Chapter 13.

Simulation of Process Control Systems

Solutions to Problems 13-1 to 13-17

13-1. Simulation of Bird Mobile of Problem 2-9.

The differential equation representing the motion of the bird mobile is, from Problem 2-9: M d y ( t) dt
2 2

= M g k y ( t) + f ( t)
2

Solve for the highest derivative:

d y ( t) dt
2

= g +

f ( t) M

k M

y( t)

Integration of this second derivative results in: From the solution of problem 2-9: For this problem: y ( 0 ) = 100cm

d y ( t) dt

and a second integartion gives y ( t) cm s

2

M := 50gm

g = 980.7

k :=

M g 27cm

k = 1816

gm s
2

f ( t) = 0dynes

The period of oscillation is, as in the solution to problem 2-9: M k

Period := 2

Period = 1.043 s The number of complete cycles in 10 seconds is: 10s Period = 9.592

The simulation plot shows the same result.

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13-2. Simulation of a Pendulum

Application of Newton's Second Law of Motion: M g tan( ) = M d x ( t) dt
2 2

For small angles , from the geometry: tan( ) = sin( ) = x ( t) L

Substitute and simplify to obtain: d x ( t) dt g = 9.807

2 2

Mg sin2 x(t)
L := 0.8m x ( 0 ) = 0.1m

x ( t)

Mg

m s
2

M := 0.5kg

The solution of the differential equation:

s2 + g X( s) = 0 L
x ( t) = x ( 0 ) cos

Roots:

g r1. = i L

g r2 = i L g L

g t L
2 g L

(Table 2-1.1)

The frequency of oscillation is:

= 3.501 Hz

Period :=

Period = 1.795 s

The number of oscillations in 10 s is: 10s Period = 5.572

The simulation plot shows the same result.

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13-3. Simulation of Punctured Air Tank of Problem 2-23.

In Problem 2-23 the mass balance on the tank produced the following equation: V Flow through the orifice: d ( t) dt = wi( t) wo ( t)

wo ( t) = Ao 2 ( t) p ( t) p o

)
( t) = M Rg T p( t)

Ideal gas law, assuming constant temperature: Rg T V M

2

Substitute and solve for dp(t)/dt:

d p ( t) dt
3

(wi(t) wo(t) )
M := 29 gm mole p o := 101300Pa

Problem parameters:

V := 1.5m

Ao := 0.785cm Pa m
3

Rg := 8.314

mole K

T := ( 70 + 273.16)K

p ( 0 ) = ( 500000 + 101300)Pa

From the linearization of Problem 2-23, we know that the time constant is: V 2 := M Rg T 601300Pa 500000Pa

Ao 2 601300Pa p o

= 42.895 s

Assume the compressor is initially off and comes on after 200 s (five time constants) with the exact flow required to maintain the initial pressure: wi := Ao 2 M 601300Pa Rg T

(601300Pa po)

kg wi = 0.194 s

As predicted by the linearized model, the pressure reaches steady state in about 200 s.

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13-4. Simulation of the turkey temperature response of Problem 2-24.

From the solution to Problem 2-24, the differential equation obtained from an energy balace on the turkey is: M cv dT ( t) dt = A Ts( t) T( t)

The parameters, given in this problem are: cv := 0.95 BTU lb R

M := 12lb T( 0 ) = 535R

A := 3.5ft

Ts := 800R
8

:= 0.6 BTU hr ft R
2 4

:= 0.1718 10

By the linearization done in Problem 2-24, the time constant of the turkey is: := M cv 4 A ( 535R) Integrate the differential equation :
3

= 5.16 hr A
4 4 Ts( t) T( t) M cv

d T( t ) dt

Run the simulation for 25 hrs (five time constants). Simulate the oven as a step function from an inital temperature of 535R to 800R.

From the response, the time constant is much less than 5 hr. This is because the time constant gets smaller with temperature. At 800R it is: M cv := = 1.54 hr 3 4 A ( 800R) From the response, the actual time constant seems to be about 2 hr, which is more in line with how long it takes to cook a turkey.

