ChE 6303

Process Control
April 2017 Semester
Date of submission 15 July 2017
Question 1:
Consider the cascade system shown in the figure below:

1. Show that the cascade loop, as drawn, is

appropriate. (Dont simply write Y or N next to
the criteria; explain your answers). You may
assume the first criterion is met, i.e. the
performance without cascade control is not suitable.

2. Determine, use clear, logical reasoning, and all your

prior engineering knowledge of heat transfer and
fluid flow whether the cascade loop would provide
performance that is better, worse or no
different to direct control of TC using the valve
position.

(a) the disturbance is change in the composition of

the fuel (i.e. the heating value changes)
(b) the feed temperature increases
(c) the pressure of the fuel decreases

Question 2:

A block diagram for a cascade loop is shown below.

1. Derive a single transfer function from input Ysp2 to output Y2, assuming D2 = 0.
2. Redraw the block diagram, replacing it now with your single block transfer function at the
suitable place, but still incorporate the disturbance effect from D2.
3. What is the characteristic equation for the inner loop?
4. If the inner loop has proportional-only controller for Gc2, and Gv = 3, and Gp2(s) = 6/2s +
1, derive a constraint (inequality) for the value of Kc so that the inner loop still has stable
behavior.
5. Explain whether this answer matches what you have learned in the course?
Question 3:

Compare the set point responses for a second order process with a time delay ( =2 min) and
without the delay. The transfer function is
e s
G p ( s)
(6s 1)( 2s 1)

a) Assume Gm Gv 1 and time constants in minutes. Use the following PI controllers.

For, =0, K c 3.02 and 1 6.5 min, while for =2 min the controller gain must be reduced
to meet stability requirements ( K c 1.23 and 1 7.0 min ).

b) Design a time delay compensator (Smith predictor) for the above mentioned second order
process when Gm Gv 1 . Show closed loop responses for unit set-point and disturbance
changes and Gc K c 1 .

Question 4:

Use the Simulink model CW2_model.mdl (find attached with the email), which represents a
complex chemical process. In a time-critical situation when the development of a process
model is not feasible it is required to design a controller for the process.
(a) Use the practical ZN method to design a PI and PID controller for the process. Simulate the
closed-loop responses using the designed PI and PID controllers. Plot the closed-loop
responses and set-point on the same figure.
(b) Simulate the open-loop step response of the original process. Using the process reaction
curve method identify a FOPTD model for the process. Simulate and compare the responses of
the identified model and the original process, by plotting the step responses on the same figure.
(c) Use the identified FOPTD model to design a PID controller, and simulate the closed-loop
response of the system.
(d) Compare the performances of the controllers by calculating the sum-of squares error criteria
(SSE), for all controllers designed.
Hint: You can download the SSE simulink block from the mathworks website.