Computer Controlled Biomass Process Unit
The main element of the unit is the biomass boiler, which will heat the water that will flow through the other components transferring its heat. The boiler is a biomass boiler of 16 kW that works with pellet and other granulated fuels. The body of the boiler is made of steel with a thickness of 5 mm that guarantees a long operating life. It includes a burner made of high temperature stainless steel with self-cleaning system, which allows the use of several granulated fuels apart from Pellet.
The boiler has ashes extraction boxes; besides it facilitates the access to cleaning and maintenance areas. The boiler heats water that is impelled by a computer controlled circulating pump through the circuit. The unit also includes a computer controlled three-ways solenoid valve that distributes the water heated by the biomass boiler towards two primary circuits: one towards the double jacket of the storage tank to obtain domestic hot water and the other towards the unit heater to generate heating.
This valve, when activated, allows the passage of water towards both directions. On the other hand, when deactivated, it closes the water passage towards the unit heater and increases the water flow towards the hot water storage tank.
The capacity of the storage tank is 60 l. and it is made of AISI 316 Ti stainless steel. This material has an excellent behavior against corrosion and high temperatures. It has a double jacket through which the water previously heated in the boiler flows, constituting the primary circuit. There is a computer controlled solenoid valve, located in the tap water inlet line towards the storage tank to be heated, that
will be opened or closed according to the requirements.
The part of the unit where the heating generation is studied is formed by a computer controlled unit heater, located inside a PMMA box.
It allows the student to control the time required to heat the box up to the required temperature. The temperature control of that box is possible thanks to a PID control via software that acts on the three-ways solenoid valve.
The primary circuit is closed with the recycling of both the water from the circuit that has already given its heat in the storage tank and the water leaving the unit heater. Both lines are joined and enter the boiler again, thus closing the primary circuit. This Computer Controlled Unit is supplied with the EDIBON Computer Control System (SCADA), and includes: The unit itself + a Control Interface Box + a Data
Acquisition Board + Computer Control, Data Acquisition and Data Management Software Packages, for controlling the process and all parameters involved in the process.
With this unit there are several options and possibilities:
- Main items: 1, 2, 3, 4, 5 and 6.
- Optional items: 7, 8, 9, 10, 11 and 12.
Let us describe first the main items (1 to 6):
1. EBMC. Unit:
Anodized aluminum structure and panels of painted steel.
Main metallic elements of stainless steel.
Diagram in the front panel with similar distribution to the elements in the real unit.
This unit includes wheels for its mobility.
Biomass boiler of 16 kW. It works with pellets and other granulated fuels:
Computer controlled hot water circulating pump.
AISI 310 stainless steel burner.
Expansion tank of 8 l.
Safety valve (2.5 Bar).
Water content in the boiler: 45 l.
Biomass boiler with a capacity of 97 Kg.
Regulation of the temperature in the boiler: from 60ºC to 87ºC.
Automatic cleaning system for the burner and ashes.
It includes boxes for separation and removal of ashes (burner, furnace and fumes passing chamber).
Fumes temperature to minimum thermal power: 90ºC.
Connection to the smokestack: 80 mm of diameter.
Double jacket storage tank made of stainless steel of 50 l. for the DHW.
Computer controlled unit heater:
Power: 14 900 Kcal/h.
Air flow (at maximum speed of the fan): 1550 m³/h.
Box made of PMMA where the unit heater is located. PID control of the box temperature.
Computer controlled three-ways electronic valve.
Computer controlled solenoid valve located at the storage tank tap water inlet line.
3 Regulation valves of the hot water through the different circuits.
Manometer, range: 0-4 Bar.
10 “J” type temperature sensors.
3 Water flow sensors, range: 1.5-30 l./min.
The complete unit includes as well:
Advanced Real-Time SCADA and PID Control.
Open Control + Multicontrol + Real-Time Control.
