Semester Two 2015

Examination Period

Faculty of Engineering

EXAM CODES: CHE3162

TITLE OF PAPER: PROCESS CONTROL

EXAM DURATION: 3 hours writing time

READING TIME: 10 minutes

THIS PAPER IS FOR STUDENTS STUDYING AT:( tick where applicable)

 Berwick  Clayton  Malaysia  Off Campus Learning  Open Learning
 Caulfield  Gippsland  Peninsula  Enhancement Studies  Sth Africa
 Parkville  Other (specify)

During an exam, you must not have in your possession, a book, notes, paper, electronic device/s, calculator,
pencil case, mobile phone, smart watch/device or other material/item which has not been authorised for the
exam or specifically permitted as noted below. Any material or item on your desk, chair or person will be
deemed to be in your possession. You are reminded that possession of unauthorised materials, or attempting to
cheat or cheating in an exam is a discipline offence under Part 7 of the Monash University (Council) Regulations.

No exam paper or other exam materials are to be removed from the room.

AUTHORISED MATERIALS

OPEN BOOK  YES  NO

CALCULATORS
Only calculators with an
'approved for use' Faculty sticker are permitted  YES  NO

SPECIFICALLY PERMITTED ITEMS  YES  NO

if yes, items permitted are:

Candidates must complete this section if required to write answers within this paper

STUDENT ID: __ __ __ __ __ __ __ __ DESK NUMBER: __ __ __ __ __

Page 1 of 21
CHE3162 Exam paper 2015
 EXAM INSTRUCTIONS

ATTEMPT ALL FIVE (5) QUESTIONS

EQUATION SHEETS are provided

Write all answers in the exam script book provided.

TOTAL MARKS for this exam equals 60.

Page 2 of 21
CHE3162 Exam paper 2015
QUESTION 1 (20 marks):
A counter-current ammonia absorber removes ammonia
(NH3) from an air stream by absorbing the ammonia into
a water steam (see equipment diagram to the right). The
air exits at the top of the column and still contains a small
amount of NH3.

The NH3 concentration in the exit gas stream must not

exceed 200 ppm. The absorber has been designed so that
at steady state conditions a flowrate of 250 kg/min of
water into the column produces an outlet NH3
concentration of 50 ppm.

The valve is designed so that a 1% increase in valve

position causes the flowrate to increase by 5 kg/min. The plot shows how the outlet NH3 concentration
responds when the water flowrate is reduced to 200 kg/min.

Response of Outlet NH3 concentration after drop in water flowate

Page 3 of 21
CHE3162 Exam paper 2015
 a) Determine the process transfer function Gp, which describes the exit NH3 concentration
as a function of the water flow. [2 marks]

b) Sketch the change in the outlet NH3 concentration if the flowrate of water to the absorber
is increased by 100 kg/min [2 marks]

c) Draw a block diagram for the control loop, clearly showing all transfer functions
[2 marks]

d) Use Zeigler-Nichols tuning rules to recommend settings for a proportional only

controller [3 marks]

e) Using the tuning settings from part (d), calculate the offset for when the setpoint is
changed to 60 ppm [2 marks]

f) After the setpoint is increased to 60 ppm, determine the final value of the NH3 exit
concentration once steady state is achieved. [2 marks]

g) Sketch the control loop using standard P&ID symbols, showing the location of the valve,
sensor and controller for this system. Note: Redraw it in your script book. [3 marks]

h) List and briefly explain the two most important disturbances you would expect in the
ammonia absorber system. [2 marks]

i) Your boss thinks Cohen-Coon tuning is better choice than Zeigler Nichols tuning. Briefly
explain whether you think the Cohen-Coon method would be suitable for tuning this
system? (Note: You do not need to calculate any tuning parameters to answer this question)
[2 marks]

Page 4 of 21
CHE3162 Exam paper 2015
QUESTION 2 (10 marks):
You have been asked to design a feed-forward controller to compensate for the effect of changes in
the distillation column feed rate F on the overhead product composition. The reflux flow R is to be
manipulated to control the overhead product composition xD (%).

