Heat Exchanger Process Control Trainer

DAC Worldwide’s Heat Exchanger Process Control Trainer (607D) is a full-sized, working fluid system that allows for hands-on training in measurement and control as it relates to temperature in an industrial fluid process system. Using optional instruments, the device allows control loops to be configured employing feedback and feed-forward control methods, which incorporates thermocouple or RTD inputs. When coupled with a comprehensive student manual, the trainer creates a complete, self-paced learning system that reflects realistic industrial and commercial applications.

Using four (4) industrial-quality heat exchangers and two immersion process heaters, learners will allow for the creation of dynamic temperature control systems. Both the hot and utility legs can be controlled using industrial-quality 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.

In general, the training device has the look and feed 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, the system can replicate many unique industrial control arrangements.

Practice Hands-On Instrumentation Skills for Various Applications

This instrumentation training system features a one-piece, welded tubular steel frame with four (4) four-inch diameter casters. Standing 76 inches tall, the Heat Exchanger Process Control Training System features an integral instrument mounting rack with instrument and controller panels. The front panels of the trainer are fabricated from ½-inch MDF board and are covered with a high-durability laminate.  Clear PVC and CPVC piping components are used throughout the system.

Areas within the piping system that are 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 also contains a 24-volts DC power supply and two (2) 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 the fundamentals of heat transfer within industrial heat exchangers in depth. Four industrial heat exchanges are provided with the trainer, including a plate-type exchanger, and three (3) 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 exchangers for use and study. These same features allow for flow reversal creating both concurrent and countercurrent flow capabilities. Four digital temperature meters are provided, which allow for direct indication and study of each exchanger using modular RTD’s in tube-side and shell-side flow as required.

The trainer also includes a primary 208/230 VAC, 3-phase, 5 wire, 60 Hz, or a 220 VAC, single-phase, 50 Hz. Other electrical configurations are possible, as well. Standard accessories include twenty (20) 36-inch test leads, twenty (20) 60-inch test leads, 150-feet of ¼” diameter instrument connection tubing, fifteen (15) quick-disconnect nipples, four (4) bi-metal thermometers, ten (10) tubing tees, ten (10) tubing couplers, and a three-piece orifice plate set.

Hands-On Exercises and Learning Activities Lead to Realistic Results

DAC Worldwide’s Heat Exchanger Process Control Training System also features exercises and learning activities that focus more on results and less on secondary academic background information. This comprehensive training system offers content in instrumentation principles, with individual learning activities provided in a self-paced or instructor-led format. The integrated course features multiple activities, all of which include background information on the topic, hands-on experiments, and related review questions.

The curriculum includes several units of activities relating to instrumentation components, application, and physical properties. Individual topics discussed within the course include investigating thermocouple operating characteristics, calibration of a flow transmitter, determining a flow process’ operating characteristics, notch tuning of a flow process, open-loop/closed-loop integral controller characteristics, and much more!

Optional Student Activity Guide Available to Enhance Learning

A copy of this course’s Student Activity Guide is available with the training system. Sourced from the Exercises and Learning Activities, the Student Activity Guide takes the technical content contained in the learning objectives, and combines it into one perfectly-bound book. Several optional textbooks are also available for order. If you would like to inquire about purchasing additional Student Activity Guides or Textbooks for your program, please contact your local DAC Worldwide Representative for more information.

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