Instrumentation and Control

Test N. 2: Practice Excercise IV

Student Monitor: Sebastián Macı́as Vera

Professor: MSc. Eng. Iván Portnoy De la Ossa

March 27, 2020

Barranquilla, Colombia

1 Problem Description
A process stream (cp = 1, 4BT U/lbm◦ F , ρsteam = 66lbm/f t3 ) needs to be heated to
react in a CSTR. Heating is carried out in a furnace with a 35% efficiency (combus-
tion heat transferred to the process fluid) burning fuel oil (HHV = 138700BT U/gal,
ρf uel = 52, 4lbm/f t3 ). The following figure shows a diagram representing the process and
instrumentation.

Figure 1: Process diagram

It has been established that the control valve is FC, equal percent (α = 25), and its ca-
pacity was calculated so that, with the maximum process stream flow (10400 gpm), it
is capable of heating up this process fluid from 90◦ F to 130◦ F. The fuel network pres-
sure is constant at 16 psig, and the furnace operates at ambient pressure. Recall that
7.48gal = 1f t3 and ρwater = 62.4lbm/f t3 .

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1. Calculate the maximum valve capacity (check solution).

2. A step identification procedure is performed, obtaining de following data:

• Initial fuel flow: 40% of maximum required flow.

• Final fuel flow: 48% of maximum required flow.
• Temperature change: +6◦ F.
• Temperature transmitter range: 50 - 200◦ F.
• Time to 28.3% change in transmitter signal: 3 minutes.
• Time to 63.2% change in transmitter signal: 5 minutes.

If a PI controller is tuned for QDR response, write the closed-Ioop transfer function.
Use the Padé approximation for the dead time term:
to
1− 2s
e−to s ≈ to (1)
1+ 2s

(check solution).

3. If a P-only controller is used, what is the maximum value that can be assign to its
gain before obtaining an unstable response? (check solution)

4. The main disturbance to the loop is the inlet process temperature. The transfer
function relating the outlet and the inlet temperatures is:

Tout e−1,5s
GD (s) = = (2)
Tin 2s + 1

If the P-only controller gain is set as Kc = 0, 6Kcu , determine the offset (in both
%TO and ◦ F) that occurs when a change of +10◦ F in the inlet temperature occurs
(check solution).

5. With the P-only controller of part 4), will the response exhibit oscillations or will it
be monotonic? (check solution)

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2 Problem Solutions

2.1 Maximum valve capacity

To calculate The maximum valve capacity, an energy balance must be done in order to
calculate the required maximum fuel flow. According to the energy balance:

Q̇f uel = (ṁsteam )(cp )(∆T ) (3)

To calculate the transferred heat from the fuel combustion to the steam, recall the following
equation:

Q̇f uel = (η)(ṁf uel )(HHV ) (4)

where η = 35%. Since the fuel’s high heat value (HHV ) is given in BT U/gal, (HHV =
138700BT U/gal):

Q̇f uel = (η)(ff uel )(HHV ) (5)

Therefore, the energy balance can be rewritten as:

(η)(ff uel )(HHV ) = (ṁsteam )(cp )(∆T ) (6)

The steam’s mass flow can be expressed in terms of its flow:

ṁsteam = (ρsteam )(fsteam )

Finally, the energy balance is stated as follows:

(η)(ff uel )(HHV ) = (ρsteam )(fsteam )(cp )(∆T ) (7)

The maximum fuel flow ff uel,max will be calculated knowing the maximum fuel flow
fsteam,max = 10400gpm:

(ρsteam )(fsteam,max )(cp )(∆T )

ff uel,max = (8)
(η)(HHV )

3
1f t gal
(66 lbm BT U ◦
f t3
)( 7,48gal )(10400 min )(1, 4 lbm◦ F )(130 − 90) F
ff uel,max =
(35%)(138700 BT U
gal )

ff uel,max ≈ 105, 86gpm (9)

The fuel’s specific gravity is:

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 ρf uel 52, 4lbm/f t3
Gf = = ≈ 0, 839 (10)
ρwater 62, 4lbm/f t3
Knowing that the pressure drop remains constant (∆P = 16psig), the maximum valve
capacity CV max is calculated:
s s
∆Pmax 16psig p
CV max = ff uel,max = 105, 86gpm ≈ 462, 28gpm/ psi (11)
Gf 0, 839

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2.2 Closed-loop transfer function with a tuned PI controller

In order to write the closed-loop transfer function of the control system with a tuned PI
controller (using the QDR response method stated by Ziegler & Nichols), let’s remember
how this closed loop transfer function (GCLT F ) looks like:

G1
GCLT F = (12)
1 + G1 GC
where G1 is the process’s transfer function and GC is the controller’s transfer function.
Due to the fact that a step identification is performed (also known as an open-loop or
off-line process characterization), we can obtain a First order plus dead time
(FOPDT) transfer function that defines the process. Thus, G1 is expressed as:

