Team: James Mazza, Andre Berwin, Peter Dunning, Nathan Fulcher, Andrew Watson, Travis Bardsley, Anthony Parker April 5, 2013

 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. This project will focus on process control via a flow tube and variable speed pump.

 An analysis of process and control interactions for three designs.  Detailed design for each process including: ◦ Process Flow Diagram (PFD) ◦ Piping and Instrumentation Drawing (P&ID) ◦ Mechanical Assembly and Fabrication Drawings ◦ Equipment List ◦ Control loop drawings ◦ Electrical drawings ◦ Operations, Technical and Equipment Reference manuals. ◦ Recommendation for spare parts and maintenance. Three assembled carts for use in ChE lab.  Evaluation results-System Capability  Experimental Protocol for teaching.

 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  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  Head tank capability  Means to regulate flow of process fluid

 RubberMaid Cart ~ $100  Metal Framing and fittings for mounts  Liquid Reservoir ◦ Holds liquid, has a ball valve port at bottom that connects to tubing  GJ MicroPump  PowerFlex Drive  MicroController (custom) or NatInstr. DAQ  MicroMotion Flowmeter  MicroMotion Transmitter  General Tubing and NPT fittings  LCD Screen ~ $15  Micocontroller ~ $25  Total Estimated Cost: $1000-$1300

 Flow Tube:  Max rate of 92 kg/hr = 1533 g/min  Accuracy for volume of flow = ±.05%  Depending on model tube diameter = 1/10-1/6 in or ¼-1/2 in  Field Mount Transmitter  Two analog outputs (in mA)  Local display  Accuracy of ±.2%  Bell 202 and/or RS-485 serial standards  Pump  Max flow rate = 6785 g/min (water)  Min flow rate = 158 g/min (water)  Input/output port = 1/8” -27 NPT(F)  DAQ Modules  NI channel 500 S/s 24 bit resolution - $617  NI 9208 – 16 SE channel 500 S/s 24 bit resolution - $565  NI 9203 – 8 channel 200 kS/s 16 bit resolution - $504

 Disturbances:  Gravity fed T-junction post pump (additive)  butterfly valve?  Gravity fed T-junction post pump (subtractive)  butterfly valve?  Intermittent flow (the toilet thing)  Control:  P (simulated noise)  PI (simulated noise)  PID (simulated noise)  Human vs. Computer  Level Controller on Tank  Different type of Pump

 First Lab (~3 hrs) ◦ Introduction to system and Labview controls ◦ Human vs. Computer control (P, PI & PID) ◦ Human vs. Computer control (P, PI & PID with noise) ◦ Average data and compare  Second Lab (~3 hrs) ◦ In depth explanation of PID control ◦ Differences in P, PI & PID control with actual flow ◦ Differences in P, PI & PID control with actual flow and noise ◦ Vary levels of noise and see impact on control ◦ Vary Kp, Ki & Kd terms and see impact on control  Third Lab (~3 hrs) ◦ Methods of eliminating noise ◦ Averaging data (filter noise) ◦ Have students develop other methods to eliminate noise? ◦ Have students create a PID control for a given scenario (flow rate/noise/ OTHER?) ◦ Share with class what was done/learned on this cart?