Process Control
Process Control
The resistances are linear. Note that two streams are flowing from Tank 1 to Tanks 1 and
2. You are expected to show clearly how you derived the transfer function.
a. For the unit step change in q, determine the deviation for H3(3).
b. For impulse change in q, determine the deviation for H2(3)
TANK 1:
Balance:
TANK 2:
Balance:
dh 1
dt
dh 1
A1
dt
q qa qb = A1
q
h1
Ra
h1
Rb
H1
Rb
h1
Ra
Deviation:
Q
dh 2
dt
dh 2
A2 dt
q a q 2 = A2
h
R2 =
2
Deviation:
H1
Ra
dH
A1 1
dt
H1
Ra
Laplace:
Q s
H1 s
Ra
H1 s
Rb
=R
= A1 sH1 s
Ra Rb
+R
a
b +R a R b A 1 s
3
3+4
dH 2
dt
Laplace:
Transfer function:
H1 s
Q s
R 2 = A2
0.75
0.75+1
1 3
3 1
= 1+3+ 1
H1 s
Ra
H2 s
R2
= A2 sH2 s
Transfer function:
H2 s
H1 s
R2
1+
2 2
2
H1
= 6+1
3
1 1+ 2 3
TANK 3:
Balance:
Solving a)
1
0.5
0.75+1 6+1
0.5
3 56
24 7
3 = +
0.75+1
6+1
4
1
4
3 = 0.5 + 14 3 7
3 =
dh 3
dt
dh
A3 dt3
q b q 3 = A3
h1
Ra
R3 =
3
3 3 = 0.1547
Deviation:
H1
Ra
R 3 = A3
3
dH 3
dt
Solving b)
2 =
Laplace:
H1 s
Ra
H3 s
R3
2 =
= A3 sH3 s
2 2.25
0.75+1 6+1
36
9
14 0.75+1
7 6+1
6
2 = 7 6 3
2 3 = 0.504
Transfer function:
H3 s
H1 s
R3
1+3 3
3
H1 s
2 3
6+1
2
3 1+ 3 2
Transfer Function:
2
Q s
2
Q s
3
Q s
3
Q s
=
=
=
=
H2
0.75
= 0.75+1
1
2.25
0.75+1 6+1
H3
0.75
= 0.75+1
1
0.5
0.75+1 6+1
6+1
2 3
6+1
Solving a)
Balance:
Solving b)
dT
mC dt
= hA(Ts T)
= 80 23 = 57
57
=
Deviation:
dT
mC dt
= hA Ts T
Laplace:
= 57(1 15 )
Laplace:
57
T s = 15s+1 Ts s = s(15s+1)
= + = 23 + 57(1 15 )
20
= 20 = 23 + 57(1 15 )
20 = 64.97
= ()
Transfer Function:
T (s)
Ts (s)
T (s)
Ts (s)
3.
1
+1
1
15s+1
= 1 2
1+2
12
= 2
1 =
2 1
2 =
+ 2 1
(1)
(1)
Solution:
= 41=2
4+1
41
= 2
= 1.25
4. Determine the values of K and k of the closed-loop system, shown in the figure below,
so that the maximum overshoot in unit-step response is 25% and the peak time is 2sec.
Assume that J=1 kgm2.
= 2
+ +
= 1.57
= 2
+ +
= , 2 =
Therefore,
= 2 = 1.722
1 2
= 0.25
1 2
= 1.72
= 2.958
2 2(0.404)(1.72)
=
2.958
Solving for ,
= 0.404
k = 0.469 sec
=2
5. A water tank with vertical sides and a cross-sectional of 2m2 (shown in the figure below)
is fed from a constant displacement pump, which may be molded as a flow source
Qin(t). A valve, represented by a linear fluid resistance (Rf), at the base of the tank is
always open and allows water to flow out. In normal operation the tank is filled to a
depth of 10m. When time is equal to zero the power to the pump is removed and the
flow into the tank is disrupted. If the flow through the valve is 10-6m3/s when the
pressure across it is 1N/m2, determine the transfer function of pressure at the bottom of
the tank.
+ =
where:
A Area of the tank
Density of fluid
g Acceleration due to gravity
=
+ = 0
2
1000 9.81
= 0
5
= 2.038 104
=
1
5
106
where:
0 = = 1000 9.81 1 2
0 = 9810 2
= 204
Answer:
1
1
=
+
= 9810
204
6. A homogenous system consists of 3 tanks. Tank 1 is nested inside the Tank 2 which is
connected to Tank 3. Heat is transferred by convection through the wall of inner tank.
