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November 19, 2014
CH E 4353
Process Control
Exam 3-Fall 2014
This is a closed book, closed note examination. You are permitted the following items.
programmable/graphing calculator
blank scratch paper
number 2 lead pencils
erasers
straight edge
one 8.5 x 11 page of equations, (1 side only)
Table 9.2 from the text. No extraneous marks.
No other materials are allowed.
There are 31 35 questions worth a total of 155 points; each question is equally weighted. Record
the answer which is most nearly correct on the Scantron sheets provided.
Five of these questions are extra credit. Those students who attended class on 11/4/14 will receive
credit for correct answers to questions 1 to 5.
You may take your copy of the test with you when finished.
1. For an electronic controller with I/O of 4-20
2. For a pneumatic controller with I/O of 3-15
mA, and a gain of 4, the proportional band is
Response No.
psig and a proportional band of 33.3%, the
gain is
Response
100%
Response No.
Response
16 mA
0.33
16%
0.33psig
25 mA
12
25%
12 psig
400 mA
15
400%
15 psig
5 mA
5%
3 psig
50%
5 psig
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Questions 3 to 8 refer to the step response of a second order system shown in Figure 1
Figure 1. A Step Response (vertical axis dimensionless)
3. The rise time for the response is (sec)
4. The overshoot for the response is
Response No.
Response No.
Response
Response
0.16
0.16
0.50
0.50
0.60
0.60
0.76
0.76
0.90
0.90
1.0
1.0
1.8
1.8
5.0
5.0
8.0
8.0
10
10
Students answering 0 or
1 will receive credit.
5. The decay ratio is
Response No.
0.35
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6. The oscillation period is (sec)
Response
Response No.
Response
0.16
0.16
0.50
0.50
0.60
0.60
0.76
0.76
0.90
0.90
1.0
1.0
1.8
1.8
5.0
5.0
8.0
8.0
10
10
7. The settling time is (sec)
8. The damping factor is
Response No.
Response No.
Response
Response
0.16
0.16
0.50
0.50
0.60
0.60
0.76
0.76
0.90
0.90
1.0
1.0
1.8
1.8
5.0
5.0
8.0
8.0
10
10
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Figure 2 depicts the flow control loop for coolant to an exothermic reactor. The final control element is a
pneumatic control valve on the coolant flow with negligible dynamics. The sensor, filter, and transducers
are all direct acting.
D2
Gd2
Gd
Yd2
Tsp
Ksp [mA/ F]
Gc
+-
KI/P
Tf
Kv
Ts
Gf
Q
+
Yd
Gp
Yp
+
Ks [mA/ F]
Figure 2. Flow Control of Reactor Coolant
The process transfer function may be accurately described by a FOPDT model relating the reactor
temperature T(s) to the coolant flow rate Q(s).
T s K pe p
Gp s
Q s ps 1
(1)
Please answer questions 9 to 12.
9. Kp is
Response No.
0
1
2
3
4
5
10. The control valve should
Response
negative
obviously critically damped
obviously overdamped
obviously underdamped
positive
none of the above
Response
No.
Response
be air-to-close
be fail-close
be quick-opening
have non-linear installed characteristics
rather be a variable speed pump
take of the total pressure drop
11. The controller action should be
12. The units of the controller gain should be
Response No.
Response No.
Response
Response
a pneumatic signal
gpm
analog
gpm/mA
direct
gpm/F
inverse
mA/gpm
P-only
mA/mA
reverse
F/gpm
through the manual mode
F/min
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In Figure 3 is shown a shell-and-tube
heat exchanger which preheats the
feed to a distillation column. The
transfer function relating tube-side
outlet temperature T(s) to steam flow
S(s) is
F 7.5min s
10
e
lbm
hr
Gp s
15.5 min s 1
600 psig steam header
FC
I/P
100
TIC
100
TT
100
Heated Reactor Feed
Reactor Feed
(2)
Condensate
Figure 3. Column Feed Preheater
Employing Cohen-Coon tuning rules, please answer questions 13 to 16.
14. The controller gain should be ( lbm F )
13. The controller action should be
hr
Response No.
Response
Response No.
Response
a pneumatic signal
-0.301
analog
-0.24
direct
-0.194
inverse
P-only
0.194
reverse
0.24
through the manual mode
0.301
a pneumatic signal
2.507
analog
12.63
direct
15.516
15. The integral time should be (min)
16. The derivative time should be (min)
Response No.
Response No.
Response
Response
-0.301
-0.301
-0.24
-0.24
-0.194
-0.194
0.194
0.194
0.24
0.24
0.301
0.301
2.507
2.507
12.63
12.63
15.516
15.516
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17. The Laplace transform F(s) of the
function in Figure 4 is
Response No.
