Process Control Example

Ruel G. Peneyra

PROBLEM # 11.1. In the process shown in Fig. Pll. 1, the concentration of salt leaving the second
tank is controlled using a proportional controller by adding concentrated solution through a control
valve. The following data apply:

1. The controlled concentration is to be 0.1 lb salt/ft 3 solution. The inlet concentration ci is always
less than 0.1 lb/ft3.
2. The concentration of concentrated salt solution is 30 lb salt/ft 3 solution.
3. Transducer: the output of the transducer varies linearly from 3 to 15 psig as the concentration
varies from 0.05 to 0.15 lb/ft3.
4. Controller: the controller is a pneumatic, direct-acting, proportional controller.
5. Control valve: as valve-top pressure varies from 3 to 15 psig; the flow through the control valve
varies linearly from 0 to 0.005 cfm.
6. It takes 30 set for the solution leaving the second tank to reach the transducer at the end of the
pipe.

Tank A Tank B

Draw a block diagram of the control system. Place in each block the appropriate transfer function.
Calculate all the constants and give the units.

1
SOLUTION:

Mass balance on Tank A at any time t

dc 1 dc 1
V1 Fci Fc1 V 1 c1  V1 Fc1 V 1 c1 Fc i
dt dt

V 1 dc 1 F V1 dc 1 1
c1 c let c1 ci
F V 1 dt F V1 i 1
F V1 1
dt 1
V1
F

At steady state

dc 1 1 dc 1s 1
using c1 ci the steady state eqn c 1s c is
1
dt 1
V1 1
dt 1
V1
F F

Equating

d c 1 c 1s 1
c1 c 1s ci c is using deviation C 1 c 1 c 1s andC i ci c is
dt 1
V1
F
dC 1 1 1
C1 Ci transforming sC 1 s C1 0 C1 s Ci s
1
dt 1
V1 1
1
V1
F F

1
V1
1 C1 s 1
F
since C 1 0 0: sC 1 s C1 s Ci s then
1
1
V1 Ci s 1 s 1
F

3
1
ft 3 C1 s 1 3 C1 s 1
since V 3 m and F 1 3
: then 3
or
min 1
4 Ci s s 1 Ci s 3s 4
4

At Tank B

dc 2 m dc 2 m
V2 Fc1 m Fc2 V 2 c2 rearranging V 2 Fc2 V 2 c2 Fc1 m
dt A dt A

m m V2
if is far less than F is negligible , dividing by F V 2 and setting
A A F V2 2

2
 dc 2 F 1 dc 2 1 1
c2 c m c2 V 2 c1 m
2
dt F V2 1 F V2 2
dt 1 F 1
V2
F F

At steady state

dc 2s 1 1
c 2s V 2 c 1s m s equating with the conditions at anytime t
2
dt 1 F 1
V2
F F

and using deviation variablesC 2 c 2 c 2s ; C 1 c 1 c 1s ; M m ms

dC 2 1 1 1 1
C2 V2 C1 M transforming s 1 C2 s V2 C1 s M s
2
dt 1 F 1
V2 2
1 F 1
V2
F F F F
Finally

1 1
V2 V2 1
1 F 1
F
C1 s M s
F 5
C2 s C1 s M s sub the given C 2 S 4
2 s 1 2 s 1 s 1
5

Evaluating m (mass of concentrate)

from steady state condition of Tank A

F 1 1
Fc is Fc 1s V 1 c 1s c 1s c c 1s c is c 1s c
F V 1 1s 1 3 4 is
ms
At tank B neglecting and setting c 2s 0.1
A

ms
Fc 1s ms Fc 2s V 2 c 2s c 2s ms Fc 2s V 2 c 2s Fc 1s ms 1 0.1 4 0.1 c 1s
A

1
if c 1s c then ms 0.5 0.25c is
4 is

CONTROL VALVE

Sensitivity Kv

0.005 0 1 cfm ms 1 1 15 3
Kv Kv since m s then p s 3 ms
15 3 2400 psi A 30 30 0.005 0

3
Hence the normal operating pressure is ps 3 80 m s
1
Valve equation is therefore m ms Kv p 3 80 m s A
30

1
by steady state ms ms K v ps 3 80m s A equating with the eqn at any time t
30

and by deviation variables M m ms and P p ps then M Kv A P

1
where M m m s and P p 3 80m s
30

M s
taking the transform of M K v A P Kv A valve transfer function
P s

TRANSDUCER

Sensitivity Km
psi
15 3
Km Km 120 lb3
0.15 0.05 ft

Normal signal = 0.1 0.05 15 3 3 9 psig

0.15 0.05

Transducer equation  b 9 K m c2 0.1

By deviation variables  B K mC2 where B b bs and C 2 c 2 c 2s

B s
By Laplace the transducer transfer function  Km
C2 s

4
CONTROLLER

Controller output pressure (p) and error relationship

p pS K c cR b ps Kc

Where

c RS b 9 psig ; K c controller sensitivity ; error c R b, psig and C R c r c RS

Then

P s
P Kc and the transfer function of the controller by laplace Kc
s

TRANSPORT LAG

30
d min 0.5 min
60

Hence the transfer function is therefore e ds e 0.5 s

CONSTANTS AT cis < 0.1

c is ms ps 1 2 c 1s c 2s ms m at
A p=ps
lb/cu.ft lb/min psig min min lb/cu.ft lb/cu.ft cfm lb/min
0.10 0.48 41.00 0.75 0.80 0.03 0.10 0.02 0.48
0.09 0.48 41.20 0.75 0.80 0.02 0.10 0.02 0.48
0.08 0.48 41.40 0.75 0.80 0.02 0.10 0.02 0.48
0.07 0.48 41.60 0.75 0.80 0.02 0.10 0.02 0.48
0.05 0.49 42.00 0.75 0.80 0.01 0.10 0.02 0.49
0.06 0.49 41.80 0.75 0.80 0.02 0.10 0.02 0.49
0.04 0.49 42.20 0.75 0.80 0.01 0.10 0.02 0.49
0.03 0.49 42.40 0.75 0.80 0.01 0.10 0.02 0.49
0.02 0.50 42.60 0.75 0.80 0.01 0.10 0.02 0.50
0.01 0.50 42.80 0.75 0.80 0.00 0.10 0.02 0.50
0.00 0.50 43.00 0.75 0.80 0.00 0.10 0.02 0.50

5
BLOCK DIAGRAM

1
C1 Ci
3s 4

CR M
P M F 1
+ v2
+ 1  1
CR  Km   Kc  Kv A   F  C2 
F +
s 1
2
psig -
B
Km e 0.5 s

psig

OR

1
Ci 
3s 4
C1 1
+ + v2
CR   KK c   1
F  C2 
+ 2 s 1
-
e 0.5 s