High-Level Project Summaryedge.rit.edu/.../public/WorkingDocuments/P13630_DDR.docx · Web...

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 review of the Metered Flow Loop (P13630)

Materials Reviewed:

Updated Customer Needs, Engineering Specs

Bill of Materials and Equipment List

Final Pugh Diagrams

Risk Assessment matrix

Circuit and Wiring Diagrams

Cart Deliverable

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:

Friday, May 3rd 2013

9:00 am – Equipment List and Updated Customer Specifications

9:45 am – Electrical Wiring and Cart Overview

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

9:05 Review Updated Customer Needs, Engineering Specs

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

Project Description...........................................................................................................................................4

Project Background:.....................................................................................................................................4

Objectives/Scope:.........................................................................................................................................4

Deliverables:.................................................................................................................................................4

Expected Project Benefits:...........................................................................................................................4

Core Team Members:...................................................................................................................................4

Issues & Risks:.............................................................................................................................................4

P13630 – Customer Needs...............................................................................................................................5

Engineering Specifications...............................................................................................................................6

Pugh Diagram 1................................................................................................................................................7

Pugh Diagram 2................................................................................................................................................8

Pugh Diagram 3................................................................................................................................................9

P&ID...............................................................................................................................................................10

BOM...............................................................................................................................................................11

Risk Assessment.............................................................................................................................................12

Electrical Design............................................................................................................................................14

Pressure Sensor...........................................................................................................................................14

Powerflex 40...............................................................................................................................................15

Microcontroller...........................................................................................................................................16

Complete Loop...........................................................................................................................................17

Electrical Box.............................................................................................................................................18

Power..........................................................................................................................................................19

....................................................................................................................................................................19

Test Plan.........................................................................................................................................................20

Feasibility Analysis........................................................................................................................................21

Pump Performance.....................................................................................................................................21

Control Valve Performance........................................................................................................................22

Calculating System Pressure and Flow Rate via Valve Position and Pump RPM.....................................22

Microcontroller Feasibility Analysis..........................................................................................................24

Cart.................................................................................................................................................................25

Drawing Final Iteration..............................................................................................................................25

CAD Model................................................................................................................................................26

3 Week Plan for MSD II.................................................................................................................................27

QUESTIONS?................................................................................................................................................28

High-Level Project Summary

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 G-4

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 I May 2013 Detailed 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 29 Detailed Design Review


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





Pugh Diagram 1



Pugh Diagram 2



Pugh Diagram 3



P&ID



BOM

Component Category Component Type Part Number Size/ID Number Buy Location PriceCart - 3ftx2ft 1 McMaster Carr $150.00Reservoir - 2L 2 Kodak $0.00Pump - - 1 Kodak $0.00Drive - - 1 Kodak $0.00Motor - - 1 Kodak $0.00Control Valve - - 1 Kodak $0.00Flow meter - - 1 Kodak $0.00DAQ-Controller* NI9208 16 Channel 1 National Instruments $585.00DAQ-MicroProcessor MSP-EXP430G2 - 1 DigiKey $10.37Shut-off Valve - - 2 Kodak $0.00Pressure Relief Valve - - 1 Kodak $0.00Needle Valve - - 1 Kodak $0.00Tubing 5181K25 3/8" & 1/2" 100 ft McMaster Carr $30.00Fittings - - Assorted Kodak $0.00Fasteners - - Assorted Home Depot $50.00Stud Nuts 3580T11 1/4" 40 McMaster Carr $188.00Connecting Plate 33125T34 90° 10 McMaster Carr $21.00Connecting Plate 33125T42 45° 8 McMaster Carr $16.40Framing 33085T43 304 SS 20 ft McMaster Carr $213.00Drive Box G1561061 16"x20"x6" 1 Zorotools $200.00Power Strip BE106001-08R-DP 6 outlets 1 Home Depot $12.97AWG20 DW-65A 65ft 1 Home Depot $4.97AWG14 147-1472G 250ft 1 Home Depot $44.00T-junction - .5" 5 Kodak $0.00Tubing Size Converters - 1/2" to 1/8" 2 Kodak $0.00Tubing Size Converters - 1/2" to 3/8" 2 Kodak $0.00I/P Converters - - 1 Kodak $0.00Power Supply - 5V 1 Kodak $0.00Pressure Regulator - - 1 Kodak $0.00Analog Pressure Sensor - - 1 Kodak $0.00Digital Pressure Sensor - - 1 Kodak $0.00Op Amp AP358SG-13 8-SOIC 10 DigiKey $10.009-Wire Cable - 5ft 1 Kodak $0.00Voltage Regulator - 3.3V 1 Digikey $10.00LCD Screen - 4x16 1 Digikey $12.00Teflon Tape 31273 520in 1 Home Depot $1.37DAQ-MicroProcessor MSP-EXP430G2 - 1 DigiKey $10.37Pump Repair Kit - - - Info. from Kodak $0.00

