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Control Lab Repair and Lab Experiment Design
Jennifer Pratt
Senior Lab Experience
December 6, 2006
Overview
Overall Goals Objectives Introduction Description of Process Challenges Work done on rig Deliverables
Overall Goals
Learn about process control Establish a lab for future Process control
classes to utilize Repair the temperature rig Gain lab experience
Objectives
Replace hoses, flow sensors, and flow transmitters
Perform all practicals in lab manual Make sure the rig runs properly while doing
practicals Prepare the lab experiment guidelines Troubleshoot problems with the rig and
experiments Prepare a repair/maintenance manual for the
rig operations
Timeline
Introduction Temperature control rig built by
Feedback Discovery Products
Figure 1: TPR
Introduction
Basic understanding of BPR, process controller, and process interface required
TPR consists of primary and secondary flow Secondary flow provided by BPR Primary flow cycles through heat exchanger
while secondary flow cools it Practicals focus on familiarization of different
types of control No data collected as in traditional
experiments
Introduction
Lab demonstrates key concepts of control such as: On/Off control Manual/Automatic control P-Pi-PID Control Modeling Dynamic Systems Mimic Diagrams Ratio Control/Dual Loop Control
Description of Process
ReservoirHt. Exch
Pump
Radiator
Header Tank
Flow sensor
Flow Sensor
Figure 2: TPR
Description of Process
Figure 3: TPR + BPRSecondary Flow In
Secondary Flow Out
Project Challenges
Broken parts Mishandling of rig Cleaning entire piping system Sharing BPR with control labs every other week Ordering parts Recent PI communication problems with BPR T.A. slow in response to requests for help
Work Done
Drained old water from system/refilled with distilled Cleaned and replaced 2 flow sensors Ordered and replaced 2 new pulse flow transmitters
and 2 new flow sensors Kept log of repair attempts and successful
techniques Performed all practicals in lab manual Created a student lab companion for completing
practicals Created a repair/maintenance manual
The Practicals
6 Assignments with 3-4 practicals each Assignment #1- Initialization of Rig Assignment #2- Familiarization of the Rig Assignment #3- Manual Flow Control Assignment #4- Temperature Process Control Assignment #5- P-PI-PID Temperature Control Assignment #6- Complex Control Loops
Issues Found in Practicals
Assignment 1 Practical 3- Questions are misprinted in student lab manual
Assignment 3 Practical 2- Patching diagram is mislabeled Practical 3- Additional patching information is included in
background but not in patching section Assignment 4
Practical 1- Additional patching information is included in background but not in patching section
Practical 2- Patching diagram is mislabeled Assignment 5
Practical 2- Questions are misprinted in student lab manual
The Student Lab Companion
Includes introduction with advice on how to approach labs
Lists questions to be answered after performing each practical
Gives helpful hints for answering tough questions
Gives additional info not provided in lab manual
Lists mistakes found in each practical
An Excerpt from the Companion
Assignment 5: Practical 1 Flow ratio is demonstrated by changing secondary flow set point and
observing the corresponding change in primary flow Questions
Explain with the aid of the diagram below, a system for automatically proportioning the flow of liquid in two separate pipelines.**
**Answer Provided in Instructor Lab Manual
Repair/Maintenance Manual Guidelines The rig should only be used with distilled water to prevent
buildup of lime and calcium on the inside of the pipes, sensors, and heat exchanger.
The rig should be handled carefully and expertly so that parts are not damaged during disassembling/assembling.
There are certain ways that components must be removed and replaced so that they function properly and are not damaged.
Maintenance should be completed as scheduled to ensure the proper functioning of the process rig for future classes to benefit from.
Ordering of new parts from Feedback Inc. is a lengthy expensive process, so great care should be taken when handling them.
Instructions Given in Manual
Removal of flow sensors from the rig Cleaning of the flow sensors Repair of flow sensor electrical components Replacement of flow sensors back on the rig Draining/Refilling of the water in the rig Troubleshooting with flow/temperature transmitters Maintenance of hose piping between BPR and TPR Scheduled Maintenance
Repair Log Example
Hose replacement
Date Performed By Date Performed By
09/06 J. Pratt
Conclusions/Recommendations
Rig should be cared for and cleaned properly Labs will be easier for future students now
that mistakes have been pointed out Use the repair manual on a regular basis Use the student lab companion questions for
the next control class (Fall 2007)
Questions?