Plant Selection:

Figure1: Process diagram

A+ B → P

The process is a continuous blending process. In the reactor, reactant A is reacting with B to
obtain a product of desired concentration (P). The control valve controls the flow of B into
the reactor, the control valves 1 closes when the component concentration sensor measures a
concentration above the desired setpoint concentration. The system is programmed to release
the product from the tank when the level of the mixtures hits a setpoint height. As B is
released into the tank, the component concentration analyser measures the concentration of
the product and sends a signal to the controller as volts or ampere on the concentration of the
product, the PID controller sends a signal to the control valve 1 to either open or shut down
valve in other for the product to attain its desired setpoint concentration. As A and B flows
into the tank and reaches setpoint level, the level sensor sends a signal to the PID controller
which tells the valve 2 to either open to release the product or close down for more reaction
to take place. The tank has a jacket around it, the purpose of this jacket is to maintain the
reaction temperature in other to prevent thermal runaway and decomposition of the reactants
in the tank. This system can be affected by disturbances such as change in temperature or
pressure arising from the environment or the jacket.

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Transfer function:

The flow of the product out of the tank(q) is a function of the liquid level(h) in the tank.

q=F ( h ) … … … .(1)

∆P
q=Cvf ( h )
√ gs
… … …(2)

q=Cv √ h … … ..(3)

Material balance of the tank

Rate of change of the volume in the tank= inlet flow of A + inlet flow of B – outflow of P

dh
A =q 1+ q2−Cv √ h … … … .( 4)
dt

The above equation is a non- linear equation due to the square root of h. Perform Taylor
series on the right-hand side of the equation;

d h , δf δf δf
A = ( q 1−q́1 ) + ( q 2−q´2 ) + (h−h́)
dt δ q 1 δ q2 δh

The right-hand side is the derivative of the function with respect to first variable at steady
state multiplied by its deviation variable plus the derivative of the function with respect to
second variable at steady state multiplied by its deviation variable.

δf δf
¿s = ¿ =1
δ q1 δ q2 s

−0.5
δf Cv s h
¿s =
δh 2

Substituting the above derivatives into the top equation

−0.5
d h , , , Cv s h
A =q 1+ q2− … … … ..(5)
dt 2

q=Cv √ h=F ( h s ) … … … .(6)

Substituting (6) into (5)

,
d h , , , F ( hs ) h
A =q 1+ q2−
dt 2 hs

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Replace d/dt with Laplace variable s:

,
d h , F ( hs ) h
A + =q ,1+ q,2 … … ..(7)
dt 2h s

F (hs)
(
A h, s+
2 Ah s)=q,1 +q ,2 … … ..(8)

To obtain transfer function relating to the change in height of liquid in the tank to the change
of flow of reactant A. we assume that the flow of reactant B is constant, so its deviation from
steady state is 0.

h, 1
= =G p 11 … … …(9)
q,2 F (h s )
(
A s+
2 Ahs )
To obtain transfer function relating to the change in height of liquid in the tank to the change
of flow of reactant B. we assume that the flow of reactant A is constant, so its deviation from
steady state is 0.

h, 1
= =G p 12 … … …(10)
q,1 F (hs)
(
A s+
2 Ah s )
Mole balance for the tank

Rate of change of moles in the tank= Reactant A inlet moles + Reactant B inlet moles–
outflow of P moles.

dn
=n1 +n 2−n
dt

n=CV

n=Cq

dC
V =q 1 C 1+ q2 C2−qC … … … .(11)
dt

Assume that the inlet concentrations are constant;

q 1=q́ 1 ; q 2=q́ 2

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Write equation 11 for steady state in concentration. Ć is the outflow steady state
concentration.

