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 Topic of Review Required Attendees Time Steve Possanza and Christiaan Richter, 9:00 Project Background Recap Full Team Review Updated Customer Needs, Steve Possanza and Christiaan 9:05 Engineering Specs Richter, Full Team Steve Possanza and Christiaan 9:15 Review Existing Pugh Diagrams Richter, Full Team Steve Possanza and Christiaan 9:20 Review Updated P&ID Richter, Full Team Steve Possanza and Christiaan 9:30 Review BOM Richter, Full Team Steve Possanza and Christiaan 9:40 Review Updated Risk Analysis Richter, Full Team Steve Possanza and Christiaan 9:45 Electrical Design Review Richter, Full Team Steve Possanza and Christiaan 10:00 Test Plan Review Richter, Full Team Steve Possanza and Christiaan 10:10 Feasibility Analysis Richter, Full Team Steve Possanza and Christiaan 10:15 Cart Review Richter, Full Team Steve Possanza and Christiaan 10:20 MSD II 3 Week Plan Richter, Full Team Steve Possanza and Christiaan 10:25 Conclusion and Questions Richter, Full Team Table of Contents

Table of Contents

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 A-2

Project Description

Project Description • Maintenance for cart and all components as well as a detailed user’s manual. Project Background: Expected Project Benefits: The Metered Flow Loop project specifically aims to • Effectively teach Process Control to future Chemical create an educational experience for future Chemical Engineering students. 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 Core Team Members: controlling a metered flow loop. The cart will be used in  Andre Berwin (Team Lead) conjunction with a detailed laboratory curriculum to  Nathan Fulcher more effectively teach process control to students.  Andrew Watson  Travis Bardsley Objectives/Scope:  Anthony Parker 1. Design Cart to be portable and easily maintained  Peter Dunning 2. Design LabVIEW interface for easy use of cart  James Mazza 3. Design Lab to be used with cart to teach various concepts of process control. Deliverables: Issues & Risks: • Insufficient time to finish lab experiments. • Fully functional cart to be used in Chemical • Change in customer needs. Engineering Laboratories. • Lead time on parts. • LabVIEW GUI that can control the flow and control parameters • DAQ issues. • Laboratory plan to be used by students • Edge issues. • Structural Failure. MSD II Final Design Review

P13630 – Customer Needs Customer Importance Description Comments/Status Need #

CN1 9 Assembled Cart Designed – Will Be Built in MSDII

CN2 9 Metered Flow Control Via Microcontroller/LabVIEW Interface

Interface with LabVIEW for CN3 9 MSD II Automatic Control

No Chance of Pressure Buildup CN4 9 Cart Is Safe Major Electrical Components in a Dry Box Rough Draft Already Completed CN5 6 Recommended Lab Protocol Thorough testing with user feedback Process and Control Interaction Initial Tests Completed, More Once CN6 6 Analysis Cart Is Assembled Initial Characteristic Curves CN7 6 Known System Capability Evaluation Completed CN8 6 Modeled After Current Lab Carts Visually Similar Via Physical Needle Valve, Ball Valve, CN9 6 Manual Control of Cart Lab View Interface CN10 6 Robust and Durable Through Normal Use CN11 6 Operated by 3 Students Will Test Group Size in MSDII Rough Lab Protocol Completed CN12 6 Takes Place in Allotted Lab Time Will Test Lab Duration in MSDII Via LabVIEW Interface into .csv file CN13 6 Automated Data Collection with Microcontroller All Swagelok Fittings are Modular CN14 3 Modular and Adaptable Can Support Control Valve in Series and Parallel Cart is on Wheels CN15 3 Easily Moved and Portable May Interface with any Computer with LabVIEW Easy to Fix for Common Problems & CN16 3 Minimal Maintenance and Cleaning Normal Wear Will Supply Basic Maintenance Kit

