Process Control: EHPCO2A Assignment 1 18 October 2023

F1, T1, cA1, cB1=0

F3, cA3, cB3 = 0, T4

Catalytic bed F2, cA2, cB2, T2 Tubular Heat Exchanger

reactor coolong water

A→B h2
Cooling water F4, cA4 = 0, cB4, T4 F4, cA4 = 0, cB4, T5
Reactor
Cooling water Fst, Tst

Separation cooling water

Evaporation with direct
steam heating

1 What are the reasons for adding a control system to the reactor? Discuss each reason as it applies to the reactor
specifically. The reactor system is operated in a meta-stable state explain how this relates to the reasons for
needing a control system.
(10)
Suppressing the influence of external disturbances✓ – disturbances to this process will include the
temperatures, compositions and flow rates of the feed streams to the Reactor✓. The control
system needs a control mechanism that will make the proper changes on the process to cancel
the negative impact that such disturbances may have on the desired operation of the process✓.
Ensuring the stability of the chemical process✓ – when a disturbance impacts on the system we
need the system to return to its normal operating conditions as soon as possible✓. The control
system will help to do this. Sometimes, like here we want to operate a reactor at temperatures
between two different stable states, normally to prevent side reactions, ensure a faster and better
product formation or because of operational constrains. The function of the control system will be
to ensure that the temperature in the reactor is kept at the meta-stable state between the high and
low temperature stable states✓✓

Optimising the performance of the chemical process✓ – once the objectives of safety and product
specifications are met, the next goal is to make the operation of the plant more profitable✓. For the
process described here it will include things like optimising usage of cooling water, maximising the
reaction ensuring minimum formation of B✓.

2 Give an explanation of the following terms and statements as they apply in a process control environment:

(a) Operational constraints, as part of the requirements a chemical plant must satisfy. (2)
The various types of equipment used in a chemical plant have constraints inherent to their
operation✓. For example: pumps must maintain a certain net positive suction head; tanks should
not overflow or run dry; distillation columns should not be flooded; the temperature in a catalytic
reactor should not exceed an upper limit since the catalyst will be destroyed; etc. ✓✓

(b) Secondary measurement, which control configuration is associated with secondary measurements. (4)
It sometimes happens that our control objectives are not measurable quantities; they belong to the
class of unmeasured outputs. In such cases we must measure other variables which can be
measured easily and reliably. Then we develop mathematical relationships between the
unmeasured control objectives and the measured variables. Such supporting measurements are
called secondary measurements. ✓✓✓
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 Process Control: EHPCO2A Assignment 1 18 October 2023
This is typically used in the design of inferential control configurations✓

(c) State variables (2)

A set of fundamental dependant quantities whose values will describe the natural state of a given
system (eg. temperature, pressure, flow rate) ✓✓

(d) The input-output model (2)

A mathematical relationship that, given the values of the inputs, provides the values of the output
directly✓✓

(e) Degrees of Freedom (2)

Degrees of Freedom are the independent variables that must be specified in order to define the
process completely. ✓✓

(f) Explain the term Dead Time as it will apply to the CSTR (Include a definition of Dead time) (3)

Whenever an input variable of a system changes, there is a time interval during which no effects is
observed on the output of the system. ✓✓

If the concentration of the incoming stream changes there will be a time delay before a change in
the outlet concentration will be measured. ✓ Any explanation from the process that makes sense

(g) Over-ride control configuration and its relationship to automatic trips systems and interlocks (5)

During the normal operation of a plant or during its startup or shutdown it is possible that
dangerous situations may arise which may lead to destruction of equipment and operating
personnel.  In such cases it is necessary to change from normal control action and attempt to
prevent a process variable from exceeding an allowable upper or lower limit. ✓ This is achieved
through the use of special types of switches. The high selector switch (HSS) is used whenever a
variable should not exceed an upper limit and a low selector switch (LLS) is employed to prevent a
process variable from exceeding a lower limit. ✓

Over-ride control is the control configuration used for automatic trip systems (normal operation of
the plant) and interlocks (during startup and shutdown), which both have the function of preventing
dangerous situations which may led to destruction of equipment and operating personnel. ✓✓
(17)

3 What are the most obvious control objectives for the CSTR? Give two secondary control objectives
(4)
The concentration of the mixture cB2 leaving the CSTR must be at a specified value
The temperature of the mixture T2 in the CSTR as this is a temperature dependant reaction

Ensuring that the CSTR does not over flow or run dry
Preventing cavitation in the pump removing the product form the reactor
(Any answers that makes sense and shows understanding)

4 Design a control system with a feed forward (cB2) and a feedback (F2) loop to satisfy the following needs:
Control objective: cB2 and F2 (the reaction is very temperature sensitive)
Disturbances: F1 and T1
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 Process Control: EHPCO2A Assignment 1 18 October 2023
(6)
Set point


CC Concentration
measurement
F3, T4, cA3, cB3=0 F1, T1, cA1, cB1=0 


FC Set point
Cooling water in Cooling water out

Catalytic Bed
F2, T2, cA2, cB2


A→B Flow
measurement

5 A cascade system is proposed to improve the temperature control in the system, because of the system’s
sensitivity to temperature changes. Identify the (a) control objective, (b) disturbance, (c) measured, (d)
manipulated, (e) input and (f) output variables for the process.

