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T a n k a t a tm o s p h e r ic
p re s s u re
E le v a tio n 1 5 '
C ir c u la t in g c h ille d w a t e r
H o t o il
9 0 oF
R e frig e r a n t
E le v a tio n 0 '
C o o le r
5 0 oF
C o o le d o il
7 0 oF
FT
H eat
exchanger
TT
TC
2. Consider the two-tank, interacting liquid-level system shown below and its block diagram.
The data for the system are: A1 = 1 ft2, A2 = 0.5 ft2, R1 = 0.5 ft/cfm, R2 = 2 ft/cfm, and R3 = 1
ft/cfm.
m 2
m 1
c1
R
A
M
c2
A
G 11 ( s )
G 22(s )
+
G
21
(s )
12
(s )
+
The transfer functions G11, G21, G12, and G22 are given as:
s5
G11 = ( s 1)( s 7)
4
G12 = ( s 1)( s 7)
4
G21 = ( s 1)( s 7)
2 s 3
G22 = ( s 1)( s 7)
Use Simulink to obtain the response of c1 and c2 for (a) M1 = 1/s, M2 = 0, and (b) M1 = 0, M2
= 1/s.
3.1 A tank is heated by steam condensing inside a coil. A PID controller is used to control the
temperature in the tank by manipulating the steam valve position. Derive the complete block
diagram and the closed-loop transfer function from the following design data.
Process. The feed has a density of 68.0 lb/ft3 and a heat capacity cp of 0.80 Btu/lboF. The
volume V of liquid in the reactor is maintained constant at 120 ft 3. The coil consists of 205 ft
of 4-in. schedule 40 steel pipe that weighs 10.8 lb/ft and has a heat capacity of 0.12 Btu/lboF
and an outside diameter of 4.5 in. The overall heat transfer coefficient U, based on the
outside are of the coil, has been estimated as 2.1 Btu/minft2oF. The saturated steam is
available at 30 psia; it can be assumed that its latent heat of condensation is constant at 966
Btu/lb. It can also be assumed that the inlet temperature Ti is constant.
Design Conditions. The feed flow F at design condition is 15 ft3/min, and its temperature Ti
is 100oF. The contents of the tank must be maintained at a temperature T of 150oF. Possible
disturbances are changes in feed rate and temperature.
Temperature Sensor and Transmitter. The temperature sensor has a calibrated range of 100
to 200oF and a time constant T of 0.75 min.
Control Valve. The control valve is to be designed for 100% overcapacity, and pressure drop
variation can be neglected. The valve is an equal percentage valve with a rangeability
parameter of 50, f(x) = x-1 = 50x-1. The actuator has a time constant v of 0.20 min.
a) Determine the parameters listed in the following table
Parameters for stirred tank heater.
A
241.5 ft2
4.93 min
o
CM
265.7 Btu/ F
0.524 min
c
o
3
KF
Kw
1.905 oF/(lb/min)
2.06 F/(ft /min)
Ks
0.383 oF/ oF
KT
1.0 %TO/ oF
Kv
1.652 (lb/min)/ %CO
0.20 min
v
0.75 min
T
b) Use simulink to simulate the temperature response to a step change in both set point
and flow rate with a PID controller for two reset rates of 0.5 min -1 and 1.0 min-1, Kc =
2, and D = 1 min.
4. A liquid stream enters tank 1 at a volumetric flow rate F in cfm and contains reactant A at
a concentration of C0 [mol A/ft3]. Reactant A decomposes in the tanks according to the
irreversible chemical reaction
A B
The reaction is first order with reaction rate constant k1 and k2 for tank 1 and tank 2
respectively. The reaction is to be carried out in a series of two continuous stirred-tank
reactors. The tanks are maintained at different temperatures with tank 2 at a higher
temperature. We will neglect any changes in physical properties due to chemical reaction.
The purpose of the control system is to maintain C2, the concentration of A leaving tank 2 at
some desired value in spite of variations in the inlet concentration C0. This will be
accomplished by adding a stream of pure A to tank 1 through a control valve using a
proportional controller. A portion of the liquid leaving tank 2 is continuously withdrawn
through a sample line at a rate of 0.1 cfm. The sample line has a length of 50 ft and the crosssectional area of the line is 0.001 ft2.
C o n t r o lle r
P u re A
F, C
F + m / A
V, T1
C 1, k 1
V, T2
C 2, k 2
( S e t p o in t )
C o m p o s itio n
m e a s u r in g
e le m e n t
S a m p le s tr e a m
P ro d u c t s tre a m
H e a t in g c o il
Data: MwA = 100, A = 0.8 lbmol/ft3, C0s = 0.1 lbmol/ft3, F = 100 cfm, ms = 1.0 lbmol/min, k1
= 1/6 min-1, k2 = 2/3 min-1, V = 300 ft3, = V/F = 3 min.
1
mA
3
Kv = 6 cfm/psi, Km = 400 lbmol/ft , KT = 0.75 psi/mA, d = 0.5 min
a) Use simulink to obtain the response to a unit step change in both the set point and the
inlet concentration C0 for Kc = 2.
b) Find the value of Kc at which the system will have a sustained oscillation.
5.2 For the control system shown, determine the ISE, ITAE, and IAE for a unit-step load
disturbance. Let the controller be a PI controller with Kc = 6, I = 4.
lo a d
+
S e t p o in t
C o n t r o lle r
G c
+
2
1 /(1 0 s + 1 1 s + 1 )
C o n t r o lle d
v a r ia b le
E rro r
e x p (-s )
M e a s u r e d v a r ia b le
Solution -----------------------------------------------------------------------------------------
6.2 Determine the Z-N and the C-C settings for the PI control system shown below.
7.1 The formula for the flow of saturated steam through a control valve is
v (x)
P12 P22
In this equation, P1 is upstream pressure (psia) and P2 is downstream pressure (psia). The
temperature of the steam-cooled reactor shown below is 285 oF. The heat that must be
transferred from the reactor into the steam generation system is 2510 6 Btu/h. The overall
heat transfer coefficient for the cooling coils is 300 Btu/hft2oF. The steam discharges into a
25-psia steam header. The enthalpy difference between saturated steam and liquid condensate
is 1000 Btu/lb. The vapor pressure of water can be approximated by
T(oF) = 195 + 1.8P (psia)
T o s te a m
header
R e a c to r
S te a m
d ru m
C o o lin g
c o ils
Feed
C o n d e n s a te
P ro d u c t
1 /(8 s + 1 )2
+
1 /(1 + s )
C (s )
IV. Consider a tank in which a solution (w1, x1) containing 10 weight % salt is blended with a
concentrated solution (w2, x2) containing 42 weight % salt, to produce 100 lb/h of a solution
(w, x) containing 20 weight % salt at design conditions.
SP
m
w 1, x 1
V
m
SP
AC
FC
AT
FT
w 2, x 2
a) Determine the open loop steady state gain on the mass percent of salt in the product stream
for an increase of 2.0 lb/h in w2
b) Determine the closed loop steady state gain on the mass percent of salt in the product
stream for an increase of 2.0 lb/h in w2 (and w1 is reduced by 2.0 lb/h).
References
1. Process Modeling, Simulation, and Control for Chemical Engineers by Luyben
2. D.R. Coughanowr and S. LeBlanc, Process Systems Analysis and Control, McGrawHill, 3nd edition, 2008.