Experiment 5 - Heat Exchanger Process Control

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SECTI ON OF OF CHE HEMI MI CAL ENGI NEERI RI NG TECHN HNOL OLOGY MALAYSI AN I NSTI TUTE OFCHE HEMI MI CAL& BI OENGI GI NEERI NG TECHNOL OLOGY

PROC OCESS CONTROL OLLABORA RATORY LABORATORY I NSTRUCTI ONSHE HEETS

COURSECODE

CPB 30004/CPD 20302/CKB 20003

EXPERI MENTNO.

EXPERI MENT5

EXPERI MENTTI TLE

HeatExc hangerPr oces sCo nt r ol

DATE GROU OUPNO. LECTURER/I NSTRUCTOR/TUTOR

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DATEOF OFREPORTSUBMI MI SSI ON  ATTENDANCE/PARTI CI PATI ON/DI SI PLI NE:

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I NTRODUCTI ON:

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RESULTS& CALCU UL LATI ONS  ANALYSI S DI STRI BUT UTI ON OFMA MARKSFOR DI SCUSSI ONS: LABOR ORATORYREPORT:  ADDI TI ONALQUESTI ONS CON ONCLUSI ON

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SUGGESTI ONS& RECOMMENDATI ONS

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STUDENT CODE OFETHI CS SECTI ON OF CHEMI CAL ENGI NEERI NG TECHNOLOGY

MALAYSI AN I NSTI TUTE OFCHEMI CAL& BI OENGI NEERI NG TECHNOLOGY

Iher ebydecl ar et hatIhavepr epar edt hi sr eportwi t hmyowneffort s.Ial soadmi tt o notacceptorprovi deanyassi st ancei npr epari ngt hi sr eportandanyt hi ng t hati si ni ti st r ue . 1)Gr oupLeader :…………………………………………. . Name :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Mat r i xNo . :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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2)Gr oupMe mber1:………………………………………. Name :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Mat r i xNo :__ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

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4)Gr oupMember3: ………………………………………. . Name : _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Mat r i xNo . :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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OBJECTI VES a)  Tos t udyOn/Offt emper at ur econt r olofel ect r i cheat er s  b)  Tos t udyt emper at ur econt r oli nheatexc hangerusi ngPI D cont r ol l er

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LEARNI NG OUTCOMES  Att heendoft hes t udy ,s t udentwi l lbeabl et o:

a  )Tobef ami l i arwi t ht hebasi cs t epsofmac hi nef r om s t ar t up t oshut down  wi t hpr operhandl i ngandse t t i ng.  b  )To i dent i f yt he maj or compone ntoft he heate xc hanger pr ocess cont r ol

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t r a i ni ngs ys t e m I NTRODUCTI ON Shel landt ubeheatexc hangeri st hemostcommonl yusedi nt hei ndust r i es.

Heatexc hanger sar eonemedi um offlui dflowsi nsi deandt hr ought hebundl esof t ubeswhi l et heot hermedi um flowsi nt heshel lsi de.Theheatf r om t hehotflui d t r ansf err edt hr ought hemet alwal loft het ubest ot hecol dflui dduet ot he

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di ffe r e nc ei nt he i rt e mpe r at ur e .Co nt r o lo ft e mpe r at ur ei nt heo ut l e ts t r e am o ft he ho t /c o l dflui di se s s e nt i a li no r d e rt omi ni mi z et hee ne r g yl o s s e sandal s ot ome e t t emper at ur especi ficat i oni nt hedownst r eam pr ocess.

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I NSTRUMENTS/APPARATUS/CHEMI CAL/REAGENTS Thepr ocesspl antcons i stoft wot ank( T61 & T62) Cent r i f ugalPump:P61,P62,P611 Shel landTubeHeatExc hange r Cont r olVal ve:TCV61 Meas ur ement :TE61/TI T61,RTD,andTE62/TI T62,Ty peK On/OffCont r ol l er :TI C62 PI D Co nt r o l l e r :TI C61

Appar at us a)HeatExchangerpr ocesscont r olt r ai ni ngsyst em.