F3, T4, cA3, cB3=0 F1, T1, cA1, cB1=0

Cooling water in
Cooling water out

F2, T2, cA2, cB2

Catalytic Bed

Thermocouple Thermocouple

Set point
TC TC
C C
Set point

(12)

(a) Objective: T2✓

(b) Disturbance: T1 and cA1 ✓
(c) Measured: T2✓ and Tcooling water out ✓
(d) Manipulated: Fcooling water ✓
(e) Input: F1, T1, cA1, F3, T4, cA3, Fcooling water in, Tcooling water in (✓½) x 8
(f) Output: F2, T2, cA2, cB2, Fcooling water out, Tcooling water out (✓½) x 6

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 Process Control: EHPCO2A Assignment 1 18 October 2023
6 What are the advantages associated with cascade control
(3)
Faster control action✓. A major benefit to be gained from cascade control is the fact that the
disturbance arising in the secondary loop are corrected in the secondary loop before they affect
the value of the primary controlled output. ✓✓

7 Design an auctioneering control configuration to ensure that T5, leaving the tubular heat exchanger remains
constant.
(5)
condensate

reagents products

Temperature Temperature Temperature

measurement measurement measurement

Set point

controller

steam
✓✓✓✓✓

8 A mathematical model is a mathematical representation of the physical and chemical phenomena, taking place in a
chemical process, giving a simple & usable description of how the outputs of a process are affected by
disturbances and manipulated variables.
How is the mathematical model used, assuming that our controller is a digital computer and what are the
mathematical relationships needed to describe a (a) feed forward control configuration, (b) feedback control
configuration and (c) an inferential control configuration? (Not an equation just an explanation)
(8)
The mathematical model is used to develop a control system for a chemical process that will
guarantee that the operational objectives of our process are satisfied in the presence of ever-
changing disturbances.  It is these equations which are programmed into the computer that are
used to calculate the control action need (eg. % closing or opening of a control valve) 

(i)Feed Forward
output = f1(disturbance) 
output = f2(manipulated variable) 

(ii)Feedback
control objective = measured output
output = f2(manipulated variable) 

(iii)Inferential
control objective = f1(measured output) 
output = f2(manipulated variable) 

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 Process Control: EHPCO2A Assignment 1 18 October 2023
9 Starting from the principle of conservation; derive the general energy balance used to develop a mathematical
model.
d (hT ) Q W
(A =  FiTi −  FjT j   ), you need to state all assumptions clearly.
dt i = inlet j = outlet cP cP
(12)

acc of energy flow energy IN flow energy OUT energy GENERATED energy USED
= − + −
time time time time time

E =U + K + P K and P → 0 steady state, tank does not move

dE dU
= dU  dH, liquids incompress ible
dt dt
= Vc P (T − Tref )
dE dH
= h enthalpy = u + pv, pv nearly constant and Tref choose as 0, henthalpy = c PT
dt dt
dH
= Ahc PT
dt

dE d (U + K + P) dH
= = =   i Fi c P (Ti − Tref ) −   j F ji c P (T ji − Tref )  Q  W
dt dt dt i =inlet j = outlet

d (Ahc PT )
=   i Fi c P (Ti − Tref ) −   j F j c P (T j − Tref )  Q  W
dt i = inlet j = outlet

ρ and c P is assumed constant for all liquids over the given temp erature range

d (hT ) Q W
A =  FiTi −  F j T j  
dt i = inlet j = outlet c P c P

10 Calculate all the balances needed to develop a mathematical model of the Catalytic Bed Reactor.
(18)
ρ and c P assumed constant over the temperature range, no phase change in the reactor

Mass Balance ✓✓
dV
= F1 + F3 − F2
dt
dV
= F1 + F3 − F2
dt

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 Process Control: EHPCO2A Assignment 1 18 October 2023
Component Balance
dc A2V
= c A1 F1 + c A3 F3 − c A2 F2 − rV
dt
dV dc
c A2 + V A2 = c A1 F1 + c A3 F3 − c A2 F2 − rV ✓✓✓✓
dt dt
c A2 (F1 + F3 − F2 ) + V A2 = c A1 F1 + c A3 F3 − c A2 F2 − rV
dc
dt
= (c A1 − c A2 ) + 3 (c A3 − c A2 ) − r
dc A2 F1 F
dt V V

dc B 2V
= −cB 2 F2 + rV
dt
dV dc
cB 2 + V B 2 = −cB 2 F2 + rV
dt dt
✓✓✓✓
cB 2 (− F2 ) + V
dcB 2
= −cB 2 F2 + rV
dt
dc B 2
=r
dt