Specialized EDIBON 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 EDIBON technical support, are always included.
Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic & Software).
Designed and manufactured under several quality standards.
Optional CAL software helps the user perform calculations and comprehend the results.
This unit has been designed for future expansion and integration. A common expansion is the EDIBON Scada-Net (ESN) System which enables multiple students to simultaneously operate many units in a network.
2. EBMC/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.
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.
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.
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.
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.
4. EBMC/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 on the computer 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 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.
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: EBMC + EBMC/CIB + DAB + EBMC/CCSOF + Cables ans Accesories + Manuals are included in the minimun supply for enabling normal and full operation.TENDER SPECIFICATIONS (for optional items)
a) Technical and Vocational Education configuration
7 EBMC/ICAI. Interactive Computer Aided Instruction Software System.
This complete software package consists of an Instructor Software (EDIBON Classroom Manager -ECM) totally integrated with the Student Software (EDIBON Student Labsoft -ESL). Both are interconnected so that the teacher knows at any moment what is the theoretical and practical knowledge of the students.
-ECM. EDIBON Classroom Manager (Instructor Software).
ECM is the application that allows the Instructor to register students, manage and assign tasks for workgroups, create own content to carry out Practical Exercises, choose one of the evaluation methods to check the Student knowledge and monitor the progression related to the planned tasks for individual students, workgroups, units, etc...so the teacher can know in real time the level of understanding of any student in the classroom.
User Data Base Management.
Administration and assignment of Workgroup, Task and Training sessions.
Creation and Integration of Practical Exercises and Multimedia Resources.
Custom Design of Evaluation Methods.
Creation and assignment of Formulas & Equations.
Equation System Solver Engine.
Report generation, User Progression Monitoring and Statistics.
-ESL. EDIBON Student Labsoft (Student Software).
ESL is the application addressed to the Students that helps them to understand theoretical concepts by means of practical exercises and to prove their knowledge and progression by performing tests and calculations in addition to Multimedia Resources. Default planned tasks and an Open workgroup are provided by EDIBON to allow the students start working from the first session. Reports and statistics are available to know their progression at any time, as well as explanations for every exercise to reinforce the theoretically acquired technical knowledge.
Student Log-In & Self-Registration.
Existing Tasks checking & Monitoring.
Default contents & scheduled tasks available to be used from the first session.
Practical Exercises accomplishment by following the Manual provided by EDIBON.
Evaluation Methods to prove your knowledge and progression.
Calculations computing and plotting.
Equation System Solver Engine.
User Monitoring Learning & Printable Reports.
Multimedia-Supported auxiliary resources.
b) Multipost Expansions options
8 Mini ESN. EDIBON Mini Scada-Net System.
EDIBON Mini Scada-Net System allows up to 30 students to work with a Teaching Unit in any laboratory, simultaneously.
The Mini ESN system consists of the adaptation of any EDIBON Computer Controlled Unit with SCADA and PID Control integrated in a local network.
This system allows to view/control the unit remotely, from any computer integrated in the local net (in the classroom), through the main computer connected to the unit.
- It allows up to 30 students to work simultaneously with the EDIBON Computer Controlled Unit with SCADA and PID Control, connected in a local net.
- Open Control + Multicontrol + Real Time Control + Multi Student Post.
- Instructor controls and explains to all students at the same time.
- Any user/student can work doing "real time" control/multicontrol and visualisation.
- Instructor can see in the computer what any user/student is doing in the unit.
- Continuous communication between the instructor and all the users/students connected.
- It allows an easier and quicker understanding.
- This system allows you can save time and cost.
- Future expansions with more EDIBON Units.
The system basically will consist of:
This system is used with a Computer Controlled Unit.
- Instructor’s computer.
- Students’ computers.
- Local Network.
- Unit-Control Interface adaptation.
- Unit Software adaptation.
- Mini ESN Software to control the whole system.
- Cables and accessories required for a normal operation.