Process Control Homework 2

CHEN 461-Fall 2012

Team Members: Cristancho Dahiyana
Leon Paola
Instructor: Jorge Seminario
Date: 09/17/2012

Team Number: 29

Question 1.2
Review the equipment sketches in Figure 1(a) and (b) and explains whether each is or is
not a level feedback control system. In particular, identify the four necessary components
of feedback control, if they exist.
(a) The flow is a function of the connecting rod position.
Solution:
Figure 1(a) represents a level feedback control system where the fours elements
(1. Process, 2. Sensor, 3. Controller and 4 Final element) are identified:
Figure 1(b) does not represent a clearly process and it is no possible to identify the four
control elements

(a)

(b)

Figure 1. (a) Level feedback control system and (b) An example of a not level feedback
control system.
Question 1.5
Review the processes sketched in Figure 1.7a through d in which the controlled variable
is to be maintained at its desired value.
(a) From your chemical engineering background, suggest the physical principle used by
the sensor.
(a) Continuous stirred-tank reactor with composition control

Solution: Composition is the variable sensed in the CSTR, which is controlled by the
valve in the heating medium. With an increase in the temperature, the control system
would sense a decrease in the outlet composition of reactant. In response, the control
system would adjust the heating coil valve, closing slightly, until the outlet composition
returned to its desired value.
(b) Flow controller
Solution: Flow is the variable sensed in the pipe, which is controlled by the valve that is
located after the pump. With an increase in the pressure drop, the control system would
sense an increase in the fluid flow. In response, the control system would adjust the valve,
opening slightly, until the fluid flow returned to its desired value.
(c) Tank level with controller
Solution: Level is the variable sensed in the tank, which is controlled by the valve that is
located after the pump. With an increase in the pressure drop, the control system would
sense an increase in the fluid flow. In response, the control system would adjust the valve,
opening slightly, until the fluid flow returned to its desired value.

( d) Mixing process
Solution: Composition of B is the variable sensed in the tank, which is controlled by the
valve in the pipe of the feed of B. With an increase in the fluid of B, the control system
would sense an increase in the composition of B. In response, the control system would
adjust the valve, decreasing slightly, until the composition of B returned to its desired
value.
(b) Explain the causal relationships between the manipulated and controlled variables
Solution: Flow control

Figure 2. Schematic of flow through valve, where P is the pression at different points in
the pipe.

Sensor: The most often used flow sensor for vapors and liquids is an orifice plate. The
relationship between the flow and pressure can be derived by applying Bernoulli equation
with Janna.
(

(1)

P1= upstream pressure

P2= Pressure at the narrowest flow
F= volumetric flow rate
= density
A= cross sectional area
This can be arranged to give

(1)

(2)

With K depending on the diameters of the pipe and the orifice, along with same friction
losses. It is determined empirically.
The pressure difference can be measured with the manometer, but this would not provide
a signal the computer. A pieza electric device generates a s signal voltage proportional to
pressure, and this signal can used for transmission to a computer.
Notice that the equation also contains the fluid density. Since density is more expensive
to measure, it is common practice to assume that density is constant, then,

with

(3)

Density can be measured if a very accurate measurement is required

Notice that the square root of the measure variable is proportional to flow rate. The
measurement of
is noisy, ie, it has high frequency interference, because of the
turbulence around the orifice plate.
Also, almost the entire pressure drop from P1 to P2 is recovered when the flow enlarges
to the entire pipe diameter at P3. Thus, P1 P3, although P3 must be slightly lower
Final element: The final element is the dominant restriction in the system, so that
adjusting the value (the way we adjust a facet) influences the flow.
Bernoulli equation for flow in a pipe with friction factors and fittings is equation ( 5.30)
is Janna
( )

( )

( ) (4)

f=friction factor which depends on Re

( ) = Minor losses which are due to elbow, expansions and values3

The term minor is unfortunate, since the flow goes to zero (K ) when the value is
completely closed.
For the simplest case with Pin=P1=constant=Pout=P4=constant, and other friction losses
in the pipe and (non-recoverable) in the orifice

(5)

The term
depends on the value design and the percentage open- see Table 5.4 for
typical values.

