CH331 - Process Control Lab

Temperature control in a heat

exchanger

Presented by :
Course Instructor : Dr. Asad Hasir Sahir
Amit - 2019CHB1037
Anukul - 2019CHB1041
Gauransh - 2019CHB1333
Pankaj - 2019CHB1054
Problem Statement and Heat Exchanger Process
We have to demonstrate the feedback and
feedforward compensators to control the temperature
of a chemical reactor by using a heat exchanger.

Heat Exchanger Process :

In fig. 1 we can see a chemical reactor that is known

as "stirring tank". Top pipe show that how inlet
delivers liquid to be mixed in the tank and the bottom
pipe is to be maintain the tank liquid at a constant
temperature by varying the amount of steam supplied
to the heat exchanger via its control valve. The main
source of disturbances in this process is the
temperature variations of the inlet flow.
Fig 1: Stirring tank with heat exchanger
Using Measured Data to Model The Heat Exchanger Dynamics
To derive a first-order-plus-deadtime model of the heat exchanger, attached a step
disturbance in valve voltage V and record the effect on the tank temperature T over time.
MATLAB code

Output :
The values t1 and t2 are the times where the response attains 28.3% and 63.2% of its
final value. Used to determine the time constant tau and dead time theta for the heat
exchanger:

Figure 2
Verifying these calculations by comparing the first-order-plus-deadtime response with the
measured response.

Code and output

Figure 3
 Feedback control
To regulate the tank temperature T around a
given setpoint Tsp, we can use the following
feedback architecture to control the valve
opening.

The PI controller :

calculates the voltage V based on the

gap Tsp-T between the desired and measured
temperatures.

Code ÷ Output :
 Feedback Control
A block diagram representation of the
open-loop process is shown here. This
Transfer function tell how a change in the
voltage V driving the steam valve opening
influences the tank temperature T.

The transfer function below shows how a

change in inflow temperature influences T.
Figure 4
 Feedback Control
Now to see that how the ITAE controller performs, we close the feedback loop and simulate the
response to a set point change

The response is fairly fast with some overshoot.

Looking at the stability margins confirms that

the gain margin is weak

Figure 5
Bode Diagram
Reducing the proportional gain Kc strengthens
stability at the expense of performance

Figure 6
Figure 7
Step Response
MATLAB code to plot the step response

Figure 8
 Feedforward Control
To reject such disturbances like temperature fluctuations in the tank an
alternative to feedback control is the feedforward architecture which is
shown below

Figure 9
 Feedforward Control
Straightforward calculation shows that the overall
transfer from temperature disturbance d to tank
temperature T is

Perfect disturbance rejection requires

Code

Figure 10
 Combined Feedforward-Feedback Control
Feedback control is good for setpoint tracking in general, while
feedforward control can help with rejection of measured disturbances

Figure 11
 Combined Feedforward-Feedback Control
We use connect to build the corresponding closed-loop model from Tsp,d to T. First name the
input and output channels of each block

Code :

To compare the closed-loop responses with and without feedforward control, calculate the
corresponding closed-loop transfer function for the feedback-only configuration:
Now compare the two designs Bode diagram
Code : The two designs have identical performance for setpoint
tracking, but the addition of feedforward control is
clearly beneficial for disturbance rejection. This is also
visible on the closed-loop Bode plot
Code :

Figure 12
Interactive Simulation

HEAT EXCHANGER TEMPERATURE CONTROL SIMULINK MODEL

Open loop response Joint Feedback And Feedforward Response
Feedforward Response Feedback Response
Task-02
To perform this we use a second order equation of transfer function Gp

Fig : Simulink
model for task-02
Results of Task-02
Feedback Response Feedforward Response
 Results of Task 2
Open Loop Response Joint FF and FB Response
 Difficulties faced
● We didn't place much difficulties in task 1 as it was demonstrated very well in the link
given.
● We had to think for sometime to derive a new example using our knowledge of heat and
mass transfer. After our analysis we used a second order equation.
● Overall these task were not very difficult but having lengthy processes.

Conclusion
● In this assessment we have learned about how to control temperature in a heat
exchanger using simulation
● We create a simulation model of heat exchanger with feedback, feedforward, open loop
and joint feedback and feedforward. And plotted graphs and bode diagrams
● For task 02 we successfully created a second order plus deadtime simulation model.
THANK YOU !!