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Project 13632

Project 13632. Process Control Flow Cart: Heat Exchange Temperature Control Loop Amanda Doucett, Dan Sacchitella, Jay Moseley, Micah Bitz, Marc Farfaglia, Rebecca Davidson. Presentation Agenda. Project Overview Customer Needs Specifications Initial Design Decisions (MSD1)

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Project 13632

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  1. Project 13632 Process Control Flow Cart: Heat Exchange Temperature Control Loop Amanda Doucett, Dan Sacchitella, Jay Moseley, Micah Bitz, Marc Farfaglia, Rebecca Davidson

  2. Presentation Agenda • Project Overview • Customer Needs • Specifications • Initial Design Decisions (MSD1) • Budget/Bill of Materials • Final Layout • Process Control Lab Plan • Results of Testing • Project Achievements • Current Project Status • Conclusion • Acknowledgments • Q&A

  3. Project Overview • The objective was to build a flow cart that would illustrate process control to future chemical engineering students here at RIT. • There were three projects with similar objectives, though the means of teaching process control varied slightly between them. • Our project (P13632) required that the process control system incorporate controls based on temperature feedback loops. • Temperature changes used for process control were achieved through the use of a shell-and-tube heat exchanger.

  4. Customer Requirements • Design for safe operation • Design for use by three students during allotted lab time • Portable • Easily connected/disconnected for lab use • Robust design • Minimal maintenance requirements • Utilize a control loop based on temperature changes • Require control of heated process flow and cooling exchange flow rates • Operate both manually and through process control programming in Labview • Capable of manual and automatic data collection

  5. Operating Requirements • 120 VAC for Instruments and Controllers • 25 psi instrument air • 80 psi compressed air • Fluid viscosity between 1 cP and 10 cP • Process mass flow rate between 500 g/min and 1500 g/min • Temperature range for process effluent of 70 °F and 130 °F • Heating fluid flow (water) rate between 1 GPM and 4 GPM

  6. Initial Design Decisions - Pugh Chart

  7. Risk Assessment

  8. Detailed Physical Design (MSD1)

  9. Piping and Instrumentation Diagram (P&ID)

  10. Functional Block Diagram (Electrical)

  11. Budget/Bill of Materials Budget = $1500

  12. Final Design Layout

  13. Labview Interface Individual Temperature Sensor Data Manual Gain Set Manual Temperature Set Point

  14. Proposed Student Lab 1:PID Control – Analyze the difference in a real system between • Proportional control • Proportional and Integral control • Proportional, integral, and differential control • Deliverables: Graphs showing process over time, Analysis of overshoot and how it was minimized 2: Temperature sensors – Fit temperature data to the sensor equations • Tt=To+T1-To [1-e-tτ] • Deliverables: Which sensor responds to control best? RTD vs. Thermocouple

  15. Operability Testing

  16. OperatingSpecificationsChart

  17. Customer Requirements – Project Achievements

  18. Current Project Status • The cart has all mechanical aspects assembled and they have been tested for operability and accuracy • The electrical component has been designed and assembled. Testing has been performed to ensure correct communication with the cart • A Labview interface has been created for use with the system that outputs all relevant data and allows user input • A lab procedure exploring the effects of process control equations on the heat exchange system has been designed. It is expected to take 3 students 3 lab periods to complete. • The thermocouples are not currently registering data correctly with the Labview interface, but their purpose is simply to provide more process transparency for the students and they are not necessary for the system to function fully. There is a plan in place to correct the malfunction before the end of the term.

  19. Project Evaluation Successes: • Functioning product • Educationally valuable lab assignment to accompany the product • Met or exceeded design specifications • Stayed within budget • Overcame equipment failures Failures: • The lack of a truly multidisciplinary group resulted in challenges with mechanical design • Lack of spare parts • Uneven distribution of work • Minor troubleshooting required

  20. Future Work • Develop a noise introduction method • Add more mechanical manual control • Integrate a digital flow sensor • Labview can be easily updated for future needs

  21. We would like to thank… …our faculty guide, Steve Possanza, for his guidance and support during this project, the Chemical Engineering Department for their guidance and support, the Multi-Disciplinary Senior Design group for their funding and support, and Kodak for their generous contributions.

  22. Questions?

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