P13630 Process Control: Metered Flow Team Members: Andre Berwin – ChemE, Nathan Fulcher -ChemE, Andrew Watson – ChemE, Travis Bardsley – ChemE, Peter Dunning – ME, Anthony Parker – IE, James Mazza - EE Meeting Purpose: A detailed final review of the Metered Flow Loop (P13630) Materials Reviewed: Customer Needs, Engineering Specs, Budget Results and Conclusions P&ID and Completed Cart Process Dynamics Circuit and Wiring Diagrams LabVIEW GUI Attendees Steve Possanza – Process Engineer, Kodak Christiaan Richter, Ph.D. – Assistant Professor, RIT Department of Chemical Engineering Paul Gregorious – Senior Laboratory Technician, RIT Department of Chemical Engineering
Transcript
P13630 Process Control: Metered Flow
Team Members: Andre Berwin – ChemE, Nathan Fulcher -ChemE, Andrew Watson –
ChemE, Travis Bardsley – ChemE, Peter Dunning – ME, Anthony Parker – IE, James Mazza
- EE
Meeting Purpose: A detailed final review of the Metered Flow Loop (P13630)
Materials Reviewed:
Customer Needs, Engineering Specs, Budget
Results and Conclusions
P&ID and Completed Cart
Process Dynamics
Circuit and Wiring Diagrams
LabVIEW GUI
Attendees
Steve Possanza – Process Engineer, Kodak
Christiaan Richter, Ph.D. – Assistant Professor, RIT Department of Chemical Engineering
Paul Gregorious – Senior Laboratory Technician, RIT Department of Chemical Engineering
Meeting Time and Location:
Thursday, December 5th 2013
ChemE Recitation Room – Institute Hall
Meeting Timeline
Start Time Topic of Review Required Attendees
9:00 Project Background Recap Steve Possanza and Christiaan Richter, Full Team
9:15 Review Existing Pugh Diagrams Steve Possanza and Christiaan Richter, Full Team
9:20 Review Updated P&ID Steve Possanza and Christiaan Richter, Full Team
9:30 Review BOM Steve Possanza and Christiaan Richter, Full Team
9:40 Review Updated Risk Analysis Steve Possanza and Christiaan Richter, Full Team
9:45 Electrical Design Review Steve Possanza and Christiaan Richter, Full Team
10:00 Test Plan Review Steve Possanza and Christiaan Richter, Full Team
10:10 Feasibility Analysis Steve Possanza and Christiaan Richter, Full Team
10:15 Cart Review Steve Possanza and Christiaan Richter, Full Team
10:20 MSD II 3 Week Plan Steve Possanza and Christiaan Richter, Full Team
10:25 Conclusion and Questions Steve Possanza and Christiaan Richter, Full Team
Table of Contents
Table of ContentsHigh-Level Project Summary...........................................................................................................................4
Test Results......................................................................................................................................................7
Test Plan.........................................................................................................................................................17
Control Loop..............................................................................................................................................18
Control Valve.............................................................................................................................................19
Motor & Drive............................................................................................................................................19
Project # Project Name Project Track Project Family
P13630 Metered Flow Loop Process Innovation Process Control
Start Term Team Guide Project Sponsor Doc. Revision
2012 Q3 Steve Possanza Kodak A-2
Project Description
Project Description
Project Background:The Metered Flow Loop project specifically aims to create an educational experience for future Chemical Engineering students in the area of Process Control. The culmination of the project will be a small (3ft x 2ft) process control cart to demonstrate the concepts of controlling a metered flow loop. The cart will be used in conjunction with a detailed laboratory curriculum to more effectively teach process control to students.
Objectives/Scope:1. Design Cart to be portable and easily maintained2. Design LabVIEW interface for easy use of cart3. Design Lab to be used with cart to teach various
concepts of process control.
Deliverables:• Fully functional cart to be used in Chemical
Engineering Laboratories.• LabVIEW GUI that can control the flow and control
parameters• Laboratory plan to be used by students• Maintenance for cart and all components as well as a
detailed user’s manual.
Expected Project Benefits:• Effectively teach Process Control to future Chemical
Engineering students.
Core Team Members: Andre Berwin (Team Lead) Nathan Fulcher Andrew Watson Travis Bardsley Anthony Parker Peter Dunning James Mazza
Issues & Risks:• Insufficient time to finish lab experiments.• Change in customer needs.• Lead time on parts.• DAQ issues.• Edge issues.• Structural Failure.
