CSTR Overall Speciﬁcationtierra.aslab.upm.es/documents/reports/pct_specs_2.0.pdf · 7.2 Basic cotrol ... The PCT testbed is a chemical reactor system intended as a platform

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Autonomous Systems Laboratory

c© 2009 ASLab

Title CSTR Overall SpecificationThe main PCT testbed

Author Jose Luis de la Mata

Reference R-2009-001Release 2.0 Draft

Date February 6, 2009

Address

Autonomous Systems LaboratoryUPM - ETS Ingenieros IndustrialesJose Gutierrez Abascal, 228006 MadridSPAIN

2 of 43 R-2009-001 v 2.0 Draft / PCT Spec. / ASLab.org

CSTR Overall SpecificationASLab R-2009-001 v 2.0 Draft of February 6, 2009

Abstract

This report describes the Continous Stirred Tank Reactor (CSTR) and itsinstrumentation which is used in the PCT testbed of the ASys Proyect. The aim ofthis document is to provide a brief and complete description of the reaction system,instrumentation and control system.

Keywords

ASLab, ASys, PCT, specifications, resources

Acknowledgements

Agustın Garcıa contributed his expertise to this document.

To Carlos Hernandez and Adolfo Hernando for their “inspiration” (Higgs OverallSpecification, The main Platform of RCT testbed).

Table of Contents

1 Introduction 7

1.1 Rationale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 CSTR Reactor 8

2.1 Reactor Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Reactor Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Stirring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Hydraulics 11

3.1 Reactants tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Products tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 Steam tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.5 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.6 Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.7 Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Intrumentation 18

4.1 pH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 ORP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3 Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.4 Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.5 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.6 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Control System 24

ASLab.org / PCT Spec. / R-2009-001v 2.0 Draft 5 of 43

5.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.2 Input current module . . . . . . . . . . . . . . . . . . . . . . . . 25

5.3 Input voltage module . . . . . . . . . . . . . . . . . . . . . . . . 26

5.4 Output current module . . . . . . . . . . . . . . . . . . . . . . . 27

5.5 Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6 Power 29

6.1 Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.2 Three-phase plug & socket . . . . . . . . . . . . . . . . . . . . . 30

6.3 Single-phase plug & socket . . . . . . . . . . . . . . . . . . . . 31

6.4 Three-phase cable . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.5 Single-phase cable . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7 Overall view 34

7.1 Overall performance . . . . . . . . . . . . . . . . . . . . . . . . 34

7.2 Basic cotrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.3 System connections . . . . . . . . . . . . . . . . . . . . . . . . . 35

8 Degree of protection (IP) 40


Chapter 1

Introduction

In this document the overall situation of the PCT platform of the ASys Projectis presented. The purpose of the document is double:

• Report the current state of the platform.

• Provide a short description of the platform.

The report is presented in the form of tables of specifications to capture themain characteristics of the different devices that compose the PCT platform.For much more detailed information on the PCT platform please refer toCSTR’s Operation Manual.

1.1 Rationale

The PCT testbed is a chemical reactor system intended as a platform to testthe technology developed in the ASys project. The PCT is a labortaory scaleCSTR reactor with its instrumentation and its control system. The aim of thePCT project is to purvey the system with the neccessary cognitive habilitiesso as to fulfill complex task (fault diagnosis, control system reconfiguration,alarm managing. . . ).

1.2 Format

In the different chapters and sections of this documents several systems anddevices are described. To make it perfectly clear, the description of each onemeets the following format:

• A table gathering the main specifications.

• A picture of the device.

In chapter 7 (page 34) an overall view of the PCT system is given and inchapter 8 (page 40) the degree of protection index tables are collected.