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13-5. Non-isothermal Chemical Reactor of Section 4-2.3

Rearranging the model equations from Section 4-2.3: d cA( t) f ( t) = c ( t) cA( t) rA( t) dt V Ai lbmole := 453.59mole cA( 0 ) = 0.2068 lbmole ft
3

rA( t) = k o e d T( t ) dt d Tc ( t ) dt Design conditions: Parameters: =

Rg T( t)

cA ( t ) Hr Cp rA( t) U A Vc c Cpc U A V Cp

f ( t) V

( Ti ( t ) T( t ) )

( T( t ) Tc ( t ) )

T( 0 ) = 678.9R

fc( t) Vc

(Tci( t) Tc( t)) +

lbmole ft
3

( T( t ) Tc ( t ) )
f := 1.3364
8

Tc( 0 ) = 602.7R ft
3

cAi := 0.5975 V := 13.46ft

3

Ti := 633.5R k o := 8.33 10

min

Tci := 540R E := 27820 BTU lbmole

ft

lbmole min Cp := 0.88 BTU lb R

3

ft fc := 0.8771 min c := 62.4 lb ft

3

Rg := 1.987

BTU lbmole R BTU lbmole

:= 55

lb ft
3

A := 36ft

Hr := 12000

U := 75

BTU hr ft R
2

Vc := 1.56ft

Cpc := 1

BTU lb R

Check that initial conditions are at steady state (derivatives = 0):

E Rg 678.9R

rA := k o e f V f

0.2068

lbmole ft
3

4 lbmole

lbmole rA = 0.039 3 ft min

cAi 0.2068

lbmole ft
3

rA = 5.87 10 U A V Cp

ft min
3 R

(T 678.9R) V i
fc Vc

Hr Cp

rA U A

( 678.9 602.7 )R = 7.915 10 R min

min

(Tci 602.7R) +

Vc c Cpc

( 678.9 602.7 )R = 0.027

The following is the Simulink diagram for the reactor:

The following are the responses for a 0.25 ft3/min increase in process flow at 1 minute followed by a 0.1 ft3/min increase in coolant flow at 30 minutes.

Observe the inverse response in the reactor temperature for the change in process flow.
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13-6. Mixing Process of Problem 3-1

The model equation, from the solution to Problem 3-1: d cA( t) dt Problem parameters: = f1 ( t) cA1( t) + f2 ( t) cA2( t) f ( t) cA( t) A h mole cm
3

cA( 0 ) = 0.025 f := 100 gal min

mole cm
3

cA1 := 0.01 f1 + f2 = f

cA2 := 0.05

mole cm
3

Ah := 200gal

Total mass balance:

(assuming constant volume)

At the initial steady state:

f1 cA1 + f2 cA2 f cA = 0

c 0.025mole cm 3 A2 f1 := f c c
A2 A1 f2 := f f1 The folowing is the Simulink diagram for the mixer:

gal f1 = 62.5 min gal f2 = 37.5 min

The responses to a step increase in f1 from 62.5 to 67.5 GPM at 1 minute:

The concentration response is typical first-order with a time constant of approximately 2 min.

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13-7. Feedback control of composition in mixer of Problem 3-1

Introduce the following blocks from the Chapter 13c public nodels: Figure 13-4.1, F401Vlv1, control valve with time constant of 1 min, linear, maximum flow of 100 gpm, and initial condition of 37.5%C.O. Figure 13-4.3, F403PI, PI controller with initial condition of 37.5% CO. Figure 13-4.7, F407Trmr, transmitter with 1 min time constant, range of 0 to 1 mole/cm3, and initial condition of 0.025 mole/cm3 The controller was tuned for quarter decay ratio response with a gain of 20%CO/%TO and an intgral time of 1.5 min. This is the Simulink diagram of the loop (the mixer block is the one from Problem 13-5):

The response to a 5 gpm increase in f1 at 1 minute is:

The outlet flow increases by 5 gpm at 1 min and then the controller increases f2 to bring the outlet concentration back up to the set point. The high controller gain rsults in a very minor deviation of the outlet concentration from its set point.

