1. » Dan Sacchitella – ChE, Project manager
» Amanda Doucett- Che, Lead Engineer
» Jay Moseley- EE, Controls Engineer
» Marc Farfaglia- Che, Controls Liason
» Rebecca Davidson- Che, Technical Engineer
» Micah Bitz- ChE, Technical Engineer
Systems Design Review MSD1 4/5/2013
2. » Project Background
» Functional Analysis
» Concept Development
» Systems Architecture
» Risk Assessment
» Schedule
Systems Design Review MSD1 4/5/2013
3. » Develop a process that will produce varied
control results
» Design the process using the skill sets of every
individual in the group
» Assemble process onto portable carts
» Test and evaluate
» Provide a recommended lab protocol for
teaching
Systems Design Review MSD1 4/5/2013
4. » Analysis for process and control interactions
» Detailed design
» Heat transfer model
» Assembled cart for use in Chemical Engineering
Lab
» Evaluation results-system capability
» Experimental protocol for teaching
Systems Design Review MSD1 4/5/2013
5. » Designs requested:
˃ PFD
˃ P&ID
˃ Fabrication
˃ Equipment list
˃ Control loop drawings
˃ Electrical drawings
˃ Operation manuals
˃ Recommendation for spare parts and maintenance
Systems Design Review MSD1 4/5/2013
6. » Design must be modular and adaptable
» Durability
» Minimal maintenance
» Interface with Labview
» Realistic to be utilized by students in the lab
» Operated by 3 students
» Control temperature by regulating flow or
temperature
Systems Design Review MSD1 4/5/2013
7. » Must fit on the cart currently in use by the
Chem E department
» Utilize donated equipment to reduce cost
Systems Design Review MSD1 4/5/2013
12. » The cart is approximately 3’ by 2’ by 2’6” high
» Uses two of the heating and cooling water recirculation baths that
were used previously in the unit operations lab
» Uses the air lines that will be available in the lab
» Air operated valve dimensions are based on the one currently used
on the existing flow carts
» Uses a shell and tube heat exchanger with countercurrent flow
» All cart components are supported by columns that attach to the
upper level of the cart
» Large components (such as the valve, controller, water baths and
LCD output) are supported by a central structure that attaches to
the lower level of the cart
» The four temperature transmitters will be a combination of two
RTD’s and two thermocouples
Systems Design Review MSD1 4/5/2013
16. Organization of following slides is as follows:
Labview interface and control through national instrument equipment
Advantages and disadvantages
Labview interface using msp430 microcontroller to sample and collect data
from rtd's and thermocouples, while using Honeywell controller to drive flow.
• Advantages and disadvantages
Complete Labview interface and control using msp430 to collect data from
rtd/thermocouples, simulate customizable control through Labview, return
data through msp430 to control flow.
Advantages and disadvantages
Risk assessment and analysis of all methods
Goal: Present multiple possibilities for data acquisition and Labview
interface while assessing the advantages and disadvantages of each in
order to determine the best course of action in continuing with the
design.
Systems Design Review MSD1 4/5/2013
17. The national instruments data acquisition chassis with associated modules for
thermocouple and rtd inputs can be used to collect temperature data and
control the flow of the system through Labview.
Systems Design Review MSD1 4/5/2013
18. Advantages
• Simple implement and interface with
Labview
• Accurate data
• Has interchangeable parts for
multiple types of inputs
• No external components will be
needed to implement
• Used in real world
applications
Disadvantages
• Expensive chassis
• Expensive modules to go
along with chassis each serving only
one purpose
• Overpaying for what it is going to be
used for
Systems Design Review MSD1 4/5/2013
19. • The Honeywell controller would be used to drive the flow control of the system.
• The microcontroller would be used to collect data from the rtd's and
thermocouples and send it to the computer
• the systems data could be plotted and observed in Labview.
Systems Design Review MSD1 4/5/2013
20. Advantages
• Shows students how to use and
calibrate physical controller
• Microcontroller transferring data to
computer can also be used to drive
LCD displays with data
• Microcontrollers are extremely
cheap and easily replaced and
reprogrammed
• Can be designed so that the
national instruments equipment can
be easily swapped in
Disadvantages
• External circuitry will be necessary
• Potential for more errors in
temperature measurement
(can be tested for)
• May potentially need EE to debug if
problems in the future
• External power will need to be
supplied (3.3v)
Systems Design Review MSD1 4/5/2013
21. 4/5/2013
The thermocouple and rtd outputs will be tied directly to microcontroller which
will interface with Labview. Data received in Labview will then go through a
modeled controller in Labview to create a new set of data which will actively be
output to another pin on the microcontroller. Data will then be processed and
sent to control the flow rate of the system.