Chapter 2

CSTR Reactor

2.1 Reactor Vessel

Description Reactor Vessel

Model n/aManufacturer TecalsaVolume 12L

Material Stainless steel 304Max. Pressure 8kg/cm2

Conections

4× 1/4′′ female (top)2× 1/2′′ female (top)1× 1/2′′ female (side)1× 2′′ male (bottom)

Jacket Cooling and Heating

Table 2.1: CSTR reactor vessel specifications.

Figure 2.1: Tecalsa CSTR Reactor vessel.


2.2 Reactor Jacket

Description Reactor Jacket

Model n/aManufacturer TecalsaMaterial Stainless steel 3004Max. Pressure 8kg/cm2

Conections 2× clamp

Steam YesWater Yes

Table 2.2: Reactor Jacket specifications.


2.3 Stirring unit

Description Stirring unit

Model 74/PRC041/TDO/B2PT/360-100A-100M-125FManufacturer VAK KIMSASpeed 290rpm

Engine

ABB H-CH/A41F (size 80)Power: 0.55kW (380Vac three-phase)Speed: 1380rpmProtection: IP55

TransmissionPRC041 (Motovario)

Rate: 1/4.75

Blades

Trilight cowles alabnet axialDimensions: 100× 100× 25mmAxis: φ12mm,L360mmMaterial: AISI 316

Table 2.3: Agitation unit specifications.

Figure 2.2: VAK KIMSA agitation unit.


Chapter 3

Hydraulics

3.1 Reactants tubing

Description Reactants tubing

Model Tubing 1/4′′OD × 0.89mmPE

Conections 1/4′′ NPTHDiameter 1/4′′

Max. Pressure 125psi

Max. Temperature 80oC

Material Polyethylene

Table 3.1: Reactants tubing specifications.

Figure 3.1: Reactants tubing.


3.2 Products tubing

Description Products tubing

Model Tubing 1/2′′OD × 0.89mmPE

Conections 1/2′′ NPTHDiameter 1/2′′

Max. Pressure 125psi


Material Polyethylene

Table 3.2: Products tubing specifications.

Figure 3.2: Products tubing.


3.3 Steam tubing

Description Steam tubing

Model Flexible Tubing TR–27Conections 1/2′′ NPTHDiameter 1/2′′

Max. Pressure 175bar


MaterialInside: PTFEOutside: AISI 316L

Table 3.3: Steam tubing specifications

Figure 3.3: Steam tubing.


3.4 Pump

Description Magnetic drive gear pump

Model GC–M25.PF5T.EManufacturer MicropumpMax. Pressure 5.2bar(75psi)

Max. Flow 5.2l/m(2850rpm)

Temp. Range −46− 177oC

Displacement 1.82ml/rev

Engine Electric Engine (220Vac three-phase)Gear 2 external gearsConections 2× 3/8′′ female NPTControl signal From inverter

Wetted materialsBase Material: TitaniumGears: PTFEStatic seals: Viton

Table 3.4: Pump specifications.

Figure 3.4: GC–M25 Gear Pump.


3.5 Inverter

Description Inverter

Model CIMR V7 AZ B0P4Manufacturer OMRONControl signal 0− 10Vdc or 4− 20mA

Output signal 220Vac (Three-phase)Power 220− 240V ac (single-phase)Max. Output Power 0.55kW


Protection IP20

Aditional featuresOverload protection.Motor overload protection.Manual frequency adjuster.

Table 3.5: Inverter specifications.

Figure 3.5: OMRON Inverter.


3.6 Control valve

Description Angle seat compact motor valve

Model Type 7210Manufacturer Schubert & SalzerControl signal 4− 20mA

Feedback signal 2− 10V

Power 24Vdc (3W )

Conections 2× 1/2′′ female

Table 3.6: Control valve specifications

Figure 3.6: Schubert & Salzer control valve.


3.7 Relief valve

Description Relief Valve

Model R6000Manufacturer HOKEDischarge Pres. 2.5bar

ConectionsProcess: 1/4′′ maleDischarge: 1/4′′ female

MaterialsBase: AISI 316LSeals: Viton

Pressure Range 2− 6bar


Table 3.7: Relief valve specifications.

