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Detailed Design P13601. Bill Dullea , Garry Clarke, Jae Ho, Kelly McNabb, Mary Medino. Process Flow Diagram. Process & Instrumentation Diagram . Process & Instrumentation Diagram . Process & Instrumentation Diagram . Process & Instrumentation Diagram . Process & Instrumentation Diagram . - PowerPoint PPT Presentation
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Detailed DesignP13601
Bill Dullea, Garry Clarke, Jae Ho, Kelly McNabb, Mary Medino
Process Flow Diagram
Process & Instrumentation Diagram
Process & Instrumentation Diagram
Process & Instrumentation Diagram
Process & Instrumentation Diagram
Process & Instrumentation Diagram
Current Specifications: Chiller
Labview Interface Design
Current Specifications: Beaker
Heat Transfer Equations
Table 1: Data Sample Set
Data Sample Current (mA)
Sample # Peak S.S
A125A126 80.6 11.1
A127A128 100.7 24
A129A130 74.5 2
A131A132 93 25.6
A135A136 101.7 23.7
A139A140 91.3 24.1
Ave 90.3 18.416667
Ave of P & SS 54.35833
• Illustrates the sample set taken from previous tests to provide a peak current and a steady-state current
Heat Transfer Equations
Table 2.1: Beaker DimensionsD 6.8072 cm
thickness 1 mm
Table 2.2: Beaker Dimensions dependent on volume of solution in a 250ml Beaker
Volume (ml) height (cm) A (m2)1 180 5.87 0.0125532 190 6.19 0.0132383 210 6.82 0.014585
•Illustrates the dimensions of the Polypropylene Beaker
•The area of heat transfer is dependent on the amount of solution that is within the beaker
•There are three different volumes of solution provided to give a range of results
Heat Transfer Equations
Table 4: Overall Heat Transfer
Overall Heat Transfer
U (W/m2K) 90.16393443
Table 3: Properties of Elements
Ethylene Glycol
Polyproplylene (Beaker) Water
k .258 0.11 .609h 500
•Utilizing the elemental properties values, the Overall Heat Transfer Coefficient.
[Reference] Forced Convection of water http://www.engineeringtoolbox.com/convective-heat-transfer-d_430.html Thermal Conductivity http://www.engineeringtoolbox.com/thermal-conductivity-liquids-d_1260.html
Heat Transfer Feasibility
Table 5: Heat Generated due to average current
V (volt) I (current) P or Q (heat) ΔT (K)
100 0.0544 5.4358 4.8026
80 0.0544 4.3487 3.6435
60 0.0544 3.2615 2.4802
•Table 5 illustrates the Heat Generated from the electrodes
•Applied an average of peak and steady state current use
•Ultimately calculate the temperature difference from Solution to coolant, to see how effective the water bath system is at cooling.
Heat Transfer Feasibility
Table 7: Heat Generated with peak current
Calc at Peak
Initial T (oC) (Solution) 65
V (volt) I (current) P or Q (heat) T (oC) @ peak
100 0.0903 9.0300 57.02192
80 0.0903 7.2240 58.9474960 0.0903 5.4180 60.87994
Table 6: Heat Generated with Steady State current
Calc at S.S Initial T (oC) (Solution) 65
V (volt) I (current) P or Q (heat) T (oC) @ S.S
100 0.0184 1.8417 63.37287
80 0.0184 1.4733 63.7655960 0.0184 1.1050 64.15971
•Table 6• Heat Generated from the
electrodes• Average steady state current• Calculated the T of the coolant
•Initial Temperature of solution was 65 Deg C
•Temperature was calculated with the Heat Transfer Equation (Previous Slide)
•Table 7• Heat Generated from the
electrodes• average peak current;• calculated the T of the coolant
Heat Transfer Feasibility
Table 9: Time needed for chiller to change temperature from Peak to Steady State
Calc Time need for chiller
V (volt) ΔT Time (s) Time (min)
100 6.35 1134.10 18.90
80 4.82 860.38 14.34
60 3.28 585.67 9.76
Table 8: Time for Chiller to change by 1oC
Chiller Transient Time
time 0.0056 oC/s
•Table 9 illustrates the time required for the chiller to translate from the peak heat generated to the steady state heat generated.
•These results provide vital information on what needs to be done with labview.
•Table 8 illustrates the time required for the chiller to change the coolant temperature by 1 degree.