0=q́1 C1 + q´2 C 2−F ( hs ) Ć

Subtract the differential and steady state equations

dC
V =q 1 C 1+ q2 C2−qC−q́1 C1 + q´2 C 2 + F ( h s ) Ć
dt

dC
V =C 1 ( q1−q´1 ) +C2 ( q 2−q́ 2) −qC + F ( h s ) Ć
dt

dC
V =C 1 q ,1+ C2 q,2−CT + F ( h s ) Ć … … .(12)
dt

At steady state;

F ( hs ) =q́1 + q´2=( q1−q ,1 ) + ( q2−q,2 )

Substitute for F ( hs ) in equation 12

dC
V =C 1 q ,1+ C2 q,2−qC+ Ć q1−Ć q,1 + Ć q 2−Ć q,2
dt

dC
V =q ,1 ( C1−Ć ) +q ,2 ( C2−Ć ) −qC+ Ć ¿ ¿
dt

note :q1 +¿q =q ¿

2

dC
V =q ,1 ( C1−Ć ) +q ,2 ( C2−Ć ) −q(C−Ć )
dt

note : C ,=C−Ć

dC
V =q ,1 ( C1−Ć ) +q ,2 ( C2−Ć ) −q C , … … ..(14)
dt

d C , dC
= as Ć is constant
dt dt

d C, , , ,
V +q C =q1 ( C1 −Ć ) + q2 ( C 2−Ć ) … ….(15)
dt

Assume q and V are constant; at steady state

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0=q1 Ć1 +q 2 Ć 2−q Ć

dC
V =q 1 C 1+ q2 C2−qC−q1 Ć1 −q2 Ć2 +q Ć
dt

dC
V =q 1 ( C1−Ć 1 ) +q 2 ( C 2−Ć 2 )−q ( C−Ć ) … … .(16)
dt

C−Ć=C '

d C, ,
V =q 1 ( C 1−Ć 1 ) +q 2 ( C 2−Ć 2 )−q C … …(17)
dt

d C, ,
V +q C =q1 ( C1 −Ć1 ) + q2 ( C2 −Ć2 ) … … ..(18)
dt

Taking Laplace transform for the above

( Vq )=q C ( s) +q C ( s ) … … ..(19)
V C, ( s ) s + 1
'
1 2
'
2

( Vq )=q C ( s) +q C ( s) … … ( 20 )
Ahs C, ( s ) s+ 1
'
1 2
'
2

Putting 20 and 15 together

C,¿

The transfer function relating to B inlet flowrate assuming A inlet flow is constant.

q ,1=0

C, C 2−Ć
= =G p 21 … … …(22)
q ,2 F (hs )
(
A h s s+
Ahs )
The transfer function relating to reactant A inlet flowrate assuming B inlet flow is constant.

q ,2=0

C, C1−V
= =G p 22 … … …..(23)
q ,1 F (hs)
(
A h s s+
Ahs )

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 1 1

[ ]
F ( hs ) F ( hs )

G ( s )=
(
A s+
2 Ahs ) (
A s+
2 Ahs ) … … …..(24 )
C2−Ć C1 −Ć
F ( hs ) F (hs )
(
A hs s +
Ahs ) (
A hs s +
Ah s )
From the transfer function matrix steady state gains are;

2 hs
K p 11 =K p 12= … …(25)
F ( hs )

C1−Ć
K p 22= … ..(26)
F ( hs )

C2−Ć
K p 21= … ….(27)
F ( hs )

Hence,

1
⋋ 11=
K p 12 K p 21
1−
K p 11 K p 22

1
⋋ 11=
2hs (C 2−Ć)
(Fhs)2
1−
2hs (C 1−Ć)
(Fhs)2

1
¿
C −Ć
1− 2
C 1−Ć

1
¿
C 1−C 2
C1−Ć

C 1−Ć
⋋ 11= …..(28)
C 1−C2

So that the Bristol array becomes;

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 C 1−Ć −(C ¿ ¿ 2−Ć) −(C ¿ ¿ 2− Ć) C1 −Ć
∧= [ C 1−C2 C 1−C 2
¿
C1−C 2
¿ ]
C 1−C 2
… …(29)

The flow of reactant A into the tank affects the level of the tank while the of reactant B into
the tank affects the concentration of the product. Hence, changing the flowrate of either
reactant A and B affects the level of the tank and the final concentration so there are coupled.