Figure 3.7: HOKE R6000 Relief Valve.


Chapter 4

Intrumentation

4.1 pH

Description pH sensor

Model 871A SeriesManufacturer FoxboropH Range 2− 12 (±0.05)

Power From AnalyzerOutput signal To AnalyzerConection Flow–ChamberTemp. Range 0− 80oC

Protection IP65

Aditional featuresFlat Glass Electrode.Automatic Temp. Compensation.

Table 4.1: pH sensor specifications.

Figure 4.1: Foxboro 871A series pH sensor and Flow Chamber.


4.2 ORP

Description ORP sensor

Model 871A SeriesManufacturer FoxboroORP Range 2000mV (±3mV )

Power From AnalyzerOutput signal To AnalyzerConection Flow–ChamberTemp. Range 0− 80oC

Protection IP65

Aditional featuresGold Electrode.Automatic Temp. Compensation.

Table 4.2: ORP sensor specifications.

Figure 4.2: Foxboro 871A series ORP sensor and Flow Chamber.


4.3 Analyzer

Description Electrochemical Analyzer

Model 873 SeriesManufacturer Foxboro

Meassurement RangepH: −2− 16ORP: −999− 1400mV

Power 220− 240Vac

Output signal 0/4− 20mA or 0− 10V


Protection IP65

Aditional featuresNon-volatile EEPROM memory.Dual independent alarms.Isolated output signals.

Table 4.3: Electrochemical specifications.

Figure 4.3: Foxboro 873 Series Electrochemical Analyzer.


4.4 Flow

Description Electromagnetic flowmeter

Model ModMAG M1000Manufacturer Badger Meter EuropeFlow Range 0.05− 17m/s (±0.5%)

Power 24Vdc (10W )

Output signal 0/4− 20mA

Conection 2× 1/4′′ maleTemp. Range −20− 60oC

Conductivity min 5µS/cm

Protection IP65

Aditional features2×M20 Cable insertion.Empty pipe detection (separate electrode).RS232 Programming conection.

Table 4.4: Flowmeter specifications.

Figure 4.4: ModMAG M1000 Flowmeter.


4.5 Pressure

Description Pressure transmitter

Model S-10Manufacturer WikaMeasurement Range 0 – 6bar (±0, 5%FS)

Power 10 – 30 Vdc

Output signal 4 – 20mAProcess conection 1/2′′ ISO maleTemp. Range −20− 85oC

Protection IP65

Aditional featuresWetted material: Stainless steelOverload limit: 80 barResponse time: 1 ms

Table 4.5:

Figure 4.5: Wika S-10 pressure transmitter.


4.6 Temperature

Description Industrial Pt100 Sensor

Model PT100 RCA-S4B-60-200-KNE-ZZManufacturer LabfacilityMeasurement Range −100− 450oC (±0, 1%FS)

Power 10 – 30 Vdc

Output signal 4− 20mA

Process conection 1/2′′ ISO maleTemp. Range −20− 85oC

Protection IP67

Aditional features

Stainless steel sheath (6× 200mm).Aluminium terminal head.Head mounted TX203 digital PRTtemperature transmitter.

Table 4.6: Temperature sensor specifications.

Figure 4.6: Labfacility temperature sensor.


Chapter 5

Control System

5.1 Chassis

Description I/O card chassis

Model CompactDAQ USB (NI cDAQ-9172)Manufacturer National InstrumentsModule slots 8Computer connection Hi-speed USPPower 11 - 30 Vdc (power supply included)

Channels

Analog input: 256Analog output: 32Digital input: 64Digital output: 64

Sampling rate Up to 400kS/s (each module)

Table 5.1: I/O card chassis specifications.

Figure 5.1: National Instruments CompactDAQ 9172 chassis.


