Process Description
The SPM-900 Condenser Process Simulation can be configured to condense
either saturated or superheated steam at a variety of process conditions.
The default configuration is to condense saturated steam at 500 PSIG and
470 Deg F to saturated liquid at 250 PSIG and 406 DEG F.
Steam vapor enters a countercurrent tube-and-shell type heat exchanger on the shell side. cooling water on the tube side is used to condense the steam. The condensate enters an accumulator, where the condensed liquid is drawn off by a pump. A vent line is provided to prevent over-pressuring or for partial condenser operations..
Approximately 50 KPPH of saturated steam vapor (500 PSIG and 470 DEG F)
is to be condensed to a saturated liquid (250 PSIG and 406 DEG F) using
217 GPM of 68 DEG F cooling water.
The condenser is a countercurrent tube-and-shell type heat exchanger.
The steam enters on the shell side while the cooling water enters on the
tube side. The condenser is designed to condense a maximum of approximately
100 KPPH (2 times the design rate) of steam.
The accumulator is a cylindrical drum 3 feet in diameter by 9 feet in length. The accumulator has a total capacity of 64 cubic feet or 476 gallons of fluid. At design conditions the accumulator provides approximately 2 minutes of holdup running half full.
In the event of a control valve failure all control valves are provided with a bypass valve that may be modulated manually.
All valves in the system have linear flow characteristics.
All piping, valves, and pumps are designed with sufficient capacity to process a maximum of approximately twice the design rate.
The vapor feed flow loop is outfitted with a flow controller (FIC-101),
a temperature indicator (TI-101) and a pressure indicator (PI-101). The
flow control valve has a bypass valve which can be modulated with HIC-101.
Cooling water flow is controlled by accumulator pressure controller PIC-201. A bypass valve (HIC-201) is provided around PCV-201. Cooling water flow rate is indicated by FI-201 and cooling water supply temperature is indicated by TI-201.
Accumulator pressure may also be controlled by PIC-301 which modulates a vent flow line. A bypass valve (HIC-301) is provided around PCV-301. Vent flow rate is indicated by FI-301.
Condensed vapor is pumped out of the bottom of the accumulator. A primary and spare pump are provided. These pumps can be started and stopped with switches HS-401 and HS-402 respectively.
Liquid level in the accumulator is maintained by level controller LIC-401, liquid flow is indicated by FI-401, and accumulator temperature is indicated by TI-401.
The condenser may be operated as a total condenser or a partial condenser.
As a total condenser, PIC-201 would be placed in automatic and PIC-301 would be placed in manual or with a setpoint higher than PIC-201.
As a partial
condenser, PIC-301 would be placed in automatic and PIC-201 would be placed
in manual with an output less than that required to totally condense all
the vapor that enters the condenser.
All faults can be failed high or low to any degree with any of 8 fault
function generators (step change, square wave, staircase, stairs, ramp,
sawtooth, slope, or sine wave). Faults can be programmed to start and/or
stop at various times during a simulation exercise.
- Fault 1: Vapor FCV-101 %
- Fault 2: Vapor HCV-101 %
- Fault 3: CW PCV-201 %
- Fault 4: CW HCV-201 %
- Fault 5: Vent PCV-301 %
- Fault 6: Vent HCV-301 %
- Fault 7: Liquid LCV-401 %
- Fault 8: Liquid HCV-401 %
- Fault 9: Vapor Temp Deg F
- Fault 10: Vapor Press PSIG
- Fault 11: CW Supply Deg F
- Fault 12: Heat Transfer %
- Fault 13: FC101 Transmitter
- Fault 14: PC201 Transmitter
- Fault 15: PC301 Transmitter
- Fault 16: LC401 Transmitter
- Fault 17: HS-401 Pump HP %
- Fault 18: HS-402 Pump HP %
You may create a virtually unlimited number of scenarios and training
exercises by programming the faults described in the previous section.
You can then establish performance standards for each one of those exercises.
Simtronics provides a number of exercises with established performance
standards for each process simulation. The objective, time to complete
the exercise, cause, effect, solution, and procedure for each exercise
is documented. You may modify these procedures to more closely reflect
your particular process plant operating procedures.
- Exercise 1: Design
- Exercise 2: Cold Start
- Exercise 3: Cooling Water Supply Fails
- Exercise 4: Pressure Transmitter PIC-201 Fails Low
- Exercise 5: Condenser Fouls