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
9:00
Project Background Recap
9:05
Review Updated Customer Needs,
Engineering Specs
9:15
Review Existing Pugh Diagrams
9:20
Review Updated P&ID
9:30
Review BOM
9:40
Review Updated Risk Analysis
9:45
Electrical Design Review
10:00 Test Plan Review
10:10 Feasibility Analysis
10:15 Cart Review
10:20 MSD II 3 Week Plan
10:25 Conclusion and Questions
Required Attendees
Steve Possanza and Christiaan Richter,
Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Steve Possanza and Christiaan
Richter, Full Team
Table of Contents
Table of Contents
High-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
Test Results .................................................................................................................................................... 7
P&ID .............................................................................................................................................................. 8
BOM ............................................................................................................................................................... 9
Budget ...........................................................................................................................................................10
Electrical Design ...........................................................................................................................................11
Pressure Sensor ..........................................................................................................................................11
Powerflex 40..............................................................................................................................................12
Microcontroller ..........................................................................................................................................13
Complete Loop ..........................................................................................................................................14
Electrical Box ............................................................................................................................................15
Power .........................................................................................................................................................16
Test Plan ........................................................................................................................................................17
Process ...........................................................................................................................................................18
Control Loop .............................................................................................................................................18
Control Valve ............................................................................................................................................19
Pump ..........................................................................................................................................................19
Motor & Drive ...........................................................................................................................................19
Pump Characterization ..................................................................................................................................20
Cart ................................................................................................................................................................21
LabVIEW GUI ..............................................................................................................................................22
Questions? ........................................................................................... Ошибка! Закладка не определена.
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
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 maintained
2. Design LabVIEW interface for easy use of cart
3. 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 Needs
Customer
Need #
Importance
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 Safe
CN5
6
Recommended Lab Protocol
CN6
6
Process and Control Interaction
Analysis
CN7
6
Known System Capability Evaluation
CN8
6
Modeled After Current Lab Carts
CN9
6
Manual Control of Cart
CN10
6
Robust and Durable
Via Physical Needle Valve, Ball Valve,
Lab View Interface
Through Normal Use
CN11
6
Operated by 3 Students
Will Test Group Size in MSDII
CN12
6
Takes Place in Allotted Lab Time
CN13
6
Automated Data Collection
CN14
3
Modular and Adaptable
CN15
3
Easily Moved and Portable
CN16
3
Minimal Maintenance and Cleaning
KGCOE MSD I
Review
Description
Page 5 of 23
Comments/Status
No Chance of Pressure Buildup
Major Electrical Components in a Dry
Box
Rough Draft Already Completed
Thorough testing with user feedback
Initial Tests Completed, More Once
Cart Is Assembled
Initial Characteristic Curves
Completed
Visually Similar
Rough Lab Protocol Completed
Will Test Lab Duration in MSDII
Via LabVIEW Interface into .csv file
with Microcontroller
All Swagelok Fittings are Modular
Can Support Control Valve in Series
and Parallel
Cart is on Wheels
May Interface with any Computer with
LabVIEW
Easy to Fix for Common Problems &
Normal Wear
Will Supply Basic Maintenance Kit
Detailed Design
MSD II Final Design Review
Engineering Specifications
Engr.
Spec
Description
ES1
Maximum Process Flow Rate
ES2
Minimum Process Flow Rate
ES3
ES4
ES5
ES6
Process Fluid Operating Temp
Process Fluid Viscosity
Max Pressure in System
Minimum Space Requirements
Instrument and Controller Power
Supply
Motor and Drive Operating Power
Supply
ES7
ES8
ES9
Sampling Rate of Controller
ES10
Response Time of Pump
Automated Operation of
Instruments
Simple Wire connectivity
Mobility adaptability in Lab
setting
Manual Operation of Instruments
Safe and Ergonomic Design
Automated Data Collection
Time it takes to complete lab
Cost
Accuracy of Flow Measurements
Lifetime of Cart
ES11
ES12
ES13
ES14
ES15
ES16
ES17
ES18
ES19
ES20
KGCOE MSD I
Measure of
Performance
Volume per unit
time
Volume per unit
time
Temperature Range
Viscosity
Pressure
Volume
Engr.