The data are enumerated below:
a. The volume of Tank 1 is 1ft2 while 2ft2 for Tank 2 and Tank 3.
b. The cross-sectional area for all tanks is 1ft2.
c. The overall heat transfer coefficient is 8BTU/(hft2F)
d. The heat capacity of the fluid in each tank is 1BTU/(lbF). The density of each fluid
is 30lb/ft3.
The flow of heat is changed according to unit step from 0 to 300BTU/h. Determine
T2(s)/T1(s) and T3(s)/T1(s).
Tank 2:
Balance:
0 + 8T1 s = T2 s 13 + 60s
wC To Tref + hA T1 T2 wC T2 Tref = V2 C
dT2
dt
Deviation:
wCTo + hA T1 T2 wCT2 = V2 C
dT2
dt
Laplace:
wCTo s + hA T1 s T2 s wCT2 s = V2 CsT2 s
Transfer Function:
T2 s
8
=
T1 s
60 + 13
Tank 1:
Balance:
Q hA T1 T2 = V1 C
dT 1
dt
Deviation:
Q hA T1 T2 = V1 C
Laplace:
Q hA T1 T2
dT 1
dt
= V1 CT1
Tank 3
Q (s) 8T 1 + T2 = 30T1
Q (s) + T2 = T1 30 + 8
300
8
+ T1
= T1 30 + 8
60 + 13
300
8
= T1 30 + 8
60 + 13
Transfer Function:
60+13
T1 = 6 2 +2.9+0.36
T1
12 + 1 60 + 13
3
8
=
2
T1
720 + 216 + 13
2
1
8
8 = 200 + 25 200 5
8 = 164.67
The tank is 6ft in diameter, and the density of each stream is 60 lb/ft3. Suppose that a pulse
change in q1 occurs as shown below:
a) What is the transfer function relating H to Q1?
b) Derive an expression for h(t) for this input change.
Solution:
a) Assume that q is constant Material Balance over the tank,
dh
q1 q 2 q
dt
( Q1 Q 2 ) Q A
dH
dt
Laplace transform,
H(s)
1
Q1 (s) As
b)
2
As
s
s2
5
5
h ' ( t ) ts( t ) ( t 12)s( t 12)
A
A
h(t) 4
5
4 0.177 t
A
h ( t ) 4 (12) 6.122
A
0 t 12
12 t
(2+4)
= (4 2 +0.8+1)
Solution:
2
1
= 4(1 + )
2
(4 + 0.8 + 1)
8
4
=
+
(4 2 + 0.8 + 1) (4 2 + 0.8 + 1)
Step response + impulse response
Now, = 4 = 2 ; 2 = 0.8
= 0.2and = 2 = 2
Impulse response = 4 0.63 = 2.52
Step response = 8 1.15 = 9.2
4 = 1.26 + 9.2 = 10.46
10. When the system as shown in Figure (a) is subjected to a unit step input, the system
output responds as shown in Figure (b). Determine the values of K and T from the
response curve.
The maximum overshoot of 25.4% corresponds to = 0.4. From the response curve we
have,
tp= 3
=
=
=
1 2 1 0.4
n=1.14
From the block diagram, the closed loop transfer function is
()
= 2
() + +
Hence
n=
1
, 2n=
1
1
=
= 1.09
2 n 2 0.4 1.14
= 2 T 1.09 = 1.42
=3
11.
Problem: Obtain transfer functions C(s)/R(s) and C(s)/D(s) of the system shown above.
Solution:
U(s) = GfR(s) + GcE(s)
C(s) = Gp[D(s) + GlU(s)]
E(s) = R(s) - HC(s)
C(s) = GpD(s) + GlGp[Gf R(s) + Gc E(s)]
C(s) = GpD(s) + GlGp{GfR(s) + Gc[R(s) HC(s)]}
C(s) + GlGpGcHC(s) = GpD(s) + GlGp(Gf + Gc)R(s)
C(s) =
Gp D s + Gl Gp Gf + Gc R(s)
. 1
1 + Gl Gp Gc H
12. A step change from 15 to 31 psi in actual pressure results in the measured response from
a pressure-indicating element shown in the figure below.
a) Assuming second-order dynamics, calculate all important parameters and write an
approximate transfer function in the form
()
= 2 2
() + 2 + 1
Where is the instrument output deviation (mm), is the actual pressure deviation
(psi).