5.2 Input current module

Description Analog input current module

Model NI 9203Manufacturer National InstrumentsSignal range 0 – 20mAChannels 8Resolution 16 bitsSampling rate 200kS/sAditional features cDAQ and cRIO compatible.

Table 5.2: Input current module specifications.

Figure 5.2: NI 9203 input current module.


5.3 Input voltage module

Description Analog input voltage module

Model NI 9201Manufacturer National InstrumentsSignal range 0 – 10VChannels 8Resolution 12 bitsSampling rate 500kS/sAditional features cDAQ and cRIO compatible.

Table 5.3: Input voltage module specifications.

Figure 5.3: NI 9201 input voltage module.


5.4 Output current module

Description Analog input current module

Model NI 9265Manufacturer National InstrumentsSignal range 0 – 20mAChannels 4Resolution 16 bitsSampling rate 100kS/sAditional features cDAQ and cRIO compatible.

Table 5.4: Output current module specifications.

Figure 5.4: NI 9265 output current module.


5.5 Computer

Description Computer

Model OptiPlex 360 MTManufacturer Dell

ProcessorIntel Core 2 Duo E73002.66GHz – 1066MHz – 3MB

Memory 2.0GB 800MHz NON-ECC DDRII (2× 1GB)Hard Disk 80GB (7,200rpm) 3.5in SATA 3.0Gb/sOptical drive 16XDVD+/-RW Drive

Ports

VGA: 1USB 2.0: 2 (front)

6 (back, optionals by PCI card)Ethernet: 1 (RJ45)Serial: 1 (9 pins)Parallel: 1 (25 pins, bidirectional)

Aditional features

No Floppy Drive.Operating System : Spanish Windows VistaBusiness to XP Pro SP3 Downgrade.European Power Cord.

Table 5.5: Computer specifications.

Figure 5.5: Dell OptiPlex 360 MT.


Chapter 6

Power

6.1 Transformer

Description Transformer

Model ML 70.100Manufacturer PULSInput voltage 220 – 240V (47 – 63Hz)Input current < 0.8AHold-up time > 40msOutput voltage 24 – 28V (adj. by front panel potentiometer)Output power 72WEfficiency 89%Protection IP20

Aditional features

2 terminals per output (connection by springclamp terminals).Ventilation/Cooling: Normal convection,no fan required.

Table 6.1: Transformer specifications.

Figure 6.1: Transformer.


6.2 Three-phase plug & socket

Description Three-phase plug & socket

Pins 5 (3 phase, neutral, earth)Max. Current 32AProtection IP44

Table 6.2: Three-phase plug & socket specifications.

Figure 6.2: Three-phase plug & socket.


6.3 Single-phase plug & socket

Description Single-phase plug & socket

Pins 3 (phase, neutral, earth)Max. Current 32AProtection IP44

Table 6.3: Single-phase plug & socket specifications.

Figure 6.3: Single-phase plug & socket.


6.4 Three-phase cable

Figure 6.4: Three-phase wire.

Description Three phase cable

Conductors

Number: 5 (3 phase, neutral, earth)Insulation material: PVCSection: 1.5mm2 (each)Material: Copper

External insulation Rubber & neopreneShield No

TemperatureConductor: max 70oCEnvironment: –20 – 85oC

Max. Power 0.6/1kWMax. Current 11A (each conductor)

Table 6.4: Three-phase wire specifications.


6.5 Single-phase cable

Figure 6.5: Single-phase wire.

Description Single phase wire

Conductors

Number: 3 (phase, neutral, earth)Insulation material: PVCSection: 1.5mm2 (each)Material: Copper

External insulation Rubber & neopreneShield No

TemperatureConductor: max 70oCEnvironment: –20 – 85oC

Max. Power 0.5/1kWMax. Current 11A (each conductor)

Table 6.5: Single-phase wire.