5. 0 PROCEDURE 5. 1 STARTUPPROCEDURES 1.Thef ol l owi ngst epsmustbecarri edoutbef ores t art i ngt he exper i ment : a)Fi l lt het ankT62andt hepr oductTankT61wi t hwat erupt hei r over flow dr ai npi pe.  b)Checkt hemanualv al v eatt hepr oductdowns t r eam pi pel i ne  TSV62i sopent ot heext er naldr ai nsys t em. c)Tur nont hemai npowersuppl yatt hef r ontcubi cl e. 2.Chec kt hevar i ousmanualval veasf ol l ow OPEN al lsuct i onand di sc har geval vepumps( P61, P62, P611) Manualbypassv al v ef oreachpumpsandcont r olval veTCV61, • •

 TSV61, TSV62andLSV61i sshut . OPEN t hemanualval veatt hei nl etofLSV61 Bot t om dr ai nval v esoft ankT61andT62al waysshut 3.Learnt ouset hePI D Cont r ol l erTI C61 • •

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Di spl ayTI C61i nManual(   mode.Se tMV  =100% t oope nt he M)

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c ont r o lv al v e .Che c kt hec ont r o lv al v ei sope n( att hepl ant ) Se tt heSV  t o40oc  Accesst hePI Dt uni ngpage“ PI D1”andc hanget hePI Dv al uest o

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t hefir s t ( I )t r i alv al ue s PB1=15% TI 1=35sec TD1=8sec  AccessOn/Offc ont r ol( TI C62,TI C611)att he“ P/TRegi s t erpageat

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PO1andPO5 St artt her ecor derTR61bypr essi ngON t heRCD pushbut t on. 4.Wi t hTI C61i nManual ( M)mode,s t r oket hec ont r olv al v ewi t hMV=25% •

,50% and100%. ( Chec kt heopeni ngofTCV61att hepl ant )

5. 2

ON/OFF TEMPERATURE CONTROL  Theheat i ngmedi um f ort heheatexc hangeri spr oducedbyheat i ng

 wat eri nt het ankT62.I t smai nt ai nedcons t antbyt heOn/Offcont r ol l er  TI C62.I t sc ont r ol l edwi t h±0. 5ocl e s so rmo r ef r o mt hes e t po i ntv a l ue s . 1.STARTt heheat i ngmedi um ci r cul at i on Makes ur et hev al v esMV62andB62ar eope ned STARTpumpP62 Ensur et hewat erflow t hr ought heheatex change randbackt o • • •

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 T62 SHUTt heby passv al v eB62 Swi t chOnt heheat er s.Makesur et her ei sat emper at ur e

i ncr easei nt het ankT62sot hatt heheat eri sON  Topupt hewat eri nt het ankT62i fnecessar y 2.STARTt hec hartr ec or derbypr ess i ngt heRCD but t onatt her ec or der •

 TR61

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Uset hesel ect orandswi t cht oTE62/TI T62t osel ectonl yGr een

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pe nt or e c o r d Observ edt her i sei nt emper at ur eofwat eri nt ankT62 o I twi l lt ake1520mi nut esf orTE62r each55c .dur i ngt hi s

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t i me,STOPt her ec or der ,bypusht heRCD but t onandpr oce eds t os t e ps( 3)and( 4) . 3.Whenev eranyannunci at orbuz z eron,pr esst heACKNOWLEDGE  but t ont osi l e ncet hebuz z er .Tr yt or at i onal i z et hecauseoft heal ar m. 4.Setparamet er soft heOn/Offcont r ol l erTI C62asf ol l ow:  Accesst hemenuandsel ect“ P/TRegi s t er ”but t ont ose tt he •

Hi ght emper at ur el i mi tandDeadBandofcont r ol l erTI C62 o PO1:Hi ght emper at ur el i mi t=55c o PO2:DeadBand=0. 5c PO3:Hi ghl i mi tf orannunci at orTAH62. ( SameasPO1) PO4:DeadBandf orannunci at orTAH61. ( SameasPO2)

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 Accesst omenuandsel ect“ I /O Dat a”but t onandnot et he

f ol l o wi ngdat a:  X2:TE62/TI T62,% of0100oc ,i nputv ar i abl et ot hec ont r o l l e r DO1:Heat erst at usi nT62.1( ON) ,0( OFF) DO2:Annunci at orTAH62s t at us.1( On) ,0( Off) o 5.Whent het emper at ur ei sappr oac hi ng55c,st artr ecor derTR61buy pushi ngt heRCD but t on. Obser v edbot hr ec or derTR61Gr ee npenandt he“ I /O Dat a” •

