ChemE Process-Control Lab Equipment Heat Exchanger

ChemE Process-Control Lab EquipmentHeat Exchanger

» Dan Sacchitella – ChE, Project manager» Amanda Doucett- Che, Lead Engineer» Jay Moseley- EE, Controls Engineer» Marc Farfaglia- Che, Controls Liason» Rebecca Davidson- Che, Technical Engineer» Micah Bitz- ChE, Technical Engineer

Systems Design Review MSD1 4/5/2013

Agenda

» Project Background» Functional Analysis» Concept Development» Systems Architecture» Risk Assessment» Schedule


Project Goals

» Develop a process that will produce varied control results

» Design the process using the skill sets of every individual in the group

» Assemble process onto portable carts» Test and evaluate» Provide a recommended lab protocol for

teaching


Deliverables

» Analysis for process and control interactions» Detailed design» Heat transfer model» Assembled cart for use in Chemical Engineering

Lab» Evaluation results-system capability» Experimental protocol for teaching


Designs

» Designs requested:˃ PFD˃ P&ID˃ Fabrication˃ Equipment list˃ Control loop drawings˃ Electrical drawings˃ Operation manuals˃ Recommendation for spare parts and maintenance


Customer Requirements

» Design must be modular and adaptable» Durability» Minimal maintenance » Interface with Labview» Realistic to be utilized by students in the lab» Operated by 3 students» Control temperature by regulating flow or

temperature


Constraints

» Must fit on the cart currently in use by the Chem E department

» Utilize donated equipment to reduce cost



Concept Selection


PFD


P&ID


Basis for cart layout

» The cart is approximately 3’ by 2’ by 2’6” high» Uses two of the heating and cooling water recirculation baths that

were used previously in the unit operations lab» Uses the air lines that will be available in the lab» Air operated valve dimensions are based on the one currently used

on the existing flow carts» Uses a shell and tube heat exchanger with countercurrent flow» All cart components are supported by columns that attach to the

upper level of the cart» Large components (such as the valve, controller, water baths and LCD

output) are supported by a central structure that attaches to the lower level of the cart

» The four temperature transmitters will be a combination of two RTD’s and two thermocouples


Overhead view of cart


Side view of cart


Drainage system contours rough sketch


Data Acquisition and Labview Interface

Organization of following slides is as follows: Labview interface and control through national instrument equipment Advantages and disadvantages Labview interface using msp430 microcontroller to sample and collect data from rtd's and thermocouples, while using Honeywell controller to drive flow.• Advantages and disadvantages Complete Labview interface and control using msp430 to collect data from

rtd/thermocouples, simulate customizable control through Labview, return data through msp430 to control flow.

Advantages and disadvantages Risk assessment and analysis of all methods

Goal: Present multiple possibilities for data acquisition and Labview interface while assessing the advantages and disadvantages of each in order to determine the best course of action in continuing with the design.


The national instruments data acquisition chassis with associated modules for thermocouple and rtd inputs can be used to collect temperature data and control the flow of the system through Labview.


Data Acquisition and Labview Interface

National Instruments Labview Interface

Advantages• Simple implement and interface with

Labview• Accurate data• Has interchangeable parts for

multiple types of inputs• No external components will be

needed to implement• Used in real world

applications

Disadvantages• Expensive chassis• Expensive modules to go along with chassis each serving only one purpose• Overpaying for what it is going to be used for


Honeywell Controller with msp430 Labview Interface

• The Honeywell controller would be used to drive the flow control of the system. • The microcontroller would be used to collect data from the rtd's and thermocouples and send it to the computer • the systems data could be plotted and observed in Labview.



Advantages•Shows students how to use and calibrate physical controller•Microcontroller transferring data to computer can also be used to drive LCD displays with data•Microcontrollers are extremely cheap and easily replaced and reprogrammed•Can be designed so that the national instruments equipment can be easily swapped in

Disadvantages• External circuitry will be necessary• Potential for more errors in

temperature measurement (can be tested for)

• May potentially need EE to debug ifproblems in the future

• External power will need to be supplied (3.3v)


4/5/2013

The thermocouple and rtd outputs will be tied directly to microcontroller which will interface with Labview. Data received in Labview will then go through a modeled controller in Labview to create a new set of data which will actively be output to another pin on the microcontroller. Data will then be processed and sent to control the flow rate of the system.

