REPORT TITLE: PROCESS CONTROL PROJECT

Criteria % Mark
Synopsis 5
Introduction 10
Content 65
Conclusion 10
Literature consulted 5
Personal impression 5
TOTAL 100

Declaration: I certify that this report is my own unaided work, except for the
assistance received by the teaching staff. I undertake not to pass this
report on to any other student.

Date: Signed:
Executive Summery

The first automatic control system on record was applied nearly 2000 years ago and process

control systems have continued to be revolutionalized over the last 100 years. Fundamentals

of Control Refining, combining, handling, and otherwise manipulating fluids to profitably

produce end products can be a precise, demanding, and potentially hazardous process.

Small changes in a process can have a large impact on the end result. However, the

underlying report is a study of a process control system whereby the application of the

understanding of process control systems and the concepts of analyzing a system which is

subject to a unit step change needs to be applied.

In this study a given process was studied and a transfer function thereof was developed

employing empirical equations where the concentration of a tank was related through the

transfer function to the concentration X in the feed.

A response of the change in concentration to a unit step change in concentration of the feed

tank was also calculated, and from that the ultimate value of the concentration was

calculated.ie alpha =0.1 and alpha equal to infinity.

ii
 Table of Contents
Executive Summery................................................................................................................................ii
List of figures.........................................................................................................................................iv
1. Introduction...................................................................................................................................1
2. Literature Review...........................................................................................................................2
2.1. 1st order system.........................................................................................................................2
2.2. Transfer function........................................................................................................................2
2.3. Transient response.....................................................................................................................2
2.4. Responses of second order systems..........................................................................................3
2.5. Interacting system......................................................................................................................4
3. Results and discussions..................................................................................................................5
4. Conclusion.....................................................................................................................................6
4. Works Cited...................................................................................................................................7
5. Appendix........................................................................................................................................8
 List of figures
Figure 1: Forcing function (King, 2008)..................................................................................3
Figure 2: Interacting and Non Interacting System...................................................................4
Figure 3: Response of � = ∞...........................................................................................................6
1. Introduction

Control in process industries refers to the regulation of all aspects of the process. Precise

control of level, temperature, pressure and flow is important in many process applications.

Fundamentals of Control Refining, combining, handling, and otherwise manipulating fluids to

profitably produce end products can be a precise, demanding, and potentially hazardous

process. Small changes in a process can have a large impact on the end result. Variations in

proportions, temperature, flow, turbulence, and many other factors must be carefully and

consistently controlled to produce the desired end product with a minimum of raw materials

and energy. Process control technology is the tool that enables manufacturers to keep their

operations running within specified limits and to set more precise limits to maximize

profitability, ensure quality and safety.

1
2. Literature Review

2.1. 1st order system

Output modeled with a first order Ordinary differential equation: (E.LeBlanc, 2009)

𝑑𝑦
𝑎 +𝑎 𝑦 = 𝑏. � � (E.LeBlanc, 2009)

1 𝑑� �

If 𝑎� ≠ 0 , then:

𝑎 1 𝑑𝑦 𝑏 𝑑𝑦
+ 𝑦= � � ⇉ 𝜏 + 𝑦 = 𝐾 . �(�) (E.LeBlanc, 2009)
𝑎� 𝑑� 𝑎� 𝑝 𝑑� 𝑝

Where: 𝜏𝑝 is the time constant.

𝐾𝑝 is the steady state gain, static gain or gain (E.LeBlanc, 2009)

2.2. Transfer function

Generally, a transfer function describes two variables in a real process; one of these is the

cause of a forcing function or input variable, and the other is the effect (response or output

variable). (Jonhson, 2010)In a case where there is a thermometer, the “bath temperature” or

rather surrounding temperature is considered as an input and the reading on the

thermometer is the output and that may be represented as follow: (Jonhson, 2010)

��
� � =
��

Where: � � is a symbol for transfer function; �(�) is the input in deviation form it is also

known as a forcing function; �(�) is the output also well known as the response of the

system. (Jonhson, 2010)

2.3. Transient response

Now that the response of the 1st order system has been established, it can easily be obtain

its transient response to any forcing function. (King, 2008)Since this type of system occurs
so frequently in practice, it is worthwhile to study its response to several common forcing

functions; step, impulse, ramp and sinosidal. These forcing functions have been found to be

very useful in theoretical and experimental aspects of process control. However, only one

(King, 2008) will be shown extensively for the underlying report.