For initial modeling, we will assume that the relationship between value opening ( 0100%) is linear with flow.

(6)

Figure 3.Graphic representation of the equation (6). Flow is linearly proportional to valve opening.

(c ) Explain whether the control valve should be opened or closed to increase the value of
the controlled variable.

Solution: the valve must be opened to increase the volumetric flow according to the
following equation:

(6)

(d) Identify possible disturbances that could influence the controlled variable. Also,
describe how the process equipment would have to be sized to account for the
disturbances
Solution:
Disturbances
Decrease in P1 and Increase in P4
The value opening would have to be large enough to allow the desired flow at the lowest
P1-P4
Change in density
The measured
will be maintained but the actual volumetric flow will change

Question 1.6
The preliminary process designs have been prepared for the system in Figure 4. The key
variables to be controlled are (a) flow rate, temperature, composition, and pressure for the
flash system and (b) composition, temperature, and liquid level for the CSTR. For both
processes, disturbances occur in the feed temperature and composition. Answer the
following questions for both processes.
Determine which sensors and final elements are required so that the important variables
can be controlled. Sketch them on the figure where they should be located
Solution:
Flash drum in figure 4 will have control added in this question:

Figure 4. Control system for a drum in which it is included final elements such as valves, heat exchangers
and pumps to keep the process to the desire conditions of performing

(a) Sensors:
Flow rate: orifice meter in the inlet pipe
Temperature: thermocouple in the vapor space of the drum
Pressure: bourbon tube in the vapor space of the drum
Composition: The sensor depends on the components in the flash. A
typical sensor would be a gas chromatograph
Final Elements
Flowrate: valve in inlet pipe
Temperature: valve in one of the heat exchanger flows. The second heat exchanger flow
is chosen here
Pressure: the valve in the exit vapor pipe is a natural selection to control the pressure
Note that this system must also have a level controller so that the liquid entering the drum
for the flash exits via the pipe at the bottom of the drum.
(b)The heat exchangers should be sized for the (i) largest process flow, (ii) lowest heating
medium temperature, and highest flash temperature. The flash drum should provide
sufficient volume for good vapor-liquid separation and sufficient volume for good vaporliquid separation sufficient liquid inventory for level control. The values should
accommodate the largest expected flow, including disturbances conditions.
(c ) The selected controller pairings are shown in the figure. Note that a causal
relationship exists between each manipulated and controlled variable pairing. However,
the manipulated variable also influences other controlled variables; thus, interaction exits.
Chemical Reactor- The chemical reactor in figure 5 will have control added in this
question

Figure 5. Control system for a CSTR.

(a) Sensors
Temperature: a thermocouple located in the reactor liquid. It would be protected with a
metal sleeve or thermo-well
Level: The level can be sensed by a float whose position is sensed
Composition: with the temperature maintained pipe could be used to influence the heat
transfer rate
Level: a valve in either the feed or effluent pipes is required. Here the effluent pipe is
selected
Composition: with the temperature maintained at a specified, the feed composition is
selected to influence the exit composition. Here, the flow rate of the reactant is
manipulated. Note that the flow of the solvent must be determined; thus, a valve is added
to the solvent inlet pipe, and its value is maintained constant

(b) Describe how the equipment capacities should be determined

Solution: The heat exchanger should be sized for the maximum cooling rate at the
highest coolant temperature. The values should allow the maximum flow, including
disturbed conditions.
(c ) Select controller pairings; that is, select which measured variable should be
controlled by adjusting which controlled variable.

