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2024 PROCESS CONTROL-WS1 QUESTION (1)································································································································································································ 1

2024 PROCESS CONTROL-WS2························································································································································································································13
2024 PROCESS CONTROL-WS3························································································································································································································19
2024 PROCESS CONTROL-WS4························································································································································································································30
2024 PROCESS CONTROL-WS5························································································································································································································35
A. Developing a process control system I

1. An engineer is developing a control configuration

to maintain the reactor outlet temperature at 60 ° C.

∗ Control configuration: the information structure that is used to

connect the available measurements to the available
manipulated variables.
1. Find appropriate variables for each item.
Input variables:
Output variables:
Manipulated variable:
Control output:

2. Complete a control configuration, following the

steps below.
Step 1: (Control objectives):
Step 2: (Select input variables):
Step 3: (Select measured variable and develop a control
configuration):
B. Developing a process control system II

1. An engineer is developing a control configuration

to maintain liquid level at 0.5 m from the bottom.
1. Devise a control system and draw all feasible
control configurations.
C. Developing a process control system III

A distillation column separates a binary mixture of

pentane and hexane into two product streams of
pentane (distillate) and hexane (bottom). Our control
objective is to maintain the production of a distillate
stream with 95 mole % pentane in the presence of
changes in the feed composition.

An engineer developed three feasible control

configurations as follows.
1. What control configuration would you like to use?
2. Please explain the reason.
Option 1
Option 2
Option 3
D. Developing a process control system IV

Let’s consider integrated chemical process this time.

A simple chemical plant is composed of two units: a CSTR

and a distillation column. The raw materials entering the
reactor are A and B with flow rates FA and FB and
temperatures TA and TB, respectively. They react to yield C:
A+BàC
The reaction is endothermic and the heat is supplied by
steam which flows through the jacket of the reactor. The
mixture of C and unreacted A and B enters the distillation
column, where A + B is separated from the top as the
overhead product and C is taken as the bottom product.
D. Developing a process control system IV
The operational objectives are:
1. Product specifications:
(a) keep the flowrate of the desired product stream FP at the
specified level.
(b) Keep the required purity of C in the product stream.

2. Operational constraints:
(a) Do not overflow the CSTR.
(b) Do not flood the distillation column or let it go dry.

3. Economic considerations
(a) Minimize the operating cost (i.e. raw materials, steam in a
reboiler, cooling water in overhead condenser).
Based on the above control objectives, develop
appropriate control configurations.
 Principle of Conservation

1. Mass, energy, and momentum can be characterized by

variables such as density, concentration, temperature,
pressure, and flow rate. These characterizing variables
are called state variables and their values define the
state of a processing system.
2. The principle of conservation of a quantity S states that:

The quantity S can be any of the following

fundamental quantities: total mass, mass of individual
2
components, total energy, momentum, etc.
 Question 1
Let us consider the problem of controlling the
temperature T of a liquid in a tank when the inlet
temperature Ti changes. Assume that the inlet and
outlet flow rates are equal. Our measurement will
be the liquid temperature and the manipulated
variable the rate of heat input , Q, provided by
steam. The question is how should Q change in
order to keep temperature T constant, when Ti
changes? In other words, we want to develop the
control system.

Assume that the heater has been operating for some time and that the
liquid temperature has been kept constant at Ts, while the volume of the
liquid has remained constant at a volume, V. We say that the heater has
been operating at steady state.

Definition of subscripts:
- i: feed stream, st: steam, s: steady state (e.g. Ts: Temp. at steady state)
 Question 1

1. Find all related control variables to the process

system and control objective.
2. Develop an equation to express the correlation
between the outlet stream temperature change
along the operating time upon the feed
temperature change.
① Develop an energy balance of the process
system at steady state: 0 = Qin – Qout
② Develop a differential equation along the
time using the equation 1: fdT/dt = Qin –
Qout
③ Subtract equation 1 from equation 2.
 Question 2

Fin, CAF◦in Assume

Fin ≈ F = const
V = const
h F, CA
F Also
A B
A B
r = - k CA
Input variables: CA◦
Output variables: CA
Calculation shows:
τ= V/F
 Question 2
Response of the system for a unit step change
in CA◦ to
• CA◦ = 10 mol/l
• CA◦ = 100 mol/l
• CA◦ = 500 mol/l
 LECTURE 3 – WORKING SESSION

