Chem E ProcessControl Lab Equipment Heat Exchanger Dan

Chem. E Process-Control Lab Equipment Heat Exchanger » » » Dan Sacchitella – Chem. E, Project manager Amanda Doucett- Chem. E, Lead Engineer Jay Moseley- EE, Controls Engineer Marc Farfaglia- Chem. E, Controls Liason Rebecca Davidson- Chem. E, Technical Engineer Micah Bitz- Chem. E, Technical Engineer Detailed Design Review MSD 1 5/3/2013

Agenda » » » » Project Background Feasibility Analysis Drawings BOM Updated Risk Assessment Issues/Actions Schedule Detailed Design Review MSD 1 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 MSD 1 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 MSD 1 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 MSD 1 5/3/2013

Feasibility Analysis System: Water cooling water through a copper pipe Hot Flow= 2 L/min Cold Flow= 3 L/min q= 627 W Detailed Design Review MSD 1 5/3/2013

PFD Detailed Design Review MSD 1 5/3/2013

Control Loop X Labview Controller Control Valve ADC in Microcontroller Detailed Design Review MSD 1 Change in Flow Rate Change in Temperature RTD and Thermocouple Sensors 5/3/2013

P&ID Detailed Design Review MSD 1 5/3/2013

Basis for cart layout » The cart is approximately 3’ 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 MSD 1 5/3/2013

Physical Layout Detailed Design Review MSD 1 5/3/2013

Physical Layout Detailed Design Review MSD 1 5/3/2013

Electrical Functional Block Diagram Sensor Inputs Resistive Thermal Device Thermocouple Computer with Labview software • Control Sampling • Data Recording • Modification of Control loop Serial to USB Analog to Digital converter in MSP 430 Clock USB to Serial DAC IC Chip Thermocouple Active LCD output Detailed Design Review MSD 1 Control Valve 5/3/2013

Electrical Enclosure Detailed Design Review MSD 1 5/3/2013

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 MSD 1 5/3/2013

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 $ 98. 00 $ 1 98. 00 X Cole-Parmer NSF-Approved Turbine Flow Meter, 0. 4 - 4 GPM, 3/8" NPT (Male) EW-98516 -92 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-RL 3 M 4 -S 4 1 $ - X Mc. Master-Carr Fast Response Thermocouple Probe 1/4" Diameter, 6" Length, Type K, 32 F to 1600 F 3872 K 39 $ 93. 30 $ 2 186. 60 X N/A Research Control Valve, 3 -15 psig N/A 1 $ - X $ 135. 00 $ 1 135. 00 X $ 46. 16 $ 3 138. 48 X $ 0. 62 $ 20 12. 40 X Mc. Master-Carr Brewers Hardware Swagelok Mc. Master-Carr 550 lb. Capacity Cart Aluminum Strut Channel, 10 ft length Single Channel Plastic End Caps Vibration Damping Strut Mount Clamps, Zinc-Chromate Steel, 1 1/2" OD Nuts for Strut Channel, Zinc Plated Steel, 10 -24 Thread 1 -1 1/2" Tri-clamp to 1/2" FNPT Stainless Steel **Street Tee, 1/2 in. Female NPT x 1/2 in. Male NPT x 1/2 in. Female NPT **SS Swagelok Tube Fitting, Male Connector, 1/2 in. Tube OD x 1/2 in. Male NPT **SS Swagelok Tube Fitting, Female Branch Tee, 1/2 in. Tube OD x 1/2 in. Female NPT **1/2" OD PE Tubing (30 ft) Nuts with Springs for Strut Channel, Zinc Plated Steel, 13/16" Titanium Bolts, 1. 5", 10 -24 thread Detailed Design Review MSD 1 3230 T 48 3312 T 56 32625 T 61 3259 T 42 SS-8 -ST SS-810 -1 -8 SS-810 -3 -8 TTF 3259 T 55 94081 A 149 $ 2. 92 $ 3 8. 76 X $ 3. 93 $ 20 78. 60 X $ 15. 00 $ 2 30. 00 X $ 60. 50 $ 2 121. 00 X X $ 15. 99 $ 6 95. 94 X X $ 53. 04 $ 2 106. 08 $ 1. 50 $ 30 45. 00 X $ 20 123. 40 X $ 20 94. 60 X $6. 17 $ 4. 73 5/3/2013

BOM 20 x 4 Character LCD-00256 Sparkfun Thermocouple Amplifier Chip $ 17. 95 1 $ 17. 95 X $ 17. 95 2 $ 35. 90 X $ 2. 58 4 $ 10. 32 X $ 2. 30 2 $ 4. 60 X $ 5. 54 1 $ 5. 54 X $ 0. 50 1 $ 0. 50 X $ 1. 25 1 $ 1. 25 X $ 1. 95 1 $ 1. 95 X SEN-00251 $ 13. 95 2 $ 27. 90 X $ 100. 00 1 $ 100. 00 X $ - 2 $ - X Total Project Cost $ 1, 546. 77 AD 595 -AQ Sparkfun MSP 430 G 2553 microcontroller 296 -28430 -1 -ND Digikey Microchip Technology 10 bit dac chip MCP 4812 A 0 T Digikey 9 volt plug in adapter N/A Mouser on/ off switch N/A Sparkfun voltage regulator 5 V N/A Sparkfun voltage regulator 3. 3 V N/A Sparkfun k type thermocouples Sparkfun Zorotools Electrical Enclosure Resitive Thermal Device ** Denotes uncertainty of origin of material

Risk Assessment Detailed Design Review MSD 1 5/3/2013

Risk Item Effect Cause Likelihood Severity Importance 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? 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 Unreliable Suppliers Disrupt 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 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 deliverables Poor communications/ Illness 2 1 2 Let group know if/ why you can’t attend meetings. Plan ahead. Poor Communication People may not know current tasks Lack of motivation/communication with group members 1 Keep everyone updated on current goals/ ideas. Ask for progress ahead of the date when the deliverable are expected. ID Action to Minimize Risk 1 2 3 6 1 1 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 Work Portray 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 MSD 1 5/3/2013

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. “Importance Score” (Likelihood x Severity) – use this to guide your preference for a risk management strategy Prevent Reduce Likelihood scale 1 - This cause is unlikely to happen Severity scale 1 - The impact on the project is very minor. We will still meet deliverables on time and within budget, but Action will be taken to prevent the cause(s) from occurring in the first place. 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. 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 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. 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. Detailed Design Review MSD 1 5/3/2013

Issues/Actions Issue 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 MSD 1 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 MSD 1 5/3/2013

Questions? Detailed Design Review MSD 1 5/3/2013