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CHE461ProcessDynamicsandControlLaboratoryManualD.E.Rivera,AssociateProfessorV.E.Sater,Professor

DepartmentofChemicalandMaterialsEngineeringArizonaStateUniversitywiththeassistanceofM.W.BraunM.E.FloresK.S.Jun,Ph.D.M.K.ShettyL.Yang

Copyrightc1993-2001ASU-ControlSystemsEngineeringLaboratory

August25,2001=Page1=

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Contents

Preface1SafetyManual2

ExperimentA:TotalPlantSolutionSystemOverviewLabA,Page1

ExperimentB:A/BMixingReactorOperationLabB,Page1

ExperimentC:First-OrderSystemsResponseAnalysisLabC,Page1ExperimentD:GasoilFurnaceSystemIdenticationLabD,Page1

ExperimentE:MixingTankDynamicModelingLabE,Page1

ExperimentF:HeatExchangerInstrumentationLabF,Page1

ExperimentG:HeatExchangerControlLabG,Page1ExperimentH:MixingTankConductivityControlLabH,Page1

ExperimentI:A/BMixingReactorControlLabI,Page1

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ExperimentJ:FurnaceCustomControlStrategyLabJ,Page1

ExperimentK:pHReactorControlLabK,Page1

AppendixI:PictureEditorReferenceAppendixI,Page1

i=Page2=

Preface

ChemicalengineeringstudentsatArizonaStateUniversityareindeedprivilegedtolearncon-

trolengineeringprinciplesinaunique,industrial-scaletestbedenvironment.Thepresence

oftheseremarkablefacilitiesandtheiruseinundergraduateins

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1=Page3=SAFETYMANUAL

UndergraduateLaboratoriesBldgSCOB,Rms190,191,and192

EMERGENCYPHONENUMBERSTempeMedical,Police,Fire..............911"PoisonControl..........................253-3334"UNIVERSITYSERVICESFireMarshall...............................5-1822"CampusPolice.............................5-3456

"StudentHealthService................5-3346"

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2=Page4=SAFETYMANUAL3

IntroductionSafetyintheundergraduatelaboratoryiseveryone sresponsibility.Experimentsconducted

inasafeandconscientiousmannerwillprotectyouandyourlaboratorypartners.The

protectionofhealthandsafetyisamoralcommitment.Certainpracticesarerequiredby

law.Thismanualhasbeenpreparedforyourownprotectioninaccordancewithfederal,

stateandlocalregulations.Youareresponsibleforcompliancewithallsafetyregulationssetforthinthismanual.GeneralSafetyPrinciplesandRegulations

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=Page6=TotalPlantSolution(TPS)SystemOverview

ObjectiveTheTotalPlantSolution(TPS)system(formerlyknownastheTDC3000)isastate-of-the-

artplantinformationandcontrolsystemmanufacturedbyHoneywellIndustrialAutomation

andControlrighthereinthePhoenixmetropolitanarea.Themajorityofthelabexperiments

inChE461revolvearoundtheTPSplatform.Thepurposeofthischapteristofamiliarizeyouwithsomeofitsmaincomponentsandthearchitectureofthesystemthatispresenton

theASUcampus.ProcedureAtthestartofthelabprepsession,youwillberequiredtowatchavideothatdescribesthe

basicarchitectureoftheTPSsystem.AlecturebasedonthematerialinExperimentsAandB(A/BMixingReactorOperation)willfollow.LabReportNolabreportisrequiredforthisexperiment.Therewillbeaquizatthebeginningoflecture

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PulseInput.Precisecontrolusinghighaccuracypulsing-typesensingdevicesispossiblewith

thepulseinputprocessor.DigitalInput.Digitalsignalsarecharacterizedbyanitenumberofstates(e.g.,ON/OFF

statesinapump;OPEN/CLOSEDstatesinavalve).Thedigitalinputprocessorprovides

thefollowingfunctionsEventcounting(accumulation)"Pushbuttonandstatustypeinputs"=Page13=TPSSystemOverviewLabA,Page8

FigureA.3:RepresentativeUniversal(left)andGlobalUser(right)Stationsthatformpart

oftheTPSsysteminASU sControlSystemsEngineeringLaboratoryTimedeadbandonalarmsforstatusinputs"

