Process Control

P 9-4
UNIVER SI D A D DE CARTAG EN A

FACULTAD DE INGENIER A
PRO G RAM A DE ING ENIER A Q UMICA
A LVA R A D O , V. ; G A L L E G O , H . ; MA R R U G O , J . ; MA RT N E Z , H . ; N I E TO , Y. ;
PA L A C I O S , J .

Consider the jacketed continuous stirred tank reactor (CSTR) shown below. The
following information is obtained from testing the reactor and its control system:
The transfer function of the reactor temperature to the jacket temperature is a
first-order lag with a gain of 0.6C/C and a time constant of 13 min. The transfer
function of the jacket temperature to the coolant flow is a first-order lag with a
gain of -2.0C/(kg/s) and a time constant of 2.5 min. The control valve is linear
with constant pressure drop and is sized to pass 12 kg/s when fully opened. Its
time constant is negligible. The reactor temperature transmitter is calibrated for
a range of 50C to 100C and has a time constant of 1 min. The jacket
temperature transmitter is calibrated for a range of 0 to 100C, and its time
constant is negligible.

TC
101

Reactant

TT
101

TT
102

Coolant

Coolant

Product

Jacketed Reactor

a)

Decide on the proper fail position of the control valve and the action of
the controller for a simple feedback control loop with the reactor
temperature controller manipulating the position of the coolant valve.
Draw the block diagram showing all the transfer function and write the
closed-loop transfer function of the reactor temperature to its set point.
Pay particular attention to the signs wich must correspond to the fail
position of the valve and the controller action.

b)

Write the characteristic equation for the singe feedback loop and
calculate its ultimate gain and period by direct substitution.

c)

Design a cascade control system for the reactor temperature with the
jacket temperature as the intermediate process variable, specifying the
action of both controllers. Draw the complete block diagram for the
cascade control system showing all the transfer functions and their signs.

d)

Assuming a proportional slave controller with a gain of 2%CO/%TO, write

the transfer function for the jacket temperature loop and redraw the
block diagram with the jacket temperature loop as a single block.

e)

Using the simplified block diagram from the previous part, write the
characteristic equation of the reactor temperature loop in the cascade
control system and calculate the ultimate gain and period by direct
substitution.

In the table below are summarized the constants and parameters given by the excercise
Element
Reactor

Data
= 0.6
= 13

= 2
Jacket
Valve

= 2.5
= 12 /

Transfer function

0.6
13 + 1

2
2.5 + 1

: 50 100
Transmitter R
Transmitter J

= 1
: 0 100

+ 1

The proper fail position of the control valve is fail-open (FO).If there is an
electric fail in the control system, the refrigerant must continue flowing to the
jacket in order to avoid any overheating in the CSTR.
The action of the controller for the valve is reverse, because when there is an
increase in the reactor temperature, the refrigerant flow of the jacket must
increase too, and the fail-open valve needs air to close so it needs less air.

The transfer function for the valve is determinated

Decide on the proper fail position of
the control valve and the action of
the controller.

Gain
=

12 /
=
= 0.12
100 100 %

The transfer function for the transmitter R is determinated

Draw the block diagram showing all

the transfer function and write the
closed-loop transfer function of the
reactor temperature to its set point.

Gain

So, the transfer function is

(100 0)%
%
=2
100 50

2
=
+1

The block diagram that represents the system with all the transfer function is shown below

()

+
%

()
/

0.12

2
+1

2
2.5 + 1

()

0.6
13 + 1

()

From the block diagram, the following equations were obtained

=

= A

=

+ =

=
1 +

Replacing the transfer functions

1+

2
2.5 + 1

0.12

2
2

+1
2.5 + 1

0.6
13 + 1

0.12

0.6
13 + 1

0.144 + 1
2.5 + 1 13 + 1 + 1 + 0.288

Transfer Function of the characteristic polynomial is obtained

2.5 + 1 13 + 1 + 1 + 0.288 = 0

Considering an equation of 1st order

=
+ 1

Write the characteristic equation for

the singe feedback loop and
calculate its ultimate gain and
period by direct substitution.