Ke−to s
G1 = (13)
τs + 1
Each parameter can be calculated using the fit 3 procedure. K is the process’s gain, which
can be calculated as follows:

∆c1−2 %T O
K= [ ] (14)
∆m1−2 %CO
To calculate ∆c recall that:

ci = KT (P Vi − P Vmin ) [%T O] (15)

KT is the transmitter’s gain, calculated with the following formula:

100%T O 100%
KT = = = 0, 66%T O/◦ F (16)
SP AN (200 − 50)◦ F
∆c1−2 is calculated:

∆c1−2 = c2 − c1 = KT (P V2 − P Vmin ) − KT (P V1 − P Vmin ) (17)

A simplified expression can be obtained:

∆c1−2 = KT (P V2 − P V1 ) (18)

P V is the abbreviation for Process Variable. In this case, temperature is our process
variable. According to the data given:

(P V2 − P V1 ) = ∆T1−2 = 6◦ F (19)

This change in temperature must be expressed in %TO:

%T O ◦
∆c1−2 = KT (∆T1−2 ) = 0, 66 ◦F
(6 F ) = 3, 96%T O (20)

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Knowing the change in the transmitter’s signal, its time to calculate to the change in the
controller’s output signal. In order to do this, the problem specifies the type of valve
implemented on the system (E.P Valve, α = 25, Fail-Closed). We must calculate the
signal m1 in which a 40% of the maximum fuel flow is achieved and the signal. The same
process must be done with m2 in which a 48% of the maximum fuel flow is achieved. Let’s
remember the equation of the valve capacity in terms of the valve position for an E.P
valve:

CV = (CV max )α(V p−1) (21)

m
For a Fail-Closed valve, V p = 100 :

m
CV = (CV max )α( 100 −1) (22)

The equation can be simplified taking into account the the pressure drop ∆P remains
constant anytime. Thanks to this consideration, it is possible to express the flow passing
through the valve in terms of the signal m:

m
CV = (CV max )α( 100 −1)

r s
Gf Gf m
f = (fmax )α( 100 −1)
∆P ∆Pmin

m
ff uel = (ff uel,max )α( 100 −1) (23)

With eq.23 it is possible to calculate m1 and m2 . For m1 , ff uel = 40%ff uel,f max :

m1
(0, 4)(ff uel,max ) = (ff uel,max )25( 100 −1)

m1
(0, 4) = 25( 100 −1)

m1 = 71, 53%CO (24)

The same process is done for m2 :

m2
(0, 48)(ff uel,max ) = (ff uel,max )25( 100 −1)

m2
(0, 48) = 25( 100 −1)

m2 = 77, 2%CO (25)

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Knowing m2 and m1 it is possible to calculate K :

∆c1−2 3, 96%T O
K= = = 0, 698%T O/%CO (26)
∆m1−2 (77, 2 − 71, 53)%CO
The process gain calculated is positive, so the tuned controller must have a reverse action!
τ is the process’s time constant calculated as shown:
3
τ = (t2 − t1 ) (27)
2
t1 is the time in which the transmitter’s signal changes by a 28,3% (in this case, 3min).
t2 is the time in which the transmitter’s signal changes by a 63,2% (in this case, 5min).

3
τ = (5 − 3)min = 3min (28)
2
The dead time to can be calculated with the next formula:

to = t2 − τ = (5 − 3)min = 2min (29)

G1 can now be written:

%T O (−2min)s
(0, 698 %CO )e
G1 = (30)
(3min)s + 1
The next step in order to tune the PI controller is to calculate the maximum controller
gain (KCu ) and the maximum period(Tu ) in which the control system looses its stability.
To do this, the characteristic equation must be used:

1 + G1 GC = 0 (31)

According to Ziegler and Nichols, we must asume that GC is a P-Only controller with its
gain equal to KCu :

%T O (−2min)s
(0, 698 %CO )e
1+ (KCu ) = 0 (32)
(3min)s + 1
Applying the Padé approximation (check eq.1) makes the equation easier to solve:

(0, 698) (1 − 22 s)
1+ (KCu ) = 0
(3s + 1) (1 + 22 s)

(0, 698) (1 − s)
(KCu ) = −1
(3s + 1) (1 + s)

(0, 698)(1 − s)(KCu ) = −(3s + 1)(1 + s)

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 (0, 698 − 0, 698s)(KCu ) = −(3s2 + 4s + 1)

0, 698KCu − 0, 698sKCu = −3s2 − 4s − 1

Now we must substitute s = iωu

0, 698KCu − 0, 698iωu KCu = −3(iωu )2 − 4iωu − 1

Remember: i2 = −1:

0, 698KCu − 0, 698iωu KCu = 3ωu2 − 4iωu − 1 (33)

As seen in eq.33, theres a complex part and a real part. Let’s split the equation into two
parts, real and complex: 
0, 698KCu = 3ω 2 − 1
u
(34)
−0, 698ω K = −4ω
u Cu u

