UN IVERSITI

TEKNOLOGI
P ETRONAS

COURSE : CCB 3013 -

CHEMICAL PROCESS DYNAMICS,
INSTRUMENTATION AND CONTROL
DATE : 2nd SEPTEMBER 2013 (MONDAY)
TIME : 9:00 AM - 12l.00 NOON (3 HOURS)

INSTRUCTIONS TO CANDIDATES

1. Answer ALL questions in the Answer Booklet.

2. Begin EACH answer on a new page.
3. lndicate clearly answers that are cancelled, if any.
4. Where applicable, show clearly steps taken in arriving at the solutions and
indicate ALL assumptions.
5. Do not open this Question Booklet until instructed.

Note: There are NINE(9)pages in this Question Booklet including the cover
page and APPENDIX L

Universiti Teknol-ogi PETRONAS

 ccB 3013/C883013

1. a. Differentiate a regulatory from a servo problem. lllustrate the responses

to each problem given changes in the input or output of a process.

[4 marks]

b. Two stirred tanks are connected in series (FIGURE Q1). The input to

Tank 1 is a stream with constant volumetric flow rate, q¡. Some portion

of the exit stream, rQ¡, from Tank 2 is recycled to Tank 1. The

parameter r, whose value is between 0 and 1, is a fraction of the q¡.

The feed composition, c¡ (mass/volume of a catalyst species), can vary

with time. Liquid density and liquid volumes of Tank 1 and Tank 2, Vt

and Vz, respectively can be assumed constant.

FIGURE Q1: Tank in series.

Develop dynamic modelsof Tank 1 and Tank2.

[4 marks]
 ccB 3013/C8B3013

ii. Show how the exit concentration, czis affected by the changes in

the inlet concentrationof Tank 1, ci.

[8 marks]

iii. Discuss how parameter raffects the process.

[4 marks]

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2. a. Define a transfer function and explain its usefulness in process control.

[4 marks]

b. A system of liquid storage tank is shown in FIGURE Q2b.The diameter

and height of the tank are 6 feetand 10 feet, respectively. The tank
system is initially at steady state with liquid level, h at 8 feet and inlet
flow, q¡at 60 ft3/min. lt is desired to assess the performance of two
types of control valves at the exit stream in regulating the liquid holdup.
The flow-head relationship of Valve lcan be described by, q:7.8h,
where q is in ft3/min and h is in feet. For Valve 2, a nonlinear
relationsh iP, q : 4.5Jhis used.

î
h

T
FIGURE Q2b: A liquid storage tank system

Linearize the flow-head relationship for Valve 2 and develop

transfer functionsfor both the nonlinear and linear systems.
[10 marks]

il lf the inlet flowrate suddenly changes from 60 to 80 ft3/minand

remains there for a long time, which tank system will overflow
first? Why?
[6 marks]

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 ccB 3013/CBB3013

3. a. A process instrumentation diagram of a flash vessel is shown in

FIGURE Q3a. Steam is condensed in a steam coil to vaporize a portion
of the liquid feed, and the liquid product is removed by a pump. There
are control valves for (1) steam flow, (2) steam chest, (3) vapor
product, (4) liquid product, and (5) feed flow. With appropriate
justifications, determine the positions (fail-close or fail-open) of all the
five valves for safe operation in the following cases:

i. The safest conditions are achieved by the lowest temperature

and pressure in the flash vessel.

[8 marks]

ii. Liquid flow to downstream equipment can cause a hazardous

situation.

[8 marks]

FIGURE Q3a: A process instrumentation diagram of a flash vessel

5
 ccB 3013/CB83013

b. An instrument engineer sets the pressure in a supply tank using a very

accurate manometer as a guide. He reads the output of a 2O-psig
pressure gauge attached to the tank as 10.2 psig. Sometime later, he
repeats the procedure and obtains a valueof 10.3 psig. Determine the
precision and accuracy of the pressure gauge.

[4 marks]

6
 ccB 3013ic883013

4. Discuss the importance of the tuning parameters in the PID control

algorithm.
[6 marks]

b. lf the input IZ, to a Pl controller changes stepwise, i.e., I,(s): 2ls, ând
the controller output changes as in FIGURE Q4b, what are the values
of the controller gain and integral time?
[6 marks]

Slope = r.2 min-l

FIGURE Q4b: Pl controller response

A proportional control system is shown in FIGURE Q4c. lf the process

gain, K: l0 and time constant, r:20, determine:

the range of the controller gain, K" that yields a stable closed-
loop response.
[4 marks]

il the value of K" that yield a pole at s:-O.lfor the closed-loop

transfer function.
[4 marks]

FIGURE Q4c:A proportional control system

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 ccB 3013/C883013

5. a. FIGURE QSa shows theblock diagram of a cascade control system.

FIGURE QSa: A cascade control system

Derive the expression for the characteristic equation.

[5 marks]

Construct a Routh aïay and determine the range of values of

the proportional controller gain that produce stable closed-loop
responses.
[5 marks]

b. Consíder the following transfer function:

Simplify the above transfer function to that of first order plus time
delay (FOPTD) model using the Skogestad half rule.
[4 marks]

ii. Neglectthe time delay term from the FOPTD model obtained in
part (bX¡).Sketch a normalized Bode plot of and determine the
break frequency, a¿.

[6 marks]

- END OF PAPER -
 ccB 3013/C883013

APPENDIX I

AELE A1: Laplace transforms for various time-domain functions

f(t) F(s)
I qù (unit impulse) 1

2. S(t) (unit step) I'

J. r (ramp) tl"
(n-r)t
4. {-1 n
.ç

1
5.
"-bt s+b

6.
7 -tt, I
-e
T øs+1

,n-t 1
7. "-bt (n>Ol
(n-t)l (s + b)n

I / r I
8. ,n-I r-t
r'(n -r)l (æ + 1)'
-tlr,
9. _(e| _e-tlt, )
1

î1-T2 (ø1s+1)(r2s+1)

bt - bt e-u,, *b3 - b2 s+b3

10.
bz -4 4 -bz "-b,, (s+{)(s+b2)
I rt-tt I tz-Tl z3.s * I
11 *
t1îy-T2 "-t/r, T2T2-t1 "-t/r, (ø1s + l)(t2s +I)

1
12. l_e-tlî s(æ +1)

I
13. ,_"_s,r"l"o ,('r212 +2Ç'æ +I)
FÇ2

14.
d"f snF(s¡ -s'-r,f(o) -s"-2 ¡(r) çg¡

dtn -....- ,f("-2) 19; - ¡{'-t) 1O¡