Department of Chemical Engineering

McMaster University
1280 Main Street West
Hamilton, Ontario L8S 4L7
Canada

FIRED HEATER DYNAMICS AND CONTROL WORKBOOK

By

Andrea Moore
San Yip
Seongkyu Yoon
Thomas Marlin

Section Topic Page

1. Introduction 2
2. Exercise 1. Process and Equipment Principles 4
3. Exercise 2. Open-loop Process Dynamics 4
4. Exercise 3. Closed-loop PID Control 5
5. Exercise 4. Student-defined Project 7
6. References 8

Appendix
A User’s Manual For Fired Heater Simulation 10
B MATLAB Controller Subroutine 15

Copyright © 2006 by T. Marlin

1
1. Introduction

Most engineers learn best by solving problems and by learning from prior experience; this is often termed
“experiential learning”. This workbook contains a set of experiential learning exercises covering
dynamics and control of a fired heater. You will be presented a set of problems to solve, and you will use
a combination of inquiry skills and simulation experiments in preparing your answers. The problems
begin with a new perspective on topics that you have seen in other courses, and they conclude with you
defining the final question and solving it.

The simulation has been programmed in MATLAB. (The programming was performed by Ms.
Andrea (DaSilva) Moore when an undergraduate and by Drs. San Yip and Seongkyu Yoon while they
were teaching assistants.) The simulation is designed to be menu-driven, so that you can consider this
close to an experimental system, without programming the process simulation. Guidance on the use of
the program is provided in Appendix A.

The fired heater in this exercise is shown in Figure 1 and associated data is given in Table 1. The
model conforms to the following assumptions.

1) the fire box gas has a uniform composition and temperature

2) the flame is well mixed
3) The process fluid travels through only one pass, one pipe without splitting
4) vapor phase dynamics in the firebox are negligible
5) the oxygen analyzer is continuous and without dead time
6) all controllers are digital and executed at the same period as the simulation time step
7) unsafe conditions can occur, but the simulation will not represent an explosion

The simulation is designed to accurately model responses for small and medium input changes. The
simulation includes combustion stoichiometry and reaction material and energy balances, radiation and
convection heat transfer, and thermal capacitance of the metal and brick refractory. As part of the program
development, the model was calibrated by comparison with an industrial-scale fired heater in a petroleum
refinery.

The simulation will not model extreme input changes, examples of which are given in the
following.
- start up and shutdown
- failure of equipment like blowers or pumps
- very low flows that could result in an unstable flame

Before beginning to consider the dynamic operation of any process, the engineer should
thoroughly understand the process and equipment principles. Some questions to help you review and
extend your knowledge are presented in the next section.

2
 Table 1. Key data for the fired heater.

Variable Value
Feed flow rate 0.122 m3/s
Feed temperature 214 °C
Fuel flow rate 0.49 Sm3/s
Fuel composition 100% Methane
Air flow rate 4.72 Sm3/s
Outlet temperature of fluid in coil 280.6 °C
Fire box (combustion zone) pressure -153 Pa, gauge
Flue gas oxygen 2.00 mole %
Flue gas temperature when entering 460 °C
the stack

flue gas

V600

A400
F600

feed
oil V600

P300
T300

F100
F200

air fuel gas

V200
V100

Figure 1. Fired heater

3
2. Exercise 1. Process and Equipment Principles

The questions in this section are designed to help you think about operating the process equipment.
Therefore, the design aspects that provide flexibility are emphasized. In addition, the equipment that are
essential for control - sensors and final elements (valves) - are covered. These topics complement and
reinforce the perspective more common in heat transfer courses, i.e., the steady-state design and
equipment sizing (e.g., heat exchanger area).

The questions are presented below. In determining answers, you are encouraged to use the
references available; textbooks, engineering handbooks, the WWW (Google), and the process control
WEB site PC-Education (www.pc-education.mcmaster.ca).

