ChemE Process-Control Lab Equipment Heat Exchanger

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

Agenda

» Project Background» Feasibility Analysis» Drawings» BOM» Updated Risk Assessment» Issues/Actions» 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


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


Feasibility Analysis


System: Water cooling water through a copper pipe

Area of Heat exchange = 3.65m^2=40C=20C=35=23Cp=4180 J/kgK

q= 627 W

Hot Flow= 2 L/minCold Flow= 3 L/min

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PFD



Control Loop

X Labview Controller Control Valve Change in Flow

Rate

RTD and Thermocouple

Sensors

ADC in Microcontroller

Change in Temperature

P&ID


CER

HPR

AOV

P

PI

½” PE Line

¼” PE Relief Line

HX

½” PE Effluent HX

½” PE Effluent Process

F

FE

F

FE

T

TE

T

TE

T

TE (RTD)

T

TE (RTD)

½” PE Line

RV

3-15 psig

Laboratory Air Line

JTCI

Data line to/from Computer (Labview)All FE, TE, TE (RTD) signals transmitted to Labview

Project 13632: P&ID for Heat Exchange Process Control Cart, 4/29/13

MP

I/P

FT

Control Signal

CSD

FT

Displayed Text DescriptionFE Turbine Flow MeterFT Flow TransmitterI/P Instrument Air Conversion

MP MicroprocessorPI Analog Pressure Gauge

TE ThermocoupleTE (RTD) RTD Temperature Element

JTCI Jay's Temperature Controller/IndicatorPR Pressure Regulator (Lab air to 25 psig)

CSD Combined Sensor DisplayAOV Research Control Valve (3-15 psig)

PE Polyethylene TubingHX Heat Exchanger, 20" lg., 1.5" OD, NPT and Triclamp

CER VWR PolyScience Cooling Exchange RecirculatorHPR VWR PolyScience Heated Process RecirculatorRV Relief Valve

D/A Digital to Analog ConverterA/D Analog to Digital Converter

Red Piping Process LinesBlue Piping Exchange Lines

Green Signal Process Control Signals

Instrument/Component List

PR

25 psig Air

25 psig Actuator Air

D/A

Signals (Digital or Analog)

Pneumatic Lines

Data

Cool Exchange Flow

Heated Process Flow

Control Signal From Process Effluent RTD

Piping and Signal Key

A/D

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


Physical Layout


Physical Layout



Electrical Functional Block Diagram

Sensor Inputs

Resistive Thermal Device

Resistive Thermal Device

Thermocouple

Thermocouple

Analog to Digital converter in MSP430

Serial to USB

Computer with Labview software• Control Sampling • Data Recording

• Modification of Control loop

DAC IC Chip

USB to Serial

Clock

Active LCD output Control Valve


Electrical Enclosure

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


BOM


Project 13632 Bill of Materials

Vendor Description Model/Series Cost (EA) Quantity Total Cost Order Kodak RIT In Hand

N/A Exergy Heat Exchanger Series 35 1 $ - X

VWR Heating/Cooling Recirculating Water Bath 2 $ - X

Cole-Parmer NSF-Approved Turbine Flow Meter, 0.4 - 4 GPM, 3/8" NPT (Male) EW-98516-92 $ 98.00 1 $ 98.00 X

Cole-Parmer 0-60 psi Dual-Scale Gauge, Bottom Connection EW-68007-04 $ 67.00 1 $ 67.00 X

Swagelok SS Proportional Relief Valve, 1/4" MNPT by 1/4" Swagelok Tube Fitting SS-RL3M4-S4 1 $ - X

McMaster-Carr Fast Response Thermocouple Probe 1/4" Diameter, 6" Length, Type K, 32F to 1600F 3872K39 $ 93.30 2 $ 186.60 X

N/A Research Control Valve, 3-15 psig N/A 1 $ - X

550 lb. Capacity Cart $ 135.00 1 $ 135.00 X

McMaster-Carr Aluminum Strut Channel, 10 ft length 3230T48 $ 46.16 3 $ 138.48 X

McMaster-Carr Single Channel Plastic End Caps 3312T56 $ 0.62 20 $ 12.40 X

McMaster-Carr Vibration Damping Strut Mount Clamps, Zinc-Chromate Steel, 1 1/2" OD 32625T61 $ 2.92 3 $ 8.76 X

McMaster-Carr Nuts for Strut Channel, Zinc Plated Steel, 10-24 Thread 3259T42 $ 3.93 20 $ 78.60 X

Brewers Hardware 1-1 1/2" Tri-clamp to 1/2" FNPT Stainless Steel $ 15.00 2 $ 30.00 X

Swagelok **Street Tee, 1/2 in. Female NPT x 1/2 in. Male NPT x 1/2 in. Female NPT SS-8-ST $ 60.50 2 $ 121.00 X X

Swagelok **SS Swagelok Tube Fitting, Male Connector, 1/2 in. Tube OD x 1/2 in. Male NPT SS-810-1-8 $ 15.99 6 $ 95.94 X X

