University of Cape Town Department of Chemical Engineering

CHE4042F PROCESS DYNAMICS AND CONTROL Paper 2 Final Examination June 2009

Time: 2 Hours

Total Marks: 50

Marks Available: 54

Instructions Open Book Examination. Course notes, handouts and textbook (Seborg, Edgar and Mellichamp, Process Dynamics and Control) allowed, plus printed course handouts and 7 pages of personal notes. Note that you will need to set up a Word document into which you place all your models and the figures of the model responses and submit it on Vula, as well as print it out for submission at the end of the exam. The final model for each question must uploaded to the Vula course website under the exam with an appropriate distinctive name. Note that where necessary you should change the simulation settings.

Internal Examiner: Prof D M Fraser Internal Moderator: Prof K Moller External Examiner: Prof S Bradshaw

Question 1

System Response

Set up a Scicos model of a simple damping tank with two sin waves added together as the input This system has the following characteristics: (i) (ii) The tank has a time constant of 10 minutes and a gain of 1.0; One sin wave has an amplitude 30 m3/h and a period 40 min; and

(iii) The other sin wave has an amplitude 3 m3/h and a period 0.4 min. You must set this system up from scratch, using the standard modules supplied in Scicos, and send the combined input wave and the output wave to a Scope and display them on the same axes. You will need to adjust the simulation time and period to show the waves properly. You will also need to adjust the Scope parameters to show the combined input wave and the output wave over a maximum of two cycles of the slower wave, and showing the input wave as large as possible on the y-axis. Copy the block diagram of your Scicos model, the normal Scope figure and a zoomed-in Scope figure into your Word document. Save your Scicos file on Vula. [10] Question 2 Control System Response

Set up a Scicos model of a simple feedback control system, with the following components: (i) (ii) A second order process with Kp = 4 (C)/(/s), p = 20 s and = 0.7; A measurement gain Km of 0.3 (mA)/(C) and time lag d of 1 s;

(iii) A PI controller with I = 60 s, an input of mA, and an output of kPa; and (iv) A control valve with a gain Kv of (1/6) (/s)/(kPa) and a first order time constant v of 1 s. You must set this system up from scratch, using the standard modules supplied in Scicos. Use a time basis of seconds in your model. Note that in the standard PID controller the I term is (Kc/I), and the D term is (Kc*D). The inherent controller gain is 0.5. Remember to include the units change in Kc as well. Now find the response of this system to a change in set-point of 0.5. How long after the change does the system first cross the new set point? What is the maximum value reached? You should use a zoomed in figure with dotted axis grids to get these answers. Copy the block diagram of your Scicos model, and the normal Scope figure and the zoomed-in Scope figure (including grids on both axes) into your Word document. Save your Scicos file on Vula. [10]

Question 3

Frequency Response

Generate the open-loop frequency response of the following system in Scilab, and hence find the frequency at a phase angle of 180, and the amplitude ratio at the same frequency: A second order process, with a time constant of (1/3) minutes, and damping coefficient of 1.0 A first order process with a time constant of 1 minute. In order to do this you will need to consult both the Scilab Help for Bode, and Section 9.2 in Master Scilab! to see how to set up the programme to do this, and how to plot the Bode diagram and annotate it. You are expected to plot all three curves (2nd order, 1st order and overall) on the same axes and to give an appropriate label for each one. Copy the programme and the Bode diagram into your Word document, and save your file on the Vula course website. Note that the AR is given in decibels (dB or db) and should be converted to a proper amplitude ratio, using the formula dB -= 20 log10(AR). [10] Question 4 Control of Distillation Column

The distillation column model proposed by Goodwin, Graebe and Salgado (2001) (see the attached extract) has been set up in Scicos for you, as shown in the diagram below.
Exam Q4
+ xD set pt

PID
FR

num(s) den(s)
xD-FR

Continuous Fix Delay

+ -

num(s) den(s)
xD-FV

xD Continuous Fix Delay

Mux

MScope

num(s) den(s)
TB-FR

Continuous Fix Delay

+ TB Set pt

PID
FV

num(s) den(s)
TB-FV

Continuous Fix Delay + TB Mux

The model has been uploaded to the course Vula site. You should download it and then load it into Scicos. Note that in the Context the Cohen-Coon PID controller settings have been set up but deactivated by comment signs.

The Context for this model is as follows:

Ymin1 = -0.5 Ymax1 = 2.5 Ymin2 = -1.0 Ymax2 = 1.5 SimTime = 450 3

xDSPStepTime = 50 xDSPStep = 2 TBSPStepTime = 250 TBSPStep = 1 Red = 1 //Kc1 = 3.64/Red //tI1 = 5.54 //KI1 = Kc1/tI1 //tD1 = 0.883 //KD1 = Kc1*tD1 //Kc2 = 4.12/ Red //tI2 = 2.23 //KI2 = Kc2/tI2 //tD2 = 0.347 //KD2 = Kc2*tD2 Kc1 = 1 KI1 = 0.25 KD1 = 0.0 Kc2 = 1 KI2 = 0.15 KD2 = 0.0

In order to get something like the response shown by Goodwin, Graebe and Salgado, the gain K12 has

been multiplied by 100, and the gain K21 has been divided by 100. The response generated with these modified gains is shown below.

Note that throughout this question you must not attempt to make sense of the actual values given by the model (they are much larger than they should be). Note that you should also not attempt to change the scales of the graph axes, nor to try to determine maximum deviations. Your evaluation of the responses must purely be qualitative on the basis of what you can see as the graphs are. You are required to do the following: (a) Test the system response for the settings given and check that you get the same curve as shown above. Save your results to your Word document. (3) Test the system closed-loop response for the same set of step changes using the unmodified Cohen-Coon controller settings. Be careful to comment out or delete the controller settings that were used before. Save your results to your Word document. (3) Now decrease the gain K12 to 0.049 and increase the gain K21 to 3.47. At the same time detune the controller settings by a factor of 2 using the variable Red in the context. Test the response and save it in your Word document. (3) Next, decrease the gain K12 to 0.0049 and increase the gain K21 to 34.7 (their original values). Test the system response for a detuning factor of 10, and again save your response to your Word document. Also upload this version of your model to Vula. (3) Then design a 2-gain static decoupling system and implement it in your model. Does this give a better response than before, and how dependent is it on the detuning factor used (only try values of 10 and 5)? Save your best response to Word and your model to Vula. (5) Finally, implement a one-way dynamic decoupler. From the results obtained so far you should be able to tell which one-way decoupler should be implemented. Test the response of this model and how detuning affects it. Again compare this with the best response obtained so far, and save your best response to Word and your model to Vula. Recommend the best control system for the original model based on what you have found in sections (d), (e), and (f). (7) [24] Remember to print your completed Word document and also to upload it on Vula.

(b)

(c)

(d)

(e)

(f)