1. Describe two applications for a fired heater.

2. Why/when is a fired heater used rather than a steam heat exchanger?
3. Why does the pipe (coil) enter the heater above the radiant section?
4. Define energy efficiency and describe how it is calculated using process measurements.
5. The pressure inside firebox is lower than outside; why does flue gas exit without compression?
6. How is the best value of the air flow rate determined?
7. Describe potential unsafe operating situations and how they are avoided.
8. A fired heater may have more than one burner. Discuss why.
9. A coil in a fired heater may be split into several pipes that pass through the heater and are
combined at the exit of the heater. Discuss why this design might be used. Do you expect
challenges with this design?
10. Flue gas exits to the environment via the stack at a high temperature. How might more energy be
recovered from the flue gas by heat transfer, with the effect of reducing fuel consumption?
11. Discuss factors that determine the minimum temperature of the flue gas as it leaves the fired
heater convection section.
12. Determine the physical measurement principle for each of the following sensors used for
distillation control and briefly explain why this is an appropriate choice. Note that several correct
answers may be possible.
a. air flow rate (F100)
b. Coil outlet temperature (T300)
c. pressure of the fuel gas after the control valve (not shown on drawing)
13. What type of valve body to you recommend for the feed flow rate? The fluid does not contain
solids, does not vaporize and has moderate viscosity.

3. Exercise 2. Open-loop dynamics

This question is to be answered using programs provided in MATLAB to simulate a fired heater. Directions
for the use of the programs are provided in Appendix A. In this problem, you will evaluate the dynamic
responses for the cases defined below and analyze the results based on your chemical engineering training.
Later, you will use the results of your open-loop tests in designing and tuning feedback digital PID
controllers for this system.

For this question, you will enter your changes via interactive menus. You need to change the
variables that determine the size of the step changes, and you might need to change the length of the
simulation to capture the entire dynamic response. All sensors are functioning, but the composition
controllers are not implemented even though the menu for the controllers exists. In later exercises, you will
continue with the same distillation tower (and simulation) by programming the controllers and tuning them.

4
 In these exercises, you are to use process reaction curve Method II, as defined in the textbook
Section 6.3 (Marlin, 2000), to fit first order with dead time dynamic models.

Your solution will report plots, show calculations, and report model structure with parameters (e.g.,
gain, time constant and dead time) for exercises a-e.

a. Determine the dynamic responses for a step change in the fuel valve of + 1% opening.
b. Determine the dynamic responses for a step change in the air damper of + 1% opening.
c. Determine the dynamic responses for a step change in the stack damper of + 1% opening.
d. Determine the dynamic responses for a step change in the process fluid valve of + 1% opening.
e. Determine the dynamic responses for a step change in the fuel valve of – 4% opening.
f. Based on results in parts (a-e), describe the qualitative relationships between the four valves in a to
d above and the following dependent measured process variables.
- Coil outlet temperature (COT)
- Flue gas oxygen
- Fire box pressure
- Feed flow rate
- Fuel flow rate
- Air flow rate

Present your conclusions in a matrix defined by the valves in the columns and the variables in the
rows. Use the results in cases a to d. Each entry in the matrix will be one of the following.
X = strong causal relationship
0 = no causal relationship
? = very weak casual relationship

Discuss your results concisely. Are you surprised by any of the results?

g. For each valve, determine a linear dynamic model between the valve and one measured variable;
you may use a graphical method for parameter estimation. The model you select must be one that
represents an X in the matrix defined in f above.

Recall that feedback control is not yet possible, although a menu exists for changing controller
parameters. In the next exercise, you will program the controllers, tune them (using results from this
exercise) and evaluate closed-loop performance.

4. Exercise 3: Closed-loop PID control

This question is to be answered using programs provided in MATLAB to simulate a fired heater; refer to
Appendix A for directions on using the program. This assignment follows Exercise 2. Be sure that the
parameters in submenu 1 are the same as used in the Exercise 2, and before running dynamic cases,
calculate the steady-state conditions using submenu 1, item 31! You will investigate the multiloop
feedback control of the fired heater in this problem.

Before performing the following exercises, you must program all of the PID controllers.
Submenu 4 is provided for the composition controllers and will function if you use the variables defined
for the tuning constants, initialization, etc. Directions and hints for programming are provided in this
handout.

Perform the following exercises and prepare a solution documenting programming, intermediate
calculations, and discussion of results. Provide a copy of your subroutine with your assignment.