Figure 1: Forcing function (King, 2008)

2.4. Responses of second order systems

Consider a linear second-order ordinary differential equation, with constant parameters;

(Jonhson, 2010)
𝑑2𝑦 𝑑𝑦
𝑎2 + 𝑎1 + 𝑎0𝑦 = 𝑏 � �
𝑑�2 𝑑�
This is often written in the form: (Jonhson, 2010)

𝑑2𝑦 +𝑦=𝑘��
𝜏2 + 2𝜁𝜏 𝑑𝑦
2
𝑑�
𝑑�
Where (obviously 𝑎0 ≠ 0): (Jonhson, 2010)
𝑎2 𝑎1 𝑏
𝜏2 = + 2 𝜁𝜏 = +𝑘=
𝑎0 𝑎0 𝑎0

Where the parameters are: (Jonhson, 2010)

���𝑝�
𝑘 = 𝑔𝑎𝑖𝑛 �𝑛𝑖� ��
𝑖𝑛𝑝��

𝜁 = 𝑑𝑎𝑚𝑝𝑖𝑛𝑔 �𝑎𝑐��� 𝑑𝑖𝑚𝑒𝑛�𝑖�𝑛𝑙𝑒��

𝜏 = 𝑁𝑎���𝑎𝑙 𝑝𝑒�𝑖�𝑑 (𝑈𝑛𝑖�� �� �𝑖𝑚𝑒)

 2.5. Interacting system

The output from system 1 is affected by the output from system 2. The overall transfer
function (King, 2008)

for the process is not merely the product of the transfer functions in series. (King, 2008)

In contrast to this, the system shown in Figure 2 is said to be interacting because the flow

Through R 1 now depends on the difference between h1 and h2. (King, 2008)

Figure 2: Interacting and Non Interacting System

3. Results and discussions

�2 � 1
�(s) = 1
s2 + 2s + 1
α+1

An appropriate transfer function that relates the concentration in tank 2 which is denoted as

c2 to the concentration of x in the feed c2(s)/X(s) was derived, taking c2 and X as deviation

variables. The technique that was employed in achieving this was through carrying out an

overall material balance around tank 1, following that a component balance was done and

the resulting equation was written in steady state and further in deviation variable.

Assumptions take were that the volume was 1m3 and that qo was 1. A laplace transform was

taken and X(s) was the resulting subject thereof.

�2 � 1
Employed Transfer Function: =
�(s) s2 + 2s + 1
1
Force function: X(t)=1; � s =
s

System Response: �2 � = 1 − e−t − te−t

Employing the above stated transfer function a unit step was forced and applied, and then it

was necessary to use a method of partial fractions to determine the unknowns. Then the

laplace was taken from the s-domain to the t-domain and simplified to give the response.

Ultimate value occurs t→∞

�2 � =1

1 = 1 − e−t − te−t

t=10min

From the response the ultimate value was determined, as it is well known that the ultimate

value is found at infinity, therefore the time to get there was determined to be 10mins
2𝜉𝜏 = 2 𝜏2 = 0.5 = 0.707

𝜉 = 1.41

𝜉>1

Response graph
1.5
C2(t)

0.5 Response graph

0
0 51015 20
time(min)

Figure 3: Response of � = ∞

4. Conclusion

Process controlling systems are extensively used in the industry in today’s world so that

companies can save a lot of money they can speed up their production rates with the

employment of process controlling systems. Based on the results that were obtained it is

witnessed that process controlling systems are quite reliable. A response of a change in

concentration to a unit step change was determined and an ultimate value of the

concentration was found. As well as for alpha = 0.1 and infinity (see appendix) and was

found by employing empirical relation of process dynamics. One of the commonly known

advantage of a control system is that human error is completely minimized, however, due to

the policies that regulate company laws is that the industrial plants should be automated to a

certain extent so that there can still be jobs available for people to be empowered. Process

control technology is the tool that enables manufacturers to keep their operations running

within specified limits and to set more precise limits to maximize profitability, ensure quality

and safety.
4. Works Cited
E.LeBlanc, D. R. (2009). Process systems analysis and control 3rd edition. New york:
McGraw Hill.

Jonhson, C. D. (2010). Process Control instrumentation technology 8th edition . London:

McGraw Hill.

King, M. (2008). Process Control: A Practical Approach. Chicago: Fire wroks.

