IME 8310 – INSTRUMENTACIÓN Y CONTROL, 2017-30

Closed Loop Exercise

The Figure shows a catalytic regenerative unit, where a hot air stream removes carbon from a solid catalyzer. The
manipulated variable is the fuel flow and the controlled variable is the regeneration temperature.

 The installed valve is Fail Closed, linear and has a flow capacity of 𝐶𝑣𝑚𝑎𝑥 = 49.33 𝑔𝑝𝑚/√𝑝𝑠𝑖, and a time constant
of 𝜏𝑣 = 0.2 𝑚𝑖𝑛.
 The fuel is supplied at 20.5 𝑝𝑠𝑖𝑎 and discharged at 15 𝑝𝑠𝑖𝑎. The fuel density is 58 𝑙𝑏𝑚/𝑓𝑡 3 . The water density is
62.4 𝑙𝑏𝑚/𝑓𝑡 3 .
 The temperature sensor/transmitter range is 50 − 275 ℉, and its time constant is 0.4 𝑚𝑖𝑛. The temperature
steady state value is 159.6 ℉.

TT
11
Aire
caliente

Aire de
regeneración vvvvvvvv

Aire de
combustión

TC
FC 11

Combustible

The main disturbance to the system is the atmospheric air temperature, which is nominally 80 ℉. The open loop transfer
function relating the controlled variable and this disturbance is:
𝑠 + 1 −1.3𝑠
𝐺𝐷 (𝑠) = 0.44 𝑒
2.3𝑠 + 1
The gain units are %𝑇𝑂/℉, while the dead time and the time constants are in minutes.

A plant operator was asked to make a step change in the signal going to the fuel valve. This signal is, in steady state,
50%𝐶𝑂. The operator takes the results to your office and tells you that he has made a change in the signal, but he has
forgotten the magnitude and sign of that change. However, from the results you observe that the fuel flow changed from
60 to 72 𝑔𝑝𝑚. Since you know the valve characteristics, you can calculate the change performed in the controller signal.

From the data recorded by the operator, you notice that the temperature response could be characterized as a first order
plus dead time (FOPDT) function, showing an initial value of 159.6 ℉ and stabilizing finally at 174.7 ℉. Moreover, once
the step change was made, it took one minute before the temperature started to change, and it took 1.5 more minutes
to reach 169.113 ℉.

The nominal condition (and set point) for the regenerative temperature is 159.6 ℉. The maximum permitted offset is
5 ℉.
a) Draw a block diagram of the control loop, indicating in each block the corresponding transfer function and, in
each connecting line, the units of the corresponding signals.

b) If a P-only controller is used, and set point changes of 15 ℉ will be made, which must be the controller action
and the minimum 𝑘𝑐 to ensure the offset will not be exceeded?

c) Determine the offset if the controller gain is set at 𝑘𝑐 = 0.8 %𝐶𝑂/%𝑇𝑂 and a change of 15 ℉ in the
atmospheric air temperature takes place.