Two step tests are performed on the column – one on the federate and one on the reflux flow set point.
In each case the response of the overhead composition is recorded and the key parameters are
summarised below:
Step test in: Process Gain Time constant Dead time
(%/(kg/hr)) (min) (min)
Feed rate F (kg/hr) 0.8 18 8
Reflux flow R (kg/hr) 1.2 4 1

The reflux flow valve has a gain of 2 (kg/hr)/%open and a time constant of 30 seconds. The
composition sensor also has a 20 second time constant. A proportional controller is in use with a gain
of Kc = 3.5.

(a) Design a realisable feedforward controller for this system [3 marks]

(b) Draw the block diagram for the complete feedback & feedforward control loop
showing all transfer functions and the location of the streams F, R and xD [3 marks]

(c) Sketch a P&ID of the feedforward and feedback control loops for xD. Note: Please draw
the P&ID diagram in your exam script book. Please only show the control loops - you do
NOT need to draw a full P&ID with flanges, interlocks, alarms, etc. [3 marks]

(d) Does the feedback loop need to be retuned after the new feedforward controller is
switched on? Briefly explain your answer. [1 mark]

Page 5 of 21
CHE3162 Exam paper 2015
QUESTION 3 (10 marks):
A process engineer is preparing to design a DMC controller. The open loop response of a process
after a unit step change in the input has the following response, where Si is the output being
controlled and the sampling time shown is in 1 minute intervals.

a) Design a suitable DMC response matrix [A]. [5 marks]

b) Briefly justify your selection of matrix size parameters in part (a) [5 marks]

Page 6 of 21
CHE3162 Exam paper 2015
QUESTION 4 (10 marks):
A feedback control system is used the
blending system (see Figure) to reduce
the effect of disturbances in the feed
composition, x1, on the product
composition x. The inlet flowrate w2
can be manipulated.

The pilot-scale blending tank is 2 m

diameter and 3 m tall. The overflow
line maintains a constant liquid
volume in the tank.

The nominal steady state operating conditions are:

w1 = 650 kg/min w2 = 350 kg/min x1 = 0.2 kg/kg x2 = 0.6 kg/kg h = 1.5 m

The control valve behaviour can be approximated by a 1st order transfer function with a time constant
of 5 seconds. Opening the control valve by 10% produces a 187 kg/min increase in w2. A one minute
time delay is associated with the composition sensor.

(a) Derive the transfer functions for the process and the disturbance [5 marks]

(b) Draw a block diagram of the feedback control system, showing all transfer functions
and stream names [3 marks]

(c) You have been summoned urgently to the control room. The sampling line to the composition
sensor has suddenly become partially plugged, so that the measurement time delay is now 3
minutes. The loop needs to be quickly retuned until the sensor can be fixed. There is no time
to do any tuning calculations. Briefly explain how you would adjust the controller settings
to ensure the process continues to run without becoming unstable. [Note: you do not need
to calculate any parameters for this question.] [2 marks]

Page 7 of 21
CHE3162 Exam paper 2015
QUESTION 5 (10 marks):

a) Why is 4-20 mA used to transmit signals in control loops? [2 marks]

b) Explain what λij means in the RGA method of loop pairing. [3 marks]

A heat exchanger is used to cool a hot process fluid, as shown below. What improvements
would you recommend to the control system ? [2 marks]

c) What is “liquid inventory” in a chemical process? List 2 advantages and 2 disadvantages

of having liquid inventory. [3 marks]

END OF EXAM QUESTIONS

Page 8 of 21
CHE3162 Exam paper 2015
CHE3162 EQUATION SHEET
Y K
=
1st order: X τs + 1 ;

Y K
= 2 2
2nd order: X τ s + 2τξs + 1
 − πξ 
overshoot = exp  ; decay ratio = overshoot2
 1− ξ 
2
 
2πτ
T=
1− ξ 2
; tr=T/4 tp=T/2

FODT: τ = 1.5(t 63% − t 28% ); θ = t 63% − τ ; K=∆/δ

Time domain: y(t)=0 from t ≤0

  − (t − θ) 
y (t ) = K 1 − exp 
  τ  for t>0

K
AR =
(1 + τ 2ω 2 ) φ = tan −1 (− τω ) − θω

K1 K2 K3
AR =
1 + τ1 ω 2 1 + τ 2 ω2 1 + τ3 ω2
2 2 2

φ = tan −1 (− τ1ω) + tan −1 (− τ 2 ω) + tan −1 (− τ 3 ω)