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13-8. Isothermal reactor of Problem 3-2

The model equations, from the solution to Problem 3-2, are: d cA2( t) dt = f c ( t) cA2( t) kcA2( t) V A1

cA2( 0 ) = 0.5

lbmole ft
3

cA3( t) = cA2 t to Design conditions: f := 50

)
ft
3

min
3

cA1 := 2

lbmole ft
3

Problem parameters:

V := 150ft

Lp := 400ft

Di := 5.5in
3

Initial conditions at steady state: The Simulink diagram is given by:

k :=

f cA1 0.5lbmole ft

V 0.5lbmole ft

k = 1 min

The responses to a 5 ft3/min step increase in process flow are:

The concentration response shows a time constant of about 0.75 min, a dead time of a little over 1 min, and a steady state change of 0.38 lbmole/ft3. The values from the linear model are: := V f + k V Di Lp 4f
2

= 0.75 min

to :=

to = 1.32 min

c 0.5 lbmole A1 3 3 ft ft cA2 := 5 f + k V min

cA2 = 0.038 lbmole ft
3

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13-9. Flash drum of Problem 3-11

Rearranging the model equation developed in Problem 3-11: d x ( t) dt = 1 M ( F z( t) V y ( t) L x ( t) ) kmole := 1000mole x ( 0 ) = 0.4

F=V+ L y( t) = Design conditions: Problem parameters: At initial steady state: 1 + ( 1) x( t) kmole s 0.4 L := 5 kmole s V := F L V= 5 kmole s x( t)

F := 10

M := 500kmole y 0 :=

:= 2.5 z0 := V y 0 + L 0.4 F y 0 = 0.625 z0 = 0.513

1 + ( 1 ) 0.4

The Simulink diagram for this problem is:

The responses to a 0.1 step increase in feed composition are:

These are typical first-order responses with a time constant of about 50 s and a gain on x of about 1 which match the results of the linear model in the solution of Problem 3-11.

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13-10. Distillation tray of Problem 3-12

The model equations from the solution to Problem 3-12 are: d h ( t) dt = 1 f ( t) fo ( t) S i
1.5

)
2

fo ( t) = 0.415 w h ( t) Problem parameters: w := 3ft

2 g
1

S := 11.2ft fi := 30 min ft
3

Initial steady state conditions:

fo := fi

fo h 0 := 0.415 w 2 g

1.5

h 0 = 0.136 ft As the response is fast, convert time units to s by multiplying the derivative by 60 s/min. The Simulink diagram for the tray is:

The responses to a 20 ft3/min increase in inlet flow are:

The first-order response has a time constant of approximately 2 s and the steady-state change is about 0.054 ft. The time costant matches the one from the linerized model from the solution of Problem 3-12. Using the gain from that solution, the steady-state change in level should be: 20ft min
2 3 1 1

= 0.06 ft

close!

331.4ft min

The students can check the results for the change in 10 ft3/min.

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13.11. Blending tank of Problems 3-18 and 6-11

The diagram for the blender is essentially the same as for Problem 13-6 with slightly different notation and the following parameter and design values: 3 %CO := % kg kg kg m 3 c1 := 80 c2 := 30 c0 := 50 f := 4 V := 40m %TO := % 3 3 3 min m m m At the intial steady state: f = f1 + f2 c0 c1 f2 := f c2 c1 f c0 = f1 c1 + f2 c2 f1 := f f2 m f1 = 1.6 min
3 3

m f2 = 2.4 min

From the results of Problem 6-11, the ultimate gain and period are: %CO Kcu := 250 %TO Tu := 3.01min

From Table 7-1.1, for a series PID controller tuned for quarter decay ratio response: Kcu Kc := 1.7 I := Tu 2 D := Tu 8 %CO Kc = 147 %TO
3

I = 1.5 min

D = 0.38 min

Control valve (from F401Vlv1):

m Kv := 0.0542 min %CO Initial position: f2 Kv

v := 0.1min = 44.28 %CO 50 20 70 20

(Solution of Problem 6-11)

Transmitter (from F407Trmr):

T := 3min

Initial output:

= 60 %TO

The series PID Controller block is taken from the Public Model Library, F405PIDs The Simulink block diagram for the blender conentration control loop is:

The responses to a 0.1 m3/min increase in f1 are: The decay ratio is somewhat greater than 1/4. Students may adjust the controller tuning parameters to improve the response. Notice that the concentration can be controlled very tightly.