5
a. Based on the open-loop dynamic experiments performed previously, calculate the tuning for the
two single-loop composition controllers (T300 controller by adjusting the fuel valve and P300 by
adjusting the stack damper). Recall that the controllers are executed with a period of 5 seconds.

Enter the tuning for both controllers via main submenu 3. (Remember to clear all step changes in
main menu item 2.)

b. Set all controllers in manual or "OFF", i.e., not in service, except for the COT (T300) controller.
The COT controller should be ON. In separate runs, determine the dynamic responses for the
following scenarios.

1) A set point change in COT of 2 degrees,

2) A set point change in COT of 20 degrees, and
3) A disturbance in fuel composition (to 80% methane and 20% ethane)

Use the tuning determined in (a) with any fine tuning you deem necessary.

c. With both COT and pressure controllers in automatic or "ON", determine the response of the
system to the same three inputs; you may further fine tune the controllers as needed.

d. If any of the dynamic responses are clearly unacceptable in (c) above, modify the control system
to achieve acceptable performance. (Corrective action could involve changing tuning, changing
loop pairing, or implementing other controllers.)

e. Compare and discuss the control performances in COT achieved in response (b) with (c) and (d).

Hints for programming your controllers are given in the following, because you need to prepare
before programming!

• First, read the attached subroutine so that you understand the variables and options within the
program.
• Second, review the digital forms of the PID controller.
• Third, prepare a flowchart of the code that you plan to write.
• Fourth, prepare hand calculations of the controller that can be used to check the program.
• Fifth, plan your solution, specifically, which variables are (i) communicated in or from the
subroutine, (2) local and must be stored between subroutine executions, and (3) local and need not be
stored
• Sixth, include displays of intermediate results in your code so that you can confirm your excellent
results (or find and correct a bug). Values of variables can be displayed in digital form in the
MATLAB window using the display function. A sample of a statement is given in “disp(VALVE)
;”, which prints values of the vector variable VALVE in the MATLAB window. These can be
removed when your results are satisfactory.

Retain a copy of your subroutine: you will need it for the next exercise.

You should be sure that your code is calculating the correct values before you send values back to the
distillation process simulation. This rule is especially true when working with the real process!

6
i) Appropriate initialization for the PID algorithm should be included; a variable (CTLINIT) is
provided to designate the first time the calculations are executed.
ii) Anti-reset-windup protection must be provided.
iii) The control calculations should function when TI=0, even though TI appears in the denominator;
prepare your program so that setting TI=0 turns off the integral mode.
iv) Remember that values of local intermediate variables, i.e., those not appearing in the function call
or GLOBAL statements are not retained for subsequent executions. Thus, variables like the
previous error or previous CV must be stored by you. Some extra GLOBAL variables SAVE?
are provided for this purpose. They can be used as scalars or vectors.
v) Do not use the variables STORE or k that are transmitted to the subroutine.
vi) The comment number 4 (under calculations) describes the behaviour of the controller after you
have completed your program. You must check in this subroutine whether the control
calculations should be executed based on the controller status that is transmitted to the controller
at every execution.

5. Exercise 4. Control Case Study

In this assignment, you will modify the process design and/or control system. You may select one of the
proposed exercises, or you may propose an exercise of your own design. The modified control design
must be described, programmed, tuned (based on new process reaction curves, as needed), and the
performance of the new design evaluated by dynamic simulation of the nonlinear process.

Only one group can perform each exercise, and the instructor will make the allocation based on
your completed project selection forms.

The group members will present the group's results in a brief (10 minute) oral presentation. The
group may prepare up to 5 power point slides for use as visual aids. (Students missing the class and not
presenting an acceptable reason in writing will receive zero for the assignment.)

The written report should be concise (not more than four pages of typed text, not including the cover,
subroutine listing, presentation hardcopy, and plots) and provide the following, in addition to a statement
of the study goals.

a. An explanation of the algorithms used for control.

b. Discussion of additional modelling required, e.g., process reaction curve experiments and
calculations.
c. A discussion of the control performance obtained. Compare with the previous results, as
appropriate.
d. A hard copy of the presentation visual aids.
e. A summary of what you learned. How did the system perform, why, conclusions, unsolved
mysteries. What principles have you reinforced and what generalizations can you support based
on these results?

