Telemark University College / Finn Haugen

Solution to exam in Course SCEV3106 Industrial Automation

Exam date: 18. December 2007. Duration: 3 hours.

1. (15% weight) Solution is not provided here because this problem

(about linear decoupling) is not relevant for exam 2009.

2. (15%) Averaging level control is about using sluggish feedback level

control to obtain smoothing of the flow through a liquid tank so that
the outflow is smoother than the inflow. Figure 1 shows such a
control system (it can also be denoted flow smoothing system).

Figur 1:

Specifications: (1) Proper stability (of course). (2) Maximum

allowable variations in the level due to a given maximum slug of the
inflow.

3. (15%) The purpose of ratio control is to control a mass flow, say F2 ,

1
 so that the ratio between this flow and another flow, say F1 , is
F2 = KF1 (1)
where K is a specified ratio which may have been calculated as an
optimal ratio from a process model.
Figure 2 shows ratio control system.

FT1 FC1

F1
Wild stream
Process
F2

FT2 FC2

K F1 = F2SP (setpoint for F2 )

MULT
Measured
F1 K (specified
ratio)

Figur 2: Ratio control

4. (15%) Figure 3 shows the cascade control system. The primary loop
performs level control. The secondary loop is a control loop for the
mass flow on the conveyor belt. The mass flow is measured by a flow
sensor. The purpose of the secondary loop is to give a quick
compensation for disturbances in the chip flow.
Order of tuning two controllers of a cascade control system: First the
secondary controller is tuned, with the primary controller in manual
mode. Then the primary controller is tuned, the secondary controller
in automatic mode. So, you start with the inner loop, and then move
outwards.
5. (15%) See Figure 4.
6. (10%) The process model is given as

Ah = qin Kv u dP (2)

2
 Conveyor belt

Screw d
Chip
tank
Control
variable Secondary
u loop h [m]
FC FT
Wood-
chip Primary loop
LC LT

wout [kg/
min]

Figur 3:

Written on standard form:

 
qin Kv dP
h = + u (3)
A

 A
=f

 
=B

The control function becomes

  t
1
u = B Kp e + Ki ed + ryf f (4)
0
 1   t
Kv dP qin
= Kp e + Ki ed + ryf (5)
A 0 A
  t
A qin
= Kp e + Ki ed + ryf (6)
Kv dP 0 A

This control function requires that the differential pressure dP is

measured, and that the inflow qin is measured.
7. (15%) A Safety Interlock System (SIS) is an emergency backup
system for the BPCS (Basic Process Control System). The SIS
system automatically starts when a critical process variable exceeds
specific alarm limits that define the allowable operating region. It is

3
 Feedforward
control

FT FC
1 1 Feedforward Feedforward
Flow(rate)
FT control FT control
setpoint 3 4

Pump 1
LT LC LT LC LT LC
1 1 Level 2 2 Level 3 3 Level
Vessel Vessel Vessel
setpoint setpoint setpoint
1 2 3

Product

Pump 2 Pump 3 Pump 4

Downstream tanks (all three )

Figur 4:

crucial that the SIS functions independently of the BPCS. Thus,

these systems should be physically separated from the BPCS, having
their own actuators and sensors.
Example: The SIS turns off the reactant pump after a high
temperature alarm in a chemical reactor.