UNIVERSITI

(:.
7G I
"I'"EKNOL,
I' ETRONA S

DATE

EAB4233 - PLANT PROCESS CONTROL SYSTEMS

26th MAY 2010 (WEDNESDAY)

TIME

9,00 AM

COURSE

12.00 PM (3 HOURS)

INSTRUCTIONS TO CANDIDATES
1

Answer ALL questions from the Question Booklet.

2.

Begin EACH answer on a new page in the Answer Booklet.

Indicate clearly answers that are cancelled, if any.

3.
4.

Where applicable, show clearly steps taken in arriving at the solutions and
indicate ALL assUmptions.

fi.

Do not open this Question Booklet until instructed.

Note

There are THIRTEEN (13) pages in this Question Booklet including

the cover page and appendices.

i. vex'si't_: i
1311:

Te}: nc,. 4.og: i. PETRONAS

EA84233
a.

FIGURE QIa shows a preliminary process design for a liquidvapor separation process. The key variables to be controlled are
flow rate, temperature, composition and pressure for the flash
system.
Heat Exchangers

Vapor

Liquid

FIGURE Q1a
As a control engineer, you are assigned to the following tasks:
i.

Determine the sensors and final elements required to

control the important variables by sketching them on the
figure where they should be located.
[4 marks]

Propose TWO (2) control loops, in which each loop shall

satisfy either product quality or profit

as its control

objectives. Sketch the control loops and describe their

operations.
[6 rnarksj

EAB4233
b.

A heat exchanger with bypass is shown in FIGURE Q9 b.

Outlet
temperature,
T, (s)

FIGURE Qlb

Draw a block diagram showing the input-output relationship

of the system, in terms of temperature variable.
[2 marks]
ii.

Using

the diagram

obtained

in part

overall transfer function of the system,

transfer function for heat exchanger

and for CV2 is C:

S+1.

b(i),

determine

the

T-' (S
given that the
T0(s)-)

.2)
& CV 1 is G, (s) _
2s-1

Prove that the system is stable.

[3 marks]

iii.

Sketch and discuss the response of the system to a unit

step input.
[3 marks]

c.

Explain why control is necessary in process plants.

[2 marks]

EA84233
As a control engineer, you are assigned to perform diagnostic

a.

evaluations on your process plant. In order to do this, you need to

perform experiments and run several simulations on your plant
model. FIGURE Q2a shows the results from the experiments that
you have conducted on a chemical reactor.

70

Output

60

-E
CD
Q
0

50 C)
U,

+'"1'I.
"rn'hw4'. w 40

o
T

Q2fJ

:3
25 5
0

Input

10

50

100

10
150

Time (min)

FIGURE Q2a

r.

List the six steps procedures in obtaining the empirical

transfer function model identification of a process plant.
[3 marks]

ii.

State THREE (3) characteristics that validate the experiment

result in FIGURE Q2a to be used for process reaction curve.
[3 marks]

iii.

Determine the model parameters using Method Il.

(4 marks]

EAi84233
b.

The following Table 2b shows some portions of data coI ected in

an experiment. The initial inputs, X;, = X(0), and outputs, Y'S,
= Y(0)
to the system are 50 and 75 respectively. To perform statistical
modeling identification, the data needs to be restructured for
regression model fitting, first-order-with-dead-time model With dead
time of two sample periods. Complete the Table 2b.
Table 2b
Data collected in
experiment (original
rmt)
rime, tN I11Pr.
It, I C)Utp

n restrUctured format for regression

model fitting

xky
0

[4 marks]
Table 2c shows the restrits obtained after* the regression analysis

C.

done. The experiments were done tour times, each with

different sampled dead time, Gamma.
Table 2c
Gamma

0.5921
().5954

0.3216
03 213

Residual
9,7503
f.___
82__
85 _-8.4339
2.7763

Select the best coefficients and calculate the parameter values

of the given system using correlation coefficient calculation in
Appendix I. Justify your selection.
[4 ma rks]

ii.

From the answers obtained in part c(i), determine the transfer

function of the model.

2 marks]

EAB4233

The Bode plots of a flow feedback loop with K, _- 1.0 is shown in

_
FIGURE Wa.
d.

Using the Ziegler-Nichols closed-loop tuning correlations

shown

in

APPENDIX

11, determine

the

PID tuning

parameters.
[6 marks]
Another method to obtain the PID tuning parameters without
using the Bode plots is by using the Ciancone correlations.
Describe the procedures in obtaining the tuning parameters
using this approach.
[4 marks)
Hode C+iarya'5m

FIGURE Q3a

EAB423
t.