Swagelok **SS Swagelok Tube Fitting, Female Branch Tee, 1/2 in. Tube OD x 1/2 in. Tube OD x 1/2 in. Female NPT SS-810-3-8TTF $ 53.04 2 $ 106.08

**1/2" OD PE Tubing (30 ft) $ 1.50 30 $ 45.00 X

McMaster-Carr Nuts with Springs for Strut Channel, Zinc Plated Steel, 13/16" 3259T55 $6.17 20 $ 123.40 X

McMaster-Carr Titanium Bolts, 1.5", 10-24 thread 94081A149 $ 4.73 20 $ 94.60 X

http://www.mcmaster.com/#3259T55

http://www.mcmaster.com/#94081A149

BOMSparkfun

20x4 Character LCD LCD-00256

$ 17.95 1 $ 17.95 X

Sparkfun

Thermocouple Amplifier Chip AD595-AQ

$ 17.95 2 $ 35.90 X

Digikey

MSP430G2553 microcontroller 296-28430-1-ND

$ 2.58 4 $ 10.32 X

Digikey

Microchip Technology 10 bit dac chip MCP4812A0T

$ 2.30 2 $ 4.60 X

Mouser

9 volt plug in adapter N/A

$ 5.54 1 $ 5.54 X

Sparkfun

on/ off switch N/A

$ 0.50 1 $ 0.50 X

Sparkfun

voltage regulator 5V N/A

$ 1.25 1 $ 1.25 X

Sparkfun

voltage regulator 3.3V N/A

$ 1.95 1 $ 1.95 X

Sparkfun

k type thermocouples

SEN-00251 $ 13.95 2 $ 27.90 X

Zorotools Electrical Enclosure $ 100.00 1 $ 100.00 X

Resitive Thermal Device

$ - 2 $ - X

Total Project Cost $ 1,546.77

** Denotes uncertainty of origin of material

http://www.mouser.com/ProductDetail/Triad-Magnetics/WDU9-100/?qs=sGAEpiMZZMs2%252bVrH5rwl1mBJCKPF4SHbt40ANpgs2vw%3D

Risk Assessment


ID Risk Item Effect CauseLikelihood

Severity

Importance Action to Minimize Risk

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?

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

2 Unreliable SuppliersDisrupt 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

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

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

5 Unavailability May delay deliverables Poor communications/ Illness 2 1 2Let group know if/ why you can’t attend meetings. Plan ahead.

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.

7 Lack of Equipment Delay Building Inaccurate Bill of Materials 1 1 1

Try to be as thorough as possible on the bill of materials so an accurate list of the materials can be made.

8 Poor Quality of WorkPortray poor professionalism on the group as a whole Conflicting workloads 1 1 1

Hold weekly meetings to make sure everyone is on task and doing their share of the work


Likelihood scale Severity scale1 - This cause is unlikely to happen 1 - The impact on the project is very minor. We will still meet deliverables on time and within budget, but

it will cause extra work2 - This cause could conceivably happen 2 - The impact on the project is noticeable. We will deliver reduced functionality, go over budget, or fail to

meet some of our Engineering Specifications.3 - This cause is very likely to happen 3 - The impact on the project is severe. We will not be able to deliver, or what we deliver will not meet

the customer's needs.

“Importance Score” (Likelihood x Severity) – use this to guide your preference for a risk management strategy

Prevent Action will be taken to prevent the cause(s) from occurring in the first place.

Reduce Action will be taken to reduce the likelihood of the cause and/or the severity of the effect on the project, should the cause occur

Transfer Action will be taken to transfer the risk to something else. Insurance is an example of this. You purchase an insurance policy that contractually binds an insurance company to pay for your loss in the event of accident. This transfers the financial consequences of the accident to someone else. Your car is still a wreck, of course.

Accept Low importance risks may not justify any action at all. If they happen, you simply accept the consequences.

Likelihood scale Severity scale

1 - This cause is unlikely to happen 1 - The impact on the project is very minor. We will still meet deliverables on time and within budget, but it will cause extra work

2 - This cause could conceivably happen 2 - The impact on the project is noticeable. We will deliver reduced functionality, go over budget, or fail to meet some of our Engineering Specifications.

3 - This cause is very likely to happen 3 - The impact on the project is severe. We will not be able to deliver, or what we deliver will not meet the customer's needs.


Issues/ActionsIssue Action

Customer Priority Changes Keep lab assignment portion flexible for now

Unreliable Suppliers Order items before the end of the quarter

Skill Set Group EE requests feedback from EE department on design

Team Dysfunction None forseen over summer, as no decisions will be made

Unavailability None forseen over summer, as no meetings will be held

Poor Communication Stay in touch over the summer, especially as parts are delivered


3 Week Schedule for MDSII

Important Items:• Parts Review• Final Layout on Structure• Final Specifications• Create test plan• Program Microcontroller• Begin Construction


Questions?


ChemE Process-Control Lab Equipment Heat Exchanger

Documents

aovfind heat flow

flow ratertd

lmincold flow

whot flow

water cooling water

existing flow cartsuses

groupassemble process

cart layoutthe cart