Test Plans
Specification Range Tests
Controlling temperature of solution within 1° 0-70°C
1)Cool solution to 0°C2)Measure temperature every couple of minutes until solution reaches 0°C3)Once at 0°C measure temperature every 5 minutes for an hour4)Heat up to 20°C5)Repeat the same tests6)Heat up to 50°C7)Repeat the same tests8)Heat up to 70°C9)Repeat the same tests
Control and monitor voltage 0-100V
1)Set voltage to 1V2)Check multimeter every 5 minutes for an hour 3)Set voltage to 25V4)Check multimeter every 5 minutes for an hour5)Set voltage to 50V6)Check multimeter every 5 minutes for an hour7)Set voltage to 75V8)Check multimeter every 5 minutes for an hour9)Set voltage to 100V10)Check multimeter every 5 minutes for an hour
Control and monitor current 100μA-5A
1)Set multimeter to 100μA2) Check multimeter every 5 minutes for an hour3)Set multimeter to 1μA4) Check multimeter every 5 minutes for an hour5)Set multimeter to 1mA6) Check multimeter every 5 minutes for an hour7)Set multimeter to 1A8) Check multimeter every 5 minutes for an hour9)Set multimeter to 5A10) Check multimeter every 5 minutes for an hour
Control humidity <15%1)Purge system with N2
2)With a data logger measure humidity every 5 minutes for an hour
Easy use for loading and unloading electrodes
1)Record how long it takes to load electrodes2)Record how long it takes to unload electrodes3)Repeat both steps 5 times
Risk Assessment
Risk Item Effect Cause
Likelihood
Severity
Importance
Action to Minimize Risk Owner Comment
Labview Coding of transient chiller
Wrong temperature range
Transient code's cooling rate
3 3 9 1)Code at steady state conditions; 2)Code transient chiller rate to start before reaction
Kelly
User Interface with Labview
Acquiring poor data analysis Programming Error 2 3 6 Integrate unit tests 1 at a time by weeks;
specification TBD Chief Programmer
Transient Cooling Time
Rapid cooling of solution
Chiller temperature change time is too long
3 2 6 Coding labview with timed equations for constant heat transfer
Garry/Bill
Controlling excess Humidity not purged by nitrogen
Changes concentration which ultimately changes the end product result
Undesired Reactions 2 2 4 Utilized CaCl as a hydrophilic material to control excess/ produced water (drierite) Team Leader
Run away reaction Materials become scrapTemperature becomes too high/current get high
2 2 4 Program Emergency Shutdown, increase cooling
Chief Design Engineer
Building Technique/ Machine Work
Lose of building integrity
Implementing wrong Technique 1 3 3 3 point check technique, basically double
check work with two different perspectiveChief Design Engineer
material/equipment budget
Can't buy needed equipment
Trying to fufill client's neededs 1 2 2
talk to client Procument
material/equipment wait time
can't start building design on time
Shipping time restrained by costs 2 1 2
work on other aspects as parts arrive Procument
Controlling Temperature with set specification
Becomes run away reaction Chiller/ Heater 3 3 9 Once we get specs 10/2/12; test the
machine for data by 10/9/12 or 10/11/12 Team Leader Decided not a risk after calculations of water bath concept. 10/23
Heat Transfer (Overall) at electrodes
Doesn't cool the soln effectively
the material used is not thermally conductive
3 3 9 increase the diameter of the tube to increase the surface area, while trying to decrease the plastic tubing; change the coolant
Chief ProgrammerDecided not a risk after calculations of water bath concept. 10/23
Bill of Materials
Product Description Dimension Catalog Quantiy Cost Vendor Purpose Notes
PFA Coated Thermocouple Probes with Standard
Connectors
PFA Coated Probes are the perfect solution when there is a need to measure the temperature of caustic or corrosive chemical solutions in industrial and laboratory environments. The superior corrosion resistance of PFA allows you to measure the temperature of sulfuric, hydrochloric, nitric and chromic acids, as well as caustic compounds.
1 /16 " or 1 /8 " Diameter 12" Probe Standard † ICSS-116G-12-PFA 1 $52.00 omega Temperature
Monitoring
TriCorner Beaker Plastic beaker with three dripless pouring spouts. Polypropylene (PP).
250 mL 76mm x 88mm (wxh) 3642 100 $31.10 globe
scientific Reaction Vessel
Scratch-Resistant Cast AcrylicColor: Clear, Temperature Range: 0° to 150° F, Tensile Strength: GoodImpact Strength: Poor
5" D 1' Length 8528K49 1 $307.06 McMaster Main Chamber
VWR® Advanced Digital Controller Refrigerated/Heated
Circulating Baths120V 60Hz Temp Rang: -40 to 200 C
Overall dimensions 54.1L x 22.1W x 61.7H
cm Working Access
15.7L x 14.2W x 12.7D cm
89202-978 1 $3,903.59 VWR Chiller/Heating
Polycarbonate (1 Chambers)Color: ClearTemperature Range: -40° to 180° FTensile Strength: GoodImpact Strength: Excellent
1' x 3' (3/16" Thickness) 8574K273 2 $26.49 McMaster Reactor May Change due to size
VWR® Dylastir® Magnetic Stirrer Cast Aluminum Top Plate Large 16.5 cm (61/2") Diameter 12620-974 1 255.83 VWR Mixer
TDK-Lambda ZUP 1203.6/U Current Out:3.6A, Voltage out:120VDC 70176888 1 1,450.00 Allied
Electronics Power Supply
Agilent Technologies Test Equipment 34405A 701801169 765.00 Allied
Electronics Multimeter
Half-Mortise/Half-Surface Mount Template Hinges 1498A12 2 9.52 McMaster Hinges for Door
Exposed Latches 13435A63 2 6.22 McMaster Door Latch
Metric O-Rings 4 mm wide 9262K371 1 7.70 McMaster O Ring for cooling Chamber
Hex Nut Zinc-Plated Grade 2 Steel 99961A450 1 10.90 McMaster HingesFlat Head screws 91253A425 1 14.02 McMaster
Barbed Tube Fittings 5463K128 1 5.26 McMaster Nitrogen fittingCompression Tube Fitting 5533K499 2 6.54 McMaster Cooling fittings
Steel Support Rectangular Bases 60110-222 1 40.87 VWR Stand
Questions, Comments, Concerns??
Why are we doing this?What problem are we
solving?Is this actually useful?Is there an easier way?What’s the opportunity
cost?Are we on our critical
path?Is it really worth it?
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