EXPERIMENT NO 6

INVESTIGATION OF THE TEMPERATURE PROCESS RIG

Theory:
Temperature process rig as shown in figure 6.1 uses water as both the process fluid and secondary cooling circuit. A two loop system using water as the process fluid which allows the study of
the principles of process control using primary and secondary circuit temperatures as the process variables to be controlled.

Fig: 6.1. temperature process rig(

http://www.feedbackgroup.com/product/temperature-processcontrol-6061)

This bench mounted temperature rig consists of temperature sensors, process interface and controllers * Basic process rig and temperature process rig can be connected to control the level, temperature and flow rate at the same time

Instruments: Thermistor Pulse flow meter

THERMISTORS
A thermistor (fig 6.2) is a type of resistor whose resistance varies significantly with temperature. Some types of materials conduct electricity more easily at high temperature than at low temperatures. These materials have the decreased resistance at increase temperature. Resistance element thermometers that decrease its resistance on increasing temperature are known as thermistors.

Fig: 6.2. Thermistors (www.tootoo.com)

WORKING PRINCIPLE
To measure temperature with the thermistor, it is placed in the environment whose temperature is to be measured. As the temperature of the environment changes, the resistance changes as well. Increase temperature decreases the resistance and vice versa. This change in the themristor resistance can be detected which will be the measure of the temperature of the substance. DISADVANTAGES More susceptible to the permanent de-calibration Use is limited to the few hundred degrees Celsius Respond quickly to the temperature changes, thus, especially susceptible to self heating errors.

PULSE FLOW SENSOR The rotor spins when liquid flows through the meter. Magnets in the rotor switch a Hall-effect sensor mounted in the meter body. The resulting pulse train is converted by the electronics to a voltage that is equal to the voltage supply. The proportional frequency pulses may be read by electronics or a display or intelligent multi-channel monitor. A typical pulse flow sensor is shown in figure 6.3.

Fig: 6.3. Pulse flow sensor(http://medical.manufacturer.com/product6465164flow+sensor.html)

APPLICATIONS Magnetic flow meters are used in water treatment plants to measure treated and untreated sewage, process water, water and chemicals. Mining and mineral process industry applications include process water and process slurry flows and heavy media flows. With proper attention to materials of construction, the flow of highly corrosive liquids (such as acid and caustic) and abrasive slurries can be measured.

LINE TRACING DIAGRAM

Secondary Flow out

Cooling radiator Header Tank Manual valve Flow sensor

T5

Servo valve Bleed valve T1

Power Pump Water reservoir T3

T4

Heat Exchanger T2 Secondary flow in

Drain valve

WORKING
The primary circuit which is used normally as heat source comprises: A heater A circular pump A servo valve for flow control A pulse flow meter A header tank A heat exchanger

The secondary circuit contains a heat exchanger and a cooler. The primary circuit is self contained and has to be filled before the system is used. The secondary circuit is normally supplied via flexible hoses, from the Basic Control Rig which is set up to provide a controlled flow. An alternative arrangement is to use a Temperature Auxiliary Control Pack to provide a control flow from a mains water tap. Alternatively if we have a forced Air Cooling Unit, the water from the Temperature Rig can be cooled and re-circulated. The Thermistor Temperature Transmitter takes temperature information from the thermistors (T1 - T5) and transmits it to the Process Interface (PI).There are five such devices included with the Temperature Process Rig. They are positioned to measure the temperature at five points around the secondary and primary flows.

In the primary flow they are positioned before (T1) and after (T2) the heat exchanger. This is obviously crucial in observing the cooling effect of the heat transfer. In the secondary flow they are also positioned before (T3) and after (T4) the heat exchanger. The fifth device is placed at the output (T5) of the radiator in order to show the temperature of the flow before and after cooling has taken place.

THE SECONDARY FLOW

Domestic heating systems often consist of a series of radiators designed to extract energy from hot water being pumped through them. The situation sometimes occurs whereby one or more of the radiators is partly filled with air instead of water. The air does not transfer heat to the metal of the radiator as effectively as the water. This can be demonstrated by the time taken for the element of an electric kettle to become too hot in the absence of water. The air around the element does not remove the energy from it fast enough to prevent overheating. The cooling radiator supplied as part of the Temperature Process Rig can sometimes fall victim to the same problem. Air can be introduced into the system in a number of ways through pumps and joints. This air can find itself trapped in the upper part of the cooling radiator, where it will remain until bleeding can be carried out. Bleeding involves the removal of air from a fluid system by whatever method. The type of domestic system mentioned earlier is usually bled from a small 'tap' on the offending radiator. Air is pushed out under the system pressure until water begins to be expelled. The tap is closed and the radiator is free of air.

OPERATION OF THE COOLER

The main reason for the cooler on the Temperature Process Rig (TPR) is to drop the temperature of the heated return fluid (secondary flow). The overall effect of this process is to prevent the secondary flow circuit (water in the tank of the BPR) from heating up too quickly. This is achieved using a cooler, which consists of a radiator and a fan unit, commonly known as an Air blow Water Cooler. The radiator itself comprises an aluminum structure of heat dissipating fins, whereby the fluid to be cooled passes behind. In order to increase the cooling efficiency, a fan is attached to the rear of the radiator to draw air through the radiator dissipating the heat from the fins. It must be noted that coolers of this type can only reduce the temperature to a minimum degree equal to the ambient air temperature. However with respect to the TPR due to the size of the cooler this would actually take a considerable amount of time depending upon the temperature of the BPR fluid. It is therefore shown that the cooler is only intended to provide a degree of cooling to the BPR (if connected).

However in industrial applications, a cooler may be the primary source (only source) for cooling a process, in which case its specification would be critical to the dissipation required. Coolers of this type tend to be relatively large with respect to their function. In this particular case the cooler is switched on to demonstrate its efficiency in cooling the secondary flow before returning to the sump tank of the BPR.

REFERENCES
http://medical.manufacturer.com/product6465164-flow+sensor.html http://www.feedback-group.com/product/temperature-process-control-6061 Dr.Shahid Naveed, Dr.Naveed Ramzan, industrial instrumentation; 1st edition, published by allied book company