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turecontroller(TIC2190#)cascadedtoasteamowcontroller(FIC2190#).Topre-

ventoverheatingofthereactor,aninterlockhasbeenimplementedinthelogicblock

LabB,Page1=Page17=ExperimentB:A/BMixingReactorOperationLabB,Page2

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FigureB.1:A/BMixingReactorSchematic=Page18=

ExperimentB:A/BMixingReactorOperationLabB,Page3

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FigureB.2:A/BMixingReactorPointsDiagram

=Page19=

ExperimentB:A/BMixingReactorOperationLabB,Page4

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ExperimentB:A/BMixingReactorOperationLabB,Page5

FigureB.3:GroupDisplay1

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FigureB.4:GroupDisplay2=Page21=ExperimentB:A/BMixingReactorOperationLabB,Page6

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FigureB.5:GroupDisplay3

FigureB.6:GroupDisplay4=Page22=

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ExperimentB:A/BMixingReactorOperationLabB,Page7

FigureB.7:GroupDisplay5

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FigureB.8:GroupDisplay5indicatingTIC2190#andFIC2190#trends

=Page23=ExperimentB:A/BMixingReactorOperationLabB,Page8

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FigureB.9:FirstpagedetaildisplayforTIC2190#

FigureB.10:FirstpagedetaildisplayforSETNK90#

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=Page24=ExperimentB:A/BMixingReactorOperationLabB,Page9

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thatyourplantiscurrentlyinadesirablenormaloperatingmode.Assuch,youmustcon-

ductyoursteptestsina plant-friendly mannerthatcausesminimaldisruptionofthese

operatingconditions.Signicantdeviationsfromthesewillresultino-specproductinthe

crackingunitandlossofprotstoyourcompany.Eventually,theplantsuersfromsubstantialdriftintheoutletgasoiltemperatureasa

resultofambientandotherunmeasureddisturbances.Underthesecircumstances, plant-

friendly steptestingmaynolongerbeanoption-itwillbenecessarytoconductalternate

identicationteststhatarenon- plant-hostile. However,greatcaremustbetakentoavoid

implementingidenticationteststhataresubstantiallydisruptiveontheplant.

LabD,Page1=Page39=ExperimentD:GasoilFurnaceSystemIdenticationLabD,Page2

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FigureD.1:GasoilFurnaceSchematic,withchangezonedisplay

FigureD.2:GroupDisplayforFurnaceSimulation

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willgiveyouinsightsregard-"ingthe true modelstructureofthefurnacesimulation,andhowvalidisarst-order

withdeadtimeapproximationforsuchasystem.Commentaboutthisinyourlab

report.Thepresentationmadeduringclassonsystemidenticationisclearlyyourbestrefer-

"enceonthismaterial.AcopyofthePRBSgeneratingprogram(whichisexecutedby

IDINP##)hasbeenpostedonthecoursewebpage.=Page46=ExperimentD:GasoilFurnaceSystemIdenticationLabD,Page9

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FigureD.4:Typidcal8hrtrendshowinglownoisepulse,highnoisepulse,andPRBStests.

ThePRBStestshowsfourcyclesoftheinputsignal.

FigureD.5:An8hrtrendrescaledtoshowthelownoisepulse,highnoisepulse,andinitial

PRBStestsinmoredetail.=Page47=

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FigureE.1:Brine-watermixingtankschematic(top)andphotograph(bottom).

=Page50=ExperimentE:MixingTankSensorCalibrationandDynamicModeling

LabE,Page4

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FigureE.2:GroupDisplayforMixingTank

FigureE.3:Firstpage,detaileddisplay,CI100point

=Page51=ExperimentE:MixingTankSensorCalibrationandDynamicModelingLabE,Page5

recordthevalueforCI100.PVRAW(keepinmindthatthissi

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=Page55=ExperimentE:MixingTankSensorCalibrationandDynamicModelingLabE,Page9

706050FeedConc[g/l]40

30y[g/l]=0.0937x[millimho]-9.3852

2010300400500600700800900

Conductivity[millimho]FigureE.4:CalibrationCurve(Conductivityvs.Concentration)for

HighConcentrationSaltSolutions500

o

400y[g/l]=4.8049x[%]-52.9517FeedSaltConcentration[g/l]300200

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100oooooo0o-1000102030405060708090100

PV[%]FigureE.5:CalibrationCurve(InletStreamSaltConcentration[g/]vs.PV[%])forCI102