SOME HINTS

1) Start early! (Have you heard this before?)

2) You can arrange to see the instructor with a plan before beginning the detailed work.
- The plan will not be graded.
- Use outline or bullet format, hand-written in preparation for discussion with instructor.
- Prepare a plan for changes in menu-entered data.

7
 - Prepare a plan documenting the new control equations and where they will be programmed,
empirical modelling cases, and tuning procedures.
- Explain what you will look for in your simulations, i.e., what are the expected results.
- Refer to the programming hints in Section 4.
3) Do NOT copy long sections of the text into your written report. Be concise!

CANDIDATE FIRED HEATER STUDIES

For all fired heater control studies, the base process is the same as for the previous studies. All systems
should have feedback control of the coil outlet temperature (T300), the flue gas oxygen and the fire box
pressure. Control performance should be investigated for the following changes.

1) A +20% increase in feed flow rate,

2) A change from 100% methane fuel to 80% methane and 20% hydrogen, and
3) An increase of 15 K in the coil outlet temperature.

A. Feedforward control for flow– You will provide feedforward compensation for changes in the
feed flow rate. You will retain all feedback control.

B. Feedforward control for feed temperature - You will provide feedforward compensation for
changes in the feed flow rate. You will retain all feedback control. You must simulate the
following additional case.

- A disturbance of –20K in the inlet oil temperature.

C. Air/fuel ratio – We have seen that the air and fuel flows should be maintained in proportion. Add
a ratio controller without losing feedback control of any of the three key variables.

D. Adaptive tuning – The tuning of feedback controllers could be compensated for changes in
dynamics due to changes to the furnace oil flow rate. Determine the needed tuning
compensations and program them so that the tuning is adjusted for changes in oil flow. You will
have to demonstrate the your tuning is good for flow rates from 50% to 110% of the base case
value.

E. Exercise defined by group - Any group may propose an exercise, which must be accepted by the
instructor.

6. References

Heat transfer fundamentals

Cengel, Y., Heat Transfer, A Practical Approach, WCB McGraw-Hill, New York, 1998.

Fired heater equipment design and operation

API, Measurement of Thermal Efficiency of Fired Process Heaters, API Recommended Practice 532, American
Petroleum Institute, Washington, 1982.

8
Berman, H. Fired Heaters – I. Finding the Basic Design for Your Application, Chem. Engin., pg. 99-104 (June 19,
1978).
Berman, H. Fired Heaters – II. Construction Materials, Mechanical Features, Performance Monitoring, Chem.
Engin., pg. 87-96 (July 31, 1978).
Berman, H. Fired Heaters – III. How Combustion Conditions Influence Design and Operation, Chem. Engin., pg.
130-140 (August 14, 1978).
Berman, H. Fired Heaters – IV. How to Reduce Your Fuel Bill, Chem. Engin., pg. 165-169 (September 11, 1978).
Reed, R., Furnace Operations, Gulf Publishing, Houston, 1981.

Combustion control

Dukelow, S., Trying to Save Energy? Don’t Neglect Your Process Heaters, Intech, pg. 35-39 (1981).
Kunz, R., D. Smith, N. Patel, G. Thompsin, and G. Patrick, Control NOX from Your Furnaces, Hydrocarbon Proc.,
pg. 57-62 (1992).

Fired heater dynamic simulation

Aspen, Aspen Dynamics™ and Aspen Custom Modeller™, Aspen Technology, 10 Canal Park, Cambridge, MA,
1999.
Hyprotech, HYSYS.PLANT v2.0 Documentation, Dynamic Modelling Manual, Hyprotech Ltd., Calgary, 1998.
Marlin, T., The Software Laboratory, Version 3.0, McMaster University, Hamilton, 1999.
Roffel, B. and J. Rijnsdorp, Dynamics and Control of a Gas-fired Furnace, Chem. Eng. Sci., 29, pg. 2083-92 (1974).
Stehlik, P., J. Kohoutek, and V. Jebacek, Simple Mathematical Model of Furnaces and Its Possible Applications,
Comp. Chem. Eng., 20, pg. 1369-1372 (1996).