Solution:The variable pairings are shown in the figure. A causal relationship exists
between the manipulated and controlled variable. However, the manipulated variable also
influences other controlled variables; thus, interaction exits.
Question 1.9
Evaluate the potential feedback control designs in Figure Q1.9. Determine whether each
is a feedback control system. Explain why or why not, and explain whether the control
system will function correctly as shown for disturbances and changes in desired value.
(a) Sensor: measured pressure drop

Figure 6. Level control for a tank.

This sensor measures the position if a rod connected to a float

Manipulated: there must be a caudal relationship
=

(7)

The flow out influences the level: Disturbances in

and influences the level, and
can compensate for their disturbances as long as it has the range, i.e, the needed flow of
can be achieved, 0 max
(b) Sensor: the sensor indicates the level to the left of the Xwhich will always remain at
the top of the X
The level of interest is to the right of the x which should be measured as shown in figure
7.

Figure 7. Level control

(c) Sensor: For the weight fraction of A (Xa)

Manipulated variable: The inlet flow influences the amount of A entering the tank. Thus,
there may be a causal relationship which appears to exist.
A material balance as the component A gives
) (8)
Adjusting F influences the rate of change but does not influence the steady-state which is
, ie, the outlet concentration equals the inlet, for any F(0). Thus , although the
flow is an input to the system, it is not possible to control composition in the tank to a
desired steady-state value by adjusting F.
Note, a feedback control system would be possible if the inlet concentration could be
manipulated

Figure 8. Composition control without chemical reaction

(c) Temperature control

The temperature in the tank is measured by a sensor, eg, thermocouple, at the exit. The
energy balance in the tank gives

(9)
Where
The control system shown influences the temperature driving force for the heat transfer
by mixing some warmer coolant recycle with the fresh constant. Thus, a causal
relationship exists between the valve change and the tank temperature.
Question 2.1
For each of the following processes, identify at least one control objective in each of the
seven categories introduced in Section 2.2. Describe a feedback approach appropriate for
achieving each objective.
Solution:
(a) Reactor-Separator in Figure 1.8 (see book)-.
Table 1. Seven control objectives for a reactor-separator
Control objective
process example

1. safety

vessels at high pressure are

dangerous.

control design
Add feedback PC to
control valve 8 on top of
the vessel based on the P1
indicator

2. environmental

sufficient air to combust

theHydrocarbons are harmful
to the atmosphere

Release system to flare in

the overhead vapour line

3. equipment

running pump should have

flow at all times, to prevent
cavitation

Add feeback LC to control

valve 5 based on the L1
indicator

4. smooth operation

Constant flow rate

add a feedback FC to
control valve V6 based on
the F3 indicator

5. product quality

6. efficiency

7. monitoring and diagnosis

Monitor composition of
vapour

add feedback AC that

measures composition to
the products streams to
adjust valve 1 on the inlet
feed.

least costly heating

Add AC to liquid product

of vessel and have it
control valve 7 on the hot
oil line into the heat
exchanger

Calculate and plot key parameters such as heat exchangers

(b) The boiler in Figure 14.17 (from the class book) and steam superheat
Table 2.Seven control objectives for a boiler

Control objective
1. safety
2. environmental

process example
safe combustion, always
sufficient air to combust the
fuel
prevent smoke in the flue
gas

3. equipment

prevent over heating the

metal due to lack of water
circulation

4. smooth operation

water flow

5. product quality

The steam temperature

(super heat) should be
constant.

control design
measure % oxygen and
achieve desired value by
adjusting air flow in
same as above
have emergency control
stop
fuel in water level is too
low
introduce water in a
smooth
manner, rather than on-off
Adjust the "spray" water
that
cools the steam.