SOLUTION:
=
11.2 8
= 0.29 /
31 15
12.7 11.2
= 0.47
11.2 8
= 2.3
1 2
= 0.47,
2
1 2
= 0.234
= 2.3
1 0.2342
= 0.356
2
()
0.2
=
2
() 0.127 + 0.167 + 1
13. The caustic concentration of the mixing tank shown below is measured using a
conductivity cell. The total volume of solution in the tank is constant at 7 ft3 and the
density ( = 70 lb/ft3) can be considered to be independent of concentration. Let Cm
denote the caustic concentration measured by the conductivity cell. The dynamic
response of the conductivity cell to a step change (at t=0) of 3 lb/ft3 in the actual
concentration (passing through the cell) is also shown in the figure.
a) Determine the transfer function
()
1()
(w1 = w2 = 5 lb/min)
b) Find the response for a step change in C1 from 14 to 17 lb/ft3
c) If the transfer function
()
1()
SOLUTION:
a) Caustic balance for the tank,
= 1 1 + 2 2
1
+
70 7 + 10 49 +
()
()
+ 1
=
30
=1
3
= 6 = 0.1 min ( )
1
0.5
0.5
=
=
1
0.1 + 1 49 + 1
0.1 + 1 49 + 1
b)
1 =
= 1.5 1 +
1.5
0.1 + 1 49 + 1
(0.1
49 0.1
0.1
49
49
c)
=
0.5
3
1.5
=
49 + 1 49 + 1
= 1.5(1
49 )
14. A heated process is used to heat a semiconductor wafer operated with first-order
dynamics, that is, the transfer function relating changes in temperature T to changes in
the heater input power level P is:
()
()
+ 1
where K has units [C/kW] and has units [minutes]. The process is at steady state when
an engineer changes the power input stepwise from 1.0 to 1.5 kW. She notes the
following:
(i)
The process temperature initially is 80C.
(ii)
Four minutes after changing the power input, the temperature is 230C.
(iii)
Thirty minutes later the temperature is 280C.
a. What are K and in the process transfer function?
b. If at another time the engineer changes the power input linearly at a rate of 0.5
kW/min, what can you say about the maximum rate of change of process temperature:
When will it occur? How large will it be?
SOLUTION:
15. A surge tank is designed with a slotted weir so that the outflow rate, w, is proportional to
the liquid level to the 1.5 power; that is,
w = Rh1.5
where R is a constant. If a single stream enters the tank with flow rate wi, find the transfer
function H(s)/W(s). Identify the gain and all time constant. Verify units.
The cross-sectional area of the tank is A. Density is constant.
SOLUTION:
16.
Problem: The figure above shows a system with two inputs and two outputs. Derive C1(s)/R1(s),
C1(s)/R2(s), C2(s)/R1(s), and C2(s)/R2(s). (In deriving outputs for R1(s), assume that R2(s) is zero and
vice versa.)
Solution:
C1 = G1(R1 G3C2)
C2 = G4(R2 G2C1)
C1 = G1[R1 G3G4(R2 G2C1)]
C2 = G4[R2 G2G1(R1 G3C2)]
C1 =
G1 R1 G1 G3 G4 R 2
1 G1 G2 G3 G4
C2 =
G1 G2 G4 R1 + G4 R 2
1 G1 G2 G3 G4
C1
C2
G1
1 G1 G2 G3 G4
=
G1 G2 G4
1 G1 G2 G3 G4
G1 G3 G4
1 G1 G2 G3 G4 R1
G4
R2
1 G1 G2 G3 G4
When R2(s) = 0, the original block diagram can be simplified. Similarly, when R1(s) = 0, the
original block diagram can be also simplified
()
=
()
17. A tank with constant outlet flow is connected to a stirred tank as shown below. The
constant flow is 2ft3/min. The cross-sectional area and volume of each tank is 2ft2 and
1ft2 respectively. The feed with temperature T1 entered the first tank and maintain the
temperature as it enter the stirred tank.
a. Determine the transfer function H1(s)/Q(s) and T2(s)/T1(s).
b. For a unit step change in the flow rate, determine the height of the fluid in the
tank at t = 3min.
c. For an impulse change in inlet temperature of magnitude 2, determine the
deviation for T2(2).
TANK 1:
BALANCE:
DEVIATION:
1 1
DEVIATION:
= 1
TRANSFER FUNCTION
1
= 2
TANK 2:
BALANCE:
1 2 =
LAPLACE:
1 2 = 2
1 2 = 2
LAPLACE:
= 1 1
1 2 =
TRANSFER FUNCTION
2
1
Solving b)
1
2
1 1
1
1 =
= 2
2 2
1 =
2
1 =
= 2+
3
= 1.5
2
= + 1.5
= 4 + 1.5
= 5.5
2
2+ 1
4
2 =
2+
2 = 4 2
2 2 = 0.0733
1 3 =
2 =
Solving c)
18. Problem: Find the time response of a standard second order system
1
= 2 2
+ 2 + 1
to a step input when = 0 (underdamped).
Solution:
o =
o =
T 2 s2
i
+ 2(0)Ts + 1
i
T 2 s2
+1
H
+ 2
s2