MANUAL AZUCARERO 2019

PRINCIPLES OF OPERATION

Eng. Silvio Peluffo

2019
IMPORTANT: The links of each chapter to MEGA, allow access to a Video,
which shows on the screen the development of the Chapter, that is, the
reading of the chapter combined with the respective images. To access,
using the link to the Cloud, where the Videos are stored by their size,
position the pointer on link (hand-converted-index), clicking left button with
the mouse. This action loads on screen from the link, the Chapter Video,
with a default MEGA video editor, which can be executed directly with
reduced or full screen. The MEGA video editor has to be used at least to
develop Chapters I and II, which have to do with the initial installation and
execution of Manual Azucarero. Afterwards, it is convenient, one at a time,
to download them all from the MEGA cloud, on the computer, clicking on
Download. This will allow you to save the video in the Download folder on
your computer. Copy or Move it to another convenient folder for Manual
Sugar 2019. Having all the Videos on the hard drive, makes it easy to run
with any .mp4 video editor, without having to be connected to the Internet.
From Chapter III onwards, the most convenient option is to run the Video
using the specific Video Editor provided by Manual Sugar 2019. In menu
bar, Prog. Auxiliares, click Abrir Video. It starts by displaying the Manual
Azucarero Editor display, in reduced mode, where the Seleccionar Video
button allows you to access the Dialog box, where you can search, select
and open the appropriate Video. The Video is automatically run and
displayed in full screen mode. The Pausa button allows you to pause it
momentarily, the display is changed to reduced mode, and the button text
changes to Continuar. Pressing it, the Video continues, the display is
displayed as full screen and the button text returns to Pausa. Thus it is
possible to continue, simultaneously running Manual Azucarero, with some
of the instructions of the Video, strengthening the learning. It is also
possible that the tracking is permanently, without stopping the Video, and
with the editor display in reduced mode, clicking on Pantalla Reducida, or
returning with Pantalla Completa, as appropriate for interactive real-time
actions between the Video and Sugar Manual. To repeat some part of the
Video without stopping it, use the mouse, click holding the left button,
dragging the slider, backward or forward as needed, restarting the Video at
the point where the mouse is released. When the Video starts, the slider
button is on the far left, and scrolls to the right automatically, to end at the
other end, when the Video ends. The Detener button terminates the
execution of the Video and allows you to select another one, while Salir
Video, stops the same and downloads the application. To restart, it is
necessary to return to the Menu of Manual Azucarero, Prog. Auxiliares –
Abrir Video.
 ÍNDICE

Chapter I: Installation – Uninstallation.

https://mega.nz/#!XUFSmKxR!MW4uoK4uOxSfyG2QCLRAD_mUVlcxpSDS9p4bGzC6pBY

Chapter II: Start the program. Description of the Available Tools.

https://mega.nz/#!2AcAFSZZ!VahoFtgW_3L6SXNGJbyE2k7TbcxO9y_sr3M5o_olj0U

Chapter III: Graphic Development of a Project.

https://mega.nz/#!bFt3WAzL!WiPTdMN9SooGnUDxBaLYdT9wQmSmnbKS7G3y0TCPk6o

Chapter IV: The Calculation Grid.

https://mega.nz/#!mBsHwChT!h_-tDJptyiTNnSOrPZ9s0roNsQKITFnaQ-9KudBZK_E

Chapter V: Calculation Grid. BombaCent.

https://mega.nz/#!DctRASba!TmMC6qfcSgdfkbdf28TllqttXP4NnaLm9-9BmfS8xOk
Chapter I: Installation – Uninstallation.
Manual Azucarero 2019 is provided with its setup.exe and Setup Manual
Azucarero 2019.msi installation files, either for the Demo version, or for the
individual of each sugar mill or institution that acquires it. Both files must
be saved in a specifically created folder, or on a pendrive, CD, or DVD. The
installation starts by double-clicking the setup.exe file. The Windows
installation system will guide you, presenting some message boxes, which
must always be approved without modifying any of the options, until the
process is complete. If the installation was successful, click the Close
option. On the screen, a sugar cane Mill icon should appear, with program
details, name and version, year, month, and number. In case the program
was already installed and an update or new version has been received, the
previous one must be uninstalled. The corresponding Windows application
must also be used to do this.
For Windows 10 : On the desktop (screen), right-click on the bottom left
(Windows icon). A list is displayed. Left-click on the first item, Applications
and Features, displaying a dialog box with the list of all the programs
installed on your computer. Search for Setup Manual Sugar, 2018 or 2019,
and right-click on Uninstall, which will start the process. This can
sometimes start late. Do nothing while the dialog box shows Preparing to
Remove.... Depending on the computer and the Operating System,
sometimes it takes a long time. Do not hurry and do not press the Cancel
button. If the uninstallation was successful, the box will close
automatically.
IMPORTANT: During installation or uninstallation, Windows interleaves a
special message box that prompts the user to continue if they are sure of
the program source. This option cannot be captured from the screen and
does not appear in the respective videos, but will be displayed in the run.
Press Yes.
For Windows 7 : On the desktop (screen), left-click at the bottom left corner
(Windows Start button). The menu is displayed. Left-click the item, Control
Panel, by displaying the Programs and Features box. Left-click Uninstall or
Change a Program and the list of all programs installed on your computer
appears. Search Setup Manual Sugar Manual 2018 or 2019, and double-click
left, and the You are sure that you want to uninstall Manual Sugar 2019
dialog box appears?.... Click the Yes option, which will start the process.
This can sometimes start late. Do nothing while the dialog box shows
Preparing to Remove.... Depending on the computer and the Operating
System, sometimes it takes a long time. Do not hurry and do not press the
Cancel button. If the uninstallation is successful, the box will close
automatically and the Mill icon will disappear from the desktop. In case of
any doubt see link below.
For Windows 8: On the desktop (screen), we position the pointer at the top
right, without pressing the mouse, and in a couple of seconds the options
menu is displayed. Swipe down and left-click on the item, Settings,
displaying another options box. Click left mouse in Control Panel. In the
box, click Uninstall or change a program and the list of all programs
installed on your computer appears. Search Setup Manual Sugar Manual
2018 or 2019, left-click, and an Uninstall button is activated. Click on the
option, which will start the process. This can sometimes start late. Do
nothing while the dialog box shows Preparing to Remove.... Depending on
the computer and the Operating System, sometimes it takes a long time. Do
not hurry and do not press the Cancel button. If the uninstallation is
successful, the box will close automatically and the Mill icon will disappear
from the desktop. In case of any doubt see link below.
These links are illustrations on YouTube and are not part of the 2019 Manual
Azucarero own videos.
https://youtu.be/jWGSK-vPaOs Windows 7
https://youtu.be/UNwNelASLpE Windows 8
Chapter II: Start the program. Description of the Available Tools.
If Manual Azucarero 2019 has been correctly installed, on the desktop
(screen) will appear the icon of a typical sugar cane Mill, with the name and
version of the program. Double-clicking on it opens the program, and
displays the window for the generation of the Flowchart, Flowsheet, or
Project, which we want to analyze. On the display, a welcome box or label,
temporarily appears, which is deleted by clicking on it or on the display. On
the display is highlighted the graphic surface or Diagram, with standard
dimensions, on which the project must be carried out. The dimensions and
background color can be modified from the menu bar. Normally the
dimensions of the Diagram are larger than those of the display, so we need
the horizontal and vertical scroll bars.
On the right side of the Diagram is a floating form called
Herramientas(tools), which contains the Elementos(elements) and Equipos
(equipments) icons available by the program for the graphic development
of a flowsheet or project. This form can be hidden or displayed again at
some point for space or aesthetic reasons by clicking on the menu bar
above the title Herramientas(tools). Both Elementos and Equipos can be
dragged from the Herramientas form to the Diagram, by clicking on the
respective icon, moving the mouse without pressing, so that with a new
click, position it in the desired place. This sets the Elementos and Equipos,
but not the Elemento Línea, which serves as special function to link one
Equipo to each other or to the Elemento Flecha.

