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We Make CHPCompetitive

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Table of Contents

40 Years of Global Experience

Turnkey Industrial Control Systems (ICS) for CHP Plants 3-4

Competitive Solutions

OPTI-TEMP System 5-8

Mita-Teknik Monitoring Unit (MMB) 9-10

Mita-Teknik Mobile Monitoring Unit (MMM) 11-12

Power Supply – Multiple Options 13-14

OPTI-SAVE System 15-18

Programming on Your Terms 19-20

Programming Languages 21-22

New and Improved Possibilities

Rødkærsbro CHP Plant’s new ICS 23-24

Rødkærsbro CHP Plant’s OPTI-TEMP System 25-26

We Make CHP Competitive

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Project ConsultingAnalysis, counselling and project description.

ServiceAttractive Service Contract – online help and updating of existing Control Systems.

TestTest, Documentation and Warranty.

Product DeliveryComplete Industrial Control System (ICS) delivery (hardware and software), Project Management and delivery of our Optimization Systems; OPTI-TEMP and OPTI-SAVE.

Contact to the AuthoritiesHandling legal documentation to the proper authorities.

Customer-specific Solutions We customize every project to the individual customer’s requirements and ensure that every step of the process is carried out according to plan;

Turnkey Solutions

Mita-Teknik delivers turnkey ICS for use in CHP Plants, and have for the past 40+ years delivered reliable Control Systems for various energy plants all over the world. We are your competent partner during the entire project, from idea to initialization of the completed plant. Our solutions are based on our extensive experience from developing and delivering more than 42,000 customized Complete Control Systems for the wind industry.

With divisions in Denmark (HQ), Ukraine, China, India and the U.S. we are positioned to handle tasks all over the world. Our customers describe us as the Precise, Quality-Conscious and Competitive partner, who in close corporation with third party suppliers ensures a quick and efficient project completion. Our dedication to Customer Partnering combined with our proactive approach to creating new solutions, ensures that we are always at the absolute forefront of the technological development.

Control Solutions

In addition to delivering complete turnkey Industrial Control Systems (ICS) for CHP Plants, Mita-Teknik can also upgrade and optimize existing systems. When choosing Mita-Teknik as your ICS supplier, you get;

› Competitive Prices› Reduced Operating Costs› High-level Customer Service

40 Years of Global Experience

In addition to delivering complete turnkey ICS for CHP Plants, Mita-Teknik can also upgrade and optimize existing systems. All projects are delivered as customized solutions.

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OPTI-TEMP is a fully automatic software and hardware package that effectively reduces your plant’s energy consumption by lowering the flow temperature. Your consumers will experience improved heating comfort as the system instantly reacts to registered data.

Wind, weather and OPTI-TEMP

A heating plant is obliged to always deliver the promised heating comfort to its consumers at the lowest possible cost. Factors, such as weather and grid insulation have critical impact on the amount of energy lost to ensure this. Increased demands from authorities and consumers to deliver more comfortable heating at lower prices, means that the heating plant operator is required to monitor wind, weather and consumption patterns 24/7 – a demanding task, which we can help you solve by introducing the OPTI-TEMP System that dynamically optimizes the flow temperature, pressure and flow of the heating plant.

Software and Gateway Trend Analysis

OPTI-TEMP consists of two software modules; one for collecting and calculating data from the Mita-Teknik Monitoring Unit (MMB) and one for collecting and calculating weather data. All data is stored and processed in Mita-Teknik’s powerful PLC, the WP4100, and presented in trend curves with 5 minute logs each day, month or year in up to 20 years in the SCADA software program, Gateway.

OPTI-TEMP System

Control Principle

The OPTI-TEMP System is a complete hardware and software system, consisting of;

› 1-5 Mita-Teknik Monitoring Units (MMB) › 1 Weather Station› 1 WP4100 PLC to collect and transfer data to Gateway or the existing SCADA software› Software module for optimizing flow temperature› Software module for optimizing pressure and flow› Gateway software or data transfer to existing ICS

Mita-Teknik Monitoring Unit (MMB) is built into a metering box, which is placed on the pressure- and temperature critical points of the grid. Data is then transferred to the PLC via the Mobile network (GPRS). Based on the collected data, the correct pressure and flow is calculated.

In order to optimize the heating plant’s flow temperature, weather data is received directly from Mita-Teknik’s compact Weather Station. Based on this data and the physical spread of the grid, a correct z-point for controlling the heating plant’s flow temperature is calculated.

