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ChemE Process-Control Lab Equipment Heat Exchanger

ChemE Process-Control Lab Equipment Heat Exchanger. Dan Sacchitella – ChemE , Project manager Amanda Doucett - ChemE , Lead Engineer Jay Moseley- EE, Controls Engineer Marc Farfaglia - ChemE , Controls Liason Rebecca Davidson- ChemE , 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 – ChemE, Project manager • Amanda Doucett- ChemE, Lead Engineer • Jay Moseley- EE, Controls Engineer • Marc Farfaglia- ChemE, Controls Liason • Rebecca Davidson- ChemE, Technical Engineer • Micah Bitz- ChemE, Technical Engineer Detailed Design Review MSD1 5/3/2013

  2. Agenda • Project Background • Feasibility Analysis • Drawings • BOM • Updated Risk Assessment • Issues/Actions • Schedule Detailed Design Review MSD1 5/3/2013

  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 Detailed Design Review MSD1 5/3/2013

  4. Designs • Designs requested: • PFD • P&ID • Fabrication • Equipment list • Control loop drawings • Electrical drawings • Operation manuals • Recommendation for spare parts and maintenance Detailed Design Review MSD1 5/3/2013

  5. 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 Detailed Design Review MSD1 5/3/2013

  6. Feasibility Analysis System: Water cooling water through a copper pipe Area of Heat exchange = 3.65m^2 =40C =20C =35 =23 Cp=4180 J/kgK Hot Flow= 2 L/min Cold Flow= 3 L/min q= 627 W Detailed Design Review MSD1 5/3/2013

  7. PFD Detailed Design Review MSD1 5/3/2013

  8. Change in Temperature Labview Controller Control Valve Change in Flow Rate X RTD and Thermocouple Sensors ADC in Microcontroller Control Loop Detailed Design Review MSD1 5/3/2013

  9. P&ID Detailed Design Review MSD1 5/3/2013

  10. 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 • The four temperature transmitters will be a combination of two RTD’s and two thermocouples Detailed Design Review MSD1 5/3/2013

  11. Physical Layout Detailed Design Review MSD1 5/3/2013

  12. Physical Layout Detailed Design Review MSD1 5/3/2013

  13. Computer with Labview software • Control Sampling • Data Recording • Modification of Control loop Sensor Inputs Resistive Thermal Device Serial to USB USB to Serial Resistive Thermal Device Analog to Digital converter in MSP430 DAC IC Chip Clock Thermocouple Thermocouple Active LCD output Control Valve Electrical Functional Block Diagram Detailed Design Review MSD1 5/3/2013

  14. Electrical Enclosure Detailed Design Review MSD1 5/3/2013

  15. 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 Detailed Design Review MSD1 5/3/2013

  16. BOM Detailed Design Review MSD1 5/3/2013

  17. BOM

  18. Risk Assessment Detailed Design Review MSD1 5/3/2013

  19. Detailed Design Review MSD1 5/3/2013

  20. Detailed Design Review MSD1 5/3/2013

  21. Issues/Actions Detailed Design Review MSD1 5/3/2013

  22. 3 Week Schedule for MDSII • Important Items: • Parts Review • Final Layout on Structure • Final Specifications • Create test plan • Program Microcontroller • Begin Construction Detailed Design Review MSD1 5/3/2013

  23. Questions? Detailed Design Review MSD1 5/3/2013

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