KGCOE MSD I Page 4 of 27 Detailed Design Review MSD II Final Design Review

Engineering Specifications

Measure of Engr. Margina Validation Method Engr. Spec Description Ideal Value Performance Units l Value (TOAD) Run Pump Maximum Process Volume per unit ES1 g/min 6785 1500 Characterization Flow Rate time tests Run Pump Minimum Process Volume per unit ES2 g/min 158 500 Characterization Flow Rate time tests Demonstrate ES3 Process Fluid operating temps for Operating Temp Temperature Range °F 70-140 70-130 equipment Process Fluid ES4 Viscosity cP 1 1 N/A Viscosity Implement Max Pressure in ES5 Pressure psi 5-80 20 Pressure Sensors in System Flow Loop Minimum Space Physical ES6 Requirements Volume ft3 30 24 measurements Instrument and Voltage ES7 Controller Power Measurements Supply Voltage V 110 120 using Multimeter Motor and Drive Voltage ES8 Operating Power Measurements Supply Voltage V 230 460 using Multimeter Test Sampling Rate of Samples per unit ES9 S/s 200,000 < 10 Microcontroller Controller time code Monitor pump Response Time of ES10 Time s 1 0.01 speed for a Pump changing flow KGCOE MSD I Page 5 of 27 Detailed Design Review MSD II Final Design Review

Simulate 4-20mA Automated signal to ES11 Operation of controller/device Instruments Operationally mA 4, 20 4 to 20 using fluke Successful ES12 Simple Wire operation by non- connectivity Operationally Binary N/A N/A technical students Mobility Successful ES13 adaptability in Lab operation by non- setting Operationally Binary N/A N/A technical students Successful ES14 Manual Operation operation by non- of Instruments Operationally Binary N/A N/A technical students Successful ES15 Safe and operation by non- Ergonomic Design Operationally Binary N/A N/A technical students Successful ES16 Automated Data operation by non- Collection Operationally Binary N/A N/A technical students Successful Time it takes to ES17 Time Hours 9 7.5 operation by non- complete lab technical students Add up costs at the ES18 Cost Dollars Dollars 2000 1500 end of project Compare it Against ES19 Accuracy of Flow Known Instrument/ Measurements Percent error % < 1 0.2 Timing Method ES20 Lifetime of Cart Time Years 5 10 N/A

Test Results

Parameter Target Test Plan results Reference Min Flow Rate 158 g/min Check flow rate at lowest Yes Pump pump settings testing, 11/8/2013 Max Flow Rate 1500 g/min Check flow rate at highest Yes, highest is 1504 Pump pump settings g/min testing, 11/8/2013 System Pressure 5 to 80 psi Check Pressure during Yes, pressure can Pump operation span 0.5-30psi with testing, supply 11/8/2013 Pump Response < 1 second Check time to new steady Yes, pump response Operating Time state after change is made time can be set via manual the PowerFlex drive pg. 3-12 Flow Accuracy < 1% error Compare flow meter value Yes, dependant on Pump against another flow flow rate, ranged testing, meter or total volume per between 0.1-1% 11/8/2013 time innacuracy Control Valve < 5 seconds Check time to new steady < 1 second Response Time state after change is made

Leakage No Leaks Check for leaks under Yes normal operating procedures Operator 2 Minimum, 3 Attempt to operate the Yes Maximum system with 2 people Automatic Functioning PID Implement new set-points Yes Control control with ability and observe system to alter constants response Manual Control Can adjust flow Adjust flow Yes manually Automatic Data Labview records Ensure it exists and check Yes Collection data that can be for accuracy graphed or exported to excel Manual Data Real time data is Ensure it exists and check Yes Collection displayed for accuracy Modularity Can alter system to Reconfigure system to put Yes put different different components in comonents in alternate order series or parallel Portability Easy to move, Connent and disconnect Yes but wheels need connect to and system from utilities. Push to be replaced disconnect from cart around. utilities Noise 2 Sources Test if our sources effect Yes the data

