Computer Controlled Organic Rankine Cycle Unit (TORC)
PL-411585
The Computer Controlled Organic Rankine Cycle Unit (TORC) allows the student to study the complete organic Rankine Cycle (ORC) process and its components, as well as all the key operating variables.
The system operates with the organic working fluid (R‑245fa) which is vaporized by a controlled heat source. Initially, the fluid is pumped through a plate heat exchanger (pre‑heater) using tap water heated from the condenser in countercurrent. It then flows into two plate exchangers acting as the main cycle evaporator, where superheated water up to 150 °C provides the heat via a computer‑controlled boiler with PID regulation and safety level switch.
Following heat transfer, the organic vapor expands through a turbine, generating electrical power which is measured. At the outlet, the vapor is condensed using a water‑cooled plate exchanger, and the warmed cooling water is redirected to the pre‑heater to recover waste heat. The condensate is collected in an intermediate tank with level actuators; once full, the working fluid is pumped back to complete the cycle. The heat and cooling circuits are completely isolated from the turbine and working fluid.
This computer‑controlled educational unit is supplied with the EDIBON SCADA System, and includes: the unit itself, a Control Interface Box, a Data Acquisition Board, and comprehensive Software Packages for Control, Data Acquisition, and Data Management, enabling full monitoring and control of all process parameters.
- TORC. 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.
- Evaporator:
- Computer controlled (PID control) boiler of 15 kW for superheated water to 150 ºC.
- It includes:
- Safety valve calibrated to 6 Bar.
- Safety pressure switch as filling safety measure for the boiler.
- Manometer of 0 – 6 Bar.
- Safety thermostat (150 ºC).
- Safety level switch.
- Automatic air purger.
- Expansion vessel.
- Automatic feeder regulated to 1.5 Bar.
- Driving pump.
- Three Plate exchangers:
- Exchanger nº 1 (preheater): six plates.
- Exchanger nº 2: twenty plates.
- Exchanger nº 3: twenty plates.
- Condenser: exchanger of twenty plates.
- Triple piston pump to impel the organic fluid, with power variator, computer controlled.
- Scroll turbine and generator.
- Electric load.
- Organic fluid condensed tank with two level actuators.
- R-245fa organic fluid storage tank with two level actuators.
- High pressure safety pressure switch to prevent overpressures.
- Two computer controlled solenoid valves.
- Air purgers.
- Sight glasses along the circuit to visualize the state of the organic fluid.
- Sensors:
- Thirteen “J” type temperature sensors distributed along the process.
- Flow sensor to measure the cooling water flow through the condenser.
- Flow sensor to measure the organic fluid flow through the circuit.
- Three pressure sensors to measure the outlet pressure of the evaporator and the inlet and outlet pressure of the turbine, pressure sensors.
- Sensor to measure the power consumed by the generator.
- Sensor to measure the power consumed by the pump that impels the organic fluid.
- Speed sensor of the turbine
The complete unit includes as well:
- Advanced Real-Time SCADA.
- Open Control + Multicontrol + Real-Time Control.
- Specialized EDIBON Control Software based on LabVIEW.
- National Instruments Data Acquisition board.
- 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 and 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 EDIBON Scada-Net (ESN) System which enables multiple students to simultaneously operate many units in a network.
- TORC/CIB. Control Interface Box.
- TORC/CCSOF. Computer Control + Data Acquisition + Data Management Software.
- Cables and Accessories, for normal operation.
- Manuals: This unit is supplied with 8 manuals. Required services, Assembly and Installation, Interface and Control software, Starting-up, Safety, Maintenance, Calibration and Practices manuals.
EXERCISES AND PRACTICAL POSSIBILITIES TO BE DONE WITH THE MAIN ITEMS
- Demonstration of the Organic Rankine Cycle (ORC).
- To measure the heat supplied by evaporator.
- Determination of the efficiency of an Organic Rankine Cycle (ORC).
- Energy balances determination in the evaporator and the condenser.
- Determination of the turbine efficiency.
- To make energy balance.
- To measure the electrical power generated.
- To study the influence of the organic fluid flow and temperatures on the generation of electrical power.
- Study of the specific vapour consumption of the turbine.
- Speed measurement of the turbine
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