McMaster Carr $618.40National Instruments $585.00

DigiKey $52.74Home Depot $113.31

Zorotools $200.00Total High $1,569.45Total Low $984.45

Equipment List / BOM

Major Components

Minor Components

Spare Parts



Risk Assessment

ID Risk Item Effect Cause

Lik

elih

ood

Seve

rity

Imp

orta

nce

Action to Minimize Risk Owner

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?

Who is responsible for following through on mitigation?

1Time Requirements of Lab

Procedures

Students will run out of time during the

experiments

Lack of proper planning/testing of

procedures2 3 6

Proper testing of lab procedure. Allow extra time on top of our

findings to ensure sufficient time allotted.

Team (Mostly ChemEs)

2 Customer Needs ChangingDeliverables may be late

or not met

Lack of communication with

customer3 3 9

Maintain communication with costumer.

Team (Mostly Andre)

3 Lead Time on Parts Deliverables may be lateProcrastination, shipping errors

1 2 2 Allow long lead times. Team

4 Cost of Parts Could go over budgetLack of proper

research into what is needed

1 2 2Research to find smart product

choices if purchases are required. (Most items donated)

Team

5 DAQ or MicroprocessorBig difference in cost of

workloadCost and time spent 3 3 9 Thorough testing of Microprocessor. Jim

6 Poor TeamworkPeople will not know

where their focus should be

Lack of communication

within group1 3 3

Ensure constant team communication

Andre

7 Unavailability Deliverables may be lateIllness/poor

communication1 3 3

Ensure constant team communication

Team

8 EDGE Issues Loss of DocumentsPoor planning/lack of

EDGE proficiency1 2 2

Entire team learns EDGE, with one member in charge.

Team (Mostly Andy)

9 LabVIEW IssuesDelay code

functionality/deliverablesOnly a few members

are proficient1 3 3

Consult other experts when issues present themselves.

Team (Mostly Peter/Andy/Andre)

10 No Defined BudgetUnsure what materials

can be purchasedUncertainty with

customer2 1 2

Compose estimated budget, and update customer of its status.

Team



12 Code BugsFail to meet system specs./deliverables

Coding errors 2 3 6 Frequent debugging. Team

13 Part FailureStudents will be unable to

operateGeneral wear or

misuse1 3 3 Spare parts Team

14 LeakageFailure to meet system

specsImproper sealing 2 1 2

Spare Teflon tape with instructions for fittings

Team

15 Structural FailureStudents will be unable to

operatePoor design 1 3 3 Structural modeling/analysis Peter

16 DAQ FailureStudents will be unable to

operatePoor handling of

electronics1 3 3

Spare Microprocessor with instruction manual for installation

Jim

17 Pump FailureStudents will be unable to

operateGear wear 1 3 3 Pump repair kit or spare pump Team

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 strategyPrevent 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 occurTransfer 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.



Electrical Design

Pressure Sensor



Powerflex 40



Microcontroller



Complete Loop



Electrical Box



Power



Test Plan

Disturbances:1. Head pressure from switching tanks2. Control Valve3. Needle Valve4. Pipe length with pressure drop

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)

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)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)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


PSPS


Feasibility Analysis

The performance of a MicroPump GJ-N27 positive displacement pump with PEEK gears was measured at various RPM’s and head pressures. The flow characteristics of a Badger Meter Inc.