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 Process Control: EHPCO2A Assignment 1 18 October 2023
Energy Balance

dH (T2 , n A2 , nB 2 )
= c p F1T1 + c p F3T3 − c P F2T2 − QCW
dt

dH  H dT   H dn A2   H dn B 2 
=  +  +  
dt  T dt   n A dt   nB dt 

H
= Vc P
T
H ~
= H A (T )
n A
H ~
= H B (T )
nB
dn A2
= c A1 F1 + c A3 F3 − c A2 F2 − rV
dt
dn B 2
= −c B 2 F + rV
dt

dH dT ~ ~
= Vc P 2 + H A [c A1 F1 + c A3 F3 − c A2 F2 − rV ] + H B [−c B 2 F2 + rV ]
dt dt ✓✓✓✓✓✓✓✓
c p F1T1 + c p F3T3 − c P F2T2 − QCW = 
dT2 ~ ~
 = Vc P + H A [c A1 F1 + c A3 F3 − c A2 F2 − rV ] + H B [−c B 2 F + rV ]
dt
~ ~
dT2 F1T1 F3T3 F2T2 Q HA HB
= + − − − [c A1 F1 + c A3 F3 − c A2 F2 − rV ] − [−c B 2 F2 + rV ]
dt V V V Vc P Vc P Vc P

11 Identify the state variables, other variables and constant parameters for the Separator balances given below and
calculate the degrees of freedom for the Separator. Explain how you could reduce the degrees freedom.

dV2  
= F2 + st Fst − F4 − v F5
dt  
dc A3 F2
= (c A2 − c A3 )
dt V2
dc B 4 F2
= (cB 2 − cB 4 )
dt V2

(T2 − T4 ) +  st csteam Fst (Tst − T4 ) + steam condensation − evaporation A

dT4 F2 Q Q
=
dt V2 c PV2 c PV2 c PV2

V2 = A2 h2 ; F4 = h2 ; Qsteam condensation =  st Fst cond st ; Qevaporation A =  v F3evap A

(16)
State variables: h2, cA3, cB4, T4 (✓½) x 4
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 Process Control: EHPCO2A Assignment 1 18 October 2023
Constant parameters: , st, v, cP, cst, cV, A2, , cond. st, evap. A (✓½) x 10
Other variables:V2, F2, Fst, F4, F5, cA2, cB2, T2, Tst, Qsteam condensation, Qevaporation A(✓½) x 11

Equations: 8(✓½)

Degrees of Freedom: 15 - 8 = 7✓

Control loops to control T4, cB4, h2, for example, will each have a measured and manipulated
variables, which will be known. Other equations can also be used, for example phase equilibria
relationships and transport rate equations. ✓✓ Any explanation that shows understanding

12 Look at the control configuration below: Explain how this control system works by identify all the hardware
elements in the system and explaining their function.

F3, cA3, cB3 = 0, T4

Separation
Evaporation with direct
steam heating
F2, cA2, cB2, T2

h2
F4, cB4, cA4 = 0, T4

Fst, Tst

TC TT

(8)
T4 is measured using an appropriate measuring device✓, the measurement is converted to a
signal that can be transmitted to the controller✓. The measured value is sent to the controller✓,
via the transmission lines, where it is compared to the set-point and the deviation is used to
calculate the adjustment needed in the steam flow rate into the system✓. The measurements and
adjustment are recorded✓. This adjustment is sent, via transmission lines, to the control valve✓,
that opens or closes as is needed✓. It T4 is high the valve will close and if it is too low the valve
will open✓. explanation must show understanding of the concepts involved

13 The valve used to control the steam entering the separator is a pneumatic control valve and operates as a fail-
open system. Explain what this means and how the valve operates.
(7)
A pneumatic valve is an air operated valve which controls the flow through an orifice by positioning
a plug✓. The plug is attached to a stem✓ which is supported in a diaphragm at the other end✓.
As the pressure (controller output) above the diaphragm increases, the stem is pushed down
restricting flow through the orifice✓(air-to-close). As the air pressure (controller output) above the
diaphragm decreases or is lost for some reason, the stem is pushed up by the spring and
consequently the plug lifts and allows the flow through the orifice✓✓✓ (fail-open)
(The answer must show a clear understanding of the air-to-open, fail-close and the operation of a pneumatic control valve)

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