Fired heater control

API, Manual on Installation of Refinery Instruments and Control Systems, Part III – Fired Heaters and Inert Gas
Generators, API Recommended Practice 550, American Petroleum Institute, Washington, 1977.
Jensen, J., Combustion Safeguards for Gas- and Oil-Fired Furnaces, Chem. Eng. Prog., pg. 77-85 (October 1978).
Kane, L., Combustion Control and Analyzers: What’s Really Needed, Hydrocarbon Proc., 65-68 (June 1980).

Industrial Instrumentation

Andrew, W. and H. Williams, Applied Instrumentation in the Process Industries, Volume I, A Survey (2nd Ed.), Gulf
Publishing, Houston, 1979.
Andrew, W. and H. Williams, Applied Instrumentation in the Process Industries Volume II, Practical Guidelines
(2nd Ed.), Gulf Publishing, Houston, 1980.
Driskell, L., Control Valve Selection and Sizing, ISA Publishing, Research Triangle Park, 1983.
Marlin, T., et. al., PC_Education WEB site, www.PC-Education.mcmaster.ca , 2006

9
 Appendix A. User’s Manual for Fired Heater Simulation

The fired heater simulation requires MATLAB version 7.0 or higher and all of the files stored in the
McMaster JHE system under the course 3E04 in the "K:\" drive in subdirectory "fhtr_2006". If you want to
perform the study on your home computer using a student version of MATLAB, copy all files in
"fhtr_2006" to your home computer.

The heater simulation has been developed to be menu-driven for most parameters you will input
during these exercises. (As you will see, later exercises will require some limited programming.) After you
have started MATLAB and defined the correct MATLAB folder for the m-files, you can start the program
by typing fhtr and enter. The screen will clear and the main menu will be displayed as shown below.

*******************************************************************************
* FIRED HEATER SIMULATION *
* Ver 2.0 *
* *
* Department of Chemical Engineering *
* McMaster University *
* September 1999 *
*******************************************************************************

1) Define Initial State

2) Define Step Changes for DV & MV
3) Controller status, Tuning and Size of SP Changes
4) Simulation Events1 (Under construction)
5) Simulation Events2 (Under construction)
6) Start Simulation
7) Plot a Previous Simulation
8) Load a Base Case
9) Save a Base Case
10) QUIT TO MATLAB
PLEASE ENTER A SELECTION :

The first item allows you to modify the process design and solve for the initial steady-state
operating conditions. You should enter the data given in the following copy of submenu 1.

10
*********************************************************************************************
* Define Initial State *
*********************************************************************************************

CURRENT INITIAL STEADY-STATE:

Air Flowrate .............. 4.70 m^3/sec Fuel Flowrate ............. 0.50 m^3/sec
Firebox Pressure ......... -181.0 Pa O2 in Stack flue Gas ..... 1.949 mpct
COT ...................... 284.6 degC Process Fluid Flowrate ... 0.122 m^3/sec
CO2 in Stack Flue Gas ..... 8.620 mpct Bridgewall Temperature ... 229.4 degC

WHICH OF THE FOLLOWING PARAMETERS WOULD YOU LIKE TO CHANGE?

Oil Inlet Temperature & Pressure Present Values
1) Oil inlet temperature .................... 214.0 degC
2) Oil inlet pressure (1600 - 2500 kPa) ...... 1600.0 kPa
Valve Opening
11) Air damper .............................. 46.50 pct open
12) Fuel valve .............................. 20.80 pct open
13) Process fluid valve ..................... 60.00 pct open
14) Stack damper ............................ 25.00 pct open
Fuel Composition
21) CH4 fraction ............................ 1.000 molfrac
22) C2H6 fraction ........................... 0.000 molfrac
23) H2 fraction ............................. 0.000 molfrac
Updating Steady State Condition
31) Calculate New Steady-State
99) Quit to main menu
PLEASE ENTER A SELECTION :

REMEMBER TO SOLVE FOR THE STEADY-STATE

OPERATION USING SUBMENU ITEM 31 BEFORE LEAVING
THIS SUBMENU!