OPTI-TEMP from Mita-Teknik can, due to our Open Protocol Communication, be used in both existing and new ICS.Use Mita-Teknik’s OPTI-TEMP System to

dynamically optimize the flow temperature, pressure and general flow of the heating plant.

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Metering box/pitMMB I/0

ADSL/GPRS

Weather StationTemperatureWind SpeedWind DirectionBarometer pressure

Control Room

SCADA SystemLogging and AnalysisParameter SettingsReporting

Variable database(VDB)

Optimization Software Module Ensure correct flow and pressure

Control flow via analog signal connection to existing ICS

Pump 1 Pump 2 Mixer valve

Control flow temperature via analog signal connection to existing ICS

Optimization Software Module Ensure correct flow temperature

PLC/Controller WP4100

OPTI-TEMP System

OPTI-TEMP is a fully automatic software and hardware package that effectively reduces energy consumption and provides the consumer with more comfortable heating service.

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The Mita-Teknik Monitoring Unit (MMB) reduces the loss of energy in the grid and gains higher heating comfort for the consumers.

Analysis and Placement of Monitoring Units

Before installation, pressure- and temperature critical points in the grid must be defined. For this, Mita-Teknik offers to conduct a thermal-hydraulic analysis to locate the optimal points and number of placements for the MMB’s.

Installation and Accessories

Necessary connections:

› 1 temperature sensor – forward› 1 temperature sensor – return› 1 flow sensor – flow (e.g. 24 m3/h)› 1 pressure transmitter – forward› 1 pressure transmitter – return

All sensors are included.

The installation is carried out by the heating plant. The MMB must be connected to a power supply (see possibilities in the Power Supply chapter). The MMB also includes a SIM Data Card.

Mita-Teknik Monitoring Unit (MMB)

Main Station at the Heating Plant

A Main Station, Mita-Teknik Data Collector (MDC), is installed at the heating plant. The MDC consists of Mita-Teknik’s PLC, WP4100, which automatically collects data every 5 minutes from the installed Monitoring Units.

The MMB has a built-in GPRS modem, which automatically transmits data to the heating plant’s MDC via the Mobile network.

Data and Analysis

At the heating plant, a PC with Internet access is installed with the Gateway SCADA analysis software. Gateway presents all data with 5 minute intervals in tables, curves or report (text). Furthermore, Gateway transfers data to the heating plant’s ICS for optimization of flow temperature and pressure.

The return:

› Detailed analysis of consumption patterns and ability to supply› Analysis aimed at reducing the flow temperature› Automatic regulation of flow temperature With Mita-Teknik Monitoring Unit (MMB) it is

possible to collect data automatically from the grid in order to optimize flow and pressure, resulting in reduced energy consumption and higher comfort for the consumer.

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Consumer Satisfaction

Mita-Teknik’s Mobile Monitoring Unit (MMM) can be installed with consumers, who are experiencing heat supply problems and it can also be used for grid analysis. Installed at the consumer, MMM will automatically transmit data for analysis to your office PC and provide the consumer with a more comfortable heating service.

Necessary connections:

› 1 temperature sensor – forward› 1 temperature sensor – return› 1 pulse input for detecting water flow

Additional connections:

› 1 pressure transmitter – forward› 1 pressure transmitter – return

All sensors are included.

Temperature sensors are attached on the outside of the pipes. Pressure sensors need to be in direct contact with the water and the MMM needs to be connected to a standard 230 V outlet. (See possibilities in the Power Supply Chapter)

Mita-Teknik’s MMM collects all gathered data in the built-in PLC and automatically transmits the data to the heating plant office via the Mobile network.

Mita-Teknik Mobile Monitoring Unit (MMM)

Data and Analysis

A PC with Internet access at the heating plant is installed with the Gateway SCADA analysis software. Gateway presents all data with 5 minute intervals in tables, curves or report (text).

The return:

› Detailed analysis of consumption patterns and ability to supply› Detailed analysis providing basis for decision on making alterations

Mita-Teknik’s Mobile Monitoring Unit (MMM) ensures the consumer more comfortable heating services, it gives you better overview and it can also be used for grid analysis.

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Consumption

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12V 12V

Consumption

Time

2,5 m Connector2 A220 V 24 V DC ~ =

220 V AC/24 V DC

A standard solution, where the electrical grid supplies the ICS.

