Post on 07-Feb-2016
description
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
Detailed Design Review MSD1 5/3/2013
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
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
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
Feasibility Analysis
Detailed Design Review MSD1 5/3/2013
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
Detailed Design Review MSD1 5/3/2013
Detailed Design Review MSD1 5/3/2013
Control Loop
X Labview Controller Control Valve Change in Flow
Rate
RTD and Thermocouple
Sensors
ADC in Microcontroller
Change in Temperature
P&ID
Detailed Design Review MSD1 5/3/2013
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
Detailed Design Review MSD1 5/3/2013
Physical Layout
Detailed Design Review MSD1 5/3/2013
Physical Layout
Detailed Design Review MSD1 5/3/2013
Detailed Design Review MSD1 5/3/2013
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
Detailed Design Review MSD1 5/3/2013
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
Detailed Design Review MSD1 5/3/2013
BOM
Detailed Design Review MSD1 5/3/2013
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
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
Risk Assessment
Detailed Design Review MSD1 5/3/2013
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
Detailed Design Review MSD1 5/3/2013
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.
Detailed Design Review MSD1 5/3/2013
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
Detailed Design Review MSD1 5/3/2013
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
Questions?
Detailed Design Review MSD1 5/3/2013