- General Description.
Texto (text), Etiqueta(label): these allow to place in the Diagram any
indicative or clarifying text. The difference between the two is that
Etiqueta(label), can be fixed to any endpoint on a equipment, and will move
with it, Texto(text), cannot be fixed. To make modifications to both, they
must be selected previously, and with a second click, on the generic text or
on the text you want to change, it is also selected as you do with any text
cell that everyone knows, to perform the correction, and from the menu bar
Modificar Fuente, you can select Fuente(source), ( Arial – Tahoma), two
classics only, since the main objective of this program is strictly technical,
so, superfluous decorative elements do not abound. Follow, Estilo (Normal
– Negrita – Itálica – Itálica Negrita), which everyone knows. The other
Tamaño, Color Letra, Color Fondo, are too explicit. If a Texto or Etiqueta is
selected, by clicking the next Copiar Fuente option, the features of that font
are copied to a second selected font by clicking Pegar Fuente – A Fuente
Seleccionada. But if you choose Pegar Fuente – A Todas las Fuentes
Iguales, all equal fonts in the Diagram will change automatically. Another
option available in the menu bar, Etiquetas-Textos, allows actions to be
viewed later when working on a particular project.
Flecha(arrow): This is a visual and passive element, because it only serves
to indicate the start or end of a flow current represented by a Línea(line).
You also have options from the menu bar such as Modificar Flechas(modify
arrows) – Ángulo(angle), with a click on 0, 90, 180, or 270 degrees, allowing
you to rotate the Flecha(arrow) as appropriate for the project. This action
can also be performed more easily by rotating the mouse wheel or by right-
clicking on the Flecha(arrow) if the wheel is not available. The next option
is Color(color), which allows you to change the color of the Flecha(arrow),
pressing on Color, and select Amarillo(yellow), Azul(blue), Blanco(white),
Negro(black), Rojo(red) or Verde(green). Finally, with the click Eliminar
Flecha(remove arrow), it is possible to remove it from the Diagram. In all
cases the Elemento(element), must be selected. There is no other way to
remove it, as Flecha(arrow),is normally connected by a Línea(line),as input
or output to a Equipo(equipment). The Línea(line) will be removed together
with the Flecha(arrow).