MSD II Final Design Review
P13630 – Customer NeedsCustomer
Need # Importance Description Comments/Status
CN1 9 Assembled Cart Designed – Will Be Built in MSDII
CN2 9 Metered Flow Control Via Microcontroller/LabVIEW Interface
CN3 9 Interface with LabVIEW for Automatic Control MSD II
CN4 9 Cart Is SafeNo Chance of Pressure BuildupMajor Electrical Components in a Dry Box
CN5 6 Recommended Lab Protocol Rough Draft Already CompletedThorough testing with user feedback
CN6 6 Process and Control Interaction Analysis
Initial Tests Completed, More Once Cart Is Assembled
CN7 6 Known System Capability Evaluation Initial Characteristic Curves Completed
CN8 6 Modeled After Current Lab Carts Visually Similar
CN9 6 Manual Control of Cart Via Physical Needle Valve, Ball Valve, Lab View Interface
CN10 6 Robust and Durable Through Normal Use
CN11 6 Operated by 3 Students Will Test Group Size in MSDII
CN12 6 Takes Place in Allotted Lab Time Rough Lab Protocol CompletedWill Test Lab Duration in MSDII
CN13 6 Automated Data Collection Via LabVIEW Interface into .csv file with Microcontroller
CN14 3 Modular and AdaptableAll Swagelok Fittings are ModularCan Support Control Valve in Series and Parallel
CN15 3 Easily Moved and PortableCart is on WheelsMay Interface with any Computer with LabVIEW
CN16 3 Minimal Maintenance and CleaningEasy to Fix for Common Problems & Normal WearWill Supply Basic Maintenance Kit
KGCOE MSD I Page 5 of 24 Detailed Design Review
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Engineering Specifications
Engr.
SpecDescription Measure of
PerformanceEngr. Units
Marginal Value
Ideal Value Validation Method (TOAD)
ES1 Maximum Process Flow Rate Volume per unit time g/min 6785 1500 Run Pump Characterization tests
ES2 Minimum Process Flow Rate Volume per unit time g/min 158 500 Run Pump Characterization tests
ES3 Process Fluid Operating Temp Temperature Range °F 70-140 70-130 Demonstrate operating temps for equipmentES4 Process Fluid Viscosity Viscosity cP 1 1 N/AES5 Max Pressure in System Pressure psi 5-80 20 Implement Pressure Sensors in Flow LoopES6 Minimum Space Requirements Volume ft3 30 24 Physical measurements
ES7 Instrument and Controller Power Supply Voltage V 110 120 Voltage Measurements using Multimeter
ES8 Motor and Drive Operating Power Supply Voltage V 230 460 Voltage Measurements using Multimeter
ES9 Sampling Rate of Controller Samples per unit time S/s 200,000 < 10 Test Microcontroller code
ES10 Response Time of Pump Time s 1 0.01 Monitor pump speed for a changing flow
ES11 Automated Operation of Instruments Operationally mA 4, 20 4 to 20 Simulate 4-20mA signal to controller/device using fluke
ES12 Simple Wire connectivity Operationally Binary N/A N/A Successful operation by non-technical students
ES13 Mobility adaptability in Lab setting Operationally Binary N/A N/A Successful operation by non-technical students
ES14 Manual Operation of Instruments Operationally Binary N/A N/A Successful operation by non-technical studentsES15 Safe and Ergonomic Design Operationally Binary N/A N/A Successful operation by non-technical studentsES16 Automated Data Collection Operationally Binary N/A N/A Successful operation by non-technical studentsES17 Time it takes to complete lab Time Hours 9 7.5 Successful operation by non-technical studentsES18 Cost Dollars Dollars 2000 1500 Add up costs at the end of projectES19 Accuracy of Flow Measurements Percent error % < 1 0.2 Compare it Against Known Instrument/ Timing MethodES20 Lifetime of Cart Time Years 5 10 N/A
KGCOE MSD I Page 6 of 24 Detailed Design Review
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KGCOE MSD I Page 7 of 24 Detailed Design Review
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Test Results
Parameter Target Test Plan results Reference
Min Flow Rate 158 g/min Check flow rate at lowest pump settings
Yes Pump testing,
11/8/2013Max Flow Rate 1500 g/min Check flow rate at highest
pump settingsYes, highest is 1504
g/minPump
testing, 11/8/2013
System Pressure 5 to 80 psi Check Pressure during operation
Yes, pressure can span 0.5-30psi with
supply
Pump testing,
11/8/2013Pump Response
Time< 1 second Check time to new steady
state after change is madeYes, pump response time can be set via
the PowerFlex drive
Operating manual pg. 3-12
Flow Accuracy < 1% error Compare flow meter value against another flow
meter or total volume per time
Yes, dependant on flow rate, ranged between 0.1-1%
innacuracy
Pump testing,
11/8/2013
Control Valve Response Time
< 5 seconds Check time to new steady state after change is made
< 1 second
Leakage No Leaks Check for leaks under normal operating
procedures
Yes
Operator 2 Minimum, 3 Maximum
Attempt to operate the system with 2 people
Yes
Automatic Control
Functioning PID control with ability to alter constants
Implement new set-points and observe system
response
Yes
Manual Control Can adjust flow manually
Adjust flow Yes
Automatic Data Collection
Labview records data that can be
graphed or exported to excel
Ensure it exists and check for accuracy
Yes
Manual Data Collection
Real time data is displayed
Ensure it exists and check for accuracy
Yes
Modularity Can alter system to put different comonents in
series or parallel
Reconfigure system to put different components in
alternate order
Yes
Portability Easy to move, connect to and
disconnect from utilities
Connent and disconnect system from utilities. Push
cart around.
