1. Project 13632
Process Control Flow Cart: Heat Exchange Temperature Control Loop
Amanda Doucett, Dan Sacchitella, Jay Moseley, Micah Bitz, Marc Farfaglia, Rebecca Davidson

2. Presentation Agenda Project Overview Customer Needs Specifications
Initial Design Decisions (MSD1)
Budget/Bill of Materials
Final Layout
Process Control Lab Plan
Results of Testing
Project Achievements
Current Project Status
Conclusion
Acknowledgments
Q&A

3. Project Overview
The objective was to build a flow cart that would illustrate process control to future chemical engineering students here at RIT.
There were three projects with similar objectives, though the means of teaching process control varied slightly between them.
Our project (P13632) required that the process control system incorporate controls based on temperature feedback loops.
Temperature changes used for process control were achieved through the use of a shell-and-tube heat exchanger.

4. Customer Requirements
Design for safe operation
Design for use by three students during allotted lab time
Portable
Easily connected/disconnected for lab use
Robust design
Minimal maintenance requirements
Utilize a control loop based on temperature changes
Require control of heated process flow and cooling exchange flow rates
Operate both manually and through process control programming in Labview
Capable of manual and automatic data collection

5. Operating Requirements
120 VAC for Instruments and Controllers
25 psi instrument air
80 psi compressed air
Fluid viscosity between 1 cP and 10 cP
Process mass flow rate between 500 g/min and 1500 g/min
Temperature range for process effluent of 70 °F and 130 °F
Heating fluid flow (water) rate between 1 GPM and 4 GPM

6. Initial Design Decisions - Pugh Chart

7. Risk Assessment

8. Detailed Physical Design (MSD1)

9. Piping and Instrumentation Diagram (P&ID)

10. Functional Block Diagram (Electrical)

11. Budget/Bill of Materials
Vendor
Description
Model/Series
Cost (EA)
Quantity
Total Cost
N/A
Exergy Heat Exchanger
Series 35 1 $-
VWR
Heating/Cooling Recirculating Water Bath 2
I/P transducer
Cole-Parmer
NSF-Approved Turbine Flow Meter, GPM, 3/8" NPT (Male) EW
$98.00
0-60 psi Dual-Scale Gauge, Bottom Connection EW
$67.00
Research Control Valve, 3-15 psig
Lowe's
Rubbermaid 550 lb. Capacity Cart
$129.98
Miscellaneous Parts
$89.67
McMaster-Carr
Aluminum Strut Channel, 10 ft length
3230T48
$46.16 3
$138.48
Single Channel Plastic End Caps
3312T56
$0.62 20
$12.40
Vibration Damping Strut Mount Clamps, Zinc-Chromate Steel, 1 1/2" OD
32625T61
$2.92
$8.76
Nuts for Strut Channel, Zinc Plated Steel, Thread
3259T42
$3.93
$78.60
 McMaster-Carr
3/8” OD PE Tubing (50 ft)
 5181K31
$0.26 50
$13.00
¼” OD tubing $0 10
Titanium Bolts, 1.5", thread
94081A149
$4.73
$94.60
Sparkfun
20x4 Character LCD
LCD-00256
$17.95
Thermocouple Amplifier Chip
AD595-AQ
$35.90
Digikey
MSP430G2553 microcontroller ND
$2.58 4
$10.32
Microchip Technology 10 bit dac chip
MCP4812A0T
$2.30
$4.60
Mouser
9 volt plug in adapter
$5.54
on/ off switch
$0.50
voltage regulator 5V
$1.25
voltage regulator 3.3V
$1.95
k type thermocouples
SEN-00251
$13.95
$27.90
3856K912
$20.33
$40.66
Zorotools
Electrical Enclosure
$100.00
Resistive Thermal Device
Total Project Cost
$977.06

