Chemical Engineering Process Lab Process Control Evaluation

Apparatus

Administrative Information

Project Name: Process Lab Process Control Apparatus

Project Number: P13630, P13631, P13632
Start term: Spring 2013
End Term: Fall 2013

Faculty Consultant: Christiaan Richter

Customer: ChE dept: Paul Gregorious (ChE lab rep), Christiaan Richter
Guide: Steve Possanza, Eastman Kodak, steven.possanza@kodak.com, 722-5896
Budget: tbd

Project Background

Process control is critical to virtually every application Engineers will come into contact
with. There are two basic aspects to learning/teaching Process Control:

 The theoretical background behind the differential equations that drive a control
loop.
 The practical application of control theory in a lab environment that demonstrates
the interactions between the process and the control.

The control equations are fundamental to all applications. However, the interactions are
significantly impacted by the design and type of process being controlled. These
interactions are best learned by actual experience in a process lab.

This project will investigate, design, fabricate and evaluate three different processes
that will be used to practically demonstrate process control (PID) in a lab environment.
This equipment will be used in conjunction with class room teaching. The three
processes are initially proposed as:

Revision 3/2/13
Process 1: Metered Flow Loop

DAQ
Drive Controller

Flow Tube

Process 2: Gravity fed flow loop with a control valve

Controller

DAQ

Cv Flow Tube
Line
Pressure

Process 3: Heat exchanger with a hot water temperature loop

Hot
Water
Controller DAQ

Cv

Regulating
Heat Exchanger Flow Valve
Line
Pressure

Revision 3/2/13
The Process Flow Diagrams (PFD) shown are representative and the students are
encouraged to innovate the final design(s). And they are not complete.

The designs shown are based on the authors experience and equipment available from
Eastman Kodak.

The overall project will be broken down into three teams that will each focus on one
process design but coordinate final designs and results together.

Detailed Project Description

Goals

 Based on this document, process knowledge and control theory, develop three
processes that will produce varied control results.
 Design the processes using ChE, ME and EE skills.
 Assemble the three processes onto portable carts.
 Test and evaluate.
 Provide a recommended lab protocol for teaching.

Deliverables

 An analysis of process and control interactions for three designs.

 Detailed design for each process including:
o Process Flow Diagram (PFD)
o Piping and Instrumentation Drawing (P&ID)
o Mechanical Assembly and Fabrication Drawings
o Equipment List
o Control loop drawings
o Electrical drawings
o Operations, Technical and Equipment Reference manuals.
o Recommendation for spare parts and maintenance.
 Heat transfer model
 Three assembled carts for use in ChE lab.
 Evaluation results-System Capability
 Experimental Protocol for teaching.

Customer Requirements

 Design modeled after and consistent with existing flow carts

 Design to be modular and adaptable
 Design to be portable, easily moved, easily connect and disconnected to lab
utilities
 Robust and durable design
 Minimal maintenance and cleaning

Revision 3/2/13
  Interface with Labview

 Utilization can take place in allotted time for lab

 Utilization safe and ergonomic
 Operated by 3 students
 Utilization requires fundamental understanding of Process Control

 Can be operated manually or through Labview interface

 Data can be collected manually
 Automated data collection through Labview
 Metered and gravity flow control
 Head tank capability
 Means to regulate flow of process fluid
 Means to regulate flow of heating fluid
 Control temperature via regulating temperature or flow

Operating requirements:

 230/460 3 phase VAC (Motor/Drive)

 120 VAC (Instruments/Controllers)
 25 psi instrument air
 80 psi compressed air
 Process fluid viscosity: 1-10 cP
 Process flow range: 1000 g/min +/- 500 g/min
 Process fluid temperature: 70 to 130 F
 Heating fluid temperature: 70 to 140 F
 Heating fluid flow: 1-4 GPM
 Heating fluid: water

Significant additional guidance will be provided based on the three existing carts in use
and proposed donated equipment.

Specifications

To be developed by team with guide and customer weeks 1-2

Constraints

The carts should be modeled and designed based on the three flow carts currently in
use by the ChE department. A 2 ft by 3 ft Rubbermaid cart is a suggested starting point.

The existing carts are also equipped with temperature measurement equipment
(specific to a shell and tube heat exchange). This equipment should be examined as a
model or for actual use on this project (shared).

Revision 3/2/13
The following equipment is available and will be donated by Eastman Kodak. Some
components will match the flow carts exactly and other equipment is compatible. The
students should utilize this equipment to reduce costs, reduce start up and to allow
commonality:

 Micromotion Flow Tubes (CMF025M321NRAUEZZZ or CMF010M321MUR)

 Micromotion Transmitters (RFT9739E4SUJ)
 Micropump (GJ-N23)
 Reliance 208/230/460 VAC 1 HP motor (P56H4508P-RW)
 Rockwell Power Flex Drives (model 40 or 70)
 Honeywell Controller (model DC300C-0-000-20-0000-0)
 Bauman Control Valves (32-24-588, ½ inch, Cv 0.5 and 1.0)
 Research Control Valves (1002GCN36SVCPEEP3G)
 Intellifaucet (375)

The project should collect the specification or cut sheets for this equipment via the
internet.

Budget

Tbd (as per Steve Weinstein)

Staffing

Approximately 12 integrated Engineers broken into 3 sub teams

1- EE
1- ME
3-4 ChE per team

Project Initiation

Week 1-2: Tour ChE lab and view flow carts.

Week 1-2: Process Design and Controls basics

Revision 3/2/13