Chapter 7

Overall view

7.1 Overall performance

In Fig. 7.1 a simplified diagram of the reaction process is shown. Table 7.1gathers the symbols used in Fig. 7.1. The reactor (R01) has two input streams(with their pumps, P01 and P02) and an outlet stream. The chemical reactionshave to be cooled down with water or warmed up with steam, depending onthe reaction. In order to achive an homogeneus composition in the reactorcontinous stirring is required. For safety reasons and to avoid overpressurethere is a relief valve.

Tag Description

P01,P02 PumpsCV01 Steam control valveSV01 Relief ValveR01 ReactorSL Steam LineCL Condense Line

Table 7.1: Figure 7.1 legend.

7.2 Basic cotrol

In Fig. 7.2 the basic control structure is described, it is a P&I diagramimplementing basic control loops. The contro strategies are as follows:

• Temperature. Jacket steam inlet flow is controlled in order to keepreactor temperature.

• Level. No level control is needed.

• Pressure. No pressure control is needed.


• Composition. A cascade loop will be used. Composition regulatorcontrols the set point of one of the inlet streams.

• Inlet flow. One of the flows is controlled by the composition loop andthe other is proportional to the former. Products must be fed in astoichiometric ratio.

• Stirring. No stirring control is needed.

7.3 System connections

Control loops are shown in Fig. 7.2 but real connections between devices aredepicted in Fig. 7.3. All of the devices are connected to the to the controlcomputer through the I/O card. The legend of Fig. 7.3 is gathered in Table7.2

Tag Description

Computer Control computerI/O card Adquisition card

Q1,Q2 FlowmetersT Temperature sensor

pH pH sensorORP ORP sensor

Analyzer pH and ORP analyzer-transmitterP Pressure sensor

Table 7.2: Figure 7.3 legend.

Reactant 1

Reactant 2

Products

SL CLCV01

SV01

R01

P01

P02

Atm

Figure 7.1: PCT process diagram.


Reactant 1

Reactant 2

Products

SL CLCV01

SV01

R01

P01

P02

Atm

FT01

FT02

AT01

FIC01

FIC02

TIC01

TT01

AIC01

K

PI01

PSH01

Figure 7.2: PCT P&I.

Reactant 1

Reactant 2

Products

SL CLCV01

SV01

R01

P01

P02

Atm

PSH

PpH

Q1

Q2

I/O card

T

Computer

Analyzer

ORP

Figure 7.3: PCT connections diagram.


Comp

uter

cDAQ

chas

sis

Outpu

tcu

rrent

(4-2

0mA)

Input

curre

nt(4

-20m

A)Inp

utvo

ltage

(0-1

0V)

Inver

terInv

erter

Stea

mVa

lve

pH se

nsorOR

P se

nsor

Analy

zer

Flowm

eter

Flowm

eter

Temp

eratu

rese

nsor

Pres

sure

sens

or

Pump

Pump

USB

220V

ac(3

-F)

220V

ac(3

-F)

Figure 7.4: Sensors connections.


Comp

uter

Stirr

ing

cDAQ

Cha

ssis

ORP

sens

orpH

sens

orPu

mpPu

mp

Stea

m va

lveFlo

wmete

rFlo

wmete

rPr

essu

rese

nsor

Temp

eratu

rese

nsor

24V dc

trans

forme

r

Inver

terInv

erter

Analy

zer

Powe

rSu

pply

single

-pha

se(2

40V ac

)Th

ree-

phas

e(3

80V ac

)

Figure 7.5: Power connections.