The dynarrric response shown in FIGURE Q3b was obtained by

introducing a step, set point change to a F'ID ccmtrr~ilar.

r ,.

W'nE_1.
ai'+'",
.,
'iCl

20

30

40

50

617

70

t30

l"hie (min)
FIGURE Q3b
Determine the settling time, decay ratio as well as the MV
variance of the system.

[3 marks]
Based on the descriptions in part (b)(i), recommend the
fine-tUning steps that you VvoUiC,
t ndertake to improve the
controller.
arks]

EAB4233
c.

A, dosed loop system is shown in FIGURE C33c. Using the final

theorem,

value

(V'
( )

lim sC.
"f"(s),
G
s-.

prove

that

PD

(proportional-derivative) controller cannot achieve zero offset due

The elements' transfer functions

to the disturbance, D(s), as t

are
G (s) -- RJ.
5

0. S.s D(s.

('1

0.2

().5
C; (s) _-.
d
(1.5s +-1

Jw

a
1.5s....

[4 marks]
D(s)

:,4)
SP(s) -...

>i,

------------

_.- --------

CV(s)

Ci2,
W;.,

(s)

CT (S)

____I
FIGURE Q3c

FAB4233
4.

a.

Design a realizable feedforward controller given that the process

and disturbance transfer functions are
d).16c

C.i

6,5,s+1

1 6e__".,
.3
;_, ._..
_..
_..
__... _

S..3s+1

For the stripping section of a distillation shown in FIGURE Q4b, the

objective is to maintain the bottom's parity, at a desired value. This
objective is commonly attained by controlling the temperature in
one of the trays (the column pressure is assumed constant) by
using the steam flow to the reboiler as the manipulated variable. A
usual "major" disturbance is the feed flow to the column.

FIGURE Q4b

Using the feedforward design criteria, select a suitable

feedforward variable to be introduced in the system.
[4 marks]

ii..

Sketch the feedforward controller connections and explain

how it will respond to the feed flow disturbance.

[4 marks]

EAB4233

OL

Briefly describe whether the dynamic compensation on the

feedforward controller to be a net lead or a net lag.

[2 marks]
C.

FIGURE Q4c shows the blending process of crude oil from two
different sources: Strearn A and Stream B. The two flow streams
must be regulated at a desired ratio to ensure the right product
blend.

Stream A

Bdended
product

Strearn B

FIGURE Q4c

Using only the equipment shown in FIGURE Q4c, design a flow

ratio control strategy to ensure the right composition for the
blended product. Describe the operating principles of your strategy.
[5 marks]
d.

Discuss the design criteria for implementing a cascade control.

[2 marks]

10

BA B4233

a.

The following transfer function were obtained from a step test

performed by manipulating the signals to the steam and product
valves, in, and rn1, respectively for an evaporator shown :,in
FIGURE Q5. The controlled variables are the product composition,
and feed flow, iv,R,As shown in the diagram, although there is a
control valve on the feed line, this valve must control the level
evaporator (l_C). This is because the feed is the largest of the three
flows in the system and thus it has the largest influence on the
level.
.

{f il')r

.
.,
i}. ';?l"-rr:

1`WC

------

---yC

f.is5,s--fl

Ik)',..
_.

a.so.,

1.ic"e'-aaa,
. _ ----

----'---,.

2.70s+1

?.97.s+1

Product

FIGURE Q5

Determine if any loop pairing can be eliminated based on

the sign of the relative gains. Explain why the eliminated
loop pairing(s)cannot be used for,control pUrposes.
[G rnarks]

Ci.

Determine which loop pairing could minirnize the effect of

interaction.State the relativegain for this pairing.
[2 marks]

i'l

EAB4233

iii.

Design the decouplers for this multivariable system and

explain their purposes.
arks]

Discuss the advantages of niultiioop approach in multivariable

control.
[3 marks]

c.

Describe reset wind-up and methods on overcoming this situation.

[4 marks[

- END OF PAPER -

12

EA84233

APPENDIX I
Y:.

nr,

/rrr<hrr.
+I

",!

[7 = (I---

(-V"
+

[: /}i

1?
r-

i..'ar.,:r; r, '; >

un. "<c, rrr.. "<I

"I " -,

b =_A, (I -F= O/ r1l

-2r!

r)

APPENDIX II

ZIEGLER-NICHOLS CLOSED LOOP TUNING CORRELATIONS

Controller

K,

P-only

Kl2

PI

K/2.2

P, 11.2

PID

K11.7

P/2.0

13

Pl8