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EH/JUN 2012/CPE562

UNIVERSITI TEKNOLOGI MARA

FINAL EXAMINATION

COURSE

CHEMICAL PROCESS CONTROL

COURSE CODE

CPE562

EXAMINATION

JUNE 2012

TIME

2 HOURS

INSTRUCTIONS TO CANDIDATES
1.

This question paper consists of three (3) questions.

2.

Answer ALL questions in the Answer Booklet. Start each answer on a new page.

3.

Do not bring any material into the examination room unless permission is given by the
invigilator.

4.

Please check to make sure that this examination pack consists of:
i)
ii)

the Question Paper

an Answer Booklet - provided by the Faculty

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

This examination paper consists of 5 printed pages
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EH/JUN 2012/CPE562

QUESTION 1

(P02, C02, C03, C3, C4, C5, C6)

a)

t h e diagram for a reactor temperature controller cascaded to a coolant flow controller is

shown in Figure 1. The control valve is linear with constant pressure drop and sized for
a maximum flow of 500 gpm. Its time constant is 0.2 min. The flow transmitter has a
range of 0 to 500 gpm and negligible time constant. The flow controller is proportionalintegral type with a gain of 1 %CO / %TO and the integral time set equal to the valve
time constant. The transfer function of the reactor temperature to the coolant flow is firstorder with a gain of 2F/gpm and a time constant of 5 min. The temperature transmitter
has a range of 160 to 200F and a time constant of 0.5 min.

^~~

Figure 1 A cascade reactor temperature control

Based on the above information, design a cascade reactor temperature control in the
form of block diagram. Include the respective transfer function for each block.
(10 marks)
b)

Explain the control strategy of a cascade control in minimizing out of specification

product. Note: Your answer shall include a comparison of purposes and process
controllabilities between cascade and feed back control.
(6 marks)

c)

State the requirements for the implementation of feed forward control to the process as
shown in Figure 1.
(4 marks)

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EH/JUN 2012/CPE562

QUESTION 2
(P02, C02, C03, C3, C4, C5, C6)
a)

An equal percentage control valve of fail-open type is used to regulate liquid flow
between 0 to 6 m /hr. If the control valve's l/P receives a 10 mA signal from the
controller,
i) calculate the control valve's stem position.
(3 marks)
ii) calculate the equivalent pressure, in psi, received by the control valve.
(3 marks)

b)

Explain the mechanism of flashing and cavitation in control valve.

(6 marks)

c)

A flow control loop, consisting of an orifice in series with the control valve, a differential
pressure transmitter, and a controller, is to be designed for a nominal process flow of
180,000 scfh of air. Valve inlet conditions are 120 psig and 60F, and the outlet pressure
is 100 psig. The valve has linear characteristics and a square root extractor is built into
the transmitter so its output signal is linear with flow. The valve time constant is 0.06
min, and the transmitter time constant is negligible. A PI controller controls the flow.
Obtain the valve capacity factor, Cv and the valve gain. Assume Cf = 0.9. Given that the
air compressibility factor is y=J
Q

q=Z36CvCf

. Valve sizing equation for gas line is given by

\Pinlet

,P,n,et
(y-0.148y 3 ).
SG
7
V gas "
(8 marks)

QUESTION 3

(P02, C02, C03, C1, C2, C3, C4, C5, C6)

a)

Figure 2 shows signal transmission from a controller to a recorder. The controller

transmits signal between 4 to 20 mA, while the recorder receives signal between 1 to
5 V. Since both signals are not in the same form, therefore a current-to-voltage (IA/)
converter card is used to convert current to voltage. However, a cheaper solution is to
use a shunt resistor. Mathematically, prove that the converter card can be replaced with
a 250 Q shunt resistor.
(4 marks)

4-20mA*^

1-5V

converter

controller

recorder
Figure 2

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b)

EH/JUN 2012/CPE562

Figure 3 show a distillation column with two input streams (A, W), one output (B) at the
bottom and one output (D) at the top. Using standard P&ID symbols and notations, draw
a P&ID for
i)
ii)
iii)
iv)
v)

flow ratio control between stream A and stream W (wild stream),

cascade liquid level control at bottom column,
top column high pressure alarm,
top column pressure relief valve,
and middle column temperature gauge.
(8 marks)

Figure 3 Distillation column

c)

Based on Figure 4, design an override control strategy to safe guard the pump from
cavitation upon low liquid level.
(4 marks)
Hot saturated
liquid

Set point

To process

Figure 4 Liquid storage tank

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d)

EH/JUN 2012/CPE562

Draw a block diagram with proper labels for the following equation:
(4 marks)
d2x2
dXi
x,3 =5T*+ 3 L - x,
2

dt

dt

'

END OF QUESTION PAPER

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