Mallory Weiler

ChE 4110 Process Control Homework 2

Please complete PPC Q3.1, Q3.2, Q3.3.
Please complete Special Problem 1 (SP1).

Problem Objectives, Purpose, and Concepts Considered:

The main purpose of this homework assignment was to study and practice with First
Order Plus Dead Time (FOPDT) processes and its parameters while becoming introduced and
accustomed to the LOOP-PRO software used for control systems. Another purpose of this
assignment, as seen in the Special Problem 1, was to identify all the control loops within a
distillation column, identify the major control loop components, and to draw block flow
diagrams for each of the control loops. Some primary objectives of this homework assignment
were to calculate the main FOPDT parameters such as KP, τP, and θP using data from Case Study
process simulations such as Gravity Drain Tanks, Heat Exchangers, and Jacketed Reactors. The
key concepts considered were the elements and parameters of FODPT models, analysis of Step
Test simulations and data, basic process control loops in a distillation column, and process
control block flow diagrams. These are foundational elements of understanding Process Control.

PPC:
For all exercises, leave the controller in manual mode and use default values for noise level, disturbance
value and all other parameters of the case study.

Q-3.1 Click the Case Studies button on the LOOP-PRO main screen and from the pop-up list of processes
click on "Gravity Drained Tanks" to start the tanks simulation.

a) To generate dynamic process data, we need to change the controller output signal. This moves the
valve position, causing a manipulation in the flow rate of liquid into the top tank. In this exercise we are
interested in a step change in the controller output.

At the upper right of the draining tanks graphic on your screen, locate the white number box below the
Controller Output label. The most convenient way to step the controller output value is to click once on
this white number box. Click once on the controller output box and it will turn blue. For the first step
test, type 55 into the box and press Enter. This will cause the controller output to change from its current
value of 70% down to the new value of 55%, decreasing the flow of liquid into the top tank and causing
the liquid level to fall.  the process variable is going to be liquid level in the lower tank

b) Watch as the process responds. When the measured process variable (liquid level) reaches its new
steady state, click on the “pause” icon on the toolbar above the graphic to stop the simulation and then
click on the "view and print plot" icon to create a fixed plot of the response. Use the plot options as
needed to refine your plot so it is well suited for graphical calculations and then print it.

PV63.2
ΔPV

ΔCO

tCOstep t63.2
tPVstart
c) Using the methodology described in this chapter, use a graphical analysis to fit a first order plus dead
time (FOPDT) dynamic model to the process response curve. That is, compute from the response plot
the FOPDT model parameters: steady state process gain, KP, overall time constant, τP, and apparent dead
time, θP.

d) Repeat the above procedure for a second step in the controller output from 55% down to 40%.
m
e) The two steps in the controller output (70→55% and 55→40%) were both of the same size. Are the
model parameters the same for these two steps? How/why are they different?

The model parameters were not the same for the two steps even though the steps were
of the same size, and this is typical. This is due to the system being at two different operating
levels. Real processes display nonlinear behavior, and this is due to the fact that the dynamic
behavior of most real processes changes as operating level changes. It’s typical for real
processes to display nonlinear behavior at different operating conditions since controllers are
designed and tuned for a particular process behavior at the DLO. Clearly, the operating level
from 70→55% is different from 55→40%, which is why the KP, τP, and θP changed from part c) to
part d). All these parameters decreased. The system reached 63.2% of its overall change faster
in part d) since τP decreased. Part d) also had less dead time, which means it responded faster
initially as well. KP was smaller in magnitude in part d) as well, which also means that the
process variable didn’t change as much in response to the same change in controller output,
CO. This all makes sense since it simulates a real process, and real processes are not linear at
differing operating levels.

Q-3.2 Click the Case Studies button on the LOOP-PRO main screen and from the pop-up list of processes
click on "Heat Exchanger" to start the simulation.

a) To generate dynamic process data, we will step the controller output signal. At the lower left of the
exchanger graphic, locate the white number box below the Controller Output label. Click once on this
box, type 49 and press Enter to change the controller output from its current value of 39% up to the new
value of 49%. This increases the flow of cooling liquid into the shell side of the exchanger and causes the
exit temperature of liquid on the tube side to fall.  the process variable is going to be exit temperature

b) Watch as the process responds. When the measured process variable (exit temperature) reaches its
new steady state, click on the “pause” icon on the toolbar above the graphic to stop the simulation and
then click on the "view and print plot" icon to create a fixed plot of the response. Use the plot options as
needed to refine your plot so it is well suited for graphical calculations and then print it.
 PV63.2 ΔPV

ΔCO

tCOstep tPVstart t63.2

c) Using the methodology described in this chapter, use a graphical analysis to fit a first order plus dead
time (FOPDT) dynamic model to the process response curve. That is, compute from the response plot
the FOPDT model parameters: steady state process gain, KP, overall time constant, τP, and apparent dead
time, θP.
d) Repeat the above procedure for a second step in the controller output from 49% up to 59%.
 PV63.2
ΔPV

ΔCO

tCOstep tPVstart t63.2

e) The two steps in the controller output (39→49% and 49→59%) were both of the same size. Are the
model parameters the same for these two steps? How/why are they different?