6. efficiency

utilize the lowest amount of

fuel possible

7. monitoring and diagnosis

monitor the heat transfer in

the convective heat
exchangers

i. prevent large excess air

by
measuring and controlling
7o
oxygen
ii. ensure good mixing by
adjusting the burner and
injecting steam to improve
mixing
calculate the heat transfer
coefficient and when too
low,
clean surface mechanically
with steam

(c) Distillation column

Table 3.Seven control objectives for a distillation

Control objective

column
process example

1. safety

maintain pressure below

upper mechanical limit

2. environmental

contain hazardous material

5. product quality

prevent large changes in

vapor
flow rate which could
damage
trays
relatively constant product
flow rates to downstream
units
off key components in
products, eg., heavy key in
distillate

6. efficiency

operate with minimum

utility
consumption

3. equipment protection

4. smooth operation

control design
measure pressure and open
vent to containment when
pressure too high
ensure large capacity of
containment

smooth manipulation of
the
reboiler flow (duty)
level controllers that are
designed to introduce slow
changes to the flows
measure the product
composition and adjust the
reflux flow
control the distillation
pressure
at conditions that
maximize
the relative volatility for
the
components

7. monitoring and diagnosis

proper operation of
equipment which could
change due to fouling

calculate the heat transfer

coefficients of reboiler and
condenser

(d) Fired Heater

Table 4.Seven control objectives for a Fired

Control objective

1. safety
2. environmental

3. equipment protection

4. smooth operation
5. product quality

6. efficiency

7. monitoring and diagnosis

Heater
process example

fully combust all fuel at

flame
prevent smoke in flue gas

control design
measure % oxygen and
control by adjusting the air
flow
same as above

prevent overheating the

metal

emergency controls that

stop
the fuel flow when the
flow of
feed is too low

smooth adjustments to the

fuel
temperature of the process
fluid

use minimum fuel

monitor the heat transfer in
the convective heat
exchangers

design temperature
controller
to implement gradual
adjustments to the fuel,
when
possible
design controls to reduce
effects of process variation
maintain % oxygen at
good
value, 1-2%
calculate the heat transfer
coefficients of reboiler and
condenser

Question 2.4
Sometimes there is no active hard constraint. Assume that the fired heater in Figure 2.11
(from textbook) has no hard constraint, but that a side reaction forming undesired
products begins to occur significantly at 850C. This side reaction has activation energy
with larger magnitude than the product reaction. Sketch the shape of the performance
function for this situation. How would you determine the best desired (average) value of
the temperature and the best temperature distribution?
Solution:

Soft constraint
For this situation, the performance curve would have a maximum, beyond which the
losses due to side reaction would involve be greater than the gain due to increased feed
conversion.

Figure 9. Performance curve of fired heater versus temperature (T)

The best value average depends on the performances curve and the distribution of T. If
the distribution represented no variation, the dashed line would be the best average
temperature. Otherwise, the (Fj) distribution which maximized

(10)

It would be used to calculate the average temperature.

Question 2.8
The performance function for a distillation tower is given in Figure Q2.8 in terms of lost
profit from the best operation as a function of the bottoms impurity, xB (Stout and Cline,
1978). Calculate the average performance for the four distributions (A through D) given
Table Q2.8 along with the average and standard deviation for the concentration, xB.
Discuss the relationship between the distribution and the average performance
Solution:
Process performance
To calculate the average, use equation (2-3)

(11)

(12)
Where
Paverage= average process performance
Fj= fraction of data in interval j=Nj/NT
M= number of intervals in the frequency distribution
Pj= performance measured at the midpoint of interval j

The standard deviation can be calculated from the frequency distribution

(13)

i=individual data
n=number of points
Sx = Standard deviation
This can be rearranged to give

] (14)
(15)

With

(16)

(17)

(17) For large NT

The calculations are easily performed with a spread sheet, and the results are:
Table 5. The average performance for the four distributions (A through D)
Case
A
B
C
D

XBave
XB
(Perf)ave
0.75
0.177
-22.3
2.06
4.00
2.17

0.967
0.71
0.63

Nearly same Xbave, but broader

-9.2 distribution
-28
-4.67 Best performance

The analysis and results highlight the importance of having a tight distribution around the
best operation for this process.