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 X2,DO1andDO2  Wr i t edownt hehi ght emper at ur el i mi tandDeadBanddat aon

t hechar tpaperbesi det heGr eenpen 6.Obser v edt het emper at ur eTE62/TI T62atX2andgot hr ought he f ol l o wi ngc he c kl i s t :  TE62/TI T62r i seandexceedst heHi ghl i mi t( 55oc)  Theheat eri sOff  Theannunci at orTAH62i sact i v at ed •

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Chec kt heSt at usDO1,DO2,andX2att he“ I /O Dat a”and

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r ecor dt hedat aont hechartpaper  TE62/TI T62cont i nuest or i se.i . eov er shootbey ondt heHi gh

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l i mi t  TE62/TI T62dr opst ot heHi ghl i mi t( 55oc )butt hehe at e ri ss t i l l

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OFF  TE62/TI T62dr opsf ur t herbyanamountequalt ot heDead

 band( 0. 5oc) Heat erar eswi t chedON agai n  Theannunci at orTAH62i sswi t c hedOFF Chec kt hes t at usDO1,DO2andX2att he“ I /O Dat a”andr ec or dt he

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dat aont hec hartpaper Co nt i nuet heobs e r v at i o nt og e taf ul lc y c l e ,i . e ;2t e mpe r a t ur e

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peaksorbot t om Not et heosci l l at orynat ur eofOn/Offcont r olatt heGr eenpen

o ft her e c o r de r 7.St opRec or dbypusht heRCD but t onatt her ecor der .Not eatt he char tpaperyourexper i mentname. 5. 3 PI D CONTROLOF TEMPERATURE 1.Thet emper at ur eoft heheat edpr oductatt heexi toft heheat exchangermeasur edbyTE61/TI T61i scont r ol l erPI D( Loop1)of  TI C61 2.TheOn/Offcont r ol l erTI C62mai nt ai nst het emper at ur eoft ankT62 at55oc .Se tt hecont r ol l e rTI C asf ol l o w: o Endur et hes et poi ntSV=40c ( M)  Wi t hTI C61i nManual   mode,se tt heout putMV=100% Che c kt hatt hePI Dv al uear es e tt ot he( I )t r i alv al ue PB1=15% TI 1=35sec TD1=8sec 3.STARTt hec ol dwat erci r cul at i on Makes ur et hatv al v esMV61andB61ar eo pened STARTpumpP61,andensur et hewat erflow t hr ough • • •

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r ot amet erFI 61 Shutt heby passB61.

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 Adj us tmanualv al v eatMV61t ose tt heflow r at et o1. 3m3/Hr STARTt heci r cul at i ngpumpP611 4.Swi t c hTI C61t oAUTO( A)mode  Wr i t et hepr oductflow r at eFI 61,Se t poi nt( SV)andPI Dv al ue • •

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ont hechartpaperbesi dei t sr esponse Obser v edt her es ponseofTE61/TI T61att her ec or derRED pen t i l li tbe c o me ss t e adyar o und40ocori tc ont i nue st oos ci l l at e s

e v eaf t e r3c yc l e  Tes tDi st ur bance–Set poi ntChange 5. Se tt hePI Dv al ue so ft hec ont r o l l e rTI C61t ot hes ec ond( I I )t r i al •

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 val ues PB1=10% TI 1=30sec TD1=7sec Changet hese t poi ntSV=42oc.Mar kont hec hartpapert henew

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se t poi ntval ue.DO NOTi ncr easeset poi ntobove44oc  Wat c ht her esponseatt her ecor dert i l li ti sal mos ts t eadyor

c ont i nue st oos c i l l at e se v e naf t e r3c y cl e  Tes tDi st ur bance–LoadChange 6. Makessur et hesyst em i satst eadyst at e St epchanget hepr oductflow r at ebyopeni ngf ul l yMV61.Not e • •

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t heflow r at eFI 61andwr i t et heval ueatt hechartpaper  Wat c ht her el ev antpor t i onsoft hec har tpaperandat t ac ht he

r e s ul ti nt her e por t 7.Ret r i evet her el evantport i onsoft hechartpaperandat t acht othe r e s ul t si nt her e por t . 8. 1. 4 SHUTDOWN PROCEDURE 1.Swi t cht hecont r ol l erTI C61t oManual ( M)mode,andse tt he MV=100% 2.Swi t c hOffheat er 3.St opal lt hepumpP61,P62andP611 4.Swi t c hOfft hemai npowersuppl y