 − 2ξτω  AR =
K
φ = tan −1  2 2 
1− τ ω  (1 − τ ω ) + ( 2ξτω) 2
2 2 2

Final Value Theorem: lim f(t) = sF(s)

t→∞ s→0

1
λ11 = , λ12 = 1 − λ11 = λ 21
K12 K 21
1−
K11 K 22

Page 9 of 21
CHE3162 Exam paper 2015
TUNING TABLES

Zeigler-Nichols Ultimate Sensitivity Tuning

Pu=2π/ωu
Kc TI τd
P 0.5Ku -- --
PI 0.45Ku Pu/1.2 --
PID 0.6Ku Pu/2 Pu/8

Cohen-Coon Tuning Rules:

R = θ/τ
Kc TI τd
(1 + R / 3)
P -- --
KR
(0.9 + R / 12) θ (30 + 3R)
PI --
KR (9 + 20 R)
(1.33 + R / 4) θ (32 + 6 R) 4θ
PID
KR (13 + 8 R) (11 + 2 R)

Laplace Transform Functions

f(t) f(s) = L [f(t)]

U(t), unit step or constant 1/s

t n −1 n!
(n − 1)! s n +1

(a − τ ) as + 1
1+ e − t /τ
τ s (τ s + 1)

τ 1 − a − t /τ τ 2 − a − t /τ as + 1
1+ e − 1
e 2

τ 2 − τ1 τ 2 − τ1 s (τ 1s + 1)(τ 2 s + 1)

1  1− ξ 2  1
1− e −ξ t /τ sin  t +φ 
1− ξ 2  τ


 s (τ s + 2ξτ s + 1)
2 2

 1− ξ 
2
φ = tan −1  
 ξ 
where  

Page 10 of 21
CHE3162 Exam paper 2015
SOLUTIONS
QUESTION1
(a) Determine Gp [2 marks] 0.5 marks per correct parameter, 0.5 marks for correct TF

Common errors: missing negative in gain. Forgetting deadtime in sketch.

Page 11 of 21
CHE3162 Exam paper 2015
(c) Block Diagram [ 2 marks]

x5 x5
x5

x5  Common error: missing Gv

when calculating AR (including me!)
-24

-12

Common errors –Trying to use ωc as the inverse of the time constant. This is the corner frequency in a BODE plot, and
is completely unrelated to the ultimate frequency where a standing wave is formed (phi = -pi radians).

Omitting the deadtime section of the frequency equation – deadtime has a huge effect on the phase lag and must be
included. Otherwise if the TF is only 1st or 2nd order and no deadtime, the equation cant be solved as it will never cross
180 degrees or –pi radians.

Page 12 of 21
CHE3162 Exam paper 2015
Common errors –. Using open loop TF Gp instead of the full closed loop TF.
Using a step change of 60, instead of 10 (since the setpoint is increased from 50 to 60, so the change in SP is 10). Use
either SP = 1 or SP = 10 in part e, as the Final Value will be different by a factor of 10, so it be correct either way.
For part (f) the final concentration was originally 50. If use a 1 unit SP change in part (e) then need to multiply the
offset by 10 (size of the step change) before you add it to the original value.
Offset for a unit SP change is always less than one, so any Final value greater than 60 (the new SP) means an error
somewhere.

Page 13 of 21
CHE3162 Exam paper 2015
(g) [3 marks]

Needs correct symbols (circles) & correct locations.

OK if use CC and CT (for concentration controller

and Conc Transmitter)
Putting the controller on the water outlet stream
(base) instead of the top exit gas stream is OK

(h) Most important disturbances [ 2 marks total]:

1. Inlet NH3 concentration (1 mark – must list this one)
2. Either Inlet flowrate OR Water flowrate/pressure (1 mark for either of these)
3. Other answers: temperature (affects absorption), humidity
4. Other answers which were not the *most important* were water purity & pressure.