BOM Equipment List / BOM Component Category Component Type Part Number Size/ID Number Buy Location Price Cart - 3ftx2ft 1 McMaster Carr $150.00 Reservoir - 2L 2 Kodak $0.00 Pump - - 1 Kodak $0.00 Drive - - 1 Kodak $0.00 Motor - - 1 Kodak $0.00 Control Valve - - 1 Kodak $0.00 Major Components Flow meter - - 1 Kodak $0.00 DAQ-Controller* NI9208 16 Channel 1 National Instruments $585.00 DAQ-MicroProcessor MSP-EXP430G2 - 1 DigiKey $10.37 Shut-off Valve - - 2 Kodak $0.00 Pressure Relief Valve - - 1 Kodak $0.00 Needle Valve - - 1 Kodak $0.00 Tubing 5181K25 3/8" & 1/2" 100 ft McMaster Carr $30.00 Fittings - - Assorted Kodak $0.00 Fasteners - - Assorted Home Depot $50.00 Stud Nuts 3580T11 1/4" 40 McMaster Carr $188.00 Connecting Plate 33125T34 90° 10 McMaster Carr $21.00 Connecting Plate 33125T42 45° 8 McMaster Carr $16.40 Framing 33085T43 304 SS 20 ft McMaster Carr $213.00 Drive Box G1561061 16"x20"x6" 1 Zorotools $200.00 Power Strip BE106001-08R-DP 6 outlets 1 Home Depot $12.97 AWG20 DW-65A 65ft 1 Home Depot $4.97 AWG14 147-1472G 250ft 1 Home Depot $44.00 T-junction - .5" 5 Kodak $0.00 Minor Components Tubing Size Converters - 1/2" to 1/8" 2 Kodak $0.00 Tubing Size Converters - 1/2" to 3/8" 2 Kodak $0.00 I/P Converters - - 1 Kodak $0.00 Power Supply - 5V 1 Kodak $0.00 Pressure Regulator - - 1 Kodak $0.00 Analog Pressure Sensor - - 1 Kodak $0.00 Digital Pressure Sensor - - 1 Kodak $0.00 Op Amp AP358SG-13 8-SOIC 10 DigiKey $10.00 9-Wire Cable - 5ft 1 Kodak $0.00 Voltage Regulator - 3.3V 1 Digikey $10.00 LCD Screen - 4x16 1 Digikey $12.00 Teflon Tape 31273 520in 1 Home Depot $1.37 DAQ-MicroProcessor MSP-EXP430G2 - 1 DigiKey $10.37 Spare Parts Pump Repair Kit - - - Info. from Kodak $0.00 McMaster Carr $618.40 National Instruments $585.00 DigiKey $52.74 Home Depot $113.31 Zorotools $200.00 Total High $1,569.45 Total Low $984.45

Budget

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.

Electrical Design Pressure Sensor

Powerflex 40

Microcontroller

Complete Loop

Electrical Box

Lab Plan

Disturbances: 1. Head pressure from switching tanks/ Pipe length with pressure drop 2. Control Valve/Needle Valve Control: 1. P (simulated noise) 2. PI (simulated noise) 3. PID (simulated noise) 4. Human vs. Computer 5. Level Controller on Tank 6. 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 controls o 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 control o Differences in P, PI & PID control with actual flow o Differences in P, PI & PID control with actual flow and noise o Vary levels of noise and see impact on control o 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 noise o Averaging data (filter noise) o Have students develop other methods to eliminate noise o 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

Process Control Loop Diagram

Control Valve

The control valve regulates flow rate or pressure of a stream by changing the valve position by the following relation:

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:

Where is the speed (angular speed, RPM) of the motor and , , 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:

Where is the frequency of the drive, which ranges between 0-60 Hz and is directly controlled via a mA signal sent by the microprocessor. is the ratio between drive frequency and motor speed, which is set to 1800RPM/60Hz.

Pump Characterization

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.

LabView GUI

QUESTIONS?

KGCOE MSD I Page 27 of 27 Detailed Design Review