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RESULTS& CALCULATI ONS

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 Ther ecor derTR61r ecor dst her esul t soft heexper i ment . 1.Submi tt heP& Idi agr am wi t hmaj orcomponent soft hes ys t em mar kedi ni t 2.Pr epar ear epor tont hes t art uppr ocedur e 3.ForOn/Offcont r ol ,not et hehi ghal arm l i mi tandDeadbandatvar i ous  v al ues.Submi tt her esul t sofOn/Offcont r ol l eri nt her esul t ss hee tt abl e  bel ow PTRegi s t er Hi ghTemp DeadBand Li mi t  TI C62,Cont r ol l er

o PO1=_ _ _ _ _ c

o  TAH62,Annunci at or PO3=_ _ _ _ _ c

I /O Dat a St at us

o PO2=_ _ _ _ c

DO1:

o PO4=_ _ _ _ c

DO2:

 Table: On/Of temperature control o the electric heaters

4.St udyandcompar et hedi ffer entr es ponsewi t hdi ffer entPI D val ue.Submi t r e l e v antpo r t i o nso ft her e c or de rc har tr e s po ns ewi t ht hef o l l o wi ngdat a mar kedon i t : Cont r ol l eri nAut o( A)modeorManual ( M)mode Set poi nt( SV) ,PB%,TIsecs,TD secs Pr oductflow r at eFI 61  Anyannuci at ori ni t i at ed • • • •

Di scuss on t he nat ur e ofr esponse,such as f ast /sl ow,smoot h/osci l l at or , o v e r s ho ot .De c ayr a t i oe t c . Pr e par et her e s ul t soft hePI Dc ont r o l l e rt e s ti sar e s ul t sshe e tt abl ebe l o w PI Dt emper at ur econt r oloft heheatexchanger  TE61–TI T61–TI C61–TCY61/TCV61 Cont r ol l erpar amet erv al ue:TI C61( PI D) PB1=_ _ _ _ _ _ %

TI 1=_ _ _ _ _ _ _ secs

TD1=_ _ _ _ _ _ _ _ _ secs

Se t po i nt( SV)=_ _ _ _ _ _ _oc Pr o duc tflo wr a t e( FI 61)=_ _ _ _ _ _ _ _ _ _m3/Hr

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 Tes tdi s t ur bance: St ep/pul se  AtSe t poi ntSV1=_ _ _ _ _ _ _ _  Atpr oductflow r at e=_ _ _ _ _ _ _ _

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ANALYSI SOF THE RESULTS

 Anal ysed cr i t i cal l y eac hr esul t s obt ai ni n sect i on 6. 0 by r ef er r i ng t ot he t heor y/i nt r oduct i on part s. Fi nd r easons ( sugge st ed r easons) on each occur r enceshowni nt her esul t s.

8. 0

DI SCUSSI ONS Di scusst heove r al lexper i mentondat aobt ai nbasedonyourunder st andi ng. Di sc uss i on shoul dr el at er eas ons f or t he phenomena/r es ul t s obt ai ned, t heor et i cal par t s,sugges t ed r easons ( i f nece ssary but back wi t h sound t heor et i calknowl edge)andyourover vi ew under st andi ng.

9. 0

ADDI TI ONALQUESTI ONS i .

Bas ed on t he r esul t s, di scuss t he di ffer ence /c har ac t er i s t i cs of meas ur ementt ake nbyTher moc oupl eandRTD.

i i .

Te mper at ur ei s consi der ed as a pr oc es sv ar i abl e wi t h a sl ow r es ponse . Di scusst hes t at ement .

10. 0CONCLUSI ON Concl usi on i smer el yasummaryoft hei mpor t antfindi ngsal r eadyr eport ed i nt hedi s cus si ons ec t i on.I tal s or e l at e st ot heobj e ct i v e ss t at e de ar l i e r .

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11. 0 SUGGESTI ONS & RECOMMENDATI ONS  Youri deasofsugges t i on & r ecommendat i on t oi mpr ov et hel ear ni ngpr ocess f o rt hi se x pe r i me nto ra ny t hi ngr e l at e dt ot hee x pe r i me nt a lpr o c e dur ee t c .

12. 0 REFERENCES Mi ni mum ofatl east5 r ef er ences( wi t h 3 oft hem ar epaper /book/chapt er  based)