Heat exchangers transfer thermal energy between fluids.

Although heat transfer is

typically efficient, controlling the temperature of the fluid being heated at a specific
and stable setpoint can be challenging.
In this experimnet the heat exchanger use are shell-and-tube heat exchanger which is
the most common type of heat exchanger used in petrochemical industries because it
is suitable for low and high pressure applications. It consists of an outer shell with a
bundle of tubes inside. The tubes are oriented in a straight or in a "U" shape. One fluid
runs through the tubes, and another fluid flows through the shell surrounding the tubes
to transfer heat between the two fluids. The set of tubes is known as a "tube bundle."
Heat is transferred from one fluid to the other through the walls of the tubes.
Heat is transferred from the tube fluid to shell fluid to remove heat, or from the shell
fluid to the tube fluid to heat the material inside. Fluids can be liquids or gases on
either the shell or the tube side. To transfer heat efficiently, many tubes are used,
which increases the heat-transfer surface area between the two fluids
Control objective

Consider the heat exchanger shown in Figure 3. The shell side fluid is the process
fluid that is required to be heated to a certain temperature setpoint. The resulting
temperature is measured at the outlet of the heat exchanger T1Out (controlled variable).
Heating is achieved by passing hot fluid through the tube side. The more hot fluid
passing through the tubes, the more heat is transferred to the process fluid, and vice
versa. Control of the process fluid flow (manipulated variable) is achieved by
throttling a modulating valve installed on the steam inlet side.
Three major disturbances can affect the process fluid outlet temperature:

Changes in process fluid flow rate, F1

Changes in process fluid inlet temperature, T1In

Changes in steam pressure, causing a change in steam flow rate, F2.

The control objective is to maintain process fluid outlet temperature T1 Out at the
desired setpointregardless of disturbancesby manipulating the steam flow rate
F2.

Feedback control

Closeloop system is based on feedback where signals from a process that can be used
to control it more effectively. The process inputs to a system have an effect on the
process outputs, which is measured with sensors and processed by the controller. The
result of the control signal is used as an input to the process, closing the loop.
In the feedback control scheme, the process variable, T1Out, is measured and applied to
a proportional-integral-derivative (PID)-based feedback temperature controller
(fbTC), which compares the process variable with the desired temperature setpoint
and in turn calculates and generates the control action required to open or close the
steam control valve (see Figure 4).
The most important advantage of the feedback control scheme is that regardless of the
disturbance source, the controller will take corrective action. Employing feedback
control requires very little knowledge of the process. Therefore, a process model is
not necessary to set up and tune the feedback scheme, although it would be an
advantage.
The major disadvantage of feedback control is its incapability to respond to
disturbanceseven major onesuntil the controlled variable is already affected.
Also, if too many disturbances occur with significant magnitude, they can create
unrecoverable process instability.

Rise time is the time the process output takes to reach the new steady state value.

Time to first peak is the time required for the output to reach its first maximum value
Settling time is the time required for the output to reach its first maximum value
whose width is equal to +- 5% of the total changes in y for 95% respond time (99%
respone time is also used for some application
Overshoot OS=a/b (% overshoot is 100 a/b)
Period of oscillation,P is the time between two successive peak or two successive
valley the respond
the dead time and time constant describes how quickly the process will respond.
Although the dead time and time constant both seem to describe the same thing, there
are several fundamental differences between how dead time and time constant affects
a control loop. The first difference is that dead time describes how long it takes before
a process begins to respond to a change in controller output, and the time constant
describes how fast the process responds once it has begun moving.
Based on the result that we obtain, the first PID 1 that we obtain are PB=2.5%, TI=45
secs and TC= 10secs. The period of oscillation Tn= 57.6secs from the graph chart that
we obtain where the successive peak are different apart of 8mm. However the settling
time we obtain are 57.6 secs also.
However for PID 2, is it obtain where the PB=4.175% and , TI=28.8secs and TD=7.2
secs. PID control mode are the combination of the proportional, integrated and
derivative controller system. Proportional control alone demonstrated control of
mainly offset and response speed, PI control cut out offset, but showed oscillations
and overshoot, and PD control indicated control over oscillations and overshoot, but
still gave way to offset. An optimal combination of proportional band (P), response
time (I), and derivative time (D) eliminated offset, overshoot, and oscillations, and
response time was minimized to a point where these errors in control do not arise.
First, we compute the parameters (KC, KI, KD) of the PID controller using relay
feedback and apply these parameters to control the pH Process. The process of
setting the optimal gains for P, I and D to get an ideal response from a control system
is called tuning. There are different methods of tuning of which the guess and check
method and the Ziegler Nichols method will be discussed. The Ziegler-Nichols
method is a popular method of tuning a PID controller. It is very similar to the trial
and error method wherein I and D are set to zero and P is increased until the loop
starts to oscillate. Once oscillation starts, the critical gain Kc and the period of
oscillations Pc are noted. The P, I and D are then adjusted as the following.
PB=1.66PB*%,TI=o.5Tn*secs, TD=0125Tn*secs

By refering to the formular , PB is define as PB=100/Kc. The controller gain Kc can

be adjusted to make the controller output changes as sensitive as desired to deviationv
between setpoint and controller variable. Small proportional band correspond to a
large controller gain, whereas a large PB value implies a small value of Kc. Therefore
for a smaller PB, the controller gain Kc will have a higher value thud higher respond
time and this make the controller output to increase, bringing it back to a steady state.
Refer to the figure attached
Therefore based in the result PID 1 has settling time of 57.6 seconds. Theoretically,
the lower the Pb, the higher the settling time, this is because higher gain correspond to
lower value of PB therefore cause a higher overshoot and signal will take a longer
time to settle. For the TI value , case1 has 45 secs case 2 have 28.8 secs. The smaller
the TI value the bigger the controller output, the easier the offset is eliminated thus the
controller output automatically change until it attains the value required to make the
steady state which is the zero error. For the TD, case 1 have higher value which is
10secs, compare to cases 2 which is 7.2secs. The bigger the TD value, it tends to
improve the dynamic response of the controller variable by decreasing the process
settling time, the time it takes the process to reach steady state, thus increasing
respond time by counteract the destabilization tendency of the integral mode.
Based on our opinion , PID is a good controller for temperature control. This is
because the temperature control system, the process variable In the system parameter
that needs to be controlled is the temperature. A sensor is used to measured the
process variable and provide feedback to the control system. The set point is the
desired temperature. The difference between the process variable and the set point is
sent to the control system and the opening of the value to determined the flowrate of
water entering the shell and tube heat exchanger is regualted to drive the system.for
instance if the desired temperature is lower than the setpoint, the control system will
send signal to the hotwater control valve to increase the flow of hot water. This result
the system temperature to increase resulting in an increase in temperature process
variable. If there is heat loss to the surrounding and this disturbs the setpoint, this call
disturbance variable. The temperature control system is usually design to minimise
the offset of the disturbance variable on the process variable. Therefore PID is
suitable for temperature control because it the process control system need to have
fast response time if any emergency or spoilage occur to prevent any explosion occur.
This also minimize the dead time from stiction and backlash minumise rise time ,
peak error and integrate error.
As an optimum behavior, a process should satisfy the regulation and command
breaking requirements. These two properties define how accurately a controlled
variable reaches the desired values. The most important characteristics for command
breaking are rise time and settling time. For some systems where overshoot is not
acceptable, to achieve the optimum behavior requires eliminating the overshoot
completely and minimizing the dissipated power in order to reach a new set point.