ProcessControlLearningPlatformUsingLabVIEWBasedControlSystems

Houran,Nadeem+Powers,Jessica

ProfessorCraigGatesandDr.PhilipHarding

School of Chemical Biological and Environmental Engineering

SchoolofChemical,BiologicalandEnvironmentalEngineering

AnEducationalLearningDeviceDesignedandImaginedByStudentsForStudents
Objective

ProblemStatement
ProcessFlowDiagram

Issue:Thereisnocurrentlabexperiencetoreinforce
concepts of process control or LabVIEW programming in
conceptsofprocesscontrolorLabVIEWprogrammingin
theSchoolofCBEEatOSU.
Solution:Abenchtopcontrolsystemresearched,
designedandconstructedtodemonstratethepractical
useofprocesscontrolandLabVIEWtoseniors.

Steam
ControlValve

House
Steam
Line

A15C liquidprocesslineforBeaverManufacturingcontainsa
holdingtank,whichrequiresaconstanttemperatureof45C.
Th
Theprocessinputisconstantlychanging,requiringtheuseofPI
i
ti
t tl h i
i i th
f PI
parameterstomaintainthedesiredsteadystatetemperature
throughtheinputofpressurizedsteam.Yourgoalisto
characterizethesteamvalveandoptimizethePIparameters.

0.55
5GPM
GPM
Rotometer
(WaterInlet)

DAQCard

Conclusions

SteamManifold

Background
v P I

d
dt D
dt

SteelTank

Temperature[C]

t
v vt 1 K p 1 D
I t

30
25
20
15
10
15
Time[min]

20

25

Thetwoequationspresentedbeloware
thenonintegratedandintegratedforms
oftheprocessmodelassumingconstant
volumedirectinjectionsteamheating.
Q(t)isafunctionofthesteamvalvelift.
dT
wi

dt
Vb b

Q (t )
T i T
V b bC

T ( t ) T 0 m steam ( t )

H v ,w
e
Vb bC

wi

Vb b

Methods

TimedelayinSteamValve
Time[s]=0.09*%lift+0.65

Unique
Factor

Process
Model

Define
Deliverables
Metrics

PreLab
Expectations
Student
T i
Testing

Write
Code

Decide
System

Test
System
Calcs/
Feasibility

February/March2011

OregonStateUniversity

Identify&
Acquire
Materials

April2011

Time[s]

WriteLab
Assignment

LabVIEWProgramming

FrontPanel

Tem
mperature[C]

Build
System

May/June2011

100
Seniors
2012

75

50

25

40
35
30
25
20
15
10
5
0

Valve Capacity
1.4

Time[s]=0.30*%lift+0.47

0
%lift

mdot[kg/min]

50

75

DisturbanceTesting
Temperature
VoltageSignal

BackPanel

Time[s]

DecidesifSetPoint
isacceptable

Decidesforautoor
manualcontrol

LongTermGoals:
Addadditionalcapabilitytothelabintheformof
levelcontrol.
IncorporatederivativecontrolintotheLabVIEW
program.

Acknowledgements

1
0.8
0.6
0.4
0

100

6
5
4
3
2
1
0

1.2

0.2

FromZero
FromMidpoint

25

48
47
46
45
44
43
42

VoltageSignal[V]

Presentedaboveisa
Presented
above is a
formofthePIDcontrol
systemallowingforeasy
programming.Expression
evaluatestheprevious
responseandadjustsits
valuebasedontheerror,
.Kp,I andD canbe
approximatedfromthe
processtransferfunction
using methods like
usingmethodslike
ZieglerNicholsmethod.

Figures:(ontheleft)AP&ID(pipingand
instrumentationdiagram)withdimensions.(above)
TheactuallabequipmentconstructedinGleesons
basement.

100gal
75gal
50gal
25gal

35

Currently:
y
Labequipmentconstructed.
Steamexperimentscompleted:
Steamflowrateoptimized,achieved3C/min
LabVIEWProgramming:
FrontpanelGUIcompleted.
Initialblockdiagramwrittenwith
proportionalandintegralcontrol(not
derivative),butnottested.
Required documents written for lab to be
Requireddocumentswrittenforlabtobe
operationalnextyear:
ProjectDeliverables
PrelabAssignment
LabSOP(standardoperatingprocedure)
Systemtestedandresultsconsistentwiththeory

Thermocouple

TankDrain

EquationabovedefinesaPIDcontrolsystemwherevistheresponse
and isTspT(t).TheP,I andD constantsinfluencethespeedatwhich
45
thesetpointisachieved.
40

LabVIEW
Control

Pneumatic
BarrelStirrer

25

50

75

100

%lift

Studentsexpectedtogenerateplotssimilartothese.

P&Iparameters
setvalveposition

Sendsanalog
signaltovalve

AndrewBrickman,InstrumentTechnologist
ProfessorCraigGates,ProjectSponsor
UCBoulder Dr.DavidE.Clough
KatherineMcAuliffe,OSUChEStudent
Dr.PhilipHarding,SeniorCBEELabProfessor

January2010

SchoolofCBEE

June2011