Research Control Valve ½’’, equal % was measured at various positions and pressure drops.

Pump Performance

0 10 20 30 40 50 60 70 80 900

500100015002000250030003500400045005000

f(x) = − 7.19920882875188 x + 4739.25634397968

f(x) = − 8.39029881293492 x + 3965.6711011052

f(x) = − 8.06053055511964 x + 3165.63849102771

f(x) = − 10.0080591959255 x + 2389.40534100146

f(x) = − 9.38460734255593 x + 1585.05826627726

f(x) = − 15.4974758770529 x + 833.200715700684

Flow Rate Performance with Increasing Head Pressure N-27 Pump

575 RPMLinear (575 RPM)1150 RPMLinear (1150 RPM)1725 RPMLinear (1725 RPM)2300 RPMLinear (2300 RPM)2875 RPMLinear (2875 RPM)3450 RPMLinear (3450 RPM)

Pressure Across Pump (∆psi)

Flow

Rat

e (g

ram

/min

)

The flow rate through the pump drops linearly with pressure increase, surprisingly showing higher efficiencies at high RPM compared to low RPM.


Air Supply and Signal


Control Valve Performance

10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110%0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

f(x) = 0.661515479036795 x³ − 0.0139039956080913 x² + 0.0755269693278586 x

Cv Coefficients of Control Valve

Valve Position

Cv C

oeffi

cien

t

The flow characteristics of the valve are typical of equal percentage control valves.

Calculating System Pressure and Flow Rate via Valve Position and Pump RPM

Flow Rateof ControlValve :FV=C v (x ) √∆ P

Flow Rateof Pump :FP=(−α+ βω )∆ P+γω ,

α ,β , γ : pump fitting parameters; ω : pump RPM ;gpm∧psi units

The system pressure and flow rate can be calculated via solving the flow equations for

both the pump and control valve. The following figures show the feasible RPM and valve

positions to attain manageable pressures and flow rates. The Flow rate of the provided N-23

pump was modeled via multiplying the flow rate of the N-27 pump by the size ratio (0.4346).



0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10

500

1000

1500

2000

2500

3000

3500

System Flow Rate with various Valve Positions and Pump RPM's

10002000300040005000

Valve Position

Flow

Rat

e (g

ram

/min

)

0 0.2 0.4 0.6 0.8 1 1.20

10

20

30

40

50

60

70

80

90

100

System Pressure with various Valve Positions and Pump RPM's

10002000300040005000

Valve Position

Syst

em P

ress

ure

(psi)



Microcontroller Feasibility Analysis

Number of Pins: 16 I/O Pins available

• 6 for LCD, 2 for Start/Stop, 1 for Flow Data, 1 for Pressure Sensor, 2 for UART

8 ADC Pins available• 1 for Pressure Sensor, 1 for Flow Data

Resolution of ADC:• Contains 10-bit ADC – 210 levels of resolution for data

• VREF = 1.5 volts – corresponds to 1.465 mV

• Range of pump ~500 -1500 g/min

• Total range of 40-200 mV with 10 Ω resistor on Op-Amp yields 109 distinct levels

• Microcontroller is accurate to within 9.1 g/min

• On average this will give .91 % error

• By increasing resistor to 75 Ω error drops to .122%

• Will test over the summer to ensure all components can handle operating conditions

Code Tests

• Code to take in analog input and convert to digital signal

• Code to take digital signal and drive LCD display

• Code to take digital signals and transmit and receive through UART

• Code to take multiple analog inputs and convert to digital signals at the same time

• Code to transmit multiple digital signals through UART on alternating clock cycles



Cart

Drawing Final Iteration



CAD Model



3 Week Plan for MSD II

Make sure all expected parts have arrived and are in working condition. Buy required parts from Home Depot. Assemble Frame. Work on DAQ/LabVIEW code and debug. Continue work on the lab design. Test Components

o Driveo Motoro Pumpo Flow Tubeo Control Valveo Needle Valveo Head pressure switch on tankso Pressure Sensorso Shut off valve



QUESTIONS?


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