UNIVERSITY of LIMERICK

OLLSCOIL LUIMNIGH

Faculty of Science and Engineering

Department of Chemical Sciences

End of Semester Assessment

Module Code: CH4404

Module Title: Process Technology 1

Lecturer(s): Dr. Seamus Mc Monagle

Dr. Peter Davern

External Examiners: Dr Grace Morgan, Dr Gavin D’Arcy

Semester: Spring 2017

Duration of Exam: 2.5 hours

Grading Scheme: 70% Exam

30% Labs

Instructions to Candidates:
_____________________________________________________________________

1. There are three questions in this paper. Answer any TWO (2) full questions. All
questions carry equal marks.
2. Please use separate answer booklets for SMcM and PD’s parts.
3. Any non-programmable calculator may be used provided it has been cleaned of
any information that would subvert the purpose of the examination.
4. Calculations must be shown in sufficient detail to illustrate your understanding of
the procedure.
5. An equation sheet is attached for your use in answering the questions.
6. Please write clearly and readably.

Q1(a) It is desired to implement a feedforward control loop on a gas storage

CH4404 Process Technology1 Page 2 of 7 Spring 2017

tank (shown diagrammatically below).

V
R

Gas enters the tank through flow valve, V. A fixed restrictor, R, allows a
constant flow of gas out of the tank. The control objective is to maintain a
constant gas pressure within the tank. The major input disturbance in the
process is fluctuations in the air temperature of the room in which the tank
is located.

(i) Draw a simple diagram to show the physical representation of how

such a control loop could be achieved (label clearly all items on your
diagram)
(7 marks)

(ii) Draw a conventional block diagram to represent this process control

system. Show clearly in your diagram the input and output variables
from each operational block and define each variable. Explain the
nature of each of the transfer functions for all of the operational blocks
in your diagram.
(10 marks)

(iii) Describe the advantages and limitations associated with your

chosen control loop configuration.
(2 marks)

Q1(b) Describe, using simple diagrams to illustrate your answer, the principles of
operation of any TWO different types of devices for measuring liquid level in
processing operations. List any strengths and weaknesses of your chosen
device types.
(8 marks)

Q1 is continued on the next page.

CH4404 Process Technology1 Page 3 of 7 Spring 2017

Q1 – continued.

Q1(c) [Peter Davern’s section: please answer in a separate answer booklet]

Define the following terms:

• hazard
• harm
• risk
(3 marks)

List three ways that a chemical can enter the body.

(1 ½ marks)

In the context of the 2016 Code of Practice for the Safety, Health and Welfare
at Work (Chemical Agent) Regulations 2001, explain what is meant by the
following terms:
• Carc 1B
• Repr 1A
(2 marks)

Briefly explain the meaning of the three CLP hazard classification

pictograms illustrated below:

Symbol A Symbol B Symbol C

(1 ½ marks)
CH4404 Process Technology1 Page 4 of 7 Spring 2017

Q2 (a) An open loop response experiment is to be performed on a controller. The

following error signal profile is to be used:

0
E (%) 0 1 2 3 4 5 6 7
-1

-2

-3
Time (sec)

Plot qualitatively the shape of the corresponding controller output signal

versus time for
(i) Integral control mode only
(ii) Derivative control mode only
Show clearly the variation in controller output during each 1 second time
interval from time = 0 to time = 6 seconds. Indicate which sections (if any) of
the plots are linear (L) and which are non-linear (N). You may assume that
error signal is defined as set-point value minus measured value, and that the
initial controller output is 50%.
(Be sure to enclose your plots with your answer booklet)
(12 marks)

Q2(b) Explain, with reference to a simple diagram, the principle of operation of

ONE of the following final control elements: a current to pressure (I-P)
converter OR an electropneumatic valve positioner. List any advantages and
limitations of your chosen device.
(8 marks)

Q2 is continued on the next page.

CH4404 Process Technology1 Page 5 of 7 Spring 2017

Q2 – continued.

Q2(c) An open loop transient response test was performed to obtain the optimum
settings for a liquid level control system in the flow storage tank shown below.

Flow
rate in = v

Change
in liquid
Controller level = L

Level
sensor

A manual increase of 10 m3.min-1 was made to the flow rate in, v. The
following results were obtained:

Time (min) 0 1 3 5 6 8 11 17 28 44
L (m) 0 0 0 2.5 5.4 9.2 13.2 17.3 19.5 20

Find the optimum controller PID settings.

(7 marks)

Q2(d) [Peter Davern’s section: please answer in a separate answer booklet]

Construct a simple diagram that summarises how active (human) failures can
be classified.
(5 marks)

In the context of occupational exposure to gases, explain the difference

between a simple asphyxiant and a chemical asphyxiant. Illustrate you answer
with one example in each case.
(3 marks)
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Q3 (a) A gas holding tank (shown diagrammatically below) is used for the
intermediate storage of gas in a continuous process. No chemical or
biochemical reactions take place in the tank.

f, [A]in

[A]

Tank volume = V f, [A]

Gas flows in and out of the tank at a constant volumetric flow rate of
f m3.min-1. The contents of the tank are well mixed and the tank volume is
V m3 and remains constant. The gas contains a chemical component, A, with
a concentration of [A]in in the tank inlet flow, and of [A] inside the tank.

(i) Starting from first principles, derive a differential equation which

models the dynamic response of [A] to changes in the inlet flow
concentration, [A]in.
(10 marks)
(ii) Using the equation from (i) derive, in a series of clearly explained
logical steps, an algebraic expression which relates [A] to time, for a
step increase in [A]in.
(8 marks)
Define clearly all of the parameters used in your derivations for (i) and (ii).

(iii) Given that V = 100 m3, f = 2m3.min-1, and that [A] = [A]in = 2M
initially, and at time = 0 [A]in increases stepwise from 2M to 8M,
calculate time required for the concentration of A in the tank, [A], to
reach 6M.
(7 marks)

Q3(b) Give a brief account of the categories of process dynamic models for higher
(>2nd) order and more complex process. Explain and distinguish between
lumped and distributed parameter systems. Use equations and diagrams to
illustrate your answer, where appropriate.
(10 marks)

Process Technology 1 CH4404 Equation Sheet

CH4404 Process Technology1 Page 7 of 7 Spring 2017

Time Function Laplace Transform

f(t) F(s)
a a/s
at a/s2
df(t)/dt sF(s) - f(0)
1
b-a
(
e − at − e − bt ) 1
(s + a )(s + b )
1
a 2
(
at − 1 + e − at ) 1
s (s + a )
2

(where a and b are constants associated with the input signal)

 4 t  t D (32 + (6t D / )) 4t D

Kp =  + D TI = TD =
Kt D  3 4  (13 + (8t D / )) (11 + (2t D / ))

Kp = 0.6K TI = Tc/2 TD = Tc/8

R = 0.08206 dm3.atm.mol-1.K-1
= 8.314 J.mol-1.K-1

Surface area of a cylinder = 2rh + 2r2