CHNG 3003 - PROCESS DYNAMICS AND CONTROL II

TUTORIAL #6 - To be held Monday, April 2/07 in the Chem. Engng. Design Office.
Consider the problem of controlling temperature in the third tank of the following system
by manipulating the heat input to the first:

PC1

PC2

PC3

Offgas

Offgas

Offgas

Air
Air

Air

LC1

LC2

LC3

Feed

Liquid
Effluent

TI

TC1

Heat
Medium

A liquid mixture of ethanol and n-pentane (15 mole % EtOH) at 40 C and 1000 kPa is
charged to the process with volumetric flowrate 30 m3/hr. A small flow of air (100 kg/hr)
is added to each vessel at the same temperature and pressure. The tanks are 10 m 3
vertical cylinders.
The pressure and level control valves are linear-trim and designed for a pressure drop of
300 kPa at the nominal flowrates. At the initial steady-state, the liquid level in the tanks
is 50% of scale and the coil is supplying 1.97 106 kJ/hr of heat to the first vessel. When
fully opened, the heat medium control valve can pass enough fluid to transfer
q max 4 10 6 kJ/hr.

The bottoms product pumps deliver a pressure rise of 300 kPa with an efficiency of 75%.
The range of the temperature transmitters is 0 100 C and the pressure transmitters are
calibrated for 500 - 1100 kPa. The temperature control loop is subject to a measurement
delay of 10 minutes.
(a) Build a dynamic model of this process using HYSYS.Plant. Choose a value of the
proportional gain K c which will ensure that the tank levels remain in the range 45
55%. Tune the remaining controllers until satisfactory servo response has been achieved.
(b) Simulate 5 hours of PID control of the Tank 3 temperature, introducing a 10 C step
change in the feed temperature at time t = 10 min. The setpoint of the temperature
controller is to remain fixed at its initial value of 75 C. Export your results to Excel and
estimate the integral of the squared error (ISE) for TC1.
(c) Switch the temperature controller to manual and implement a 5% step increase in
controller output. Fit a first-order-plus-deadtime model to this reaction curve.
(d) With TC1 on manual, make a 10 C step decrease in the process fluid inlet
temperature and fit a first-order-plus-deadtime model to this response.
(e) Apply the IMC Design feature of the HYSYS PID controller block to determine
K c , I and D for the temperature controller. Repeat part (b) using these parameters
and compare your results to those obtained in part (h) of Tutorial #4.
(f) Apply the Autotuner feature of the HYSYS PID controller block to tune TC1 and
repeat part (b).
(g) As indicated in the process schematic, a second thermocouple has been installed to
provide a continuous measurement of the inlet temperature. Design a feedforward
controller which compensates for the effect of feed temperature on the measured outlet
temperature. Simulate the performance of the combined feedforward/feedback control
scheme for the step decrease in feed temperature and compare your results to those
obtained in part (i) of Tutorial #4.