Process Control Instrumentation Technology ( Chapter 9 )

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9.3 A velocity control system has a range of 220 to 460 $\mathbf{\mathrm{~mm} / \mathrm{s}}$ . If the setpoint is 327 $\mathbf{\mathrm{~mm} / \mathrm{s} }$ and the measured value is $\mathbf{294 \mathrm{~mm} / \mathrm{s}}$ , calculate the error as percentage of span.

$e_{p}=100\left(r-b\right) /\left(b_{\max }-b_{\min }\right)=100\times (294-327) /(460-220)=-13.75 \%$

9.5 A 5-m-diameter cylindrical tank is emptied by a constant outflow of $\mathbf{ 1.0 \mathrm{~m}^{3} / \mathrm{min}}$ . A two-position controller is used to open and close a fill valve with an open flow of $\mathbf{2.0 \mathrm{~m}^{3} / \mathrm{min}}$ . For level control, the neutral zone is $\mathbf{1 \mathrm{~m}}$ and the setpoint is $\mathbf{12 \mathrm{~m}}$ .
a. Calculate the cycling period.
b. Plot the level versus time.

a. Suppose the fill value opens when the level is at 11.5 m, we can get that the fill value closes when the level is at 12.5 m.

$\because t=V/Q=\pi R^2H/Q$

$Q_{in}=-Q_{out}=1.0m^3/min$

$\therefore T=2t=2\times \pi\times (2.5m)^2\times (1m)/(1m^3\cdot min^{-1})=39.2min$

$\because H=Qt/\pi R^2=\pm 0.051t$

9.7 A floating controller with a rate gain of $\mathbf{6 \% / \mathrm{min}}$ and $\mathbf{ p(0)=50 \%}$ has a $\mathbf{\pm 5-\mathrm{gal} / \mathrm{min}}$ deadband. Plot the controller output for an input given by Figure 9.25. The setpoint is $\mathbf{60\, \mathrm{gal} / \mathrm{min} }$ .

A setpoint of $60 \mathrm{gal} / \mathrm{min}$ with $\mathrm{a} \pm 5 \mathrm{gal} / \mathrm{min}$ deadband means that the trip points are,

$\begin{array}{c} Q_{\text {upper }}=65 \mathrm{gal} / \mathrm{min} \\ Q_{\text {lower }}=55 \mathrm{gal} / \mathrm{min} \end{array}$

The controller output is determined by the relations,

$\begin{array}{ll} p(t)=p(0)+6 t & \text { for } \quad Q>Q_{u p p e r} \\ p(t)=p(0)-6 t & \text { for } \quad Q<Q_{\text {lower }} \end{array}$

Examination of Figure 9.25 and use of the above output relations shows the following events:

For t<1 min, $Q<65 \mathrm{gal} / \mathrm{min}$ , so $p(t)=50 \%= constant$
(1) at $t=1 \mathrm{~min}$ , Q reaches 65

$p(t)=50+6(t-1)$

(2) at $t=4.25 \mathrm{~min}, \quad Q<65$ again, so
$p(t)=50+6(4.25-1)=69.5 \% (constant)$
(3) at $t=4.75 \mathrm{~min}, \quad Q<55$ ,

$p(t)=69.5-6(t-4.75)$

(4) at $t=8 \mathrm{~min}, \quad Q>55$
$p(t)=69.5-6(8-4.75)=50 \% \quad (constant)$
This is plotted in the following graph of output versus time.

9.8 For a proportional controller, the controlled variable is a process temperature with a range of 50 to $\mathbf{130^{\circ} \mathrm{C}}$ and a setpoint of $\mathbf{73.5^{\circ} \mathrm{C} }$ . Under nominal conditions, the setpoint is maintained with an output of 50% . Find the proportional offset resulting from a load change that requires a 55 % output if the proportional gain is (a) 0.1 , (b) 0.7 , (c) 2.0, and (d) 5.0 .

$\because p_0=50\%$

$p=K_pe_p+p_0$

When zhe output is 55%, zhe offset error will be:

$e_p=(55-50)/K_p=5/K_p$

$\because$ To make the error zero, the output should be 50% when $T=73.5^{\circ}C$

$\therefore e_{p}=100(73.5-\mathrm{T}) /(130-50)=1.25(73.5-T)$

$T=73.5^{\circ}C-0.8e_p$

$\begin{array}{lll}\text { (a) } K_{P}=0.1 & e_{p}=50 \% & T=33.5^{\circ} \mathrm{C} \\ \text { (b) } K_{P}=0.7 & e_{p}=7.14 \% & T=67.8^{\circ} \mathrm{C} \\ \text { (a) } K_{P}=2.0 & e_{p}=2.5 \% & T=71.5^{\circ} \mathrm{C} \\ \text { (a) } K_{P}=5.0 & e_{p}=1 \% & T=72.7^{\circ} \mathrm{C} \\ \end{array}$

9.11 How would a derivative controller with $\mathbf{K_{D}=4 \mathrm{~s}}$ respond to an error that varies as $\mathbf{ e_{p}=2.2 \sin (0.04 t)}$ ?

$p(t)=K_{D} \frac{d e_{p}}{d t}=0.352\cos(0.04t)$

9.15 A PID controller has $\mathbf{K_{P}=2.0, K_{I}=2.2 \mathrm{~s}^{-1}, K_{D}=2 \mathrm{~s} ,}$ and $\mathbf{ p_{I}(0)=40 \%}$ . Plot the controller output for the error of Figure 9.26 .

$p(t)=2 e_{p}+4.4 \int e_{p} d t+4 \frac{d e_{p}}{d t}+40$

(1) 0<t<2

$p_{1}=2 t+2.2 t^{2}+40$

$p_{1l}=48.8 \%$

(2) 2<t<4

$p_{2}=-5 t+14-5.5\left(t^{2}-4\right)+30.8(t-2)+48.8$

$p_{2l}=44.4 \%$

(3) 4<t<6

$p_{3}=3 t-18+3.3\left(t^{2}-16\right)-39.6(t-4)+44.4$

$p_{31}=31.2\%$

9.19 A PI controller has $\mathbf{ K_{P}=4.5}$ and $\mathbf{K_{I}=7 \mathrm{~s}^{-1}}$ . Find the controller output for an error given by $\mathbf{ e_{p}=3 \sin (\pi t)}$ . What is the phase shift between error and controller output?

$\begin{align*} p&=4.5 e_{p}+31.5 \int_{0}^{t} e_{p} d t+p_{}(0) \\ &=13.5 \sin (\pi t)+94.5 \int_{0}^{t} \sin (\pi t) d t\\ &= 13.5 \sin (\pi t)-30\cos (\pi t)+30\end{align*}$