Línea(line): It is a visual and active element, with a few exceptions, and

allows you to connect the Equipos(equipment), inserted in the Diagram, to
each other, to configure the flowsheet or project to be simulated. In a
Simulator, such as Manual Azucarero 2019, the Línea(line), represents the
pipe that links and transports a fluid, liquid, steam, gas, from one
Equipment to another, with a direction of flow. Each Equipo(equipment)
shown in Herramientas(tools), has its inputs and outputs specified in fixed
and precise positions that are displayed with small squares above the edge
of the representing figure, in the inlets and outlets , visibles only when is
selected the figure. Lines must be drawn in the correct direction, always
from one exit of the equipment to the entrance of another, for the
connection to be successful. When you try to do this, for example, from one
output to another output, the program warns you with an error message
and removes the faulty connection. A Line is primarily a conductor of all
the information of the transported fluid, i.e. the mass, volumetric flow, its
physical and thermodynamic properties and the flow of electrical or
mechanical energy. A connection can be made from an Flecha(arrow) to a
Equipo(equipment), or vice versa, being this passive connection, since it
does not carry information, it only has a visual effect. It is necessary as we
will see later, to enable certain actions. The active connection is the one
between two or more Equipos(equipments), and they are the main active
components, and each of them is represented, by a typical figure, similar
or sketch to real form. The figure highlights what the inlet and outlet pipes
would be for the different fluids, the ends of which are above the edge of
the figure, and on which the connection points, already defined above, are
located. All endpoints are displayed when a Equipo(equipment) is selected
by clicking on it. At those endpoints, the Líneas(lines) begin or end. The
figure is framed in a transparent container so that the figures do not suffer
clippings when they are overlapping. Equipos(equipments) are dragged
from the Herramientas(tools) floating form, just like the other
Elementos(elements), to position themselves according to the need for the
flowsheet or project in the Diagram. Equipos(equipments) represent a type
of Unit Operations, which can be found in the sugar industry. Below is an
overview of those used by Manual Azucarero 2019, and available in
Herramientas(tools). Each Equipos(equipments) will have its own chapter
with all the operational details of the Mathematical Model that rigorously
solves how it works in the flowsheet or project. Each Equipment inserted
in the Diagram has fixed, a Etiqueta(label), scrolling together, with a basic
text, which, in general, can be changed.
BombaCent : the title is an abbreviation of Centrifugal Pump, but in reality
this Equipment operates as any type of pump, centrifuges, or positive
displacement. Its figure and therefore its connection points, can change
position mirroring, i.e. it flips horizontally, to change the input, facilitating
the connection with other Equipment, and achieve a harmonic diagram
visually, since operationally it does not have changes. Mirroring occurs
with the mouse wheel, or with a right mouse click on the figure.
Caldera(Boiler) : is exactly a defined pressure and temperature steam
generator, whose fuel can be bagasse and natural gas. Its Mathematical
Model is complex and allows to analyze various operational options,
generally producing overheated steam. His figure does not support
mirroring.
Calentador(Heat Exchanger) : generic name, since it is a water, sugar and
alcoholic liquids, heat exchanger,with steam. Operationally it can be
selected as Vertical, Horizontal, or Plate Tube Heat Exchanger, typical of
the sugar industry. Like all equipments that support it, the selection is done
with the mouse, wheel or right click, which modifies the figure, with the
connection points, including the mirroring, and mainly the Mathematical
Model that solves it.
CentrífugaAut : represents an Automatic Centrifuge, for Sugars Pans
Massecuite, Type Batch, which can produce rich molasses and poor
molasses as appropriate. You can't mirror.
CentrífugaCont : is a Continuous Centrifuge, inclined basket, typical of the
sugar industry, which produces only poor molasses. You can't mirror.
Colectores(Collectors) : are Steam and Condensed Collectors or
Distributors only. Operationally they are active, as they can produce
variations in flow, pressure or temperature, which modify their energy
balance.
Colector5E1S : this is a Collector, which has 5 fluid inputs (steam,
condensates, hot water), and 1 outlet. Like most collectors in the sugar
industry, the dominant variable is pressure. In general, it is intended that a
Collector maintain a certain pressure, the regulation of which is automated,
injecting steam or decompressing it by a valve. Fluids of different pressure
and temperature can enter, but the output pressure must always be set, so
that the energy balance closes, calculating the output temperature. This
Collector can be rotated, to facilitate connections, with the mouse, right-
click or right-click, 0º, 90º, 180º, 270º, or menu bar, Modificar Diagrama –
Girar Equipo Seleccionado, left click on Girar 0º - Girar 90º - Girar 180º -
Girar 270º. (Modify Diagram - Rotate Selected Equipment, left click on
Rotate 0º - Rotate 90º - Rotate 180º - Rotate 270º).
Colector5E1S-H : is a generic name only, since it is a Collector that can
have from 2 to 10 fluid inputs. When this Equipment is selected from
Herramientas(Tools), dragged and inserted into the Diagram, it is presented
as a Collector of 2 upper inputs and 1 right side output. With the mouse,
right-click, you can increase the inputs one by one, up to a maximum of 10.
From the menu bar, you can rotate it, like all collectors. It is generally rarely
used.
Collector1E5S : this is a Collector (or rather a distributor), 1 input and 5
outputs. Therefore, pressure and temperature are defined, and only that
steam or condensate is distributed to other equipment. In fact, in practice,
i.e. in the factory, the equipment to which it is connected, are steam
demandings. Therefore, the pressure and temperature data are typical of
the fluid, while the mass flow is owned by the Consumer Equipment. This
will look better when analyzing the Machine's Mathematical Model in the
particular chapter. With the mouse or from the menu bar, it can be rotated.
CondensadorBar : is a typical Barometric Condenser. You don't need too
many explanations, for now. Operational details will be seen in the specific
chapter of this Equipment. You can't mirror.
Cuchillas-Defibrador(Knives-Shredder): This equipments, specifics in the
sugar industry, can be configured independently as Knives or Shreder,
selecting the option with the mouse, wheel or right click. Your operation
will also be detailed in the specific chapter.
Decantador(Clarifier) – Its name indicates it. The Mathematical Model is
common to all types of this Equipment, used in the sugar industry. The
mass and energy balance include the flash effect that occurs during the
input of the hot mixed juice flow, although in the figure, the output of this
steam does not have a connection point because it is not recovered. You
can't mirror.
Distribuidor(Splitter): This Equipment, with 1 inlet and 3 outputs, is a
