Ch26b Final Exam 2002 (Revised)

THE UNIVERSITY OF THE WEST INDIES
EXAMINATIONS OF
Code and Name of Course:
APRIL/MAY
2002
CH26B Process Dynamics and Control I
Paper:
Date and Time:
Duration:
INSTRUCTIONS TO CANDIDATES: This paper has
pages and
3 hrs.
questions
Calculators may be used in this examination. They must be silent, cordless and non-programmable.
Calculators will be examined to ensure that they comply with these requirements.
Answer questions 1, 2, and two of questions 3, 4, 5, 6.

1.
(a)
Solve the ordinary differential equation:

d y (t )
5 y (t ) 50
dt
(1.1)
with initial condition y (0) 0.

(b)
The following ODE describes the response of reactant concentration C A2 (t ) in

the second of two CSTRs in series to a step change of magnitude C A0 in the feed
concentration:
d 2 C A2 (t )
1 d C A 2 (t )
1
2 k
k
2
dt
dt
C A2 (t ) C A0 ,
t 0
(1.2)
The relevant boundary conditions are

C A2 (0) 0,
d C A2 (t )
dt
0
t 0
Solve Eqn. (1.2) to obtain an expression for C A2 (t ) in terms of the constants

k , and C A0 .
The University of the West Indies
Course Code
CH26B
2001/2002
DO NOT WRITE ON THE BACK OF THIS SHEET: USE ONE SIDE ONLY
INSTRUCTIONS: Each page of this draft must be signed by the UNIVERSITY EXAMINER. Completed forms should be handed to the Assistant
Registrar (Examinations). The EXTERNAL EXAMINER is requested to sign the draft paper and return it with comments, if any, to the Assistant
Registrar (Examinations).
...........................................
First Examiner
...........................................
University Examiner
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Second Examiner
External Examiner (where applicable)
Date: 20....../......./......
Date: 20././.
page 2
(c)
A tank is filled with 10 litres of brine solution in which is dissolved 2 kg of salt. At

time zero, a brine feedstream containing 1 kg of salt per litre is introduced to the
tank at a constant flowrate of 2.5 litres per minute, and the well-stirred mixture
leaves at the same rate. How much salt is present in the tank after ten minutes?
[20 marks]
2.
Consider the problem of controlling air pressure in the experimental apparatus illustrated
below.
CO(t)
SP(t)
PC
PV(t)
Digital-to-Analog
Converter
Analog-to-Digital
Converter
I/P Converter
PT
Air from
Compressor
(40 psig)
Surge
Tank
Discharge to
Atmosphere
Figure Q2 - Air pressure control apparatus.

The pressure transducer (PT) is calibrated for the range 0 40 psig and linearly converts
the measured line pressure to a 4-20 mA current which is re-scaled by the analog-to-digital
converter to produce the PV signal in units of percent. Conversely, the controller output
in percent of scale is translated to a 4-20 mA signal in the digital-to-analog converter. The
system is initially operating at steady-state with PV = SP = CO = 50%.
(a)
Explain the function of the I/P converter in Fig. Q2.
(b)
The pressure control valve is air-to-close. Should the action of the pressure
controller be reverse (i.e. increase-decrease) or direct (increase-increase)?
(c)
Table Q2 contains experimental observations of the process variable made

following a 10% step increase in controller output CO(t) with the pressure
controller operating in manual mode. Plot the data on the graph paper provided
and fit a first-order-plus-deadtime transfer function to this response.
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.
page 3
Table Q2 - Response of line pressure to step change in valve position.

Time
Process Variable
<%>
<sec>
5
44.5
10
40.8
15
38.5
20
37.1
25
36.3
30
35.8
35
35.5
40
35.3
45
35.2
50
35.1
(d)
Calculate the value of the proportional band PB ( 100% / K c ) which will

guarantee that the pressure in the line remains in the range 10 30 psig if the
control strategy is proportional-only and the setpoint remains constant at 50% (i.e.
20 psig).
(e)
Employ the model obtained in part (c) to derive the closed loop response PV(t) to
a 20% step increase in setpoint SP(t) occurring at time zero. Quantify the offset to
be expected using proportional-only control with proportional gain K c 1.
(f)
Use the final value theorem to prove that zero offset will be achieved for step
changes in setpoint when integral action is added to the proportional pressure
controller of part (e).
(g)
Discuss the relative strengths and weaknesses of the proportional-only and

proportional-integral feedback control algorithms.
[30 marks]
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.
page 4
3.
Figure Q3 is a schematic representation of a temperature control strategy for the effluent

stream of a continuous stirred tank heater (CSTH):
F , T0 (t )
V,
T (t )
F , T (t )
TC
CO(t)
Steam
Heat, q(t)
Figure Q3 - Control of temperature in a CSTH.