Power Supply – Multiple Options

The flexibility of our products is supported by our flexible power supply options – choose between 220 V AC, 24 V DC batteries or solar panels.

Gel Battery

A professional maintenance-free solution that can sustain many discharges.

› Capacity = 90% availability (min. 14 days)› Lifetime at 50% discharge = 1000 times› Lifetime at 100% discharge = 450 times› Size: L = 165 mm W = 175 mm H = 125 mm/25Ah (11 kg)

Solar Panels

A sustainable power supply can be achieved by installing a solar panel to charge the battery.

› Solar panel 24 V› Charge regulator 24 V› Gel battery to supply the solution in periods without sufficient sunlight. (Min. 3 days without sunlight)› Cable set 10 m/ Cable set 2 m

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OPTI-SAVE System

Mita-Teknik’s OPTI-SAVE System ensures reduced energy consumption and enables the gas engine to reach its operating temperature faster.

OPTI-SAVE System

Mita-Teknik’s OPTI-SAVE System controls the air shutters in the gas engine- and heater room and ensures reduced energy consumption for production- and space heating.

The system is built around the ‘Gas Detective’, a robust gas detector developed by Mita-Teknik. When the gas engine or gas heater shuts down, the air shutters automatically close.

Benefits:

› Less energy is used for the production heat in the gas engine› Lower CO2 emissions› Faster gas engine start-up (operating temperature is reached faster)› Less energy used to heat the heater room

Control Principle

The OPTI-SAVE System, consist of one or more ‘Gas Detectives’ and an electrical cabinet, which handles the signal exchange with the Control Units for the gas engine- and heater.

The system is also connected to the air shutters, which in case of gas leak or power blackout, will open immediately and give off an alarm relay signal.

Before starting up the gas engine- or heater, OPTI-SAVE ensures that the air shutters are open. On the front of the electrical cabinet, you can choose between manual or automatic control of the air shutters. The control lights indicate the shutters current position.

OPTI-SAVE can also be combined with an automatic fire alarm (ABA) and automatic fire door shutter (ABDL).

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Engine-/Heater Room

Gas DetectiveSmoke Detector

Air Shutter Control

Air-Intake

Open Shutters

Open Alarm

Auto Manual

Gas engine

Gas heater

OPTI-SAVE System

Mita-Teknik’s OPTI-SAVE System controls the air shutters in the gas engine- and heater room and ensures reduced energy consumption for production- and space heating.

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Module-based Solution

Mita-Teknik’s powerful PLC Concept is used for control tasks that require high operational reliability. All module I/O’s are fitted with extra protection and all data is presented in trend curves.

WP4100 is our powerful PLC, which is used in all sorts of Control-, Regulation- and Monitoring tasks. WP4100 has an extended operating system, which ensures easy, quick and safe programming of the system’s functions. Communication is secured via Ethernet, CANopen, Profibus and similar standard systems. WP4100 enables you to program in as many I/O’s, as your system requires.

Programming (Open Protocol Communication)

Whatever programming language you prefer, our PLC can meet your needs and demands.

Optional programming language:

› Structured Text - ST› Instruction List - IL› Ladder Diagram - LD› Function Block Diagram - FBD› Sequential Function Chart - SFC› Continuous Function Chart - CFC› C/C++ Programming› Matlab Simulink

Programming on Your Terms

Complete Control – the Versatile PLC WP4100 MK II is a secure and robust hardware platform that:

› Features a powerful database› Has an operating system with many help functions› Can communicate with third party products› Ensures flexibility and reliability› Enables you to choose your own programming language

Development Tool – IEC61131-3 Standard

Use e.g. CoDeSys, which meets the IEC 61131-3 Standard. CoDeSys is the leading hardware-independent development tool for the IEC 61131-3 Standard and has established itself as the standard tool for PLC and controller programming.

Mita-Teknik’s powerful PLC Concept is used for control tasks that require high operational reliability.

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Programmering Languages

Structured Text - ST: A high-level programming language that resembles PASCAL.

Ladder Diagram - LD: A graphic programming language that shows the logic of an electric circuit.

Programming Languages

Whatever programming language you prefer, our PLC will meet your needs and demands.

Sequential Function Chart - SFC: Helps you structure your program.

C/C++ Programming: C is one of the most used high-level languages in the world for “embedded systems” and C++ is the safe choice when you need object oriented programming. Common to both programming languages is the flexibility and efficiency.