=Page56=

ExperimentF:HeatExchangerInstrumentation

ObjectiveTheobjectofthisexperimentisto congure orprogramtheTDC3000systemtoread

thetemperatureofastreamintheheatexchangerapparatus,displaythetemperatureon

theconsoleandusethedisplayedtemperaturetoevaluatethedynamicsofthesystem.BackgroundProcessManager

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FigureF.2:HeatExchangerHardwareSchematic

=Page64=ExperimentF:HeatExchangerInstrumentationLabF,Page9

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FigureF.3:HeatExchangerControlStrategy

=Page65=

ExperimentG:HeatExchanger

ControlObjective

Thepurposeofthisexperimentisto1)obtainadynamicmodelrelatingsteamvalveposition

tooutlettubewatersidetemperatureintheSCOBB190heatexchangerand2)usethis

modeltogenerateProportional-Integral(PI)controllersettingsfortheregulatorycontrol

pointTIC552.Youwillbeaskedtocomparetheperformanceobtainedfromvarioustuning

rulesontheclosed-loopresponsesobtainedfromtheexchangerfo

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orthecontrollergainandintegraltimeconstant.Inthisexperiment,yourteamwillbeaskedtocomparethe

performanceoftheimprovedIMC-PIandITAE-optimalrulesforbothsetpointtrackingand

disturbancerejectionintheheatexchanger.Fordetailsonthesemethodsyoumayreferto

thefollowingportionsofyourtextbooks:=Page67=ExperimentG:HeatExchangerControlLabG,Page3

ImprovedIMC-PISection12.3SEM,Table15.6,OgRay

ITAE-optimalTable12.3SEM,Table15.4,OgRay

DetailedinformationregardingtheimprovedIMC-PItuningrulesisprovide

dintheInternalModelControl:AComprehensiveApproachreportdevelopedbyDr.Rivera.

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FigureG.3:UniversalStation-HeatExchangerTDC3000Schematic(HTEX5).

=Page70=

ExperimentG:HeatExchangerControlLabG,Page6

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entertheIMCcontrollerparameterswithltervaluesetfordisturbancerejection.Introduce

aloadchangeintothesystembychangingthetubesidewaterowratesetpoint(FIC551.SP)

to1.5gpm.Recordtheresponse.Howwellwasthecontrollerabletomaintainthesetpoint

inspiteofthisdisturbance?Repeattheloadchange(from1.5gpmto1.0gpm)butusethe

ITAE-optimalloadtuningrulesettingsinstead.

FigureG.5:A2hrtrendsummarizingaseriesofrepresentativec

losed-loopcontrolresultsontheheatexchanger.Topcurvesshowthesetpointandcontrolledvariableresponses

(TIC552.SPandTIC552.PV,respectively);centercurvetrendsthemanipulatedvariable

response(TIC552.OP),whilethebottomcurveshowsthedisturbancevariable(FIC551.PV).

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FigureJ.1:UniversalStation-basedfurnacecontrolschematic,showingswitchandregulatory

controlpoints.

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insertionpointnames.

PST_CTPRPST_PVPRFigureJ.3:AMRegulatoryControlPointProcessingSteps

=Page83=ExperimentJ:FurnaceCustomControlStrategyLabJ,Page5

FigureJ.4:GraphicalUserInterfaceforfurntuneprogram

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FigureJ.5:Figurewindowforfurntune,comparingidealPI,PI

D,bumplessPID,andPIDwithlterclosed-loopresponses=Page84=ExperimentJ:FurnaceCustomControlStrategyLabJ,Page6

Procedure

ActionPlanLabJisthe capstone experimentforChE461andisassignedthemostpointsofany

laboratoryworkproduct.Asaresult,Iexpecttoseeyourbesteortsappliedtothis

experiment.Pleaseuseyourtimeinlabwiselyanddistributeyourtasksecientlyamong

yourteammembers.Paycloseattentiontothelabprepsessionon

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LabSessionPleasecarryoutthefollowingtasks:1.First,familiarizeyourselfwiththevariouspoints,groupdisplays,andschematicsthat