You can define step changes to various variables using submenu 2. These changes will be
introduced during the dynamic simulation; these changes will define process reaction curves (changes to
manipulated variables) or disturbances (changes to uncontrolled inputs). For each variable, you define a
step size and time for introduction of the step. All steps are introduced, so a zero size should be given for
those variables that you want to be unchanged. More than one variable step may be nonzero. A sample of
the submenu with one step defined is given below; the opening of the fuel valve is changed by –2% at a time
of 50 seconds.

Remember to enter the desired change from the base case (initial steady-state) value!

11
*********************************************************************************************
* Define Time and Size of Step Disturbance Changes *
*********************************************************************************************

CURRENT INITIAL STEADY-STATE:

Air Flowrate .............. 4.70 m^3/sec Fuel Flowrate ............. 0.50 m^3/sec
Firebox Pressure ......... -181.0 Pa O2 in Stack flue Gas ..... 1.949 mpct
COT ...................... 284.6 degC Process Fluid Flowrate ... 0.12 m^3/sec
CO2 in Stack Flue Gas ..... 8.620 mpct Bridgewall Temperature ... 229.4 degC

WHICH OF THE FOLLOWING PARAMETERS WOULD YOU LIKE TO CHANGE?

Size of Disturbance Change
Disturbance in Fuel Composition
1) CH4 fraction (dDV) ................. 0.000 molfrac
2) C2H6 fraction (dDV) ................ 0.000 molfrac
3) H2 fraction (dDV) .................. 0.000 molfrac
Disturbance in Pressure and Temperature
4) Oil inlet temperature (dDV) ........ 0.000 degC
5) Oil inlet pressure (dDV) ........... 0.000 kPa
6) Fuel gas source pressure (dDV) ..... 0.000 kPa
Size of Valve Change
11) Air damper (dOP) .................. 0.00 open%
12) Fuel valve (dOP) .................. -2.00 open%
13) Stack damper (dOP) ................ 0.00 open%
14) Process fluid VLV (dOP) ........... 0.00 open%
Returning to main menu
99) Quit to main menu
PLEASE ENTER A SELECTION :

The simulation can be executed by selecting the simulation submenu, main menu item 6. The first
two entries are the total time for the simulation and time step used in solving the process simulation. For
this exercise, do not change the values of entry 2, the time step. The total time is initialized to a
reasonable value, but you can change this value if necessary.

*****************************************************************************************
* Define Step Changes *
*****************************************************************************************

WHICH OF THE FOLLOWING PARAMETERS WOULD YOU LIKE TO CHANGE?

Runnung Parameter Present Values

1) Total simulation time ....... tend ...... 600 sec
2) Simulation time step ........ delt ...... 5 sec
Simulation and Returning to main menu
31) Start simulation
41) Replot current results
99) Quit to main menu
PLEASE ENTER A SELECTION :

When you select submenu item 31, you are asked to provide a case name (without extension),
which is used as the file name for saving the results for later retrieval; the extension will be “.MAT”. You
should provide a unique name, because the program will overwrite (without a warning) the contents of
any existing file with the same name in the default folder that exists in the active MATLAB path directory.
Therefore, name each case that you want to save with a unique name, such as “Marauder_Case_2a”.

When the simulation is being executed, numerical values are displayed on the screen to give you an
update on the case. This enables you to recognize and stop any case that is clearly wrong due to incorrect
data input. The variables displayed are summarized below.

12
 SimTime AIR FUEL FBPres %O2 COT HOIL
30 4.70 0.505 -181.0 1.949 284.64 0.122
60 4.70 0.505 -181.0 1.949 284.64 0.122
90 4.70 0.505 -181.0 1.949 284.64 0.122
120 4.70 0.505 -181.0 1.949 284.64 0.122
150 4.70 0.505 -181.0 1.949 284.64 0.122
180 4.70 0.505 -181.0 1.949 284.64 0.122
210 4.70 0.505 -181.0 1.949 284.64 0.122
240 4.70 0.505 -181.0 1.949 284.64 0.122
270 4.70 0.505 -181.0 1.949 284.65 0.122
300 4.70 0.505 -181.0 1.949 284.65 0.122
330 4.70 0.505 -181.0 1.949 284.65 0.122
360 4.70 0.505 -181.0 1.949 284.65 0.122
390 4.70 0.505 -181.0 1.949 284.65 0.122
420 4.70 0.505 -181.0 1.949 284.65 0.122
450 4.70 0.505 -181.0 1.949 284.65 0.122
480 4.70 0.505 -181.0 1.949 284.65 0.122
510 4.70 0.505 -181.0 1.949 284.65 0.122
540 4.70 0.505 -181.0 1.949 284.65 0.122
570 4.70 0.505 -181.0 1.949 284.65 0.122
600 4.70 0.505 -181.0 1.949 284.65 0.122

