PROGRAM: BACHELOR OF ENGINEERING TECHNOLOGY
CHEMICAL ENGINEERING
SUBJECT: PROCESS CONTROL A2
CODE: PRCCHA2
DATE: 26 May 2022 (Sick Test 1 Memorandum)
DURATION: 08:00 – 10:00 [2 Hours]
TOTAL MARKS: 70
EXAMINER: Mr. Rama Iloy
MODERATOR: Prof. Bilainu Oboirien
NUMBER OF PAGES: 9
REQUIREMENTS: Use of scientific (non-programmable) calculator is permitted
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Question 1 [20 marks]
1.1. Vapor feed to an adiabatic tubular reactor is heated to about 700 °F in a furnace as shown in
the Figure below. The fuel gas provides the necessary heat in the furnace. The reaction is
endothermic. The exit temperature of gas leaving the reactor is to be controlled at 600 °F. It
is assumed that the vapor feed flow may fluctuate and can be measured but the operator has
no control over it. By means of a diagram, show how you would achieve the control
objective using:
a) Feedback control
b) Feedforward control
In each case, state the control objective, the controlled variable, the manipulated variable and the
disturbance [16 marks].
a) Feedback control [4 marks for the diagram]
Control objective: Keep reactor exit at target temperature [1 mark]
Controlled variable: Reactor exit temperature [1 mark]
Manipulated variable: Fuel gas flow [1 mark]
Disturbance variable: Vapor feed [1 mark]
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b) Feedforward control [4 marks for the diagram]
Control objective: Keep reactor exit at target temperature [1 mark]
Controlled variable: Reactor exit temperature [1 mark]
Manipulated variable: Fuel gas flow [1 mark]
Disturbance variable: Vapor feed [1 mark]
1.2. What are the advantages and disadvantages of feedback and feedforward control systems? [4
marks]
1 mark for each
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Feedback Feedforward
If all sources of the disturbances are known
Corrective action is taken regardless
Advantages and these values can be measured accurately,
of the source of the disturbance
a good control can be achieved
The controlled variable must deviate
No corrective action for unmeasured
Disadvantages from the set point before corrective
disturbances
action is taken
Question 2 [21 marks]
2.1. A PID controller is used to control levels in a tank. The controller has the PID equation
( )
( ) ( ) ∫ ( )
a) If the set point is 14 mA and the process value is 9 mA, determine the error ε. [2 marks]
b) Determine the output signal u(t) of the controller if Kc = 0.2, b = 12, τi = 0.1 second, τd = 0.5
second and ε = 5 mA. [4 marks]
( )
( )
2.2. Consider a proportional controller whose output signal is given by the following expression
( )
Determine the following parameters for this controller:
a) The manual reset [2 marks]
b) The controller gain [2 marks]
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c) The proportional band [2 marks]
2.3. Give the difference between a primary measurement and a secondary measurement. Provide
an example for each. [5 marks]
- 1 marks for correct definition of primary measurement
- 2 marks for correct definition of secondary measurement
- 1 mark for each example
In a primary measurement, the process variable of interest is measured directly. For example, the
temperature of a liquid in a tank can be measured directly using a thermocouple. In a secondary
measurement, other variables are measured and related to the process variable of interest. As an
example, the hydrostatic pressure at the bottom of a tank containing some liquid can be measured
and related to the level of liquid in the tank.
2.4. Explain the term ultimate controller gain. [4 marks]
The ultimate controller gain is the value of Kc from which the system will oscillate indefinitely.
Question 3 [29 marks]
3.1. Is there a difference between a sensor and a transducer? Use examples to justify your
answer. [4 marks]
Yes there is a difference. A sensor is a device that performs the initial measurement and energy
conversion of a variable into analogous electrical or pneumatic information. A thermocouple for
example converts thermal energy to electrical energy. A transducer is a device that converts any
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signal (or energy) from one form to another. As an example, a device that converts voltage to
current is a transducer. Therefore all sensors are transducers but not all transducers are sensors.
3.2. Name the basic hardware instruments required for process control. [4 marks]
1 mark each
Sensor, transducer, controller, and final control element
3.3. Distinguish between open-loop and closed-loop systems. [4 marks]
2 marks each
In a process control system, open loop means while no control action is available in the process.
A process with controlling instruments where the controller takes the action is a closed-loop
system.
3.4. The EMF of a thermocouple with its hot junction at different temperatures as tabulated
below and cold junction at 0 °C are observed as
Hot junction temperature (°C) 0 20 50 70 90 110
EMF (mV) 0.00 0.50 1.8 2.1 3.5 5.0
If the cold junction of the thermocouple is placed in a bath at 20 °C, what will be the EMF of the
thermocouple for the above hot junctions? [7 marks]
According to the law of intermediate temperature
( ) ( ) ( )
( ) ( ) ( )
( ) ( ) ( )
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( ) ( ) [1 mark]
The calculated values are reported in the table below [1 mark for each value]
Hot junction temperature (°C) 0 20 50 70 90 110
EMF E(Th, 20), mV -0.5 0.0 1.3 1.6 3.0 4.5
3.5. Find the voltage of a type J thermocouple with a 0 °C reference if the junction temperature is
– 172 °C. [5 marks]
From the table under additional information we find E = – 7.181 mV
3.6. A voltage of 14.82 mV is measured with a type J thermocouple with a 0 °C reference
temperature. Find the temperature of the sensing junction. [5 marks]
From the table under additional information we find
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Additional information
Controller gain
P – Controller output signal
( )
Table for type J thermocouple (Reference junction 0 °C)
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Table for type J thermocouple (Reference junction 0 °C)
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