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13-12. Non-interacting tanks in series of Fig. 4-1.1

The model equations developed in Section 4-1.1 are: d h 1( t) 1 = f ( t) fo ( t) f1 ( t) dt A1 i

( (

h 10 := 2.5m

d h 2( t) dt

f ( t) f2 ( t) A2 1

)
f2 ( t) = Cv2 h 2 ( t)

h 20 := 2.5m

f1 ( t) = Cv1 h 1 ( t) Design conditions: Problem parameters: m fi := 5 min A1 := 9m

2 3

m fo := 2 min A2 := 9m f2 := f1 f2 h 20
2 3

At initial steady state:

f1 := fi fo f1 h 10

m f1 = 3 min Cv1 = 1.897 Cv2 = 1.897 m

2.5

Cv1 :=

Cv2 :=

min m
2.5

min

The linearized gains and time constants are: K1 := 2 h 10 Cv1 1 := 2 A1 h 10 Cv1 2 A2 h 20 Cv2 K1 = 1.667 min m
2

1 = 15 min

Cv1 h 20 K2 := Cv2 h 10

2 :=

K2 = 1

2 = 15 min

The Simulink diagram for this problem is:

The responses to a 0.2 m3/min step increase in inlet flow are:

The responses of the level and flow for the first tank are first-order with a time constant of 15 min. The gains are 1.0 for the flows and the steady-state changes in level are about 0.35 m, as predicted by the linear model: m K1 0.2 = 0.333 m min The responses for the second tank are second order with the same steady-state change in level, meaning that the gain K 2 is unity as predicted by the linear model.
3

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13-13. Interacting tanks of Fig. 4-2.1

The model equations developed in Section 4-2.1 are the same as for problem 13-12, except for the flow betwen the tanks: f1 ( t) = Cv1 h 1 ( t) h 2 ( t) Design conditions are the same except for the initial condition in tank 1: At the initial steady state: Cv1 := f1 h 10 h 20 h 10 := 5m Cv1 = 1.897 m
2.5

min

It can be shown that the gain of the inlet flow on the level in the second tank is the same as K1 in Problem 13-12. min K1 = 1.667 2 m The following is the Simulink diagram for the interacting tanks is series:

The responses to a 0.2 m3/min step increase in inlet flow are: The change in the level in the second tank is the same as in Problem 13-12. Students may want to study the effect of reducing the resistance between the two tanks by changing the initial condition on h1 and recalculating Cv1. For example, for h 10 = 2.6 m, Cv1 := f1 2.6m h 20 Cv1 = 9.487 m
2.5

min

The response of the second tank becomes first-order and the two tanks behave as a single tank.

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13-14. Non-interacting thermal tanks in series of Fig. 4-1.5

The model equations developed in Section 4-1.2 are: d T2 ( t ) dt d T4 ( t ) dt Design conditions: = fA V1 1

( T1 ( t ) T2 ( t ) ) ( )

=
3

f T ( t) + fB T3( t) fA + fB T4 ( t) V2 A 2
m 3 3 V1 := 5m V2 := 5m fB := 0 min T4 := fA T2 + fB T3 fA + fB
3

m fA := 1 min T2 := T1

T1 := 500K T3 := 500K T4 = 500 K K1 = 1 1 = 5 min 2 = 5 min

At initial steady state:

T2 = 500 K

This problem is linear with a gains and time constants: fB K2 := fA + fB 1 := V1 fA 2 := V2 fA + fB

fA K1 := fA + fB K2 = 0

The Simulink diagram for this problem is:

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The resposes to a 10 K step increase in inlet temperature are:

The response for the first tank is first-order with a unity gain and a time constant of 5 min, matching the theoretical model. The response for the second tank is second-order also with unity ain for these conditions. Students may study the effect of changing flows fA and fB and temperature T3 on these responses.