Response
5 4e2 s e6 s
5S t 4S t 2 S t 6
1
5 4e2 s e6 s
5S t 4S t 2
1
5 4e2s
s
1
5 4e2 s
2
s
4
5
Figure 4.
Note: S(t) =unit step function
(t)=Dirac delta function
Figure 5 illustrates two tanks in
series whose liquid levels interact.
The transfer function relating the
level in Tank 1, h1, to the inflow to
Tank 1, qi, is given by equation (3).
The valves are linear, with
resistances R1 and R2. A1 and A2 are
the cross sectional areas of Tanks 1
and 2, respectively.
5t 4S t 2
5 t 4S t 2 S t 2
Figure 5. Two interacting tanks in series.
R1R2 A2
s 1
H1 s
R1 R2
2
Qi s R1R2 A1 A2 s R2 A2 R1 A1 R2 A1 s 1
R1 R2
(3)
The two tanks are each 2 m in diameter, and the valves are identical with resistances equal to 0.5
min/m2. If the inlet flow to Tank 1 increases suddenly by 1 m3/min at time zero, please answer
questions 18 to 23.
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18. The process gain is
19. The natural period is
Response No.
Response
Response No.
Response
-1.273 min-1
-1.273 min-1
0.785 min
0.785 min
1 min/m2
1 min/m2
1 min
1 min
1m
1m
1 m3/min
1 m3/min
1.5
1.5
1.571 min
1.571 min
21. The final level in Tank 1 is assuming it's initially empty
20. The damping factor is
Response No.
Response
-1.273 min
Response No.
Response
-1.273 min-1
0.785 min
0.785 min
1 min/m2
1 min/m2
1 min
1 min
1m
1m
1 m3/min
1 m3/min
1.5
1.5
1.571 min
1.571 min
-1
22. Qualitatively, the step response h1(t) is
Response No.
Response
23. Under what conditions will the level in Tank
1 oscillate?
Response
No.
Response
critically damped, inverse
overdamped, inverse
3A2R2>2(A22R22)1/2
underdamped, inverse
3A1R1>2(A22R22)1/2
critically damped,direct
overdamped, direct
R1 R2 A2
0
R1 R2
underdamped, inverse
R2 A2 R1 A1 R2 A1 <1
unstable, inverse
R1 R2 0
unstable, direct
response is always critically
damped
response is always overdamped
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Figure 6 depicts the block flow diagram of a nondimensionalized process. The setpoint to the process
stepped up by 1 unit at time=1. Please answer questions 24 to 27.
Ysp
+-
Kc
Figure 6.
24. The open loop response is stable for what values
of Kc?
25. The closed loop response exhibits stable, but
Response No.
0
Response
No.
Response
Kc 25
16 K p
25
Kc 1
16 K p
Kp
Response
Kc 25
25
16 K p
16 K p
Kc 1
Kp
5 Kc 20
20 Kc
5 Kc 20
The process is open-loop unstable
20 Kc
The process is closed-loop unstable
Kp
Kc
underdamped behavior for
26. The closed loop response is unstable for
Response No.
0
1
Response
Kc 25
16 K p
25
Kc 1
16 K p
Kp
Kc
27. The closed loop response exhibits stable,
overdamped behavior for
Response No.
Response
Kc 25
16 K p
0
1
25
16 K p
Kc 1
5 Kc 20
20 Kc
5 Kc 20
The closed loop response is
unconditionally stable
20 Kc
Kp
Kc
Kp
Kp
Kp
Kc
The process is closed-loop
unstable
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You have implemented the velocity
form of a digital PID controller on a
control loop. The strip chart of the
process appears in Figure 7, where the
setpoint to the controller (ysp), the
measured value of controlled variable
(ys), the error signal to the controller
(e), and the controller action (c) are
plotted. All signals are in mA. The
controller settings are given in Table 1.
Table 1. Controller Settings
Setting
Value
Kc
0.256
2.408 min
0.36 min
control
interval
1 min
Figure 7.
At 6 minutes, the error signal to the controller jumps +0.972 mA. Please answer questions 28 to 31
28. The controller action c at t=6 min is (mA)
Response No.
29. If proportional kick is eliminated, the controller
action c at t=6 min is (mA)
Response
Response No.
Response
0.088
0.18
0.088
0.436
0.18
0.588
0.436
0.618
0.588
0.936
0.618
5.18
0.936
5.18
30. If both proportional and derivative kick are
eliminated, the controller action c at t=6 min is
(mA)
Response No.
Response
0.088
0.18
0.436
0.588
0.618
0.936
5.18
31. The amount of integral windup at t=6 min is (mA)
Response No.
Response
0.088
0.18
0.436
0.588
0.618
0.936
5.18