The system parameters appearing in this diagram are defined as
V
Cp
Volume of fluid in tank = 5 m3

Heat capacity of process fluid = 3 kJ/(kg K)
Density of process fluid = 800 kg/m3
Volumetric flowrate of process fluid = 30 m3/hr
The control valve is linear and can pass enough steam to transfer q max 10 10 6 kJ/hr
of heat into the vessel. The values of the process temperatures at initial steady-state
conditions are T0,ss 40 C and Tss 75 C.
(a)
Show that the open-loop dynamics of the stirred tank heater are described by the
differential equation
d T (t )
T (t ) K p CO (t ) T0 (t )
dt
where the time constant

(3.1)
and process gain K p are given by
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.
page 5
V
,
F
Kp
q max / (100%)
F Cp
(b)
Calculate the steady-state steam valve position COss .
(c)
Draw a block diagram which clearly indicates the locations of the signals T (s ),
TSP ( s ), T0 ( s ), and CO ( s ) and specifies the transfer functions between them.
The temperature control algorithm is proportional-integral with tuning parameters
K c 1 % / C and I 1 min . Dynamics associated with the sensor and final
control element may be neglected. (N.B. T ( s ) L [ T (t ) Tss ], etc.)
(d)
Derive the closed loop regulatory transfer function between T (s ) and T0 ( s )

and calculate the damping coefficient of this response. Would you expect the
controlled tank temperature to oscillate following a step change in feed
temperature?
(e)
Prove that the tank temperature is inherently stable under proportional-integral

control for all proportional gains K c 0. In answering this question, you may
wish to make use of the Routh array
Row
1
2
3
4
a0
a2
a4
a6
a1
a3
a5
a7
b1
b2
b3
c1
c2
c3
where
b1
a1 a 2 a0 a3
a a a 0 a5
, b2 1 4
,
a1
a1
c1
b1 a3 a1 b2
b a a1 b3
, c2 1 5
,
b1
b1
[25 marks]
4.
Figure Q4 is a schematic diagram of a variable-area flooded reboiler which is installed in

some distillation processes because it permits the use of lower-pressure steam. Changes in
steam flow are achieved by increasing or decreasing the area used for condensing steam in
the reboiler.
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.
page 6
The condensing temperature of the steam is 120 C and the process into which heat is to
be transferred is at a constant temperature of 95 C. The overall heat transfer coefficient
is 1.7 kW/(m2 K). The reboiler has 509 tubes that are 3 m long with inside diameter 2.54
cm. The steam and condensate are inside the tubes. The density of the condensate is 1000
kg/m3, and the latent heat of condensation of the steam is 2112 kJ/kg. Sensible heat
transfer effects may be neglected.
Steam
120 C
FT
95 C
FC
Condensate
Figure Q4 - Variable-area steam reboiler.

The steam flow meter acts like a first order lag with a 6-second time constant. The
control valve on the liquid condensate line can be assumed to respond instantaneously and
to have linear characteristics. Derive a transfer function model of the flooded reboiler
system which relates steam flowrate to condensate flowrate by formulating a dynamic
mass balance on the condensate in the tubes. Using a PI controller with I 0.1
minutes, calculate the closed-loop time constant corresponding to a closed-loop damping
coefficient of 0.3.
[25 marks]
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.
page 7
5.
The dynamic behaviour of the liquid level in a certain cylindrical storage tank is modelled
by
A
d h(t )
Fin (t ) c h(t ) 2 / 3
dt
(5.1)
where A is the uniform cross-sectional area (m2), Fin (t ) is the inlet flowrate (m3/min),
h(t ) is the liquid level (m) and c is a constant.
(a)
Linearize this process model around a steady-state level hss , and obtain an
approximate transfer function model relating the deviation variables h (s )
L [ h(t ) hss ] and Fin ( s ) L [ Fin (t ) Fin ,ss ]. Explicitly specify what the
steady-state gain and time constant of the approximate transfer function are.
(b)
Assume that the storage tank has a total height of 1 m and take c = 0.5 (m7/3/min)
and A = 0.25 m2. The tank exhibits a steady-state liquid level of 0.512 m when
operating with a throughput of 0.32 m3/min. It is believed that if the flowrate were
to increase in step fashion from this initial value to 0.52 m3/min, the approximate
linearized model will mislead us into concluding that the tank will not overflow;
the more accurate nonlinear model, on the other hand, would suggest the contrary.
Confirm or refute this statement.
[25 marks]
6.
Figure Q6 presents a control scheme for regulating the effluent temperature of a CSTR in
which an exothermic reaction is taking place.
Reactants
Coolant
Return
Cooling
Water
FT
Reactor
Products
TC
TT
Figure Q6 - Temperature control of jacketed reactor.