Units
Marginal
Value
Ideal
Value
Validation Method (TOAD)
g/min
6785
1500
Run Pump Characterization tests
g/min
158
500
Run Pump Characterization tests
°F
cP
psi
ft3
70-140
1
5-80
30
70-130
1
20
24
Demonstrate operating temps for equipment
N/A
Implement Pressure Sensors in Flow Loop
Physical measurements
Voltage
V
110
120
Voltage Measurements using Multimeter
Voltage
Samples per unit
time
Time
V
230
460
Voltage Measurements using Multimeter
S/s
200,000
< 10
Test Microcontroller code
s
1
0.01
Monitor pump speed for a changing flow
Operationally
Operationally
mA
Binary
4, 20
N/A
4 to 20
N/A
Simulate 4-20mA signal to controller/device using fluke
Successful operation by non-technical students
Operationally
Operationally
Operationally
Operationally
Time
Dollars
Percent error
Time
Binary
Binary
Binary
Binary
Hours
Dollars
%
Years
N/A
N/A
N/A
N/A
9
2000
<1
5
N/A
N/A
N/A
N/A
7.5
1500
0.2
10
Successful operation by non-technical students
Successful operation by non-technical students
Successful operation by non-technical students
Successful operation by non-technical students
Successful operation by non-technical students
Add up costs at the end of project
Compare it Against Known Instrument/ Timing Method
N/A
Page 6 of 23
Detailed Design Review
MSD II Final Design Review
Test Results
Parameter
Target
Test Plan
results
Reference
Min Flow Rate
158 g/min
Check flow rate at lowest
pump settings
Yes
Max Flow Rate
1500 g/min
Check flow rate at highest
pump settings
Yes, highest is 1504
g/min
System Pressure
5 to 80 psi
Check Pressure during
operation
Yes, pressure can
span 0.5-30psi with
supply
Pump
testing,
11/8/2013
Pump
testing,
11/8/2013
Pump
testing,
11/8/2013
Pump Response
Time
< 1 second
Check time to new steady
state after change is made
Yes, 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
Functioning PID
control with ability
to alter constants
Attempt to operate the
system with 2 people
Implement new set-points
and observe system
response
Yes
Can adjust flow
manually
Labview records
data that can be
graphed or
exported to excel
Adjust flow
Yes
Ensure it exists and check
for accuracy
Yes
Automatic
Control
Manual Control
Automatic Data
Collection
Yes
Manual Data
Collection
Modularity
Real time data is
displayed
Can alter system to
put different
comonents in
series or parallel
Ensure it exists and check
for accuracy
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
Yes
KGCOE MSD I
Review
Page 7 of 23
Yes
Detailed Design
MSD II Final Design Review
P&ID
KGCOE MSD I
Review
Page 8 of 23
Detailed Design
MSD II Final Design Review
BOM
Equipment List / BOM
Component Category
Component Type
Cart
Reservoir
Pump
Drive
Motor
Control Valve
Major Components
Flow meter
DAQ-Controller*
DAQ-MicroProcessor
Shut-off Valve
Pressure Relief Valve
Needle Valve
Tubing
Fittings
Fasteners
Stud Nuts
Connecting Plate
Connecting Plate
Framing
Drive Box
Power Strip
AWG20
AWG14
T-junction
Minor Components
Tubing Size Converters
Tubing Size Converters
I/P Converters
Power Supply
Pressure Regulator
Analog Pressure Sensor
Digital Pressure Sensor
Op Amp
9-Wire Cable
Voltage Regulator
LCD Screen
Teflon Tape
DAQ-MicroProcessor
Spare Parts
Pump Repair Kit
