.
Process quick-disconnect hose fittings, allowing for connection to other process control trainers.
Packaging for shipment via motor freight.
#060-1010 - CD, Process Control Basics
#080-467-1 - Video on temperature measurement (ISA).
#080-467-2 - Video on pressure measurement (ISA).
#080-467-3 - Video on level measurement (ISA).
#080-467-4 - Video on flow measurement (ISA).
#464-003 - Basic DC/AC/Analog Allen-Bradley SLC-500 PLC Package. - Allen-Bradley, Model SLC-5/03 PLC with features as follows: - 5/03 CPU with 8K memory. - 7-Slot rack. - DC Input card (16 inputs). - DC Relay output card (16 outputs). - AC Combination card (4 inputs and 4 outputs). - Analog Combination card (2 inputs, 2 outputs). - Power supply, 5A.
#464-009 - On-line/Off-line Programming Software w/Comp. Interface
#581-002 - Textbook, "The Condensed Handbook of Measurement and Control"
#581-012 - Textbook, "Industrial Control Electronics" (3rd edition) (Bartelt).
#582-002 - Textbook, "Measurement and Control Basics" (Hughes).
#583-002 - Textbook, "Fundamentals of Process Control" (Murrill).
#584-002 - Textbook, "Process Control Instrumentation" (Johnson).
#600-008B - Storage/Lockbox Accessory
#600-031 - Pitot tube flow assembly.
#600-032 - Venturi tube flow assembly.
#600-040 - Valve Positioner, Pneumatic
#600-041 - Control valve positioner, electro-pneumatic.
#600-097 - Descrete/Analog Allen-Bradley SLC-500 PLC Package (2 analog channels)
#600-098 - Descrete/Analog Allen-Bradley SLC-500 PLC Package (4 analog channels)
#607-001 - Instrument and Control Package for Temperature
#607-500 - Use/Exercise Guide (Additional)
• Twenty, 36" test leads.
• Twenty, 60" test leads.
• 150', 1/4" Diameter instrument connection tubing, of two colors.
• Fifteen, quick-disconnect nipples.
• Four, Bi-metal, Thermometers.
• Ten, tubing tees.
• Ten, tubing couplers.
• Orifice plate set, 3-piece.
• Use/Exercise Guide
208/230 VAC, 3-phase, 5 wire, 60 Hz or 220 VAC, single-phase, 50 Hz, city water, floor drain. Other electrical configurations are possible.
The courseware, useful in both a instructor-led and or a self-directed format, includes one of several optional textbooks, a course guide and hands-on exercises. Exercises include:

• Introduction to the Process Trainer, Heat Exchanger.
• Review of process instrumentation terms, abbreviations and designations.
• Investigating thermocouple operating characteristics.
• Temperature measurements using a thermocouple in a process.
• Investigating RTD operating characteristics.
• Temperature measurements using a RTD in a process.
• Flow versus differential pressure for an orifice plate.
• Calibration of a flow transmitter.
• Calibration of a square root extractor.
• Installation and calibration of an electronic flow measurement channel.
• Review of process control theory terms, abbreviations, and designations.
• Introduction to the Honeywell UDC 3300 universal digital controller.
• Introduction to the Foxboro 762 digital controller.
• Determining a temperature process’ operating characteristics.
• Determining a flow process’ operating characteristics.
• Open loop integral controller characteristics.
• Closed loop integral control in a temperature process.
• Closed loop integral control in a pressure process.
• Closed loop integral control in a flow process.
• Open loop proportional controller characteristics.
• Closed loop proportional control in a temperature process.
• Closed loop proportional control in a flow process.
• Open loop proportional plus integral controller characteristics.
• Closed loop proportional plus integral control in a temperature process.
• Closed loop proportional plus integral control in a flow process.
• Open loop proportional plus integral plus derivative controller characteristics.
• Closed loop proportional plus integral, plus derivative control in a temperature process.
• Closed loop proportional plus integral, plus derivative control in a flow process.
• Notch tuning of a flow process.
• Ultimate tuning of a flow process.
• Open loop tuning of a temperature process.
• Cascade control of a temperature process.
• Additional lessons to come specific to heat exchanger study.

This device has been designed for professionals for use under controlled circumstances for training only. DAC assumes no liability for injury resulting from the use or misuse of this product.
This device is being offered for training purposes only, and components cannot be used as replacement hardware in actual applications.
In accordance with DAC’s established policy of continuous improvement, these specifications and product descriptions are subject to change without notice. This information is the latest technical information as of the time of viewing or printing.