Senior Project


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Senior Project

  1. 1. Control Lab Repair and Lab Experiment Design Jennifer Pratt Senior Lab Experience December 6, 2006
  2. 2. Overview <ul><li>Overall Goals </li></ul><ul><li>Objectives </li></ul><ul><li>Introduction </li></ul><ul><li>Description of Process </li></ul><ul><li>Challenges </li></ul><ul><li>Work done on rig </li></ul><ul><li>Deliverables </li></ul>
  3. 3. Overall Goals <ul><li>Learn about process control </li></ul><ul><li>Establish a lab for future Process control classes to utilize </li></ul><ul><li>Repair the temperature rig </li></ul><ul><li>Gain lab experience </li></ul>
  4. 4. Objectives <ul><li>Replace hoses, flow sensors, and flow transmitters </li></ul><ul><li>Perform all practicals in lab manual </li></ul><ul><li>Make sure the rig runs properly while doing practicals </li></ul><ul><li>Prepare the lab experiment guidelines </li></ul><ul><li>Troubleshoot problems with the rig and experiments </li></ul><ul><li>Prepare a repair/maintenance manual for the rig operations </li></ul>
  5. 5. Timeline
  6. 6. Introduction <ul><li>Temperature control rig built by Feedback Discovery Products </li></ul>Figure 1: TPR
  7. 7. Introduction <ul><li>Basic understanding of BPR, process controller, and process interface required </li></ul><ul><li>TPR consists of primary and secondary flow </li></ul><ul><li>Secondary flow provided by BPR </li></ul><ul><li>Primary flow cycles through heat exchanger while secondary flow cools it </li></ul><ul><li>Practicals focus on familiarization of different types of control </li></ul><ul><li>No data collected as in traditional experiments </li></ul>
  8. 8. Introduction <ul><li>Lab demonstrates key concepts of control such as: </li></ul><ul><ul><li>On/Off control </li></ul></ul><ul><ul><li>Manual/Automatic control </li></ul></ul><ul><ul><li>P-Pi-PID Control </li></ul></ul><ul><ul><li>Modeling Dynamic Systems </li></ul></ul><ul><ul><li>Mimic Diagrams </li></ul></ul><ul><ul><li>Ratio Control/Dual Loop Control </li></ul></ul>
  9. 9. Description of Process Reservoir Ht. Exch Pump Radiator Header Tank Flow sensor Flow Sensor Figure 2: TPR
  10. 10. Description of Process Figure 3: TPR + BPR Secondary Flow In Secondary Flow Out
  11. 11. Project Challenges <ul><li>Broken parts </li></ul><ul><li>Mishandling of rig </li></ul><ul><li>Cleaning entire piping system </li></ul><ul><li>Sharing BPR with control labs every other week </li></ul><ul><li>Ordering parts </li></ul><ul><li>Recent PI communication problems with BPR </li></ul><ul><li>T.A. slow in response to requests for help </li></ul>
  12. 12. Work Done <ul><li>Drained old water from system/refilled with distilled </li></ul><ul><li>Cleaned and replaced 2 flow sensors </li></ul><ul><li>Ordered and replaced 2 new pulse flow transmitters and 2 new flow sensors </li></ul><ul><li>Kept log of repair attempts and successful techniques </li></ul><ul><li>Performed all practicals in lab manual </li></ul><ul><li>Created a student lab companion for completing practicals </li></ul><ul><li>Created a repair/maintenance manual </li></ul>
  13. 13. The Practicals <ul><li>6 Assignments with 3-4 practicals each </li></ul><ul><li>Assignment #1- Initialization of Rig </li></ul><ul><li>Assignment #2- Familiarization of the Rig </li></ul><ul><li>Assignment #3- Manual Flow Control </li></ul><ul><li>Assignment #4- Temperature Process Control </li></ul><ul><li>Assignment #5- P-PI-PID Temperature Control </li></ul><ul><li>Assignment #6- Complex Control Loops </li></ul>
  14. 14. Issues Found in Practicals <ul><li>Assignment 1 </li></ul><ul><ul><li>Practical 3- Questions are misprinted in student lab manual </li></ul></ul><ul><li>Assignment 3 </li></ul><ul><ul><li>Practical 2- Patching diagram is mislabeled </li></ul></ul><ul><ul><li>Practical 3- Additional patching information is included in background but not in patching section </li></ul></ul><ul><li>Assignment 4 </li></ul><ul><ul><li>Practical 1- Additional patching information is included in background but not in patching section </li></ul></ul><ul><ul><li>Practical 2- Patching diagram is mislabeled </li></ul></ul><ul><li>Assignment 5 </li></ul><ul><ul><li>Practical 2- Questions are misprinted in student lab manual </li></ul></ul>
  15. 15. The Student Lab Companion <ul><li>Includes introduction with advice on how to approach labs </li></ul><ul><li>Lists questions to be answered after performing each practical </li></ul><ul><li>Gives helpful hints for answering tough questions </li></ul><ul><li>Gives additional info not provided in lab manual </li></ul><ul><li>Lists mistakes found in each practical </li></ul>
  16. 16. An Excerpt from the Companion <ul><li>Assignment 5: Practical 1 </li></ul><ul><li>Flow ratio is demonstrated by changing secondary flow set point and observing the corresponding change in primary flow </li></ul><ul><li>Questions </li></ul><ul><ul><li>Explain with the aid of the diagram below, a system for automatically proportioning the flow of liquid in two separate pipelines.** </li></ul></ul>**Answer Provided in Instructor Lab Manual
  17. 17. Repair/Maintenance Manual Guidelines <ul><li>The rig should only be used with distilled water to prevent buildup of lime and calcium on the inside of the pipes, sensors, and heat exchanger. </li></ul><ul><li>The rig should be handled carefully and expertly so that parts are not damaged during disassembling/assembling. </li></ul><ul><li>There are certain ways that components must be removed and replaced so that they function properly and are not damaged. </li></ul><ul><li>Maintenance should be completed as scheduled to ensure the proper functioning of the process rig for future classes to benefit from. </li></ul><ul><li>Ordering of new parts from Feedback Inc. is a lengthy expensive process, so great care should be taken when handling them. </li></ul>
  18. 18. Instructions Given in Manual <ul><li>Removal of flow sensors from the rig </li></ul><ul><li>Cleaning of the flow sensors </li></ul><ul><li>Repair of flow sensor electrical components </li></ul><ul><li>Replacement of flow sensors back on the rig </li></ul><ul><li>Draining/Refilling of the water in the rig </li></ul><ul><li>Troubleshooting with flow/temperature transmitters </li></ul><ul><li>Maintenance of hose piping between BPR and TPR </li></ul><ul><li>Scheduled Maintenance </li></ul>
  19. 19. Repair Log Example <ul><li>Hose replacement </li></ul>J. Pratt 09/06 Performed By Date Performed By Date
  20. 20. Conclusions/Recommendations <ul><li>Rig should be cared for and cleaned properly </li></ul><ul><li>Labs will be easier for future students now that mistakes have been pointed out </li></ul><ul><li>Use the repair manual on a regular basis </li></ul><ul><li>Use the student lab companion questions for the next control class (Fall 2007) </li></ul>
  21. 21. Questions?