At the completion of each simulation case, the results are plotted automatically and also stored in
the file named at the beginning of the case. A sample of the plots is given in Figure 2. You can repeat the
plot of any saved simulation by selecting main menu item 7 and entering the name of the appropriate stored
case. The plot provides the following three graphs:

- the fuel and air valves with the measured fuel and air flows
- the fuel valve and stack damper with the measured COT and flue gas % oxygen
- the feed valve and stack damper with the measured feed flow and fire box pressure
- the common disturbances: oil feed pressure, fuel gas composition, oil feed temperature, and fuel
gas supply pressure

When the plot is displayed, you can copy it and paste it in a MS WORD document where you can
add descriptions of the cases. The word processor document can be printed so that you can perform the
process reaction curve calculations. You can save the word processor and the data MATLAB case files as
described previously for each case. This will allow you to recover from computer restarts, printing errors,
check for errors (unlikely that you will make any!), and transport the results to your home computer. Better
safe than sorry.

13
 Air Flowrate Coil Outlet Temperature
4.7 47.5 286 21

284 20.5

Fuel valve, v200 (%)

Air valve, v100 (%)
4.699 47

T300 (deg C)
F100 (m /s)

282 20
3

4.698 46.5
280 19.5

4.697 46
278 19

4.696 45.5 276 18.5

0 100 200 300 400 500 0 100 200 300 400 500 0 100 200 300 400 500 0 100 200 300 400 500
Time (sec) Time (sec) Time (sec) Time (sec)

Fuel Flowrate O2 in Flue Gas Stack damper % open

0.6 21 4 26

20.5
Fuel valve, v200 (%)

0.55 3.5
25.5

Damper, v600 (%)

F200 (m /s)

A400 (mol%)
20 3
3

0.5
25
19.5
2.5
0.45
19 24.5
2

0.4 18.5
0 100 200 300 400 500 0 100 200 300 400 500 1.5 24
0 100 200 300 400 500 0 100 200 300 400 500
Time (sec) Time (sec)
Time (sec) Time (sec)

Process oil flow rate

1.5 61 215 1601

Oil Feed Pressure (kPa)

1
Feed valve, v600 (%)

60.5 214.5 1600.5

Oil Feed Temp (C)

F600 (m /s)

0.5
3

60 214 1600
0

59.5
-0.5 213.5 1599.5

-1 59
0 100 200 300 400 500 0 100 200 300 400 500 213 1599
0 100 200 300 400 500 0 100 200 300 400 500
Time (sec) Time (sec)
Time (sec) Time (sec)
Fire box pressure Stack damper % open
-180 26 Solid = Meth, Dashed = Ethane
406.5
1
Fuel gas supply Pres. (kPa)

-181 25.5
Damper, v600 (%)

406

Fuel gas composition

0.8
P300 (Pa)

-182 25 405.5
0.6

405 0.4
-183 24.5

404.5 0.2
-184 24
0 100 200 300 400 500 0 100 200 300 400 500
404 0
Time (sec) Time (sec) 0 100 200 300 400 500 0 100 200 300 400 500
Time (sec) Time (sec)

Figure 2. Sample Plot for –2% step change in the fuel valve opening.

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 Appendix B. MATLAB Controller Subroutine

This is the subroutine stored in file fhtrcont.m. You should store the original (fhtrcont.bak) and
modify the m-file. Only the file with the extension “.m” will be executed.

function [SP,CV,VALVE] = fhtrcont(STORE,k,SP,CV,VALVE,Kc,Ti,Td,MVmax, ...

