ProcessControl

Universidad Central de Venezuela

School of Engineering
School of Chemical Engineering
Department of Design and Control
Process Control

Solved Exercise

It is desired to control the temperature of a reactor with continuous agitation, in

donde se lleva a cabo una reacción exotérmica; mediante la manipulación de la
amount of cooling water that passes through the coil (See Figure No. 1).
The operating conditions are as follows:

Temperatura del reactor : 210 ºF

Water flow for cooling: 350 gpm
Pressure drop in the coil: 10 psi
Temperature range of the transmitter: 180-230 ºF
Valve feature: Equal percentage valve, with a parameter of
range adjustment equal to 50. The actuator time constant equal to 0.20
min.

An open loop test was performed on the system and it was found that with a
an increase of 10 gpm in the water intake rate results in a drop of
temperature of 3 ºF, after a long period, which lasted ¼ of an hour.

Nutrition
CW

P1 =30psi Product

P2 =15psi

Figure 1 Complete Mix Reactor

a) Establish the control loop scheme according to ISA standards, for the
studied system and establish the type of controller to use. Justify.
yourselection.
b) Create a representative block diagram of the process.

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 Processcontrol

c) According to your analysis, establish the valve failure and the action of the
controller. Justify your response.
d) Determine the valve coefficient Cv, for a safety factor
of 2.
e) Build the transfer functions and adjust the controller
by the method of direct substitution and by the POMTM method.
Consider that all signals are electrical. Justify any.
assumptionthatrealice.
f) Find the deviation when a change is made at the point of
control (set point) for a temperature of 215 º F.

Answers

a)

P
TS TC TT
01 01

I/P
TY
01 Food
CW TCV
01

P1 =30psi
Product

P2 =15psi

The type of controler to be used is the PID controler. The reason for this
selection is mainly based on the fact that this type of controllers
in addition to having the advantage of correcting the effect of disturbances,
without producing any type of error in steady state (integral action),
it has the ability to anticipate future errors and introduce an action
appropriate (derivative action) producing a stabilizing effect for the
closed-loop response, thus avoiding pronounced oscillations such as
the responses of the PI controllers. Consequently, they are generated
faster and more robust responses. For this process that is characterized
due to having long response time constants, it is advisable then
a PID controller.

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 Processcontrol

b) Below is the Closed Loop Block Diagram.

F. T related to the Process

(Perturbations and V.M)
TI
Gp

TW
Gp

CAO Gp

Controller FI +++ T
Gp -
TC-01 -
Valve
Fw
TCV-01
mA mA gpm °F
TSP + Gc Gv Gp
-

Sensor/T
TT-01
mA H °F

c) Taking into account the safety of the equipment, it is determined that the
The control valve must remain open at the time of a failure.
system. This condition is established in order to always reduce the
temperature in the reactor since it is carried out there
exothermic reaction and to prevent damage to the equipment due to
overheating. In this analysis, the effect it has is not considered.
a marked decrease in temperature at the reactor exit
theprocess'downstream'.

Regarding the action of the controller, it is established that it must be of action

inverse. This action is established as the requirements of the process
They make it so that for an increase in temperature, it must be opened more.
valve in this way will allow the passage of a greater flow, and for
heat transfer, decrease the temperature of the reactor. As it is
the valve is air to close (ATC), that is to say, it fails open; to cause

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 ProcessControl

this effect on the reactor temperature with the water flow is

it is necessary for the output signal of the controller to decrease.
consequence as the controller signal must decrease at a
increase in temperature then it is established that the action of
the controller is inverse.

d) It is known that for liquids, the valve coefficient is determined at

part of the following equation:

ΔP
F= C v⋅
Gf
So to calculate theCvdesign conditions are given

Fmax
C v=
ΔP
Gf

Donde
ΔP= ΔP−Total
ΔP serpentine
= 15psi−10psi= 5psi
G f= 1
Fmax= 2 ⋅ Fop= 2 ⋅ 350 gallons per minute= 700 gpm

700 gallons per minute

C v= = 313.04 gpm/psi
5psi

e)TransferFunctions:

Sensor-Transmitter:

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fnashret

KH
H(s)=
τ ⋅ s+ 1
m
rnedsL
dsitaebyga:nic

Δexit
K H=
Δentry

(20− 4)mA
K H= = 0.32mA/°F
(230−180)ºF

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 Processcontrol

How is the response time established as data for the function of

transfer

0.32mA/ºF
H(s)=
0.8 minutes⋅ s + 1
Valve:

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onls:iosalufnretcT
fnashret

Kv
Gv(s)=
τ ⋅ s+ 1

To determine the gain of the valve, the following equation is used:

ΔP Vp−1
K V= CV→Vp=1⋅ lnα ⋅ ⋅α
Gf

Since the opening of the valve is not knownυ p), first it is calculated
mediate the following equation:

ΔP
F= CV→Vp=1⋅ α Vp−1 ⋅
Gf

5psi Vp−1
⋅
350 gallons per minute= 313.04gpm/psi⋅ 50
1

By solving the equation, it is found that the valve opening is:

υ p = 0.82

The calculation of the valve gain is proceeded with:

5psi
K V= 313.04 gpm/psi⋅ ln(50)⋅ ⋅500.82−1
1

K V= 1354.17gpm/(adim)

However, this profit only flows through the valve and

its opening. Now this opening of the valve is related
with the controller signal, in order to maintain consistency
of units. In this way, we can integrate these gains to
obtain the relationship between the flow that passes through the valve and the signal of

ElaboratedbyGustavoVilarroel
 Processcontrol

controller output. The following equations describe what is

commentedearlier:

K Valve= K v ⋅ K υ'
Where:

Kυ' Gain that relates the opening of the valve with the signal of
controller output.

Substituting values and relating the opening condition for a

a certain control signal is obtained:

gpm ⎛ (0−1A.V
) ⎞
K V= 1354.17 ⋅ ⎜⎜ ⎟⎟ = −84.64gpm/mA
A.V ⎝ (20− 4mA
) ⎠

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onls:iosalufnretcT
fnashret

− 84.64gpm/mA
GV(s)=
0.2 min⋅ s + 1

Process:

With the provided data, it can be assumed that the function of

transfer of the controlled variable with the manipulated one
it can be modeled as a first-order delay:

Δexit
K P=
Δentry

− 3⋅ºF
K P= = −0.3ºF/gpm
10gmp

For the calculation of the system response time, the following is considered:

t total= t process+ t dead

[Link]≅ 5 ⋅ τ P
So:

5 ⋅ τ P= τ TOTAL− τ D

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In this way:

15min− 0.4min
τ P= = 2.92 minutes
5
onih:euosnfrtcepT
rfnashret

− 0.3ºF/gpm⋅ e −0.4⋅s
G P(s)=
2.92 minutes⋅ s + 1

Once the transfer functions are obtained, the adjustment will be made
controller selected by the Z-N method settlement ratio 1/4
andtheZ-NPOMTMmethod.

• Closedloopmethod:

− 0.3ºF/gpm⋅ e −0.4⋅s − 84.64 gpm/mA 0.32mA/ºF

G P(s)= , GV(s)= , H(s)=
2.92 min⋅ s+ 1 0.2 minutes⋅ s+ 1 0.8 minutes⋅ s + 1

How is the presence of a dead time, in order to apply it.

characteristic equation, it should be applied to the process approximation of
Padé,whichindicates:

D
1− ⋅s
e − D⋅s = 2
D
1+ ⋅ s
2

0.4
1− ⋅s
2 1 − 0.2⋅ s
e −0.4⋅s = =
0.4 1 + 0.2⋅ s
1+ ⋅s
2

Substituting the transfer function of the process, it results in:

G P(s)=
(− 0.3ºF/gpm ) ⋅ (1 − 0.2⋅ s)
(2.92 minutes⋅ )s+
⋅ (0.2⋅
1 s+ 1 )

Applyingthecharacteristicequation:

1 + GC(s)⋅ GV(s)⋅ G P⋅ H ( s ) = 0

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 Processcontrol

Substituting:

(− 0.3ºF/gpm ) ⋅ (1 − 0.2⋅ s) − 84.64 gpm/mA 0.32 mA/ºF = 0

1 + K C⋅ ⋅ ⋅
(2.92 minutes⋅ )s⋅ (+11+ 0.2⋅ s) 0.2min⋅ s+ 1 0.8min⋅ s + 1

Performing mathematical operations, we have:

0.0931⋅ s 4+ 1.08⋅ s 3+ 3.86⋅ s 2+ 4.12⋅ s+ 1 + 8.18⋅ K C−1.64⋅ K C⋅ s = 0

Substituting:

s = i⋅ wu
K C= K See you

By direct substitution:

0.0931⋅ (i⋅ wu ) 4+ 1.08⋅ (i⋅ wu) 3+ 3.86⋅ (i⋅ wu ) 2+ 4.12⋅ (i⋅ wu) + 1 + 8.18⋅ K C−1.64⋅ K C⋅ (i⋅ wu) = 0

As:

i 4= 1
i 3= −i
i 2= −1
i= I

Substituting:
4 3 2
0.0931⋅ wu− 1.08⋅ i⋅ wu− 3.86⋅ i⋅ wu+ 4.12⋅ i⋅ wu+ 1 + 8.18⋅ K C− 1.64⋅ K C⋅ i⋅ wu= 0

Groupingtheimaginarytermsandseparatingthemfromtherealterms,
it is had:

0.0931⋅ w 4− 3.86⋅ w 2+ 1 + 8.18⋅ K C= 0

−1.08⋅ w 3+ 4.12⋅ w−1.64⋅ K C⋅ w= 0

Solving the system of equations gives:

K See you= 0.96mA/mA

Wu= 1.55 minutes−1

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 Processcontrol

ApplyingtheZiegler-Nicholsmethodofsettlementratioof¼:

Derivative time, Integral time,

Controller Profit, Kc τD τI
P 0.48 ------ ------
PI 0.44 3.34 ------
PID 0.56 2.03 0.51

• Open-loopmethod:

− 0.3ºF/gpm⋅ e −0.4⋅s − 84.64gpm/mA 0.32mA/ºF

G P(s)= , GV(s)= , H(s)=
2.92 minutes⋅ s + 1 0.2min⋅ s + 1 0.8 minutes⋅ s+ 1

To apply the open loop method, the practical rule must first be applied.
of approximation where:

τ = 2.92 minutes
τ D= (0.4+ 0.2+ 0.8)min= 1.4min
⎛ °F gpm mA⎞ mA
K= ⎜⎜− 0.3⋅ ⋅ −84.64 ⋅ 0.32 ⎟⎟ = 8.12
⎝ gpm mA °F ⎠ mA

ApplyingthePOMTMmethodofZiegler-Nichols,wehave:

Derivative time, Integral time,

Controller Ganancia,Kc τD τI
P 0.26 ------ ------
PI 0.231 4.66 ------
PID 0.308 2.80 0.70

f) To find the deviation when the control point changed to 215º F,

the final value theorem is applied, having as a function of
transfer the relationship between the controlled variable and the control point.

5
lims⋅ G(s)⋅
s→0 s
Where:

T(s)
G(s)=
Tsp(S)

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 ProcessControl

So:

⎡ Gc (s)⋅ GV(s)⋅ G p(s) ⎤ 5

lims⋅ ⎢ ⎥⋅
⎣⎢ 1 + G(s)⋅ G(s)⋅ G(s)sp ⎦⎥
s→0
c V

Given that the transmitter's dynamics are negligible and its gain is equal to
the unit. Substituting each F.T of the closed loop:

⎡ 1 KV Kp ⎤
⎢ K c(1+ τ ⋅ s + τ D⋅ s)⋅ τ ⋅ s+ 1τ ⋅⋅ s+ 1 ⎥
lims⋅ ⎢
I V p ⎥ ⋅5
s→0 ⎢ 1 KV Kp ⎥ s
⎢ 1 + K(1+
c
+ τ D⋅ s)⋅ ⋅ ⎥
⎢⎣ τ I⋅ s τ V⋅ s+ 1τ ⋅ s+p1 ⎥⎦

Evaluating and applying the limit yields:

5
lims⋅ G(s)⋅ =5
s→0 s
It is said that with the PID controler, a final temperature of:
T f= T+ ΔT= 210ºF+ 5ºF= 215ºF
dveonnehiltcw
T
et rnthew
laurbehafim
htevadtfrtpedi
fixed temperature system as control point:

Deviation= 215ºF− 215ºF= 0

It is then verified that there are no errors for a PID controller.

insteadystate(offset).

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