The cooling water control valve is linear and air-to-close. It is sized for a maximum flow
of 500 gpm (gallons per minute) and exhibits a time constant of 0.2 min. The transfer
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.
page 8
function relating changes in cooling water flowrate to reactor temperature is first order
with a gain of 2 F/gpm and a time constant of 5.0 min. The temperature transmitter has
a time constant of 0.5 min.
(a)
Draw a well-labelled block diagram for the temperature control loop of Fig. Q6,
clearly indicating the transfer functions representing the dynamic behaviour of each
device. The feedback control algorithm is proportional-only.
(b)
Calculate the ultimate gain of the proportional temperature controller. (Hint: The
Routh array defined in Question 3(e) may be of use in solving this problem.)
(c)
It has been decided to implement a cascade control system in which the primary
reactor temperature controller manipulates the setpoint of a cooling water flow
controller. Specify the action (i.e. reverse or direct) of the flow controller and of
the reconfigured temperature controller.
(d)
Draw the block diagram for the process under the cascade strategy and compute
the ultimate gain of the primary temperature controller assuming that it remains
proportional-only. The secondary controller is to be specified as a proportionalintegral controller with K c 2 0.1 % / gpm and I 2 0.2 min; you may
neglect the sensor dynamics associated with this inner loop.
[25 marks]
END OF QUESTION PAPER
Course Code
CH26B
2001/2002
.........................................
First Examiner
...........................................
University Examiner
..........................................
Second Examiner
Date: 20....../......./......
Date: 20././.

Ch26b Final Exam 2002 (Revised)

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Ch26b Final Exam 2002 (Revised)

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THE UNIVERSITY OF THE WEST INDIES

CH26B Process Dynamics and Control I

Date and Time:

INSTRUCTIONS TO CANDIDATES: This paper has

Answer questions 1, 2, and two of questions 3, 4, 5, 6.

Solve the ordinary differential equation:

with initial condition y (0) 0.

The following ODE describes the response of reactant concentration C A2 (t ) in

The relevant boundary conditions are

Solve Eqn. (1.2) to obtain an expression for C A2 (t ) in terms of the constants

The University of the West Indies

External Examiner (where applicable)

A tank is filled with 10 litres of brine solution in which is dissolved 2 kg of salt. At

Figure Q2 - Air pressure control apparatus.

Explain the function of the I/P converter in Fig. Q2.

Table Q2 contains experimental observations of the process variable made

The University of the West Indies

External Examiner (where applicable)

Table Q2 - Response of line pressure to step change in valve position.

Calculate the value of the proportional band PB ( 100% / K c ) which will

Discuss the relative strengths and weaknesses of the proportional-only and

The University of the West Indies

External Examiner (where applicable)

Figure Q3 is a schematic representation of a temperature control strategy for the effluent

Figure Q3 - Control of temperature in a CSTH.

Volume of fluid in tank = 5 m3

where the time constant

and process gain K p are given by

External Examiner (where applicable)

Calculate the steady-state steam valve position COss .

Derive the closed loop regulatory transfer function between T (s ) and T0 ( s )

Prove that the tank temperature is inherently stable under proportional-integral

Figure Q4 is a schematic diagram of a variable-area flooded reboiler which is installed in

The University of the West Indies

External Examiner (where applicable)

Figure Q4 - Variable-area steam reboiler.

The University of the West Indies

External Examiner (where applicable)

Figure Q6 - Temperature control of jacketed reactor.

External Examiner (where applicable)

END OF QUESTION PAPER

The University of the West Indies

External Examiner (where applicable)

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