With negligible time constant, and =

2.5 + 1 13 + 1 + 1 + 0.288 = 0
Developing

32.5 3 + 48 2 + 16.5 + 1 + 0.288 = 0

Using the direct substitution method, the values = y = are replaced in the characteristic equation

32.5 3 3 + 48 2 2 + 16.5 + 1 + 0.288 = 0

Then, solving for 2 = 1 and separating the real and imaginary parts

48 2 + 1 + 0.288 + 32.5 3 + 16.5 = 0 + 0

From this complex equation, we obtain the following two equations, because both the actual and the imaginary parts
must be zero.

48 2 + 1 + 0.288 = 0
32.5 3 + 16.5 = 0

If = 0.7125 = 81.13

= 81.13

At this gain, the loop response oscillates with a frequency of 0.7125 or a period of

2
2
=
=
= 8.81
0.7125

Initially the transfer function for the transmitter J is determinated.

The gain of the transmitter is given by

=

(100 0)%
%
=1
100 0

Assuming a first order lag with a negligible time constant, the transfer function
for the transmitter J is
= 1

Design a cascade control system for

the reactor temperature with the
jacket
temperature
as
the
intermediate process
variable,
specifying the action of both
controllers.

Action of the controllers:

Draw the complete block diagram

for the cascade control system
showing all the transfer functions
and their signs.

Reactor temperature controller (master): The action of the controller for the
valve is reverse, because when there is an increase in the reactor
temperature, the temperature fluid of the jacket must increase too, and the
fail-open valve needs air to close so it needs less air.

Jacket temperature controller (slave): The action of the controller for the
valve is reverse, because when there is an increase in the jacket temperature,
the coolant flow must increase too, and the fail-open valve needs air to close
so it needs less air.

TC
101
TT

Reactant

101

TT

TC

102

102

Coolant

Coolant

Product

Jacket CSTR with cascade control system

The block diagram that represents the system with all the transfer function for a cascade control system is shown below

%+

1 ()
% +

()

2 ()
%

1 ()
%

2 () 0.12
%

2
+1

()
/

2
2.5 + 1

()

0.6
13 + 1

()

Assuming that the slave controller is proportional with a gain of 2%CO/%TO

the block diagram can be simplified by writing a new function for the jacket
temperature loop to a single block.
The new transfer function for the jacket temperature loop is given by
=

Assuming a proportional slave

controller with a gain of 2%CO/%TO,
write the transfer function for the
jacket temperature loop and redraw
the block diagram with the jacket
temperature loop as a single block.

2
2.5 + 1

0.12 2 1 1

2
0.12 2
2.5 + 1
=
1
2
0.12 2 1 + 1
2.5 + 1

Given then, the proportional gain for the controller 2 = 2%/%

=
1 ()

2
0.12 2
0.48
2.5 + 1
=
2
0.12 2 1 + 1 2.5 + 1.48
2.5 + 1

Dividing the last expression for giving the proper form we obtain the simplified
transfer function

0.324
=
1 () 1.68 + 1

Redrawing the block diagram

()

%TO

1
-

1()
%/co

1()
%TO

0.324
1.68 + 1

2
+1

()
C

0.6
13 + 1

()
C

Transfer Function of the characteristic polynomial is obtained

1+

0.388
=0
1.68 + 1 13 + 1 + 1

Developing

21.84 3 + 36.52 2 + 15.68 + 1 + 0.388 = 0

Using the simplified block diagram
from the previous part, write the
characteristic equation of the
reactor temperature loop in the
cascade control system and
calculate the ultimate gain and
period by direct substitution.

Using the direct substitution method, the values = y = are

replaced in the characteristic equation

21.84 3 3 + 36.652 2 2 + 15.68 + 1 + 0.388 = 0

Then 2 = 1 separate the real and imaginary parts

36.52 2 + 1 + 0.388

+ 15.68 21.84 3 = 0 + 0

From this complex equation, we obtain the following two equations, because both the actual and the imaginary parts
must be zero.

36.52 2 + 1 + 0.388

=0

21.84 3 + 15.68 = 0

If = 0.8473

= 64.995

= 64.995

At this gain, the loop response oscillates with a frequency of 0.846 or a period of

2
2
=
= 7.415
0.8473