13-15. Interacting thermal tanks of Fig. 4-2.4

The model equations developed in Section 4-2.2, ignoring fB, are: d T1 ( t ) dt d T4 ( t ) dt =

f T ( t) + fR T4( t) fA + fR T2 ( t) V1 A 1
f + fR T1 ( t) T4 ( t) V2 A 1

)(

The design conditions and problem parameters are the same as in Problem 13-14, plus the recycle flow: m fR := 1 min
3

(The results for fR = 0 are identical to those of Prob. 13-14)

Note: In the model of Section 4-2.2, the recycle flow is assumed to be 0.2*(f A + fB). The Simulink diagram for this problem is:

The temperature responses for a 10 K step increase in inlet temperature are: The students should study the effect of the recycle flow on the responses. As the recycle flow is increased, the temperatures in the two tanks approach each other and the two tanks behave as one perfectly mixed tank with the combined volume of the two tanks. They should notice that increasing the recycle flow does not appreciably change the time to steady state, or the gain.

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13-16. Reactors with recycle of Problems 4-9 and 6-15

The model equatios are developed in the solution to Problem 4-9: d cA1( t) dt 1 f c ( t) + fR cA2( t) f1 cA1( t) k 1 cA1( t) V1 o Ao d cA2( t) f1 = c ( t) cA2( t) k 2 cA2( t) dt V2 A1 =

( (

cA1( 0 ) = cA10 cA2( 0 ) = cA20

1 1

Design conditions from Problem 6-15:

cAo := 7

lbmole ft
3 3

k 1 := 0.2min
3

k 2 := 0.2min
3

ft fo := 10 min For the base case let: ft fR := 10 min f1 := fo + fR cA20 = f1 cA10 f1 + k 2 V2

3

V1 := 125ft

V2 := 125ft

At the initial steady state:

ft f1 = 20 min

cA10 :=

fo cAo f1 + k 1 V1 fR f1 + k 2 V2 f1

cA10 = 1.726

lbmole ft
3

cA20 := The Simulink diagram for the reactors is:

f1 cA10 f1 + k 2 V2

cA20 = 0.767

lbmole ft
3

The responses to a 0.5 lbmole/ft3 step increase in inlet concentration with a recycle flow of 10 ft3/min are:

Students shall study the effect of changing the recycle flow as indicated in the statement of the problem. Notice that the initial steady state conditions vary with the recycle flow.

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13-17. Extraction process of Problem 4-6

The model equations developed in the solution to Problem 4-6 are: d c1 ( t ) 2 f1 ( t) = ci( t) c1 ( t) Ka c1 ( t) me c2 ( t) dt V

c1 ( 0 ) = c10 c2 ( 0 ) = c20

d c2 ( t ) dt Design conditions:

= Ka c1 ( t) me c2 ( t) m f1 := 5 min me := 3.95
3

2 f2 ( t) V kmole m
3

c2 ( t ) Rec := 90%
1

ci := 0.4

Problem parameters:

Ka := 3.646min

V := 25m

At the initial steady state:

c10 := ( 1 Rec) ci c20 :=

2 f1 ci c10 + Ka V c10 Ka me V

c10 = 0.04

kmole m
3 4 kmole

c20 = 1.2776 10

f2 :=

Ka V c10 me c20 2 c20

m f2 = 14088.6 min

The Simulnk block diagram for the extractor is:

The responses to a 1000 m3/min step increase in solvent flow are: Obviously the problem parameters are unreasonable. The large solvent flow makes for an almost instantaneous response of the extract composition. The effect on the raffinate composition is negligible, as the extract composition is essentially zero under the design conditions. Ask students to try more reasonable parameter values: me := 0.95 Ka := 209min
1

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