5. Appendix
CALCULATIONS

TANK 1

OMB

�1 = �0 + 𝛼�0
�1 = (𝛼 + 1)�0

Component balance
𝑑�𝑖
𝑉 = �0𝑥 + 𝛼�0�2 − �0(𝛼 + 1)�1
𝑑�
Steady state equation

𝑑�𝑖�
𝑉 = �0�� + 𝛼�0�2� − �0(𝛼 + 1)�1�
𝑑�
Deviation equation

𝑑�𝑖
𝑉 = �0� + 𝛼�0�2 − �0(𝛼 + 1)�1
𝑑�
Assuming V=1m3 and q0=1

𝑑�𝑖
= � + 𝛼�2 − (𝛼 + 1)�1
𝑑�

Taking Laplace transform

𝑑 �𝑖
L = 𝐿 � + 𝛼𝐿 � − (𝛼 + 1)𝐿 �
𝑑� 2 1

��𝑖 � + 𝛼 + 1 �𝑖 � − 𝛼�2 = �(�)

�𝑖 � + (𝛼 + 1) − 𝛼�2 = �(�)

Balance on Tank 2
𝑑�2 − � � − 𝛼 � 𝑥�
𝑉 =�𝛼+1�

0 1 0 2 0 2
𝑑�

= �0 𝛼 + 1 �1 − �0�2(1 + 𝛼)

Assuming V=1 and q0=1

𝑑�2
= 𝛼 + 1 � − � (1 + 𝛼)
1 2
𝑑�
Steady state equation
𝑑�2� − � (1 + 𝛼)
=𝛼+1� 𝑑� 1 2�
�

Deviation
form:
𝑑�2�
=𝛼+ − (1 + 𝛼)
�
1�
1� 2�
𝑑�

Taking Laplace transform.

𝑑�2�
𝐿 =𝛼+1 −𝐿 (1 + 𝛼)
�
𝐿�
1� 2�
𝑑�

��2 � + 𝛼 + 1 �2 � = 1 + 𝛼 �1� (�)

(� + 𝛼 + 1 )�2 �
�1� � = (1 + 𝛼)

Substituting for �1� � in the component balance of tank 1:

� + (𝛼 + 1) � + (𝛼 + 1)
�2 � = �(�)
(𝛼 + 1)
�2 + 2� 𝛼 + 1 + (𝛼 + 1)2 − 𝛼(𝛼 + 1)
�2 � = �(s)
𝛼+1
�2 � 1
�(s) = 1
s2 + 2s + 1
α+1

)
=

1
1
�s=
s
Case 1 α=0
�2 � 1
=
�(s) s2 + 2s + 1

1
�2 � = 2
s s + 2s +
1
1

�
=
ss+12
= +
� (� +
+
1)2 � + 1

9
C=-1
1 1 1
�2 � = − 2
−
� (� + 1) � + 1

Taking inverse Laplace transform:

�2 � = 1 − e−t − te−t

Ultimate value occurs t→∞

�2 � =1

1 = 1 − e−t − te−t

t=10min

CASE 2:

α=1

�2 � 1
= 2
�(s) 0.5s + 2s + 1

1
�2 � = 2
s 0.5s + 2s + 1

2𝜉𝜏 = 2 𝜏 2 = 0.5 = 0.707

𝜉 = 1.41

𝜉>1
1 A B C
�2 � = = + +
s 0.5s2 + 2s + 1 s s + 0.586 s + 3.414

A=1

2 = −1.2068
�=
−0.586(−0.586 + 3.414)

2 = 0.2072
�=
−3.44(−3.44 + 0.586)

1 1.2068 0.2072
�2 � = − +
s s + 0.586 s + 3.414

Taking the Laplace transform:

�2 � = 1 − 1.2068e−0.586t + 0.2072e−3.414t

Solving for t when �2 � = 0.6

10
Ultimate value occurs when t→∞

11
�2 � = 0.5

0.5 = 1 − 1.2068e−0.586t + 0.2072e−3.414t

t=1.5min

CASE 3

𝛼=∞
1 � �
�2 � = = +
s 2s + 1 1 2� + 1

A=1

B=-1

Taking the Laplace transform:

−t
�2 � = 1 − e 2

Ultimate value occurs when t→∞

�2 � = 1
−t
1=1−e2

t=15.1min

C)

Response graph
1.5
C2(t)

0.5 Response graph

0
0 51015 20
time(min)