collector that distributes, to another Equipment, the liquid fluid, water or
sugar, according to a percentage factor that is fixed and that in practice, in
the plant, is determined by a valve, manual or automatic. In general this
Splitter provides a certain amount of fluid to the connected equipment, but
under special conditions the destination Equipment may need a certain
amount, therefore, the mass flow is fixed by the destination Equipment.
This reverses the operational concept and the Distributor takes the value
of the mass flow and calculates the percentage factor of distribution. The
thermodynamic properties are of the fluid in the Splitter. It can be rotated
with the mouse or from the menu.
Distribuidor1E7S : is a splitter of 1 input and 7 outputs. Operationally it
works the same as the previous one.
Energía(Power) : works as an electrical power collector only. Many of the
Equipment in Herramientas(Tools), need or consume energy, this is a
collector that can be connected to its input with a Turbogenerator or not,
depending on the project, or a Start Flecha(Arrow), to indicate that that
electrical energy comes from outside the project.
Evaporador(Evaporator) : this equipment, although it can be analyzed
individually, usually works as a multi-effect project, with two, three, or the
necessary, and ending in a Barometric Condenser. This will be seen in more
detail in the respective chapter, where its operability is shown. With the
mouse, wheel or right click, you can select the options: Without Vegetable
Steam Extraction, with Extraction, and with or without input for Flashed
Steam, modifying the connection points for each. A design constraint in the
flowsheet requires always forming a multiple effect, sequencing
evaporators, without interspersing other Equipment. This means that,
although other Equipment has already been pre-inserted, once the first
evaporator has been inserted, it should only be continued with this
Equipment to be completed in an expected number. Also, if for any problem
you need to remove an Evaporator, you must eliminate them all before
generating another multiple effect.
Filtro(Filter) : As the name implies, this Equipment basically functions as a
Vacuum Filter of the mud that comes out of the clarifier.
Flash : works normally by evaporating a fraction of a pressurized liquid,
when discharged into another Lower Pressure Equipment, where it reaches
its new saturation temperature. This operation is known as flashing, and is
applied to condensates generally, to recover the steam produced, typically
in a multi-effect evaporator. This equipment has been designed with a slight
variant that allows, or not, to also enter the steam current that will receive
the flashing.
Intercambiador Calor(Heat Exchanger) : is similar to horizontal heater, but
applies only to the exchange of heat between two liquids, water,
condensates, and sugar solutions. You can mirror.
Intercambiador de Placas(Plate Heat Exchanger) : is similar to plate heater,
but applies only to the exchange of heat between two liquids, water,
condensates, and sugar solutions. You can mirror.
Mezclador(Mixer) : only serves to mix two flows of liquids, water and / or
sugar solutions.
Molino(Mill) : is one of the most important Equipment of a cane sugar
factory, and as such, its Mathematical Model is complex as you will see in
the corresponding chapter. It always integrates a project as a tamden
forming the Trapiche, of two or more Mills.
Refundidor(Remelter or Magma Mingler) : in the factory, it is more complex
mechanically, but, for the purposes of mass balance and energy in steady
state, it is a simple liquid-solid mixer with a different figure. It can be
mirrored.
Tacho Cocimiento(Vacuum Pan) : is a typical and very important UO in the
sugar industry. It is an Evapo-Crystalizer, individual, whose Mathematical
Model is not complicated, is only a concentrator of a mixture of sugary
liquids, operating in a vacuum, resolved from a balance of mass and energy
in steady state. The phenomenon of crystallization is too important and
complex, and although there are models that try to represent it, the
operational variables are so many and very specific to the design, type of
operation, quality of the fluids, etc. , that errors accumulate, and it is
difficult to arrive at reliable values. It will be seen in detail in the
corresponding chapter.
Tanque(Tank) : is a Distributor of 1 input and 3 outputs of sugary fluids,
and works the same as the one explained above.
Tanque1E5S : is the same as Tank with 5 outputs.
Tanque5E1S : works the same as the Mixer, but with 5 inputs.
Termocompresor(Temocompressor) : is a well-known equipment and used
in many process industries, as it allows, by its Venturi effect a high-
pressure, usually overheated steam flow, to drag a low-pressure, usually
saturated, steam current, increasing its energy so that it can be reused.
Your Mathematical Model solves the balance of mass and energy flows, but
not their dimensions and design, which can be obtained from a catalog of
different manufacturers.
Turbina(Turbine) : it is also a widely known and widely used equipment in
the process industries. It does not require further general explanations and
it is necessary to refer to the specific chapter by the operational details and
the Mathematical Model that solves them. It can be used as a Turbine, in a
mechanical drive and also as a Turbogenerator when the power consumed
comes from an electric power collector.
Turbina Extac.(Extrac. Turbine). : is a Turbine with a steam extraction,
intermediate pressure of high pressure steam, to operate other smaller
turbines or to power heating equipment. The Mathematical Model allows
you to analyze the Backpressure Turbine or Condensation option.
Chapter III: Graphic Development of a Project.
Manual Azucarero 2019, allows to assemble a flowchart, from Operation
Units(OP), whose basic description is presented in the previous chapter,
and each of them, using its Mathematical Model, rigorously simulates and
calculates each Equipment, characteristic of the sugar industry, such as
evaporators, centrifuges, cane mills, vacuum pans, turbines and steam
generators, etc., available in the Herramientas(Tools) floating form. The
previously selected units of operation are linked to each other with
Líneas(Flow Lines), through which they should circulate, hypothetically,
the actual fluids, representing part or all of the production process.
We start a flowchart or flowsheet, from the Archivo(File) menu, click Nuevo
Proyecto(New Project), or click Abrir Proyecto(Open Project), to analyze or
modify a previously saved one. All available equipments can be selected
from the Herramientas(Tools) floating form. The program works on two
planes, the flowchart itself and the Grillas de Cálculo(Calculation Grids),
one for each Equipment, where all the information of each one is displayed
and the calculation is performed automatically. The Diagram and Grillas de
Cálculo(Calculation Grids), can be saved or printed. Manual Azucarero
2019, is completed with the Programas Auxiliares(Auxiliary Programs),
which allow to solve other tasks such as conversion of units, physical and
thermodynamic properties of water, water vapour, sugar solutions, air,
ethanol, cyclohexane, etc., flow of fluids and others. These are dynamically
linked to the Calculation Grids of each Equipment, allowing to immediately
modify the results based on changes in variables such as pressure,
temperature, brix, flows, etc.