(i) Cohen Coon model assumes that the open loop process can be modelled as a First Order dead Time process. If
there is no deadtime, Cohen Coon wont work (R=0 in table), Since this process has significant deadtime
(25.5min) then Cohen Coon will be suitable.
(no marks for calculating parameters – looking for explanation) [2 marks]

Common incorrect answers–

Myth #1: “CC would work better as ZN does not take into account deadtime”
Both tuning methods work for any PID loop, including loops with deadtime. The difference is how the tuning
parameters are calculated – ZN uses frequency and oscillations to calculate loop tuning parameters, while CC
uses a FODT model to calculate the parameters. Regardless of which method is used, the final parameters are
pretty similar and will work in similar situations.
Myth #2: “CC only works for open loop control”
Both ZN and CC are methods for working out tuning parameters for a CLOSED control loop. Many students
are confused by the CC rules, which model the open loop response as a FODT model, and use this to calculate
the closed loop tuning parameters. So CC uses the open loop information to calculate the closed loop
parameters.

Page 14 of 21
CHE3162 Exam paper 2015
Question 2
(a) Design a realisable feedforward controller for this system [3 marks]

-0.33

-0.33 -0.33

(b) Draw the block diagram for the complete feedback & feedforward control loop showing all transfer functions
and the location of the streams F, R and xD [3 marks]

Page 15 of 21
CHE3162 Exam paper 2015
(c) Sketch a P&ID of the feedforward and feedback control loops for xD. Note: Please draw the P&ID diagram in
your exam script book. Please only show the control loops - you do NOT need to draw a full P&ID with flanges,
interlocks, alarms, etc. [3 marks]

(d) Does the feedback loop need to be retuned after the new feedforward controller is switched on? Briefly
explain your answer. [1 mark]
No – the loop does not need to be retuned as FF does not affect the FB loop at all. Students can state this, or show using
block diagram logic. Any comments about returning or changing type of controller are incorrect.

Page 16 of 21
CHE3162 Exam paper 2015
QUESTION 3:
DMC
First, set P to be within range of 10-30 = lets choose p=20
Divide SS which occurs at 80 min into a prediction horizon of p=20. This means the time interval is about 4 minutes.
Control horizon is between 3-8, so lets choose c=5 so 5 columns

Need to show a correct matrix with correct time points, diagonal zeros in right places, rows/columns shown correctly
and reasonable approach.

Need to choose c in the range of 3-8

time interval based on dividing SS time of 80 min by 10-30

Page 17 of 21
CHE3162 Exam paper 2015
 QUESTION 4:
(a) Derive the transfer functions for the process and the disturbance [5 marks]

0.35

18
Gv(s)=

(b) Draw a block diagram of the feedback control system, showing all transfer functions & stream names [3 marks]

0.35

Page 18 of 21
CHE3162 Exam paper 2015
(c) You have been summoned urgently to the control room. The sampling line to the composition sensor has suddenly
become partially plugged, so that the measurement time delay is now 3 minutes. The loop needs to be quickly
retuned until the sensor can be fixed. There is no time to do any tuning calculations. Briefly explain how you would
adjust the controller settings to ensure the process continues to run without becoming unstable. [Note: you do not
need to calculate any parameters for this question.] [2 marks]

Switch to P only and reduce the gain. Longer deadtime means less stable loop, and therefore ultimate gain will be
lower. Could adjust integral time as well but easier to just turn it off.

QUESTION 5:
a) Why is 4-20 mA used in control loops? [2 marks]

b) Explain what λij means in the RGA method of loop pairing. [3 marks]

c) A heat exchanger is used to cool a hot process fluid, as shown below. What improvements
would you recommend to the control system ? [2 marks]

d)

Page 19 of 21
CHE3162 Exam paper 2015
 e) What is liquid inventory in a chemical process? List 2 advantages and 2 disadvantages of
having liquid inventory. [3 marks]

Page 20 of 21
CHE3162 Exam paper 2015
 Page 21 of 21
CHE3162 Exam paper 2015