Systems Design Review MSD1


msp430 Control and Interface through Labview

Advantages• Very adaptable, many different

systems with can be modeled and tested through Labview. For example part of the lab could involve varying set pole locations and seeing their diminishing effect as their magnitude increases

• Cheap to implement• Can be designed where the

National Instruments equipment can be easily swapped in

• No real maintenance would be necessary

• Students would get a better feel for labview by creating the controller with the software instead of just using it to show data

Disadvantages•Difficult to implement and as a result more difficult to debug if something goes wrong in the future•Although systems can be modified quickly in Labview, it will still be necessary to wait on the fluids to return to they're initial state temperature to run multiple experiments.•External circuitry will be necessary•Potential for more errors in temperature measurement (can be tested for)•External power will need to be

supplied (3.3v)


Possible Lab Applications» PID equation» Valve characteristics

˃ Inherent vs installed

» Noise introduction and filtering» Manual Control

˃ Manual pressure regulator on AOV

» Find heat flow through the heat exchanger» Fit sensor data to the ideal equation of operation» RTD vs Thermocouple performance


Risk Assessment


ID Risk Item Effect Cause

Likelihood

Severity

Importance Action to Minimize Risk Owner

Describe the risk briefly What is the effect on any or all of the project deliverables if the cause actually happens?

What are the possible cause(s) of this risk?

L*S What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring?

Who is responsible for following through on mitigation?

1

Customer Priority Changes Delay of project progression Poor communication/ Uncertainty

2 2 4 Have weekly meetings with guide and keep both sides updated on project

Project Manager

2 Unreliable Suppliers

Disrupt our project budget plan, and delay design process.

Parts are not available through Kodak 1 2 2

Take initiative and request parts from Guide, and compile a list of what we have and what needs to be ordered Group

3 Skill Set

Alters design slightly, and will change list of parts that we need to order

Only one EE to develop controls, and rest of team members have little experience in that field 1 2 2

Group EE seeks feedback from EE department to make sure concepts are feasible EE

4 Team Dysfunction

Poor team chemistry will demotivate group and may cause delays in deliverables.

Differences in opinions/ concepts 1 1 1

Reach consensus on ideas/concepts to make sure everybody is on board Group

5 Unavailability May delay deliverables

Poor communications/ Illness 2 1 2

Let group know if/ why you can’t attend meetings. Plan ahead. Individual

6 Poor CommunicationPeople may not know current tasks

Lack of motivation/communication with group members 1 1 1

Keep everyone updated on current goals/ ideas. Ask for progress ahead of the date when the deliverable are expected.

Project Manger


Risk Assessment and Analysis – Data Acquisition Methods

National Instruments risk :• Cost of equipment, expensive to replace

Honeywell controller risk :• not easily replaceable since it was donated and a new controller would have

to be bought if anything happens to it.

microcontroller risk:• difficult to develop and ensure accurate results

Not much to lose with complete microcontroller interface and control with Labview and the advantages that it will provide

• More teaching flexibility• Can replace with national instruments equipment if problems• little cost, so hardly any loss if anything breaks


Cost Analysis

• This project incorporates many expensive components, similar to those used in industry, to facilitate learning

• Many parts are being generously donated by Kodak

• A few components, such as the cart on which the system will be built, have to be bought

• The proposed budget will cover the cost of these parts

• We propose a budget of $1500 dollars to complete this project Total Cost

Transmitters

Reliance motor

Honeywell ControllerIntellifaucet

Remaining Need

0

2000

4000

6000

8000

10000

12000

10410

2000

3000

400410

700500

300600

1000

1500

Cost of Building a Heat Exchange/Process Control Lab Cart

Equipment Needed

Cost

in $


3 Week Detailed Schedule


Overall Schedule-Current Status


Questions?

Initial Design Concepts

Initial Design Concepts

Documents

ChemE Process-Control Lab Equipment Heat Exchanger