Start.
Initiated the New Project, a Centrifugal Pump is inserted into the Diagram,
dragging it from Herramientas(Tools). Then a Vertical Heater. This
elementary project will basically analyze the flow behavior of a sugary
liquid, such as Mixed Juice, driven from the pump through the heater. In
this chapter you will only work on the graphic plane, leaving the calculation
for the next chapter. Correct development of the flowsheet is vital, as an
error in it will invalidate the calculations. So linking Equipments correctly
is the initial and fundamental operation of a simulator. In this simple case
there is only one possible connection: the output from the pump drive to
the inlet to the heater. The other possible connections should be with other
equipment. Already arranged the two Equipments in the Diagram, proceed
to link them, clicking on the Línea( Line) icon in the floating form
Herramientas(Tools), and without pressing the mouse direct the pointer,
which now took the shape of a pencil, towards an exit of the Equipment ,
the flow of which shall be transported to the other. When the pointer-pencil
is positioned over the outlet, the figure may or may not be framed with a
double red line, which should not be paid attention, but to the small squares
that are clearly displayed on the inlet and outlet ducts on the edges , also
red, indicating the starting position, or termination, of a Line. When the
pointer-pencil is over the small square of red borders, transforms into
pointer-hand , which certifies that the position is correct and a Line can be
started by clicking left mouse on it. This requirement is indispensable.
Clicking starts plotting a temporary thin gray line, which starts from the
output and has a right-angle dwelling break or vertex. As you move the
mouse without pressing, the line extends horizontally or vertically
following the mouse pointer that now takes the pointer-pencil shape again.
If the Line is started from a Equipmente with a vertical output, the pointer-
pencil, drag the horizontal part of the Broken Line. Conversely, if you start
from a horizontal output, the pointer-pen drags from the vertical part. To
change direction, left-click on a clean surface of the Diagram to generate
another vertex or break, leaving the first parts fixed, vertical and horizontal,
and variables the new two. That generated vertex that is visible is very
important because it is a limit for the pointer-pen, which should not go back
over it, because it generates a faulty line. For a Line to be visually pleasing,
it must contain the vertices needed to overcome the obstacles in the
Diagram, i.e. the other Elements and Equipment, trying not to draw the Line
on any. It is also convenient, for visual effects, that the completion of the
Line, the arrow-point, ends in the same direction as the input, although if it
does not occur and the Line is left at right angles to the input, for lack of
practice, the connection is still correct. The Line is connected by left-
clicking on an entry on the destination Equipment, when the pointer-pen
becomes the pointer-pointer-index hand, over the red square of the entry,
which is called the endpoint. If the connection is successful, the Line from
the Source Equipment, to the Destination Equipment, the gray timeline
becomes a green double line, and the connection points, start and end, and
vertices (breaks) are visible. This condition or appearance is same that of
a Selected Line. If we click on the Diagram, the Line is no longer selected,
and it takes the default red color, with a minimum thickness whose value is
1. You can reselect it by clicking on it and take the double-line appearance
already described. Equipments can also be selected as will be seen later.
The default red line can be modified. By selecting a menu bar, Modificar
Líneas(Modify Lines) – Tipo(Type), you can click Llena(Full) – Rayas(Stripe)
– Puntos(Points) – Punto-Raya(Point – Strip), achieving a different look for
a clear identification, which can be enhanced by selecting Color and
clicking on Amarillo(Yellow)-Azul(Blue)-Blanco(White)-Negro(Black)-
Rojo(Red)-Verde(Green). Finally you can choose the Espesor(Thickness),
and click on 1-2-3-4, to complete a more than enough number of variations.
You can simplify the task by clicking Copiar Estilo(Copy Style) (from a
selected Line), and preselect another one to make it identical by clicking
Pegar Estilo(Paste Style). Sometimes it is necessary to remove a
connection, for which selecting it, click Eliminar Línea(Delete Line). This
operation removes the Line and if you have an Arrow at some end it also
disappears. A simple action is to access Usar Estilos Estándar(Use
Standard Styles), and click on one of the 11 styles shown. These styles are
fixed.
To this elementary project can be added other lines that will only be
passive, that is to say to or from an Arrow, which also has options from the
menu bar such as Modificar Flechas(Modify Arrows) – Ángulo(Angle), with
a click on 0, 90, 180, or 270 degrees, allowing you to rotate the Arrow as
appropriate in the project. This action can also be performed more easily
by rotating the mouse wheel or by right-clicking on the Arrow if the wheel
is not available. The next option is Color, which allows you to change the
color of the Arrow, depending on the Color, Yellow, Blue, White, Black, Red
or Green. Finally, with the click Eliminar Flecha(Remove Arrow), it is
possible to remove it from the Diagram. In all cases the Element must be
selected. There is no other way to remove it, as Arrow is normally
connected by a Line as input or output to a Computer. The Line will be
removed along with the Arrow.
As previously noted this elementary project and all the others are born with
a Label anchored to each Equipment, with a generic name that can be
modified for a more precise identification, that is to say change the name
and also the Source. To make modifications, you must select the Label,
previously, and with a second click, on the generic text or on the text you
want to change, it is also selected as you do with any text cell in other know
programs. From the Modificar Fuentes(Modify Fonts) menu bar, you can
select Font( Arial – Tahoma), two classics only since the main objective of
this program is strictly technical, so superfluous decorative elements do
not abound. Follow Estilo(Style), (Normal – Bold – Italic – Italic Bold), widely
known. The other options, Size, Color Letter, Background Color, are quite
explicit. If a Label is selected by clicking the next Copiar Fuente(Copy Font)
option, the features of that font are copied to replace in another Label, to
its font by clicking Pegar Fuente(Paste Font) – A Fuente Seleccionada(To
Selected Font). But if you choose Pegar Fuente(Paste Font) – A Todas las
Fuentes Iguales(To All Equal Fonts), all equal fonts in the Diagram will
change automatically. Another option available in the menu bar, Etiquetas-
Textos(Labels-Texts), allows actions to be viewed later when working on a
particular project. The project can be added a Text, which differs from the
Label, because it is not anchored or linked to a Equipmente. This can be
viewed when a Label is selected, as a double line appears from the Label's
selection frame to either the connection point of either a Equipmente or an
Arrow, which, when scrolling, drags the Label preserving the relationship
of Distance. In contrast, the Text is floating and can be located as
appropriate. In the Text, you can modify the font in the same way as in the
Label. Do not forget that an Arrow can be rotated, as explained above, from
the menu or with the mouse, as long as it is not connected to a Line; an
error message will appear on the display. Some Equipmente can also be
rotated, or mirrored (flipped horizontally), as specified in the descriptive
chapter, but must have no connection.
Typically, a project is designed graphically as easily as possible, trying to
minimize aesthetic availability, which you should just apply once it has
been completed and calculated or analyzed. It is not worth wasting time
with aesthetics, if we do not have results, except some, necessary not to
be confused visually. It is also convenient to save the project regularly, to
avoid any error that permanently invalidates it. This is done from the bottom
menu bar, selecting Archivo(File) and clicking Guardar Proyecto(Save
Project) or Guardar Proyecto Como(Save Project As...). It can also be saved
in top menu bar, click on the respective icon. In Archivo(File), click Nuevo
Proyecto(New Project), or top menu, click on the respective icon, far left,
download the Diagram with the current project and load a new Clean
Diagram. In general the top menu bar contains buttons, i.e. they are direct
action, have no options, some include their name next to an icon, others
only the icon, but all show their name when the pointer is moved over. In
Archivo(File), click Abrir Proyecto(Open Project), or the top bar icon, let
select an already developed project and put it in the Diagram. It is
noteworthy that while designing a new project or modifying a previous one,
it is necessary to save it from time to time to avoid loss by some error. In
Archivo(File), click Cerrar Proyecto(Close Project) works almost like Nuevo
Proyecto(New Project). Finally, in Archivo(File), click Exportar
Proyecto(Export Project), allows you to copy and save the Diagram, in one
of the detailed formats (.bmp, .gif, .jpg, .png). That is to say that it is not the
copy of the screen, but the copy of the Diagram, which has larger
dimensions generally. In this way, you can display the Diagram using any
graphic design program, pictures, photographs, etc. It should be clear that
what was obtained is only an image of the project, which is saved with the