youwillbeworkingwithduringtheexperiment.Whenyouarriveinthelab,youwill

noticethatyourpartition sassignedgroupdisplayhasbeenmodiedwiththeaddition

=Page85=ExperimentJ:FurnaceCustomControlStrategyLabJ,Page7

FigureJ.6:GroupDisplayforFurnaceControlatthebeginningofthelaboratorysession

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FigureJ.7:GroupDisplayforFurnaceControl,illustratingpropersettingsfortheFIC41##

andSWITCH##points.=Page86=ExperimentJ:FurnaceCustomControlStrategyLabJ,Page8

oftheswitch(SWITCH##),standardPID(PID1##),andcustomPIDwithlter

(PIDWF##)points.InitiallyallthreepointsareinactiveandinMANUALmode,as

seeninFigureJ.6.Pleasegototherstpageofthedetaildisplayforeachpointand

makeeachpointactivethroughtheproperselectionofthePTEXECSTparameter.

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FigureJ.8:GroupDisplayforFurnaceControl,illustratingproperPIDcontrolleroperation

FigureJ.9:GroupDisplayforFurnaceControl,illustratingproperPIDwithltercontroller

operation=Page88=

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Goodmixing."LabK,Page1=Page94=ExperimentK:pHControlLabK,Page2

FigureK.1:pHReactorSchematicMinimizedeadtimeintheentireloop."Enoughresidencetimeshouldbeallowedforneutralizationtotakeplace.

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14EffluentpH

20

200CausticFlowratecc/minFigureK.2:TitrationCurve-Strongacid-basemixture

=Page96=

ExperimentK:pHControlLabK,Page4BecauseHCLandNAOHrepresentastrongacid-basepair,wecanassumetotaldissociation,

leadingtothematerialbalance[H+]+xB=xA+[OH" ]

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FigureK.4:OperatingGroupforthepHreactor

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=Page102=ExperimentK:pHControlLabK,Page10

IFRESET_C=ONTHEN(SETER,ER1,ER2,MOVE,KERR,KERR1,KERR2=0;&SETRESET_C=OFF)SETPVCLC=(10**(PV-14)-10**(-PV))SETSPCLC=(10**(SP-14)-10**(-SP))SETER=SPCLC-PVCLC--CALCULATECONTROLCOEFFICIENTSSETKERR=K*(1+STP/T1+T2/STP)SETKERR1=-K*(1+2*T2/STP)SETKERR2=K*T2/(STP)--CALCULATECURRENTMOVESETMOVE=KERR*ER+KERR1*ER1+KERR2*ER2--STOREPREVIOUSERRORSSETER2=ER1

SETER1=ER--CALCULATECURRENTOUTPUTSETCV=OPEU+MOVEENDPHCNTRLENDPACKAGE=Page103=

Bibliography

[1]Ast rom,K.J.,B.Wittenmark,AdaptiveControl,Addison-Wesley,Massachusetts,

1989.[2]HorwitzB.A.,pHrustrationsofaProcessEngineerChemica

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lEngineeringProgress,,March1993[3]Kulkarni,B.D.,S.S.Tambe,N.V.ShuklaandP.B.Deshpande,NonlinearpHControl,

ChemicalEngineeringScience,Vol46,No.4,1991[4]McMillan,G.K.pHControl,InstrumentSocietyofAmerica,1985.

[5]Wright,R.A.andC.Kravaris, NonlinearcontrolofpHprocessesusingthestrongacid

equivalent, Ind.Eng.Chem.Res.,30,1561,1991.[6]Wright,R.A.,M.Soroush,andC.Kravaris, StrongacidequivalentcontrolofpH

processes:anexperimentalstudy, Ind.Eng.Chem.Res.,30,2437,1991.

LabK,Page11

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=Page104=AppendixI:PictureEditorReference

GraphicDisplayGuidelinesOverviewAccessingthePictureEditor:SelectingPictureEditortargetlocatedonEngineeringPersonalityMainMenudisplay.

"SelectCommandProcessorfromMainMenudisplay.TypePEoncommandline.This

"loadsthePictureEditoroverlay.ExitingthePictureEditor:CTLand[HELP],ortypinginEND,returnsyoutotheEngineeringMainMenu.

Pressthe[ESC]key.YouarenowintheCommandProcessor.Whendone,press

"[CTL]and[HELP]toreturntoPictureEditor.1.Tomodifyanexistinggraphic,typeREADXXXXXwhereXXXXXistheschematic

name.Iftheschematicexistsonavolumeotherthanwhereyouhavesetpath,then

>

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=Page112=