12. Final Design Layout

13. Labview Interface Individual Temperature Sensor Data Manual Gain Set
Manual Temperature Set Point

14. Proposed Student Lab
1: PID Control – Analyze the difference in a real system between
Proportional control
Proportional and Integral control
Proportional, integral, and differential control
Deliverables: Graphs showing process over time, Analysis of overshoot and how it was minimized
2: Temperature sensors – Fit temperature data to the sensor equations
Tt=To+T1-To [1-e-tτ]
Deliverables: Which sensor responds to control best? RTD vs. Thermocouple 

15. Operability Testing Test ID Test Name Relevant Specification
Relevant Customer Need
Description
Critical Value
Pass/Fail T1
Leak Test
Minimal Cleaning
Robust Design
Ensure all connections are tight and no liquid leaks from the system
Pass/Value
Pass T2
Accuracy of Rotameter
N/A
Robust design
The measurement the flow meter outputs should be confirms by experimentally measuring a volume of fluid collected over a set time period
20%
Pass, 8% discrepancy T3
Temperature Sensor Accuracy
The temperature value the temperature sensors return will be confirmed by comparing the readout to known values T4
Optimize ΔT
Temperature Control
Teaching
Test heat exchange over a range of inlet temperatures for the hot and cold streams to optimize heat exchange settings
Change in hot stream 10°
15° in 30 minutes T5
Labview Runthrough
Student Use
Full testing of all labview interfaces to ensure communication with the computer
Pass/ Fail T6
Lab Assignment Runthrough
Full testing of lab assignments to confirm the time requirments and results

16. Operating Specifications Chart
Parameter
Customer Specification
Status
Description
Instrument Air
25 psi air
Converter functions as specified
Compressed Air
80 psi air
Supplied through the building
Process Viscosity
1-10 cP
Water is used for both flow streams
Process Fluid Flow Range
500 g/min to 1500 g/min
Process bath rate falls within that range
Exchange Fluid Flow Range
1 to 4 GPM
Water bath limited to a max of 0.5 GPM
Process Temp. Range
70° F to 140° F
Bath will operate between -4° F and 392° F
Exchange Temp. Range
Status Key
Specification Met
Working exception to specification, will not negatively impact functionality
Needs to be addressed in order to function as required

17. Customer Requirements – Project Achievements
Parameter
Status
Description
Safety
Hot fluid is contained in the inner tube of heat exchanger, Electrical components are all contained within a sealed electrical box
Portability
All aspects of the cart are contained on the cart or on another portable cart. The only location restriction is access to a computer
Used by 3 students for 3 lab sections
Lab assignment is enough work for 3 students over 3 days
Control Based on Heat Exchange
Heat exchange flow system
Minimal Maintenance
Only fluid used is water no cleaning necessary
Manual Control
Valve position can be changed through an input in Labview
Status Key
Completed
Working exception to specification, will not negatively impact
functionality
Needs to be addressed in
order to function as
required

18. Current Project Status
The cart has all mechanical aspects assembled and they have been tested for operability and accuracy
The electrical component has been designed and assembled. Testing has been performed to ensure correct communication with the cart
A Labview interface has been created for use with the system that outputs all relevant data and allows user input
A lab procedure exploring the effects of process control equations on the heat exchange system has been designed. It is expected to take 3 students 3 lab periods to complete.
The thermocouples are not currently registering data correctly with the Labview interface, but their purpose is simply to provide more process transparency for the students and they are not necessary for the system to function fully. There is a plan in place to correct the malfunction before the end of the term.

19. Project Evaluation Successes: Failures: Functioning product
Educationally valuable lab assignment to accompany the product
Met or exceeded design specifications
Stayed within budget
Overcame equipment failures
Failures:
The lack of a truly multidisciplinary group resulted in challenges with mechanical design
Lack of spare parts
Uneven distribution of work
Minor troubleshooting required

20. Future Work Develop a noise introduction method
Add more mechanical manual control
Integrate a digital flow sensor
Labview can be easily updated for future needs

21. We would like to thank…
…our faculty guide, Steve Possanza, for his guidance and support during this project, the Chemical Engineering Department for their guidance and support, the Multi-Disciplinary Senior Design group for their funding and support, and Kodak for their generous contributions.

22. Questions?