respective extension. Continuing with other features of the project, this
when saved, is done in protected mode, that is, both Elements and
Equipment cannot be moved, to avoid unintentionally altering the visual
appearance of the Diagram. To remove this protection, in the bottom menu
bar, select Modificar Diagrama(Modify Diagram), click Eliminar Protección
en Diagrama(Remove Diagram Protection). In protected mode, when an
Element or Equipment is selected, the pointer remains as a pointer-arrow,
and cannot be moved. Removed protection, when a Equipment or Element
is selected, the pointer takes the form of a pointer-four points, and it can
moved. The Diagram may have dimensions smaller or larger than the
display, depending on the project needs. The default dimension is 1600x800
pixels, but selecting Modificar Diagrama(Modify Diagram), Modificar
Dimensiones Actuales(Modify Current Dimensions), click Altura(Height) or
Ancho(Width), and change the values. Similarly in Modificar
Diagrama(Modify Diagram), Modificar Color de Fondo(Modify Background
Color), Color, Modify Color, Select Available Colors, and in Estilo(Style),
Modify Style, you can select Gradiente(Gradient),intense color effect
degrading one direction of the Diagram, and Sólido(Solid), color intense
evenly.
Chapter IV: The Calculation Grid.
Manual Azucarero 2019 works on two planes, one graphic, the Diagram on
which the project is drawn, designed or assembled, or Flowsheet, which
will be analyzed and/or calculated, using the Elements and Equipment
available in the Herramientas(Tools) floating form. The information
generated from the Flowsheet automatically allows the formation of the
background, the so-called Grillas de Cálculo(Calculation Grids). As the
name implies, it is a set of true spreadsheets, one for each Diagram
Equipment, where all the information of each Equipment, flows, physical
and thermodynamic properties, input data, output, constructive data, and
others, by which the equations of the Mathematical Model solve the
calculation. The Grids generally remain hidden, but are displayed one at a
time, instantly, clicking on the Equipment. The Grid of that Equipment
contained in a floating form, can be moved as appropriate. It is hidden by
clicking on a clean point in the Diagram. The Calculation Grid takes various
dimensions, width and height, according to the information that is detailed,
but generally has a number of specific Columns and Rows. Columns, in
almost all computers correspond, that is, each one contains the same data
type for each flow. The Rows, except the 1, which describes the property
and the units of it, usually represent between 2 and 11, each flow that enters
(the first, dark gray background), and each flow that comes out (the others,
light gray background). The Grids of some Equipments are much more
complex than others, depending on the importance of the same and its
Mathematical Model. Some Rows particularly may be hidden, if the
Equipment is not connected in all its outputs and inputs. On other
Equipments, the Columns in your Grid are hidden, when the property it
represents does not exist.
The Grids must be loaded, i.e. displayed for the first time on the Diagram,
only when the Project Flowsheet is finished in its basic stage, that is,
complete, but with a minimum of aesthetics, by pressing the button on the
bar of the top menu Grillas de Cálculo(Calculation Grids) , and one will
appear for each Equipment, and for the same time, all together. They hide
by clicking on a clean point in the Diagram. Other possible actions with
Grids are executed from the bottom bar of the menu. Selecting Grillas de
Cálculo(Calculation Grids), and clicking Cargar Grilla Equipo
Seleccionado(Load Selected Equipment Grill), only the Equipment that was
previously selected is loaded. If, on the other hand, the Cargar Total Grillas
del Diagrama(Load Total Grids of the Diagram) is clicked, the same action
is executed as by clicking the Grillas de Cálculo(Calculation Grids) button.
This action is checked. Then click on Descargar Total de Grillas(Total Grids
Download), remove all of them, and the commented check disappears. The
last action Imprimir Grillas del Diagrama(Print Grids in the Diagram), which
is also executed from the Imprimir(Print) in Top Bar button, enables the
Print Grid form, which groups all the individual Grids, by Equipments and
alphabetical order. This is just a view of what the print will look like on the
paper, so it's not active. Like any print form, it can be configured to define
margins, Margen Inferior(Bottom Margin), Margen Izquierdo(Left Margin),
and Margen Derecho(Right Margin), value in centimeters. Dimensions, A3,
A4, Letter and Legal, with Sheet Orientation, Horizontal and Vertical. You
can also select Color Print or Black and White Print. With a check in Fit to
Page, the program will attempt to insert all grids into a single page. It is not
a good choice and is used very little. You should select Adjust Print %,
selecting a value that allows you to adjust the width of the Grids to the width
of the paper, which can be checked with Preview. The variable will be the
number of sheets to print, depending on the number of Grids in the project.
Finally click Print, and then CLOSE.
To explain how a Calculation Grid works, you start an elementary project
that contains only one BombaCent(Pump), dragging it to the Diagram from
Herramientas(Tools). Flow Lines will be added with the corresponding
Arrows to highlight all equipment entrances and exits. The project is saved.
Click the top menu Grillas de Cálculo(Calculation Grids) button, and it is
displayed in a reduced mode(width), i.e. the Grid is not displayed in its
entirety, so, to see the other hidden columns, make use of horizontal
scrolling. The Pump Grid has 6 rows and 21 columns. In all Grids, the first
column is used to display active connections with a value of 1 in the cell
and with a green background, which is now not visible because the
connection to Arrows is passive. Column 2 identifies the input streams
(cells with dark gray background) and the output streams (cells with light
gray background) with generic names. From column 3 to column 22, row 1,
they are descriptive only and detail the properties of the fluid and units.
Yellow cells are called data cells, and receive the information needed for
the calculation of the Grid containing the Mathematical Model of that
equipment, which has been selected as the better, for the most rigorous
results. Data in yellow cells can and should always be entered manually.
The data cells, when a Equipment is not connected are yellow, and only
have this color necessary for calculation, but if one Equipment is
connected to another, there is data that can come from that connection and
therefore the cell takes the white color and this is locked , cannot be
modified, meaning that the data that needs that cell is provided by another
Equipment and can’t be entered manually. Therefore, when a Equipment is
fully connected, it may be the case that it does not have any yellow cells. In
reality, most Equipment always have yellow data cells, because that data is
typical of the Equipment, i.e. it does not depend on the flow of information.
Particularly in this Equipment row 2 is the Input Fluid. It can be Water,
Sugary Fluid or Alcoholic Fluid and the calculation of its physical and
thermodynamic properties is automatic using the equations available in the
bibliography that give the most rigorous results. In the example grid you
can see that there are 6 cells for data that do not need further explanation.
When you manually enter a data, the numeric value takes red, simply to
indicate that the example data has been changed in black.
Chapter V: Calculation Grid. BombaCent.
The title is an abbreviation for Centrifugal Pump, but really this Equipment
operates as any type of pump, centrifuges, or positive displacement. Its
figure and therefore its connection points, can change position mirroring,
i.e. it flips horizontally, to change the input, facilitating the connection with
other Equipment, and achieve a harmonic diagram visually, since
operationally it does not have changes. Mirroring occurs with the mouse
wheel, or with a right mouse click on the figure. To explain how its
Calculation Grid works, an elementary project already shown as an example
is loaded again, containing only the Pump, with passive Flow Lines and the
corresponding Arrows, to highlight all the inputs and outputs of it. Clicking
on the top menu Grillas de Cálculo(Calculation Grids) button, and it is
displayed the same. The Pump drives the Input Fluid, which reaches the
aspiration of the Equipment, with a value of Pressure and Temperature,
data that are entered manually in this case, but that could come from
another equipment and then the respective cells would have been white
and white and blocked. The Output Fluid is supposedly done through a
pipe, and even another Equipment, located at a certain height. In this
example, because it is not connected, the pipe discharges into the
atmosphere and atmospheric pressure is calculated from the data to be
entered manually, from Alt.s/Nivel Mar(Height Above Sea Level), cell(3,10),
where the Pump is being operated. The suction is also supposedly
connected to a pipe, and both pipes, suction and output have a diameter,
necessary data, and it is possible to assign them an suction height that can
be negative or positive, and load losses resulting from the accessories,
valves, curves, etc., that are needed. Each of the data will be analyzed, with
comments in addition to the rather explicit title of the Grill. The default data
is zero when the cell is empty. Below is a little more detailed about the data,
