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ChemE Process-Control Lab Equipment Heat Exchanger

ChemE Process-Control Lab Equipment Heat 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

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ChemE Process-Control Lab Equipment Heat Exchanger

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  1. 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

  2. Agenda • Project Background • Functional Analysis • Concept Development • Systems Architecture • Risk Assessment • Schedule Systems Design Review MSD1 4/5/2013

  3. 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 Systems Design Review MSD1 4/5/2013

  4. 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 Systems Design Review MSD1 4/5/2013

  5. Designs • Designs requested: • PFD • P&ID • Fabrication • Equipment list • Control loop drawings • Electrical drawings • Operation manuals • Recommendation for spare parts and maintenance Systems Design Review MSD1 4/5/2013

  6. 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 Systems Design Review MSD1 4/5/2013

  7. Constraints • Must fit on the cart currently in use by the Chem E department • Utilize donated equipment to reduce cost Systems Design Review MSD1 4/5/2013

  8. Systems Design Review MSD1 4/5/2013

  9. Concept Selection Systems Design Review MSD1 4/5/2013

  10. PFD Systems Design Review MSD1 4/5/2013

  11. P&ID Systems Design Review MSD1 4/5/2013

  12. 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 Systems Design Review MSD1 4/5/2013

  13. Overhead view of cart Systems Design Review MSD1 4/5/2013

  14. Side view of cart Systems Design Review MSD1 4/5/2013

  15. Drainage system contours rough sketch Systems Design Review MSD1 4/5/2013

  16. Data Acquisition and Labview Interface 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. • 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 Systems Design Review MSD1 4/5/2013

  17. Data Acquisition and Labview Interface 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. Systems Design Review MSD1 4/5/2013

  18. 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 Systems Design Review MSD1 4/5/2013

  19. Honeywell Controller with msp430 LabviewInterface • 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. Systems Design Review MSD1 4/5/2013

  20. Honeywell Controller with msp430 LabviewInterface • 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 if • problems in the future • External power will need to be • supplied (3.3v) Systems Design Review MSD1 4/5/2013

  21. Honeywell Controller with msp430 LabviewInterface 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 4/5/2013

  22. 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) Systems Design Review MSD1 4/5/2013

  23. 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 Systems Design Review MSD1 4/5/2013

  24. Risk Assessment Systems Design Review MSD1 4/5/2013

  25. Systems Design Review MSD1 4/5/2013

  26. 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 Systems Design Review MSD1 4/5/2013

  27. 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 Systems Design Review MSD1 4/5/2013

  28. 3 Week Detailed Schedule Systems Design Review MSD1 4/5/2013

  29. Overall Schedule-Current Status Systems Design Review MSD1 4/5/2013

  30. Questions?

  31. Initial Design Concepts

  32. Initial Design Concepts

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