UK Weblab – Setup and Use
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UK Weblab – Setup and Use
Markus Kraft, Andreas Braumann,
Charles Immanuel, Phillip Robbins
14 March 2008
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CoMo [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
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CoMo [email protected]
Cambridge Weblab
• Chemical Reactor
• Industrial Process Control System (PCS7)
• Set up in 2006
• used at different
universities
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CoMo [email protected]
Equipment
• Chemical Reactor
• Ancillary equipment
• SIMATIC S7-400 controller
• Siemens Industrial PCs
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CoMo [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
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CoMo [email protected]
Ancillary Equipment
• Storage tanks
• Siemens Coriolis flow meters
• Peristaltic pumps
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CoMo [email protected]
Ancillary Equipment
• Dosing unit
• Heater bath
• Flow cell with fibre optics
• Spectrophotometer
• Webcam
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CoMo [email protected]
Computers
• Programmable Logical Controller (PLC) SIMATIC S7-400
• Engineering Station
• Operating System Server
• Web Server
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CoMo [email protected]
Stirrer, 0-5V
SITRANS T
OS Server
Web Server(PCS7 Client)
Plant Bus (Industrial Ethernet)
DP Link
DP/PA Coupler
S7 400
PROFIBUS PA
PROFIBUS DP
ET 200M
AI AO DI DO
Analogue and Digital Inputs/Outputs
Peristaltic pumps, 0-4V
Dosing
Heater bathHot watercirculatio
n
MASSFLO
MASS DI 1.5
Engineering Station
Terminal Bus (Industrial Ethernet)
Internet
SPM4-20 mA
PCS7 OS Web Client
Plant wiring scheme
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CoMo [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
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CoMo [email protected]
Users
• University of Cambridge
• MIT
• Imperial College London
• University of Birmingham
• University of Newcastle
• Loughborough University
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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
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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
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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
Manipulated variable
Controlled variable
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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
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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.
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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.
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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.
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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.