following an order from the top row and to the last column. It simplifies the
position of cells by displaying in parentheses the first number as Row, and
separated by a comma, the second number as Column.
Data(2,3) : Mass Flow of Input Fluid (tn/hr). Data(4,3) : Output Fluid Mass
Flow (tn/hr). When the Grid of a Bomb is loaded individually, as is the
example that is currently analyzed, both cells have a yellow border, to
highlight that only one of this data can be used as such, that is, if you
manually enter a value in the cell(2,3) , Input Flow, the opposite data,
cell(4,3), Output Flow, stops being data to become a result, and the cell
becomes white. Conversely, entering a value in the cell(4,3), even if it is
white, changes to yellow, becomes data, and the cell(2,3), is modified as a
result and turns white. The Grid operates like this, because when a Bomb
is connected to another Equipment whose Grid requires its Input Flow to
be data, it is provided by the Pump exit. Therefore the cell that remains
yellow is the cell(2,3) of the Pump.
Data(2,7) : Input Fluid Temperature (ºC), value in suction. It is an elementary
data and does not require additional explanation.
Data(2,8) : Pressure of the inlet fluid (bar), at the inlet end of the suction
pipe. This value is automatically repeated in the cell(6,3).
Data(2,13) : Brix of the Input Fluid (%); by having a zero value, i.e. empty
cell, the program assumes that it is the water fluid, and calculates its
properties with the respective formulas. If a value is entered, the program
assumes that it is a sugary fluid and uses the corresponding equations.
Data(2,14) : Purity of Input Fluid (%). Data needed for a sugary fluid.
Data(2,20) : Solids in Input Fluid Suspension (%). To see this data, move
horizontal scroll, and the Gril go to the end, with the bar at the foot.
Data(3,9) : Height above the sea level of the Pump (m), that is, where the
factory plant is located. With the value in meters, the Grid calculates the
atmospheric pressure in the cell(6,10).
Data(4,7) : Pressure of the Output Fluid (bar), value at the end of the output
pipe(backpressure). That value can be the atmospheric pressure, or the
pressure of a collector, tank, or other equipment to which the Pump is
connected. This is the same value as in the cell(6,9), such as Presión
Impulsión(Drive Pressure).
Data(6,4) : Suction height (m), is the height of the suction pipe of the pump,
which can be negative, that is that the water column is a resistance to
overcome when the pump sucks from a source, or positive, when the
column apply a positive pressure on the aspiration when receiving the
discharge from another Equipment. It should not be forgotten that the
Pump is a Equipment that modifies the dynamic conditions of the fluid,
resulting in a balance of static energy (pressure per height) and dynamics
(pressure loss by the speed of the fluid circulating through the pipe and its
accessories).
Data(6,5) : Pressure Loss in Suction Pipe Accessories (m). Estimated value
for possible accessories, such as valves, curves, elbows, etc., that has the
pipe in the suction section, usually expressed in meters of water column.
Data(6,6) : Pump Output Height (m). Generally positive value, i.e. upwards,
but if there were some downward runs, the data will be the difference
between the two.
Data(6.7) : Pump Output Length (m). Logically it includes all sections
lengths, positive, negative and horizontal.
Data(6,8) : Pressure Loss in Output Pipe Accessories (m). Estimated value
for possible accessories, such as valves, curves, elbows, etc., that has the
pipe in the output section, usually expressed in meters of water column.
Data(6.9) : Rend(Efficiency) (%). It is the Hydraulic Efficiency of the Pump,
which can be obtained from the respective catalogues.
Data(6,16) : Diámetro Interior(Inner diameter) of the pipe (mm). Shown by
scroll the horizontal bar to the foot, to the far right.
In summary, the Grid calculates the Hydraulic Power (kW), necessary to
operate the Pump, shown in the cell(6,14), and the Effective Power,
cell(6,15), which is the value (kW) corrected by the Efficiency, which is
repeated in the cell(3,6), highlighted in green. Another important value is
NPSH (Net Positive Suction Head), i.e. the difference between the liquid
pressure in the pump suction and the liquid vapour pressure, usually in the
height units, and is calculated in the cell(6,21), also highlighted in green.
This value must be less than the value published by the manufacturer, in
the catalog with the characteristic curves of the selected Pump.
Next, we will analyze some simple examples for better illustration, which
will be in the folder Ejemplos Capítulo V(Examples Chapter V) obtained by
downloading the folders and files from the link:
https://mega.nz/#F!PR1hiAjA!YDLjqAvRC3NJ_w49alPY6A
this one that was sent opportunely by LinkedIn.
EXAMPLES CHAPTER V-Pumps.
Bomba-1.xml – This project is loaded, the most elementary, i.e. a Pump,
without any connection to another Equipment. Flecha(Arrow) connections
are only illustrative, but necessary, in order to properly operate the
Calculation Grid. With the Pump in the Diagram. From the menu click
Archivo – Abrir Proyecto(Open Project), and then click on Grillas de
Cálculo(Calculation Grids), to load the corresponding one for the Pump.
The Grid displays a default amount of data, in several yellow cells, and they
serve as guidance for the user, but others are empty because they are too
explicit. To run the project, you have to insert in the yellow cells, all the data
available or assumed to analyze the behavior of the Pump, changing, if
necessary, the existing ones or applying new values, which must be
meticulously controlled so that all grids have the desired data. Data cells
can only be empty, if the inserted or default data is zero. For the purposes
of assisting in the control, when a new data is inserted, the font color
changes to red, italic, and slightly higher. A few data are located on the
hidden right end of the Grid, so you always have to scroll it completely to
find a possible data, and return to its initial view. Some Grids, for a practical
matter, are in automatic mode, that is, when the value of a cell is changed,
the calculation is performed immediately. In the most, the calculation of the
Grid is in manual mode, and can be done with a double click on some empty
and white cell, to avoid errors, or by clicking on the Cálculo
Automático(Automatic Calculation) menu. In some Grids, the Mathematical
Model needs an iterative calculation, and while the Grids has a built-in
number of iterations, sometimes when the project is large, it is advisable to
repeat two or three times the click to Cálculo Automático(Automatic
Calculation), for greater safety. Changes in calculation values by iterations
can be tracked dynamically, in a Grid chosen and displayed in the Diagram.
In complex projects, it is advisable to always put some Grid in the
foreground, the one that best represents the important data, to see the
dynamic evolution of the convergence of results until stabilization. In this
example simply insert a mass flow of 200 t/h, mixed juice, with 15.0 Brix%,
84.0 Purity %, and 3.0% Solids (in suspension). All other data, by default, is
maintained. Cálculo Automático(Automatic Calculation) a two or three
times and the result shows that the power needed for the Pump is 81.10 kW.
If the fluid is changed to water, 0 % Brix and 0 % Purity, click Cálculo
Automático(Automatic Calculation), and the result shows that the power
rises to 86.94 kW, which was to be expected, since the pump handles a
volumetric flow, which changes from 188.98 m3/h, increasing to 200.60
m3/h , by effect of density. Any other data that is modified, for example, the
diameter of the pipe, Data(6,16), from 100 mm to 150 mm, produces
changes, in this case, a significant power drop to 39.21 kW. This type of
analysis, elemental, is multiplied when all variables are manipulated and
interacted, so a manual calculation is virtually impossible, and less if you
are to obtain reliable results.
Bomba-2.xml : this is another simple project, from the folder Ejemplos
Capítulo V(Examples Chapter V) obtained by downloading the folders and
files from the link to MEGA, as explained above. In it, the Pump drives the
fluid, feeding to a Juice Heater, which uses exhaust steam. From the menu
click Archivo – Abrir Proyecto(Open Project), and then click on Grillas de
Cálculo(Calculation Grids), and the two Grids are displayed. It is necessary
to clarify that the inputs or outputs of the Equipments, may not be data,
since their value can be calculated by the Mathematical Model, so, if there
is a connection, with a sense of natural circulation, the flow information
virtually goes in the opposite direction. That is, the equipment in question
does not receive a flow amount from the other equipment, it asks to the
other equipment the amount that it needs by calculation. However, in
general, the other data that defines the physical and thermodynamic
properties come with the flow in the right direction. In this example, the
Pump feeds the Heater, which under normal conditions receives the flow
as it is a data. Therefore, the information carried by the Flow Line is the
mass flow rate, and the data, usually pressure and temperature, that will
define the properties of the fluid, physical and thermodynamics, which are
automatically calculated in each Grid. The data is then inserted into the
remaining yellow cells in the Pump Grid, or the default ones are used, while
in the Heater, the grids that receive the Pump data, which were originally
yellow, are transformed into white cells , which are also locked, and cannot
be modified. In this case it feeds 200 t/h, of a sugary fluid such as Mixed
