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

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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

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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.

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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

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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

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Initial Design Decisions - Pugh Chart

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Risk Assessment

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Detailed Physical Design (MSD1)

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Piping and Instrumentation Diagram (P&ID)

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Functional Block Diagram (Electrical)

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Budget/Bill of Materials VendorDescriptionModel/Series Cost (EA)QuantityTotal Cost N/AExergy Heat ExchangerSeries 35 1 $- VWRHeating/Cooling Recirculating Water Bath 2 $- N/AI/P transducer$- Cole-ParmerNSF-Approved Turbine Flow Meter, 0.4 - 4 GPM, 3/8" NPT (Male)EW-98516-92 $98.001 Cole-Parmer0-60 psi Dual-Scale Gauge, Bottom ConnectionEW-68007-04 $67.001 N/AResearch Control Valve, 3-15 psigN/A 1 $- Lowe'sRubbermaid 550 lb. Capacity CartN/A $129.981 Lowe'sMiscellaneous PartsN/A $89.671 McMaster-CarrAluminum Strut Channel, 10 ft length3230T48 $46.163 $138.48 McMaster-CarrSingle Channel Plastic End Caps3312T56 $0.6220 $12.40 McMaster-CarrVibration Damping Strut Mount Clamps, Zinc-Chromate Steel, 1 1/2" OD32625T61 $2.923 $8.76 McMaster-CarrNuts for Strut Channel, Zinc Plated Steel, 10-24 Thread3259T42 $3.9320 $78.60 McMaster-Carr3/8 OD PE Tubing (50 ft) 5181K31 $0.2650$13.00 N/A OD tubing$010$- McMaster-CarrTitanium Bolts, 1.5", 10-24 thread94081A149 $4.7320 $94.60 Sparkfun 20x4 Character LCDLCD-00256 $17.951 Sparkfun Thermocouple Amplifier ChipAD595-AQ $17.952 $35.90 Digikey MSP430G2553 microcontroller296-28430-1-ND $2.584 $10.32 Digikey Microchip Technology 10 bit dac chipMCP4812A0T $2.302 $4.60 Mouser 9 volt plug in adapterN/A $5.541 Sparkfun on/ off switchN/A $0.501 Sparkfun voltage regulator 5VN/A $1.251 Sparkfun voltage regulator 3.3VN/A $1.951 Sparkfun k type thermocouples SEN-00251 $13.952 $27.90 McMaster-Carrk type thermocouples3856K912$20.332$40.66 ZorotoolsElectrical Enclosure $100.001 Resistive Thermal Device $-2 Total Project Cost $977.06 Budget = $1500

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Final Design Layout

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

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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 T t =T o +T 1 -T o [1-e-t ] Deliverables: Which sensor responds to control best? RTD vs. Thermocouple

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Operability Testing Test IDTest Name Relevant Specification Relevant Customer Need DescriptionCritical ValuePass/Fail T1Leak Test Minimal Cleaning Robust Design Ensure all connections are tight and no liquid leaks from the system Pass/ValuePass T2 Accuracy of Rotameter N/ARobust design The measurement the flow meter outputs should be confirms by experimentally measuring a volume of fluid collected over a set time period 20% Pass, 8% discrepancy T3 Temperature Sensor Accuracy N/ARobust Design The temperature value the temperature sensors return will be confirmed by comparing the readout to known values Pass/FailPass T4Optimize T Temperature Control Teaching Test heat exchange over a range of inlet temperatures for the hot and cold streams to optimize heat exchange settings Change in hot stream 10 15 in 30 minutes T5 Labview Runthrough N/AStudent Use Full testing of all labview interfaces to ensure communication with the computer Pass/ FailPass T6 Lab Assignment Runthrough N/AStudent Use Full testing of lab assignments to confirm the time requirments and results Pass/Fail

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Operating Specifications Chart ParameterCustomer SpecificationStatusDescription Instrument Air25 psi air Converter functions as specified Compressed Air80 psi air Supplied through the building Process Viscosity1-10 cP Water is used for both flow streams Process Fluid Flow Range500 g/min to 1500 g/min Process bath rate falls within that range Exchange Fluid Flow Range1 to 4 GPM Water bath limited to a max of 0.5 GPM Process Temp. Range70 F to 140 F Bath will operate between -4 F and 392 F Exchange Temp. Range70 F to 140 F Bath will operate between -4 F and 392 F Status Key Specification Met Working exception to specification, will not negatively impact functionality Needs to be addressed in order to function as required

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Customer Requirements Project Achievements ParameterStatusDescription Safety Hot fluid is contained in the inner tube of heat exchanger, Electrical components are all contained within a sealed electrical box Portability All aspects of the cart are contained on the cart or on another portable cart. The only location restriction is access to a computer Used by 3 students for 3 lab sections Lab assignment is enough work for 3 students over 3 days Control Based on Heat Exchange Heat exchange flow system Minimal Maintenance Only fluid used is water no cleaning necessary Manual Control Valve position can be changed through an input in Labview Status Key Completed Working exception to specification, will not negatively impact functionality Needs to be addressed in order to function as required

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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.

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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

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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

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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.

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Questions?