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EH/JAN 2013/CHE624/642

UNIVERSITI TEKNOLOGI MARA FINAL EXAMINATION

COURSE COURSE CODE EXAMINATION TIME

PROCESS CONTROL AND INSTRUMENTATION CHE624/642 JANUARY 2013 3 HOURS

INSTRUCTIONS TO CANDIDATES 1. 2. 3. 4. This question paper consists of five (5) questions. Answer ALL questions in the Answer Booklet. Start each answer on a new page. Do not bring any material into the examination room unless permission is given by the invigilator. Please check to make sure that this examination pack consists of: i) ii) iii) iv) v) the Question Paper a one - page Appendix 1 a one- page Appendix 2 a one - page Appendix 3 an Answer Booklet - provided by the Faculty

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO This examination paper consists of 7 printed pages
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EH/JAN 2013/CHE624/642

QUESTION 1 (P02, C03, C3, C4) a) A unit step applied to a system generates the response in Figure 1 (Appendix 1). i) Determine the type of response. (2 marks) ii) Use the plot to label and determine the values of settling time, time of first maximum, rise time, decay ratio and overshoot. Show your work in Appendix 1 and submit it together with your answer's booklet. (10 marks)
UNIT Step Response

3 75

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i/ i \

I
i \r \ I

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i i I i

i
i i l i

'

1 '
i i i i

1 ' 1 '
i i I i i i i i

1
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i
i i I i

i
i i i i

i
i. t i i .

25
25 2
1.7$ 1.5 1.25 1

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/1

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i i

I \
'

I /
\ y i i i l 1 I i 7 i

Ti
1' I i

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i

i
i i i t l 1 i i i i

i
i i

i
i i

i
i i

i
i i i i l i I i i i

7
i i

T
i i

i
i i t i I v I i i i . 1 '

/ i i Jf i i 1 l l -4- i- + f t I I i 05j L JT i 7 'J i i 0J2S-! 0'1

r i < i i f I l 1- i . -1 I I I i I a i i i i i i

i f i i l f *.-- + I I i i i i i i

S 7 Time (sec)

10

11

12

Figure 1 Process response b) Graph in Figure 2 shows a response curve for a process with the following transfer function

(5/y-^
p

(1/^1)^+1

Determine how increment the value of A affects the response curve. Compare the responses and justify your answer. (8 marks)

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EH/JAN 2013/CHE624/642

tim*

1 0

15 t

time Figure 2 Process response

QUESTION 2 (P02, P06, C 0 1 , C02, C4, C5) a) Consider the typical control system for the double-effect evaporator shown in Figure 3. The evaporator is equipped with simple feedback control strategies.

Concentrated solution

Condensate

Condensate

Figure 3 Process Control for Double Effect-evaporator


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i) List ALL controlled variables and the corresponding manipulated variables for the double-effect evaporator. (4 marks) ii) Determine the correct pair of the valve fail-position (in consideration of safety) and controller action for control loop A and B. Justify your answer. (6 marks) b) Given the CSTR process in Figure 4. Develop the feedforward/feedback controller for disturbance rejection taking CA as controlled variable, Tc as manipulated variable and CAi and T| as disturbances. Draw the P&ID and block diagram. (10 marks)

F, CAi, T.

Fc* T CI

J
V

->F T
0
o [><<a o
c'
A

F, C A , T

Figure 4 CSTR QUESTION 3 (P06, C03, C04, C3, C5) a) Figure 5 (Appendix 2) presents an open loop test for a pressure control loop for which the test was performed three times sequentially with AMV=10%. Each sequential loop test was performed once the previous process had achieved steady state. The changes made to the manipulated variable (MV) are MVi, MV2 and MV3. The corresponding process response are A, B and C.

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< Ej > ; jft t


DSS'B a I -i -.1 . : 3-

Figure 5 Open loop test of pressure control loop

i) Calculate the response rates (RR) for process responses A, B and C. Show your work in Appendix 1 and submit it together with your answer's booklet. (9 marks) ii) Analyze the RR values in 3a (i) and justify why they have different values. (3 marks) iii) Propose an advanced control system that can be used to overcome problem in 3a (ii). Discuss how this advanced control system improves the controllability of controller. (5 marks)

b)

Consider the distillation column shown in Figure 6. In this column, the bottom product composition is regulated by adjusting the steam flows to the reboiler. Design a feedback control scheme that ensures the bottom product composition is maintained. (3 marks)

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c)

For the distillation column in 3(b), the level in the column must be maintained below the maximum level to avoid column flooding. It is more important that the column level be below its maximum than that the bottom product composition be at its set point. Propose a suitable control scheme for the distillation column. (5 marks)

^_^J
I
QUESTION 4 (P02, P06, C 0 1 , C02, C3, C5)

Bottom Product

Figure 6 Distillation Column

a) A flow control system need to be designed to maintain the inlet flowrate to a reactor. The flow control loop, consisting of an orifice meter in series with the control valve, a differential pressure transmitter, and a controller is to be designed for a nominal process flow of 180,000 scfh of air. Valve inlet conditions are 100 psig and 60F, and the outlet pressure is 80 psig. The valve has linear has linear characteristics and a square root extractor is built into the transmitter so that its output signal is linear with flow. The valve time constant is 0.06 min and the transmitter time constant is negligible. A proportionalintegral (PI) controller controls the flow. (Cf=0.9) i) Propose a feedback flow control system and draw a complete P&ID of the control system. (4 Marks) ii) Obtain the valve capacity factor, Cv and size it for 100% overcapacity. (9 marks) iii) If the installed control valve is an air-to-close valve and has constant valve pressure drop, determine the transfer function of the control valve. (4 marks) iv) Calculate the gain of the transmitter if it is calibrated for a range of 0 to 250,000 scfh. (3 marks) CONFIDENTIAL

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QUESTION 5 (P06,C01,C4, C5) *** Flue 0B9

FURNACE

2
-(FT) Gas

OIL IN - * OIL OUT

JL ITT]

(FC)./TC

Figure 7 Close-Loop System a) Develop a block diagram for the closed-loop system of Figure 7 for the specific situation in which the transfer functions are given as follow:

Gv(s) =

0.5* + l'

H^s) = 4, H2(s) = 6
r

(^

-5

i\

The inner controller is specified as a proportional controller with gain Kc2=5.0 and the outer controller is under PI control with Kc1=3.0 and Ti = 0.2. (6 marks) b) Determine the closed-loop transfer function equation relating changes in the temperature setpoint TSP (s) to the outlet temperature T(s). (9 marks)

END OF QUESTION PAPER


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APPENDIX 1

EH/JAN 2013/CHE624/642

UNIT Step Response

S.75 r/~ 2.5 2.25 2

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6 Tlm& (sec)

10

11

12

Figure 1 Process response

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APPENDIX 2

EH/JAN 2013/CHE624/642

Figure 5 Open loop test of pressure control loop

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APPENDIX 3

EH/JAN 2013/CHE624/642

Related Equation

f =C

W Gf / )

ft (scfh) =836 Cv Cf -L=(y-0.148


TJGT

1.63 APv
y=-

Cf V P

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Kv=T^-(lna) % \^100 (\ + kLclrl2iGf Kv=+T^r(^a)Cv 100


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Kv=+-^-cv^d v,maxv
100

kLc2vy^
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iAp

\Gf

K =+ C \^~ v m 1 0 0 ' \Gf

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