The model parameters were pretty close to being the same for the two steps, but they
were a little different even though the two steps in controller output were both of the same
size. As described in Q3.1, it’s typical for real processes to display nonlinear behavior at different
operating conditions since controllers are designed and tuned for a particular process behavior.
Clearly, the operating level from 39→49% is different from 49→59%, which is why the K P, τP, and
θP changed slightly from part c) to part d). However, the τP values did not really change much
(92 seconds to 93 seconds), and human error could have been the difference here. The process
gain, KP, was of slightly smaller magnitude in part d), but this change was very minimal (-0.484
to -0.333), which also means that the process variable didn’t change quite as much in response
to the same change in controller output, CO. This all makes sense since it simulates a real
process, and real processes are not linear between differing operating levels. However, this
controller does not operate drastically differently at these two operating levels, as seen by the
fact that the FOPDT parameters were only slightly different between the two operating levels.
The process displayed almost linear behavior between the two operating levels shown here, but
not exactly.

Q-3.3 Start the jacketed reactor simulation (not the cascade case) by clicking on the Case Studies button
on the LOOP-PRO main screen and then clicking on "Jacketed Reactor."

a) To the right of the graphic, locate the white number box below the Controller Output label. Click once
on this box change the controller output from 42% up to a new value of 52%. This increases the flow of
cooling liquid through the cooling jacket side of the reactor and causes the measured exit temperature
of liquid from the reactor to fall.  the process variable will be exit temperature here

b) Watch as the process responds. When the measured process variable (exit temperature) reaches its
new steady state, click on the “pause” icon on the toolbar above the graphic to stop the simulation and
then click on the "view and print plot" icon to create a fixed plot of the response. Use the plot options as
needed to refine your plot so it is well suited for graphical calculations and then print it.
 PV63.2
ΔPV

ΔCO

tCOstep tPVstart t63.2

c) Using the methodology described in this chapter, use a graphical analysis to fit a first order plus dead
time (FOPDT) dynamic model to the process response curve. That is, compute from the response plot
the FOPDT model parameters: steady state process gain, KP, overall time constant, τP, and apparent dead
time, θP.
d) Repeat the above procedure for a second step in the controller output from 52% up to 62%.

PV63.2
ΔPV

ΔCO

tCOstep tPVstart t63.2

e) The two steps in the controller output (42→52% and 52→62%) were both of the same size. Are the
model parameters the same for these two steps? How/why are they different?

The model parameters were not the same for the two steps even though the steps were
of the same size, and this is typical. This is due to the system being at two different operating
levels. Real processes display nonlinear behavior, and this is due to the fact that the dynamic
behavior of most real processes changes as operating level changes. As described previously, it’s
typical for real processes to display nonlinear behavior at different operating conditions since
controllers are designed and tuned for a particular process behavior. Clearly, the operating level
from 42→52% is different from 52→62%, which is why the KP, τP, and θP changed from part c) to
part d). All three of these parameters decreased in magnitude, but not by a ton. The system
reached 63.2% of its overall change a bit faster in part d) since τP decreased slightly. Part d) also
had less dead time which means it responded faster initially as well. K P was smaller in
magnitude in part d) as well, which also means that the process variable didn’t change as much
in response to the same change in controller output, CO. This all makes sense since it simulates
a real process, and real processes are not linear at differing operating levels.
SP1:

1
2
3

The five control loops are labeled in blue on the diagram above, from top to bottom. The
following table summarizes each control loop’s controlled variable, manipulated variable, type
of sensor, and final control element.
Control Loop Control Loop Controlled Manipulated Type of Final Control
Number Description Variable Variable Sensor Element
1 Pre- Vapor Cooling Pressure Control Valve
Condenser Pressure Liquid Flow Sensor
Pressure entering the Rate (via
Control Loop Condenser Control
Valve)
2 Reflux Flow Reflux Flow Reflux Ratio / Flow Meter / Control Valve
Control Loop Rate from Flow Rate Sensor
Pump back to from Pump
Column through the
Valve back to
the Column
(via Control
Valve)
3 Post- Liquid Level Flow Rate Level Sensor Control Valve
Condenser After from
Level Control Condenser Condenser to
Loop Distillate (via
Control
Valve)
4 Reboiler Temperature Boil-Up Temperature Control Valve
Control Loop of Process Ratio / Flow Sensor
Fluid in Rate of
Bottom Steam or
Portion of Heating Fluid
Distillation into the
Column) Reboiler (via
Control
Valve)
5 Sump Level Fluid Level in Flow Rate to Level Sensor Control Valve
Control Loop Sump Bottoms (via
Control
Valve)