A stirred-tank heating system is used to preheat a

reactant containing a suspended solid catalyst at
constant flow rate (wi) of 1,000kg/hr. The volume (V) in
the tank is 2 m3, and the density (ρ) and specific heat
(Cp) of the suspended mixture are, respectively, 900
kg/m3 and 1 cal/g ◦C. The process initially is operating
with inlet and outlet temperature (Ti, T) of 100 and 130
◦C, respectively.
LECTURE 3 – WORKING SESSION
 LECTURE 3 – WORKING SESSION

1. What is the heater input at the initial steady

state and the value of k and ?
Please refer to a derived Laplace
transformation in the following page.
 LECTURE 3 – WORKING SESSION

Dynamic model is shown below, assuming

constant liquid holdup and flow rates:
dT
V rC = wC (Ti - T ) + Q (2-36)
(1)
dt

Suppose the process is at steady state:

0 = wC (Ti - T ) + Q (2)

Subtract (2) from (1):

dT
V rC = wC éë(Ti - Ti ) - (T - T ) ùû + ( Q - Q ) (3)
dt
 LECTURE 3 – WORKING SESSION

Then,

dT ¢
V rC = wC (Ti¢ - T ¢ ) + Q¢ (4)
dt

Where, the “deviation variables” are

T ¢ �=T - T , Ti¢ �=Ti - Ti , Q¢ =

� Q -Q

Laplace transformation of (4):

V r C éë sT ¢ ( s ) - T ¢ ( 0 ) ùû = wC éëTi¢( s ) - T ¢ ( s ) ùû - Q¢ ( s ) (5)

At the initial steady state, T′(0) = 0.

 LECTURE 3 – WORKING SESSION

Rearrange (5) to solve for

æ K ö ¢ æ 1 ö ¢
T ¢( s) = ç ÷ ( ) ç
Q s + ÷ Ti ( s ) (6)
è t s +1 ø è t s +1 ø
where

1 Vr
�
K= and t �=
wC w
 LECTURE 3 – WORKING SESSION

2. If the heater input is suddenly increased by

+30%, what will be the final temperature, T
at steady state? How long will it take for the
tank temperature to achieve 99% of the final
temperature change?
Please refer to a diagram and table of “step
response of the first-order process” in the
next page.
 LECTURE 3 – WORKING SESSION

With a Step input magnitude for the first order

process:
M
F (s) =
s
KM
Y (s) =
s (ts + 1)

(
y (t ) = KM 1 - e - t /t
)
LECTURE 3 – WORKING SESSION

t (
y (t ) / KM = 1 - e - t /t
)
0 0
τ 0.6321
2τ 0.8647
3τ 0.9502
4τ 0.9817
5τ 0.9933
 LECTURE 3 – WORKING SESSION

3. Assume the tank is at its initial steady state.

If the inlet temperature is increased
suddenly from 100 to 120 ◦C, how long will
it take before the outlet temperature change
from 130 to 135 ◦C?
 LECTURE 4 – WORKING SESSION

1. A liquid storage system is shown in the next

page. Show that this process is not self-
regulating by considering its response to a
step change in inlet flow rate.

Please use the following mass balance

equation to develop a transfer function.

A ∙ dh(t)/dt = qi(t) – q(t)

Where, A = area of tank

 LECTURE 4 – WORKING SESSION

q
i

h
q
 LECTURE 4 – WORKING SESSION

2. Please show that the storage system

becomes self-regulating if the pump is
replaced by a valve.

Q(t) becomes 1/R∙h.

Where, R = valve resistance

 LECTURE 4 – WORKING SESSION

q
i

h
q
 LECTURE 5 – WORKING SESSION

An engineer is planning to build a control system

to maintain liquid level in a tank, as shown below.
 LECTURE 5 – WORKING SESSION
The level h is the controlled output while Fi is the
load (disturbance) and Fo is the manipulated
variable. The transfer function for each
component of the feedback loop are as follows.

a. Process: the material balance gives the

following equation.

b. Measuring device: this device estimates liquid

level, measuring liquid pressure in a tank.
 LECTURE 5 – WORKING SESSION

c. Controller: the engineer decided to use PI

controller as follow.

d. Control valve: the valve has the first order

system.
 LECTURE 5 – WORKING SESSION

Q 1. Based on the information above, please

complete the block diagram of the control
loop. Process
Gd=

Controller Control device

+

Gc= Gf= Gp=

+
-
-

Measuring device

Gm=