Juice, of 15.0% brix, 84.0 % purity, powered by a Pump whose general data
is kept by default, to a Heater, which uses exhaust steam of 2.00 bar and
155.0 ºC. The fluid reaches the Heater at 25.00 ºC and is heated to 75.03 ºC,
leaving the construction data of the Equipment by default, since the
operational details will be seen in Chapter VII, specific to the Heater.
Another detail to observe is the pump's output pressure, which was initially
explained, and is the pump drive pressure at the end of the virtual pipe. This
value that in the original Pump Grid was a data, cell(4,7) yellow, is converted
to white cell because the information comes from the Heater, cell(2,7), since
it is a product of the calculation of it, that is the sum of the pressure drop
of the fluid in the Heater , cell(7,10), plus discharge or output pressure,
cell(4,7), yellow, Hot Out flow, data, which could be atmospheric pressure,
if the Heater supposedly discharged into the atmosphere, or the pressure
of a hot juice receiving equipment. So the backpressure that has to
overcome the Pump, cell(4,7), is the data that returns from the Heater,
cell(2,7). It should be clear that all this analysis is done automatically when
the Grids are loaded. The following example will show in more detail how
some of the information or data flowing in the normal direction of the Flow
Line, and others go in the opposite direction. Finally, to complete the
example, you can enable Information Labels linked to Equipment inputs
and outputs, which can be preloaded with the Etiquetas(Labels) button on
the menu, or from the Etiquetas-Textos(Labels-Texts) menu, select Cargar
Etiquetas Total Equipos(Load Total Equipments Labels). Both actions
create small default labels with the word Text, located approximately, at an
ideal position, and other Input and Output. This Label text will then change
to a series of values, selected by default, as the most representative of the
Equipments, by clicking the Actualizar Grillas(Update Labels) button. This
last action will also save in the project all the data of the Grids, that is, those
that remain as such in the yellow cells, and the names of the fluids flowing,
either the default originals, or those that were modified for a better
identification. It is important to note that, if the grids were calculated, with
the Cálculo Automático(Automatic Calculation) menu button, the new
values will not be saved in the project file, if you do not click Actualizar
Etiquetas(Update Labels) again. There is an option, if you do not want to
insert the labels, to save the data, going to the bottom bar of the menu,
select Datos(Data), clicking Guardar Datos Total de Equipos(Save Total
Equipment Data). In addition, by selecting Ver Datos Equipo
Seleccionado(View Selected Equipment Data), another Special Label
opens, yellow background, that allows to show the data to be saved, which
will be hidden by clicking Datos(Data) again, which took yellow color, and
selecting Ocultar Datos Equipo Seleccionado(Hide Selected Computer
Data), also on a yellow background. The other actions will be seen later.
Bomba-3.xml : this more complex example consists of feeding water to a
boiler, previously heated in a Vertical Heater with exhaust steam, through
a Pump that takes cold water from a tank, which also supplies two other
heaters. While the Bomb is the Equipment explained in this Chapter, the
others in this example project, will only be basically detailed, to understand
how they operate in this case. From the menu click Archivo – Abrir
Proyecto(Open Project), and then click on Grillas de Cálculo(Calculation
Grids), to display them on the Diagram. By selecting the Boiler, the Grid is
visible, hiding the others. It is a complex grid, with a lot of data, and a lot of
information resulting from the calculation.
The Boiler produces steam burning bagasse and/or natural gas, based on
the default data shown, or from new values. Clearly it is observed that the
feed water, cell(4,3), the only connection enabled in this example from the
Heater, is not a data, is a result of calculation of the Mathematical Model,
applied in the grid of this equipment. The goal, as a fundamental rule for all
the equipments, is to make the Model work virtually, just like the Actual
Equipment in the factory. The Caldera only produces the steam requested
by consumers and for this, keeping the working pressure fixed,
automatically consumes the necessary bagasse and water, the latter being
the one that is interested in the project. That is, the flow of water to the
Boiler, is obtained by calculation, and therefore that data cannot be
modified and its cell remains white and blocked. It has already been
observed previously, that during the loading of the Grids, the program
analyzes all Equipments connections to define the virtual sense of the data
flow, which generally accompanies the sense of the Flow Lines, except for
some special cases such as this data from the feed water flow to the Boiler,
which goes in the opposite direction, and is automatically taken by the
Heater as data for its output flow, copies it into your Grid as input flow and
also transfers it as output flow for the Pump , and it copies it to your Grid
as an input stream and transfers it as an output stream for the Tank. A
similar thing happens with the pressure. In this case, analyzing the Boiler
Grid, you can see that the pressure is a data that must be inserted manually,
or leave the one provided by default, since its cell remains yellow. Just the
pressure on a real Boiler is a data of its own, and is set according to
operating conditions, such as Set-Point, of the Automatic Control System.
Therefore, this data will also go the other way, as described for the flow of
water, but with a variant in the Heater, since in this one adds its own loss
of load. This value received by the Pump at the end of the pipe is what was
explained above as Presión de Impulsión(Drive Pressure), in the Pump
Grid, Cell(4,7) and Cell(6,9). The total pressure that the Pump needs to
overcome, as already defined, will be the sum of the necessary drive
pressure, plus load losses, static and dynamic pipe and mounting
accessories. The Boiler Grid, having no connections, leaves the cell
enabled yellow(7,3), to manually enter the operation data, Steam Produced
120.0(tn/h), Pressure 20(bara) and Temperature 310(oC). The others will be
explained in Chapter VI, Boiler, and will not be modified. In the remaining
Equipment, as you can see by selecting each one, and showing your Grid
there is a lot of data, yellow cells, which could be changed, but in this
example, the default values are left. Always carefully check all grids so that
the data entered are correct and avoid errors in the calculation. Be careful
with the default data, as in some examples it may be suitable and in others
not and must be modified. With the data Vapor Produced, Pressure and
Temperature data, click Cálculo Automático(Automatic Calculation) menu
button, two or three times, leaving a Boiler Grid in the Diagram, or the most
significant, to see the dynamic evolution of the calculation until its
convergence. In this case it can be the Boiler Grid. In this one you can see
that for a production of 120.0 tn/h of 20.0 bara and 310.0 oC, are required
121.83 tn/h of water and 62.34 tn/h of bagasse. The other results will be
analysed later when this same example is used in Chapter VI, Boiler. The
flow data, Feed Water, is taken by the Pump, Heater and Tank, as seen in
the respective Grids. Pressure is increased from 20.0 bara to 20.14 bara, at
the heater entrance, cell(2,7), by its own loss of load, cell(7,10), and that
value is taken by the Pump as Drive Pressure, cell(6,9), replicated in
cell(4,7). As explained above, the total pressure to be overcome by the
Pump will be the sum of the static and dynamic load losses of the pump
assembly circuit. In this case, the Total Load Loss, cell(6.13), is 23.89 bar,
and the Effective Power, cell(6.15), 162.43 kW (corrected by Performance).
The Pump Inlet Fluid Pressure, cell(2,7), 1.0 bar, is set by the Tank, usually
given by its location at height within the plant, open to the atmosphere, or
failing that, plus its internal pressure, if it is a closed one. The Temperature,
cell(2,8), travels the way in the direction of the Flow Lines, from the Tank,
initial data, to the Boiler. As long as the Pump drives a cold fluid, the value
of NPSH (Net Positive Suction Head), in a project like this, will be greater
than the catalog value. For the current case, with a fluid at 30.0 ºC, the NPSH
cell(6.25) is 10.74 m, but if the water temperature in the tank rises to 90.0
ºC, the NPSH drops to 4.05 m, below the typical pump values that are
usually above 6.5 m. In other words, a suction pressure, cell(6,4), positive,
of 2.0 m is not enough to prevent the cavitation of the pump. Increasing the
value to 5.0 m, click Cálculo Automático(Automatic Calculation) two or
three times and the NPSH is increased to 6.33 m. In addition, other results
such as the Effective Power rising to 165.63 kW can be considered, for the
combined effect of the lower density (increment), and the higher suction
height (reduction). In turn the Heater improves its temperature, cell(4.8),
from 61.99 ºC, to 107.88 ºC, which impacts on boiler performance,
cell(11.19), increasing from 78.17%, to 78.23 %, but productivity,
Ratio(Vapor/Bagazo)Ratio(Steam/Bagasse),cell(6.11),improves from 1.92
(tn vap./tn bag.) to 2.07(tn vap./tn bag.). Manual Azucarero 2019, allows,
even with this simple example, to make many variations of the available
data, solving the project, and obtaining reliable results in a few seconds, to
select the most efficient or the most convenient option.