Transcript – UK Weblab Setup and Use Markus Kraft, Andreas Braumann,

UK Weblab –
Setup and Use
Markus Kraft, Andreas Braumann,
Charles Immanuel, Phillip Robbins
14 March 2008
People
• Markus Kraft,
Andreas Braumann
• Charles Immanuel
• Phillip Robbins
CoMo group
[email protected]
The Weblab project
• Cambridge-MIT Institute (CMI)
• Prof Clark Colton (MIT), Dr Markus Kraft (CU)
• Explore the use of remotely accessible
experiments in chemical engineering curriculum
• MIT heat exchanger
• Cambridge reactor
CoMo group
[email protected]
Cambridge Weblab
• Chemical Reactor
• Industrial Process Control System (PCS7)
• Set up in 2006
• used at different
universities
CoMo group
[email protected]
Selmer and Goodson
Anders Selmer
Mike Goodson
CoMo group
[email protected]
Equipment
• Chemical Reactor
• Ancillary equipment
• SIMATIC S7-400 controller
• Siemens Industrial PCs
CoMo group
[email protected]
Reactor
• 100 – 300 ml variable volume
• Variable, ideal – non ideal
• Variable stirrer speed
• Temperature controlled
• Three controlled feeds
• Conversion monitored by spectrometer
• Dosing of tracer
CoMo group
[email protected]
Ancillary Equipment
• Storage tanks
• Siemens Coriolis flow meters
• Peristaltic pumps
CoMo group
[email protected]
Ancillary Equipment
• Dosing unit
• Heater bath
• Flow cell with fibre optics
• Spectrophotometer
• Webcam
CoMo group
[email protected]
Computers
• Programmable Logical Controller (PLC) SIMATIC S7-400
• Engineering Station
• Operating System Server
• Web Server
CoMo group
[email protected]
Plant wiring scheme
S7
400
Analogue and Digital Inputs/Outputs
AI AO DI DO
ET 200M
Plant Bus (Industrial
Ethernet)
OS Server
Dosing
Heater bath
Hot water
circulatio
n
Stirrer, 0-5V
PROFIBUS
DP
Engineering Station
SPM
4-20 mA
Peristaltic pumps, 0-4V
Terminal Bus (Industrial Ethernet)
MASSFLO
SITRANS T
MASS DI 1.5
DP
Link
Web Server
(PCS7
Client)
Internet
DP/PA Coupler
PROFIBUS PA
PCS7 OS Web Client
CoMo group
[email protected]
Graphical User Interface
• Mimic
• Block Icons
• Faceplates
• Trends
CoMo group
[email protected]
Non-ideal Reactor Exercise
Ideal and non-ideal reactor
• Reaction constants based on
batch data
• RTD tests
• Predict required flow rates
for desired conversion under
continuous operation
• Experimental session to test
predictions
CoMo group
[email protected]
Users
• University of Cambridge
• MIT
• Imperial College London
• University of Birmingham
• University of Newcastle
• Loughborough University
CoMo group
[email protected]
Imperial College London
• Enormous educational value in hands-on laboratory
experiments
- Course: Process Modelling, Dynamics and Control
• Industry standard control software
- Siemens distributed control system
• Ideal process
- Challenging yet realistic
Process Dynamics & Control Exercise
• Dynamic modelling
- experimental data for validation
• Design of feedback controllers
- tuned through experiments,
empirical tuning laws, and
theoretical considerations
• Design of feedforward
controllers
• Experimental testing of the
controller effectiveness
- faced with real-life vagaries
Process Dynamics & Control Exercise
Manipulated Variable Plot
Manipulated
variable
• Dynamic modelling
35
- experimental data for validation
NaOH Feedrate
30
25
• Design of feedback controllers
20
15
10
5
0
12:23:02
12:25:55
12:28:48
12:31:41
12:34:34
12:37:26
12:40:19
12:43:12
- tuned through experiments,
empirical tuning laws, and
theoretical considerations
Time
• Design of feedforward
controllers
Controlled variable
plot
Controlled
variable
2500
Light Intensity
2000
1500
• Experimental testing of the
controller effectiveness
1000
500
0
12:23:02
- faced with real-life vagaries
12:25:55
12:28:48
12:31:41
Time
12:34:34
12:37:26
12:40:19
Process Dynamics & Control Exercise
• Student comments
- very enjoyable/ challenging
- opportunity to appreciate
limitations of theory
• Lecturer comments
- excellent motivational tool
- cover much ground through single
exercise
Weblab – University of Birmingham
• Who used it?
– 2nd Year chemical engineering undergraduates
• Which course?
– Forms part of a linked control course, the first half is
Process Systems, and the second Principles of Process
Control within the Chemical Engineering at Birmingham.
• Why?
– Wanted to have an experiment as part of the control
laboratories that showed something of what a modern PLC
control interface would look like and something of what is
technically possible in terms of remote operation.
Weblab – University of Birmingham
• How?
– A lab experiment sheet was written to take the
students through the use of the Weblab and then
to look at estimating some suitable control
parameters from performing step changes.
– It forms one of a series of labs the students look
at. The other labs cover aspects of control more
related to the taught material than the ‘real’
world.
Weblab – University of Birmingham
• Overall experience?
– Staff/demonstrators: Has worked well, it is ‘low’
maintenance and the additional details available
on the website allow the students to get a good
feel for what the control equipment actually looks
like and what it is for.
– Students: A very positive response, most like the
idea of being able to control a rig in Cambridge,
having the webcam means they can also see
changes occurring.
Weblab – University of Birmingham
• Thanks to staff at Cambridge who have
supported the Weblab use
– Markus Kraft
– Andreas Braumann
– Mike Goodson
– Jon Etheridge
• And at Birmingham to Dr Chris Kent and
various demonstrators.