Yes but wheels need to be replaced
Noise 2 Sources Test if our sources effect the data
Zorotools $200.00Total High $1,569.45Total Low $984.45
Equipment List / BOM
Major Components
Minor Components
Spare Parts
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Budget
Predicted (Low) Predicted (High) Actual Budget0
500
1000
1500
2000
2500
984.45
1569.451760.62
2000
Team Spending
Spending
Amou
nt ($
)
In the spring we have estimated our expenses to be $984.45 with the microprocessor. We estimated our expenses to be $1569.45 by replacing the microprocessor with the National Instruments controller. We decided to save money and use a microprocessor; however, we did not anticipate having to buy a drive which greatly changed out expenses. Ultimately we spent $1760.62 which was still in our allotted budget, but greatly exceeded our expectations.
KGCOE MSD I Page 11 of 24 Detailed Design Review
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Electrical Design
Pressure Sensor
KGCOE MSD I Page 12 of 24 Detailed Design Review
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Powerflex 40
KGCOE MSD I Page 13 of 24 Detailed Design Review
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Microcontroller
KGCOE MSD I Page 14 of 24 Detailed Design Review
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Complete Loop
KGCOE MSD I Page 15 of 24 Detailed Design Review
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Electrical Box
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Power
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Lab Plan
Disturbances:1. Head pressure from switching tanks/ Pipe length with pressure drop2. Control Valve/Needle Valve
Control:1. P (simulated noise)2. PI (simulated noise)3. PID (simulated noise)4. Human vs. Computer5. Level Controller on Tank6. Different type of Pump
Lab Design: First Lab (~3 hours)
Scope: Introduce LabVIEW, PID control, and noise basics to students.Objective: Prove the necessity of control systems and their advantage over manual control.Deliverables: Manual Data vs. P, PI & PID Data
o Introduction to system and LabVIEW controlso Human vs. Computer control (P, PI & PID)o Human vs. Computer control (P, PI & PID with noise)o Average data and compare
Second Lab (~3 hours)Scope: Provide a deep understanding of PID control and each of its individual elements.Objective: The complete PID equation is understood, as well as the role each piece plays in a control system. The understanding of how to manipulate PID control and the effect of noise.Deliverables: Data of a control scenario with P, PI & PID control with an explanation of differences. Repeat except with noise. Data illustrating the limits of the system with noise. Data showing the improvement of a control scenario by manipulating PID constants.
o In depth explanation of PID controlo Differences in P, PI & PID control with actual flowo Differences in P, PI & PID control with actual flow and noiseo Vary levels of noise and see impact on controlo Vary Kp, Ki & Kd terms and see impact on control
Third Lab (~3 hours)Scope: Provide knowledge of noise management. A final scenario to challenge and test students’ prowess of PID control.Objective: Provide insight in real-world methods of managing noise. Verify that the students have mastered a basic understanding of PID control.Deliverables: A new method for eliminating noise, or parameters used to properly control the scenario.
o Methods of eliminating noiseo Averaging data (filter noise)o Have students develop other methods to eliminate noiseo Have students create a PID control for a given scenario (flow rate/noise/pressure drop)o Share with class what was done/learned on this cart
KGCOE MSD I Page 18 of 24 Detailed Design Review
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Process
Control Loop Diagram
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Control Valve
The control valve regulates flow rate or pressure of a stream by changing the valve position by the following relation:
FV=C v (x ) √∆ P
The Cv(x) parameter is a function of the valve position, which is regulated between 0-100%. The valve position is controlled by sending a pressurized air signal to the valve, which moves a diaphragm connected to the valve stem. The air signal is regulated by a current to pressure (I/P) converter, which takes an analog current signal being sent by a processor (4-20mA) and converts it linearly to a (3-15psi) air signal. The converter is supplied with pressurized air via a regulator, which converts the pressure from 80 psi to 30 psi. An additional 30 psi air line is sent to the control valve to speed the valve dynamics.
Pump: Micropump GJ.N-25
The positive displacement pump also regulates stream flow and pressure by driving a pump rotor via a motor, which is controlled via voltage supplied by a drive. The voltage sent by the drive is controlled via an analog current signal sent from the processor. The characteristic of the pump is the following:
FP= (−α+ βω )∆ P+γω≈γω
Where ω is the speed (angular speed, RPM) of the motor and α , β, γ are fitting parameters characteristic to the pump.
Motor and Drive
The speed of the motor is regulated by the following equation which relates the frequency of the drive and the angular speed of the pump:
ω=kfWhere f is the frequency of the drive, which ranges between 0-60 Hz and is directly controlled via a mA signal sent by the microprocessor. k is the ratio between drive frequency and motor speed, which is set to 1800RPM/60Hz.
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Pump Characterization
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Cart
A modular and adaptable cart was modeled after and consistent with existing flow carts. The cart was designed to house the process control system; prioritizing usability, safety and reliability for the students. The cart was designed to be portable, easily moved, and easily connected and disconnected to lab utilities. The cart was augmented with stainless steel framing to mount and support all of the system components. All of the system components may be removed and rearranged if needed. In order to avoid the previous balance issues, the frame was designed to be located in the center of the cart. In addition, the system components weights were evenly distributed across the whole cart, keeping the bottom of the cart weighted heavily.