The first equation shows the real part of the equation, while the second one shows the the
complex counterpart. Attacking the complex equation first we see the following:

− 0, 698ωu KCu = −4ωu (35)

−4ωu −4
KCu = = = 5, 73%CO/%T O
−0, 698ωu −0, 698
Now we can solve for ωu in the first equation:

0, 698KCu = 3ωu2 − 1 (36)

0, 698(5, 73) = 3ωu2 − 1 (37)

Solving for ωu :
ωu ≈ ±1rad/min (38)

The maximum period is calculated as shown:

2π 2π
Tu = = ≈ 6, 28min (39)
ωu 1rad/min
Knowing Tu and KCu its time to tune our PI controller using the Formulas stated by
Ziegler & Nichols:

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 Figure 2: Ziegler & Nichols tuning equations for QDR response

According to the table shown, the tuned parameters for a PI controller are:

KCu
KC = = 2, 6%CO/%T O
2, 2
Tu
τI = = 5, 23min
1, 2

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2.3 Maximum gain calculation

The answer to this question was already obtained in the previous subsection! the maximum
possible gain that we can assign before producing instability is KCu = 5, 73%CO/%T O

2.4 Offset calculation

Recall the formula to calculate the error:

E = (∆C set )(KCLT F ) − (∆D)(KCLT

D
F) [%T O] (40)

No changes in the controller’s set point are mentioned, so the equation can be simplified
to:

D
E = −(∆D)(KCLT F) (41)
D
∆D is the change in the main disturbance and KCLT F is the gain of the closed loop
transfer function associated to the main disturbance (known as GD
CLT F ). In this case,
the inlet temperature is our main disturbance, and the value of its variation is known
( ∆D = 10◦ F). With that said, in order to calculate the gain, remember that we need
to know which is the transfer function that relates the controlled variable with the main
disturbance (outlet temperature in %TO and inlet temperature in ◦ F). Let’s call it G2 :

G2 = GD (s)H(s) (42)

H(s) is the sensor/transmitter’s transfer function and GD is the transfer function that
relates the outlet temperature and inlet temperature (Both in ◦ F, as shown in eq. 2). In
this case, the problem doesn’t specify if the transmitter has a noise filter or anything else,
so we can asume its simply a pure gain transfer function, H(s) = KT . Thus, G2 can
be written as:

e−1,5s
G2 = (KT ) (43)
2s + 1

O −1,5s
(0, 66 %T
◦ F )e
G2 = (44)
2s + 1
The closed loop transfer function associated to the disturbance is expressed as: (Remember
that a P-controller is implemented [GC = KC ] with a gain equal to 0, 6KCu ):

(0,66 %T O −(1,5min)s
◦ F )e
G2 2s+1
GD
CLT F = = %T O (−2min)s
(45)
1 + G1 GC (0,698 %CO )e
1+ (3min)s+1 [(0, 6)(5, 73 %CO
%T O )]

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A simpler version is shown below:
(0,66)e−1,5s
G2 2s+1
GD
CLT F = = (0,698)e−2s
1 + G1 GC 1+ (3, 438)
3s+1

(0,66)e−1,5s
G2 2s+1
GD
CLT F = = −2s (46)
1 + G1 GC 1 + (2,4)e
3s+1
The control of the closed loop transfer function is calculated as follows:

D D
KCLT F = lim GCLT F (47)
s→0

(0,66)e−1,5(0) 0,66
D 2(0)+1 1 %T O
KCLT F = = = 0, 194 ◦F
(48)
+ 2,4
−2(0)
1 + (2,4)e
3(0)+1
1 1

Finally:

%T O
E = −(10◦ F )(0, 194 ◦F
) = −1, 94%T O (49)

The offset obtained in ◦ F is:

E −1, 94%T O
Of f set = = %T O
= −2, 94◦ F (50)
KT 0, 66 ◦ F

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2.5 Verifying the type of response

To verify if the response will be oscillatory or monotic, recall the characteristic equation:

1 + G1 GC = 0

Knowing that GC = KC = 0, 6KCu = 0, 6(5, 73%CO/%T O) = 3, 438%CO/%T O:

(0, 698)e−2s
1+ (3, 438) = 0 (51)
3s + 1
Applying the Padé approximation:

(0, 698) (1 − s)
1+ (3, 438) = 0
(3s + 1) (1 + s)

(0, 698)(3, 438)(3s + 1) = −(3s + 1)(1 + s)

(0, 698)(3, 438)(3s + 1) = −(3s + 1)(1 + s)

2, 4(3s + 1) = −(3s2 + 4s + 1)

2, 4(3s + 1) = −(3s2 + 4s + 1)

7, 2s + 2, 4 = −3s2 − 4s − 1

3s2 + 11, 2s + 3, 4 = 0

The roots of the equation must be calculated to verify the type of response. The results
were:

s1 ≈ −0, 33 s2 ≈ −3, 4 (52)

According to the results we see that the roots are negative, meaning the response will be
monotonic.

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