Systems Design Review MSD1
22. Advantages
• Very adaptable, many different
systems with can be modeled and
tested through Labview. For example
part of the lab could involve varying
set pole locations and seeing their
diminishing effect as their
magnitude increases
• Cheap to implement
• Can be designed where the
National Instruments equipment
can be easily swapped in
• No real maintenance would be
necessary
• Students would get a better feel for
labview by creating the controller
with the software instead of just
using it to show data
Disadvantages
• Difficult to implement and as a
result more difficult to debug if
something goes wrong in the future
• Although systems can be modified
quickly in Labview, it will still be
necessary to wait on the fluids to
return to they're initial state
temperature to run multiple
experiments.
• External circuitry will be necessary
• Potential for more errors in
temperature measurement
(can be tested for)
• External power will need to be
supplied (3.3v)
Systems Design Review MSD1 4/5/2013
23. » PID equation
» Valve characteristics
˃ Inherent vs installed
» Noise introduction and filtering
» Manual Control
˃ Manual pressure regulator on AOV
» Find heat flow through the heat exchanger
» Fit sensor data to the ideal equation of operation
» RTD vs Thermocouple performance
Systems Design Review MSD1 4/5/2013
25. ID Risk Item Effect Cause
Likelihood
Severity
Importance
Action to Minimize Risk Owner
Describe the risk briefly What is the effect on any or
all of the project
deliverables if the cause
actually happens?
What are the possible
cause(s) of this risk?
L*S What action(s) will you take (and by when)
to prevent, reduce the impact of, or
transfer the risk of this occurring?
Who is
responsible for
following
through on
mitigation?
1
Customer Priority Changes Delay of project progression Poor communication/
Uncertainty
2 2 4 Have weekly meetings with guide and
keep both sides updated on project
Project
Manager
2 Unreliable Suppliers
Disrupt our project
budget plan, and delay
design process.
Parts are not
available through
Kodak 1 2 2
Take initiative and request parts from
Guide, and compile a list of what we
have and what needs to be ordered Group
3 Skill Set
Alters design slightly,
and will change list of
parts that we need to
order
Only one EE to
develop controls, and
rest of team
members have little
experience in that
field 1 2 2
Group EE seeks feedback from EE
department to make sure concepts
are feasible EE
4 Team Dysfunction
Poor team chemistry will
demotivate group and
may cause delays in
deliverables.
Differences in
opinions/ concepts 1 1 1
Reach consensus on ideas/concepts to
make sure everybody is on board Group
5 Unavailability May delay deliverables
Poor
communications/
Illness 2 1 2
Let group know if/ why you can’t
attend meetings. Plan ahead. Individual
6 Poor Communication
People may not know
current tasks
Lack of
motivation/communi
cation with group
members 1 1 1
Keep everyone updated on current
goals/ ideas. Ask for progress ahead
of the date when the deliverable are
expected.
Project
Manger
Systems Design Review MSD1 4/5/2013
26. National Instruments risk :
• Cost of equipment, expensive to replace
Honeywell controller risk :
• not easily replaceable since it was donated and a new controller would have
to be bought if anything happens to it.
microcontroller risk:
• difficult to develop and ensure accurate results
Not much to lose with complete microcontroller interface and control with Labview
and the advantages that it will provide
• More teaching flexibility
• Can replace with national instruments equipment if problems
• little cost, so hardly any loss if anything breaks
Systems Design Review MSD1 4/5/2013
27. • This project incorporates
many expensive
components, similar to
those used in industry, to
facilitate learning
• Many parts are being
generously donated by
Kodak
• A few components, such as
the cart on which the
system will be built, have to
be bought
• The proposed budget will
cover the cost of these
parts
• We propose a budget of
$1500 dollars to
complete this project
10410
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410
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0
2000
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12000
Cost
in
$
Equipment Needed
Cost of Building a Heat Exchange/Process Control
Lab Cart
Systems Design Review MSD1 4/5/2013