Reac

tor

Pump

Pump

Stea

m va

lve

Flow

Cham

ber

Relie

f Valv

e

Temp

eratu

reSe

nsor

Pres

sure

Sens

or

pH -

ORP

Sens

or

Flowm

eter

Flowm

eter

1/2"

1/4"

3/8"

3/8"

3/8"

3/8"

1/2"

1/2"

1"

Tricl

amp

Tricl

amp

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/2"

1/4"

1/4"

1/4"

1/4"

1/4"

1/4"

Tubin

g 1/4"

Tubin

g 1/4"

Tubin

g 1/4"

Tubin

g 1/4"

Tubin

g 1/4"

Tubin

g 1/4"

Tubin

g 1/2"

Tubin

g 1/2"

Stea

m tub

ingSt

eam

tubing

Stea

m tub

ing

Figure 7.6: Hydraulics connections.


Chapter 8

Degree of protection (IP)

The IP Code —or International Protection Rating, sometimes also interpretedas Ingress Protection Rating— consists of the letters IP followed by twodigits and an optional letter. As defined in international standard IEC60529, it classifies the degrees of protection provided against the intrusionof solid objects —including body parts like hands and fingers—, dust,accidental contact, and water in electrical enclosures. The standard aims toprovide users more detailed information than vague marketing terms suchas “waterproof”.

The digits indicate conformity with the conditions summarized in the tablesbelow (Table 8.1 and Table 8.2). Where there is no protection rating withregard to one of the criteria, the digit is replaced with the letter X.

The first digit indicates the level of protection that the enclosure providesagainst access to hazardous parts (e.g., electrical conductors, moving parts)and the ingress of solid foreign objects (Table 8.1). The second digit indicatesthe level of protection of the equipment inside the enclosure against harmfulingress of water (Table 8.2).

The standard defines additional letters that can be appended to classify onlythe level of protection against access to hazardous parts by persons (Table8.3). Further letters can be appended to provide additional informationrelated to the protection of the device (Table 8.4).

For example, an electrical socket rated IP22 is protected against insertionof fingers and will not be damaged or become unsafe during a specifiedtest in which it is exposed to vertically or nearly vertically dripping water.IP22 or IP2X are typical minimum requirements for the design of electricalaccessories for indoor use.


1st digit Contact Foreign bodies

0 No protection. No protection.

1 With large parts of thebody (back of the hands).

Large foreign bodies,diameter greater than orequal to 50mm.

2 With a finger.

Medium-sizeforeign bodies, diametergreater than or equal to12mm.

3With tools and wires,diameter greater than orequal to 2.5mm.

Small foreign bodies,diameter greater than orequal to 2.5mm.

4With tools and wires,diameter greater than orequal to 1mm.

Grain-shapedforeign bodies, diametergreater than or equal to1mm.

5 Complete protection. Dust deposit.

6 Complete protection. Ingress of dust.

Table 8.1: Protection against contact and foreign bodies.

2nd digit Protection against water

0 No protection.

1 Vertically falling drops ofwater.

2Obliquely falling drops ofwater up to 15o towardsvertical.

3 Sray water up to 60o towardsvertical.

4 Splash water from all sides.

5 Jets of water.

6 Powerful jets of water.

7 Partial immersion.

8 Immersion.

Table 8.2: Protection against water.


LevelProtected againstaccess to hazardousparts with

A Back of hand

B Finger

C Tool

D Wire

Table 8.3: Aditional letters (I).

Letter Meaning

H High voltage device.

M Device moving duringwater test.

S Device standing stillduring water test.

W Weather conditions.

Table 8.4: Aditional letters (II).


Title: CSTR Overall SpecificationSubtitle: The main PCT testbedAuthor: Jose Luis de la Mata

Date: February 6, 2009Reference: R-2009-001 v 2.0 Draft

URL: http://wwww.aslab.org

c© 2009 ASLab

Autonomous Systems LaboratoryUNIVERSIDAD POLITECNICA DE MADRIDC/JOSE GUTIERREZ ABASCAL, 2MADRID 28006 (SPAIN)

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CSTR Overall Speciﬁcationtierra.aslab.upm.es/documents/reports/pct_specs_2.0.pdf · 7.2 Basic cotrol ... The PCT testbed is a chemical reactor system intended as a platform