Bristol Relative Gain Array-RGA:

Assuming the following operating conditions for the plant;

Reactant A inlet temperature C 1=0.7 mol /m3

Reactant B inlet temperature C 2=0.2 mol/m3

Product P outflow temperatureĆ=0.3 mol /m3

3
Steady state flow F ( hs ) =1.5 m /min

Cross sectional area of the tank A=4 m2

Steady state height h s=1.5 m

1 1

[
G ( s )= 4 s+ 0.5
−0.1
6 s+1.5
4 s+0.5
0.4
6 s+1.5
]
The first element for the Bristol array is;

0.7−0.3
⋋ 11= =0.8
0.7−0.2

∧= 0.8 0.2
[
0.2 0.8 ]
Single Loop PID Controller Design:

The controller used for the simulation of the process is a PI controller. The PI controller
parameters was each control loop was tuned continuously until the output response reached
the setpoint values. The tank level PI parameter used for tuning was P= 3, I=0.5, final value=
5 and step time =5 while the concentration loop control setting was P=2.5, I= 0.5, final

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value= 1 and step-time =0. Due to the interaction between the two loops, a setpoint change in
the level loop affects the concentration loop and vice versa. The blackline in the graph below
is the level setpoint, the green line is the level response, the yellow line is the concentration
setpoint and the red is the concentration response.

Figure2: design loop for level and concentration

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Figure 3: coupled loop response

Use of Decouplers:

The purpose of decoupling control is to reduce the interaction between multiple control loop
by the addition of additional controllers and to reduce the effect of a setpoint change of a
controlled variable on the other controlled variable. This makes it possible for the stability of
the individual closed loop system to be determined.

The decoupler D21 and D12 can be designed as follows;

For dynamic decoupling

G p 21 U 11 + G p 22 U 21 =0

U 21=D21 U 11

(G ¿ ¿ p 21+ G p 22 D 21)U 11=0¿

−G p 21 ( s)
D21 ( s ) =
G p 22 ( s)

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 −G p 12 (s)
D 12 ( s ) =
G p11 (s )

For static decoupling, static decouplers can be obtained by setting s=0. The process transfer
function above is replaced with the corresponding steady state gains;

−K p 21
D21=
K p 22

−K p 21
D 12=
K p 22

1
D21=
4

−1
D12=
1

Figure 4: decoupler design loop

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Figure 5: decoupled loop response

Controller performance:

Controller Setpoint Response to Setpoint, Ise

PID-level 5 4.071
PID- concentration 1 0.375
PID- DC level 5 4.146
PID-DC concentration 1 0.000012
From the table above, the performance of the controllers can be evaluated from the integral to
the squared error obtained. There was no overshoot or oscillation and the closed loop system
was continuously tuned until the output reached setpoint. The ISE values for the
concentration loop reduced more when a decoupler was added to the system while the ISE for
the level control loop showed mild increase with disturbance when the loops were decoupled.
Since there was no oscillation and the output variables damped quickly to setpoint, this PI
control system performance is said to be satisfactory.

Loop stability:

Odaro_19174578
A feedback control system is stable if and only if all roots of characteristic equations are
negative or have negative real parts. From the simulation graph, has a negative real root thus
the loops are stable.

The concentration loop is a stable a negative real root closed loop response. This loop when
the decoupler was added to it gave an ISE of 0.000012. This value shows that there is
reduced interaction between the two loops and the concentration loop has little or no
disturbance on the level loop. The level loop is also stable having, the output response
reaches setpoint quickly even when a disturbance is introduced.

Discussion and conclusion:

The multiple loop system is coupled together by the flow of the reactants into the tank. The
flow affects both tank level and product concentration. Hence the reason why a change in
flow of any of the reactant to attain the desired concentration would also lead to the level
changing. Therefore, we can say that flow is a function of tank level height and product
concentration. The errors and ISE obtained from the simulation of the process showed that
there is a higher disturbance or error from setpoint when both loops are coupled than when
they are decoupled. The ISE of the concentration decreased at a large rate from 0.375 to
0.000012 when the interaction was eliminated. Therefore, the disturbance on each loop is
caused by other factors such as environment and not by each other. PI controllers were used
because the system responded at a quicker and better rate to the implemented PI parameters
than it did for PID. When the system settings were in PID, the system recorded high
overshoot and oscillations and was almost impossible to get to setpoint.

In conclusion, the overall performance of the feedback control loops is satisfactory and the
decoupling control loop successfully eliminated the interaction between the level and
concentration loops creating stability for the individual loops. Also, a better controller
performance can be attained from another tuning method such as continuous cycling method
or simply a different controller.

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