KGCOE MSD I
Review
Part Number
NI9208
MSP-EXP430G2
5181K25
3580T11
33125T34
33125T42
33085T43
G1561061
BE106001-08R-DP
DW-65A
147-1472G
AP358SG-13
31273
MSP-EXP430G2
-
Size/ID
3ftx2ft
2L
16 Channel
3/8" & 1/2"
1/4"
90°
45°
304 SS
16"x20"x6"
6 outlets
65ft
250ft
.5"
1/2" to 1/8"
1/2" to 3/8"
5V
8-SOIC
5ft
3.3V
4x16
520in
-
Page 9 of 23
Number
1
2
1
1
1
1
1
1
1
2
1
1
100 ft
Assorted
Assorted
40
10
8
20 ft
1
1
1
1
5
2
2
1
1
1
1
1
10
1
1
1
1
1
-
Buy Location
McMaster Carr
Kodak
Kodak
Kodak
Kodak
Kodak
Kodak
National Instruments
DigiKey
Kodak
Kodak
Kodak
McMaster Carr
Kodak
Home Depot
McMaster Carr
McMaster Carr
McMaster Carr
McMaster Carr
Zorotools
Home Depot
Home Depot
Home Depot
Kodak
Kodak
Kodak
Kodak
Kodak
Kodak
Kodak
Kodak
DigiKey
Kodak
Digikey
Digikey
Home Depot
DigiKey
Info. from Kodak
McMaster Carr
National Instruments
DigiKey
Home Depot
Zorotools
Total High
Total Low
Price
$150.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$585.00
$10.37
$0.00
$0.00
$0.00
$30.00
$0.00
$50.00
$188.00
$21.00
$16.40
$213.00
$200.00
$12.97
$4.97
$44.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$10.00
$0.00
$10.00
$12.00
$1.37
$10.37
$0.00
$618.40
$585.00
$52.74
$113.31
$200.00
$1,569.45
$984.45
Detailed Design
MSD II Final Design Review
Budget
Team Spending
2500
2000
Amount ($)
2000
1760,62
1569,45
1500
1000
984,45
500
0
Predicted (Low) Predicted (High)
Actual
Budget
Spending
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
Review
Page 10 of 23
Detailed Design
MSD II Final Design Review
Electrical Design
Pressure Sensor
KGCOE MSD I
Page 11 of 23
Detailed Design Review
MSD II Final Design Review
Powerflex 40
KGCOE MSD I
Page 12 of 23
Detailed Design Review
MSD II Final Design Review
Microcontroller
KGCOE MSD I
Page 13 of 23
Detailed Design Review
MSD II Final Design Review
Complete Loop
KGCOE MSD I
Page 14 of 23
Detailed Design Review
MSD II Final Design Review
Electrical Box
KGCOE MSD I
Page 15 of 23
Detailed Design Review
MSD II Final Design Review
Power
KGCOE MSD I
Page 16 of 23
Detailed Design Review
MSD II Final Design Review
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
KGCOE MSD I
Review
Page 17 of 23
Detailed Design
MSD II Final Design Review
Process
Control Loop Diagram
KGCOE MSD I
Review
Page 18 of 23
Detailed Design
MSD II Final Design Review
Control Valve
The control valve regulates flow rate or pressure of a stream by changing the valve
position by the following relation:
𝐹𝑉 = 𝐶𝑣 (𝑥)√∆𝑃
The Cv(x) parameter is a function of the valve position, which is regulated between 0100%. 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 (420mA) 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 = 𝑘𝑓
Where 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.
KGCOE MSD I
Review
Page 19 of 23
Detailed Design
MSD II Final Design Review
Pump Characterization
KGCOE MSD I
Review
Page 20 of 23
Detailed Design
MSD II Final Design Review
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.
KGCOE MSD I
Review
Page 21 of 23
Detailed Design
MSD II Final Design Review
LabView GUI
KGCOE MSD I
Page 22 of 23
Detailed Design Review
MSD II Final Design Review
QUESTIONS?
KGCOE MSD I
Page 23 of 23
Detailed Design Review