MVmin,EUhi,EUlo,CTL_STAT,CTLINIT, Dt )
% ********************************************************************
%
% Fired Heater Simulation
%
% Copyright : McMASTER UNIVERSITY, 1998, 1999
% Version : 1.0
% Last Updated : Sept 99,
% Programmed by : T. Marlin
% Filename : fhtrcont.m
%
% ********************************************************************
% Usage:
% This function m-file is a subroutine which can be called
% using the following statement.
% [SP,CV,VALVE] = fhtrcont(STORE, k,SP,CV,VALVE,Kc,Ti,Td, ...
% MVmax,MVmin,EUhi,EUlo,CTL_STAT, CTLINIT,Dt)
% Decription:
% This function returns the values of the 4 valve opening.
% If necessary, flowrate is compensated.
% ********************************************************************
% Inputs:
% These variables and parameters are available for use
% in the controller calculation. The values are provided
% from the menu entries and the plant measurements.
% STORE The stored data of all past SPs, CVs and VALVESs.
% SP(i) is the setpoint of CV i (i=1,6) at the current time
% SP that isn't specified in
% menu would be changed here.
% CV(i) is the value of CV i (i=1,6) at the current time
% Any of them can be compensated here.
% VALVE(j) valve of valve opening (0-100%)
% j=1 air
% 2 fuel
% 3 stack
% 4 feed
% MVmin(i)
% MVmax(i) are the lower and upper bounds for the manipulated
% variable used to control the CV i
% NOTE: These values are applied to the controller
% outputs.
% Kc(i)
% Ti(i)
% Td(i) are Controller tuning parameters specified in menu
% EUhi(i)
% EUlo(i) is Lower and upper bounds for the measured variables.
% CTLINIT is a flag that indicates if this function is being called
% for the first time in the simulation, in which case
% the controllers have to be initialized. The value
% reported to this function is given below, and you
% may use this information to decide when to initialize
% you controller calculations.
% CONTINIT = 1, if is this is the first call
% = 0, otherwise.
% CTL_STAT(i) is a controller status specified in menu.
% values are 1=ON or 0=OFF
% *********************************************************************
% Output:
% These are the variables and parameters which can be changed
% through the controller calculations and will be transmitted
% to the plant.

15
% SP(i) is the setpoint of CV i (i=1,8) at current time
% CV(i) is the value of CV i (i=1,8) at current time
% VALVE(J) is the current value of the VALVE j = see above
% **********************************************************************
% Sensor Information
% i = 1, Air flowrate
% 2, Fuel flowrate
% 3, Box pressure
% 4, Stack O2 mol percent
% 5, COT
% 6, Process oil flowrate
% 7, Stack CO mol percent
% 8, Fuel density
% 9, Compensated fuel flow. CV(9)=CV(2) unless you compensate fuel flow.
% **********************************************************************
% STORE data information
% STORE(kk,:) = [T ...
% CV(1) CV(2) CV(3) CV(4) CV(5) CV(6) CV(7) CV(8) ...
% SP(1) SP(2) SP(3) SP(4) SP(5) SP(6) ...
% OP(1) OP(2) OP(3), OP(4) OP(5) OP(6) ...
% CV(9) ];
%
% **********************************************************************
% Calculations:
% Some suggestions and hints are given below.
% 1. The convention is that the integral mode of a controller is turned off
% by setting the integral time constant to zero in the menu for editing
% controllers. If at some point you will want to turn off the integral mode
% of a composition controller this way, make sure that your code
% treats the case TI=0 as a special case; if not, a division by zero will
% occur (recall: Integral Mode = (Error integral)/TI ).
% 2. The controller can be turned off two ways via the menu.
% i) select "off" in the menu.
% ii) give the controller gain a value of zero.
% 3. Any special calculations for initialization must be included.
% 4. When a controller is "OFF", this subroutine is executed but the
% values of OP are ignored. When the controller is "ON", this
% subroutine is executed and the values of OP are implemented.
% *********************************************************************
%
% The global variables enable the programmer to store results of
% calculations for use in the next execution. Intermediate
% values not placed in SAVE will not be available

global SAVE1 SAVE2 SAVE3 SAVE4 SAVE5 SAVE6 SAVE7 SAVE8 SAVE9

% ------- Put your code here ----------

%
% *****************************************************************

return;

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