Instruction List - IL: An assembler-like programming language.

Continuous Function Chart - CFC: Used for e.g. programming loops.

Matlab Simulink: Technical design-, simulation-, and code generation.

Function Block Diagram - FBD: A graphic programming language.

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New and Improved Possibilities

”Our new ICS from Mita-Teknik enables us to get a whole new overview of our facility and it gives us new possibilities for optimizing and simplifying our operation.” says Operations Manager at Rødkærsbro CHP Plant, Vagn Rasmussen.

The CHP Plant needed a new ICS as the old was worn down and at times out of operation. Mita-Teknik was hired to solve the problem, and install a new complete ICS consisting of the WP4100 PLC and the SCADA Software System, Gateway. Mita-Teknik also delivered a new motor-control for the plant’s Rolls Royce gas engine.

“We had issues handling the heat delivery from our external supplier, a local biogas plant and make it interact with our own production. We focused on fixing our supplier connection and then turned our attention to our own gas engine. Today our ICS automatically collects data from the local biogas plant online, which enables us to react in time and compensate for cold spots in the grid.”

“Mita-Teknik carried out the integration quickly and effectively for both the biogas plant and the CHP Plant. The result has been a much more efficient supply control.”

Running-in

“Mita-Teknik delivered the ICS and the new motor-control on time. The initialization went as planned and with no inconvenience to the heating plant, which even Rolls Royce commended.”

“In addition we have a Service Agreement with Mita-Teknik, which we have been very happy with. The intelligent solution enables Mita-Teknik to log on to our SCADA System and perform immediate analysis of potential issues. This means that Mita-Teknik can perform corrections to our system and at the same time update our documentation materials and operation manuals.”

“Our new ICS contains several statistical data which gives us complete overview and new opportunities to improve efficiency and simplify our operation. This gives us significant cost reductions on our operational expenses and our investment will be paid back within 4 years.” Vagn Rasmussen explains.

Rødkærsbro CHP Plant’s new ICS

“Regulation, Control and Monitoring are keywords to us and I must say that we are very pleased with the features of our ICS from Mita-Teknik.” - Vagn Rasmussen, Operations Manager - Rødkærsbro CHP Plant.

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Optimizing Flow Temperature “Our new OPTI-TEMP System from Mita-Teknik is used to automatically regulate the flow temperature. The energy optimization is based on the plant’s local Weather Station and the optimal flow temperature is calculated in order to cover the consumer’s heating needs 24/7. The system automatically allows for changes in weather and consumption pattern.”

“Our OPTI-TEMP System came fully equipped with Weather Station, Monitoring Units and two metering boxes, a software module for regulating flow temperature, a software module for regulating flow and differential pressure as well as registering the system’s forward- and return temperature and flow. All data is sent to the Gateway SCADA System.”

All data is presented in curves and graphs in the SCADA System, Gateway. The data is stored in the PLC, which can store as much as 20 years of data.

“Our Weather Station provides us with outside temperature, wind speed, wind direction and chill factor. The chill factor is used in the regulation schematics together with my day/night compensation log. It is typically in the morning and in the evening I need to be ahead with the heat volume for the consumers.”

“I can choose how many degrees to regulate per hour and predetermine set-points for how high and how low the flow temperature must be. Consequently, the ICS automatically optimizes the flow temperature during the day.” says Vagn Rasmussen.

If any of the predetermined set-points are exceeded, Vagn Rasmussen receives an alarm via mobile text message, and he can then perform potential corrections from his home office.

“We were promised savings in the region of EUR 12,000 to EUR 16,000 a year. Today, after running the OPTI-TEMP System for one and a half years, we can see that our savings are approximately EUR 13,500 per year which is very satisfying.”

“I am very satisfied with the OPTI-TEMP System and I would recommend it to anyone looking to optimize their CHP Plant.” Vagn Rasmussen concludes.

Rødkærsbro CHP Plant’s OPTI-TEMP System

“I am very satisfied with the OPTI-TEMP System and I would recommend it to anyone looking to optimize their CHP Plant.” - Vagn Rasmussen,

Operations Manager, Rødkærsbro CHP Plant

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Contact Mita-TeknikHåndværkervej 18840 RødkærsbroDanmark

Tel: +45 8665 8600mail@mita-teknik.comwww.mita-teknik.com