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CONFIDENTIAL

EH/OCT 2010/CPE562

UNIVERSITI TEKNOLOGI MARA


FINAL EXAMINATION

COURSE

CHEMICAL PROCESS CONTROL

COURSE CODE

CPE562

EXAMINATION

OCTOBER 2010

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

the Question Paper


a one-page Appendix
an Answer Booklet - provided by the Faculty

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


This examination paper consists of 4 printed pages
Hak Cipta Universiti Teknologi MARA

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EH/OCT 2010/CPE562

QUESTION 1
Consider a pressure control system shown in Figure 1 below. The pressure in the
tank is controlled by variation of the flowrate of gas stream leaving the tank. The
controller receives a signal from a pressure transmitter with a range of 0 to 1000
kPa. The controller is a proportional-integral controller with a gain 3%CO/%TO and
an integral time of 5 min. The control valve is linear with transfer function of 15
gpm/%CO and the time constant of the valve actuator is 0.08 min. The transfer
function of the gas flow to the pressure in the tank is first-order with a gain of 50
kPa/gpm and a time constant of 0.5 min.
a) Draw the complete block diagram for the control loop showing the transfer
function of each device.
(12 marks)
b) If the proportional-integral controller receives 45%TO signal from the transmitter,
determine the pressure measured by the pressure sensor in the tank.
(4 marks)
c) Reduce the block diagram in a) to canonical form.
(6 marks)

Gas

Figure 1 Column gas pressure control.

Hak Cipta Universiti Teknologi MARA

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EH/OCT 2010/CPE562

QUESTION 2
a) Table 1 show a process data for liquid crude oil flows in a pipeline.
i)

recommend the size of an equal percentage control valve for liquid crude oil with a
specific gravity of 0.8.
(6 marks)

ii)

verify that your selection is correct by comparing the installed characteristic to shelf
characteristic.
(4 marks)
The control valve specification data sheet is given in Appendix 1.
Table 1 Process data
Flow condition

Flowrate, gpm

AP, psi

Stem position, %

Maximum

183

10

90

Normal

41

15

50

Minimum

20

10

b) Elaborate in detail the differences between air-to-open and air-to-close control valves in
terms of their applications and constructions.
(6 marks)
c) State the advantage of feedforward control over feedback control.
(2 marks)
QUESTION 3
You are working as Engineering Manager of a chemical processing company. Your company
received a visit from a group of third-year engineering students where you brought them to
several plants.
a) One of your task is to explain to the visiting group about liquid level measurement using
differential pressure transmitter in a closed cylinderical vessel. With an aid of a diagram,
describe your task.
(6 marks)
b) One of the engineering student asked a question about the difference between
resistance temperature detector (RTD) and thermocouple (TC) for liquid temperature
measurement. Elaborate to the group the difference between RTD and TC in term of
their working principles, constructions and range of measurements.
(6 marks)

Hak Cipta Universiti Teknologi MARA

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EH/OCT2010/CPE562

c) Later, you brought the group to the control room and explained to them about the
SCADA system installed. Sketch a SCADA system with a simple feedback control loop.
(6 marks)
d) Finally, you are explaining about signal transmission to the group. Demonstrate the
calculation of equivalent signal that a pressure transducer (l/P) emitted, in psi, when it
receives a 10 mA signal from a controller.
(2 marks)

END OF QUESTION PAPER

Hak Cipta Universiti Teknologi MARA

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EH/OCT 2010/CPE562

APPENDIX 1

CONFIDENTIAL

FLOW COEFFICIENTS

Equal Percentage
Body
Port
Total
Size.
Diameter, TfavBI,
10
In.
In
In
20
1 & 1-1/4 1-5/16
3/4
.783
1.S4
1-1/2
1-7/8
3/4
1.52
2.63
2
2 5/16
1.66
1-1/8
233
3.43
2-1/2
2-7/8
1-1/2
7.13
4.32
3
3-7/16
1-1/2
7.53
4
4-3/B
2
5.85
11.6
6
7
2
12.9
25.8
8
B
2
1-8.5 38.0
(Liquid)
8
8
3
27.0
58.1
3/4
1-1fi, 1-5/16
1.12
.136 i
1-S/16
-a
3 / 4 * ^323
1-7/8 - 3 / 4
.3=1/2
-K57 . -5237-5
2
5
/
1
6
.
'a
13/8"
-4
' 2-7/8
.1-1/2* 3 2 2
--7.65 '
"6
,4-3/8
'5.40 - T O J - .
"2
I & 1-1/4 1-5/16
3/4
31.2
48.3
1-1/2
1-7/8
3/4
S3.7
902
2
2-5/16
60.4
1-1/S
107
2-7/8
2-1/2
1-1/2 121
239
3-7/16
3
1-1/2 1S2
253
4
4-3/8
2
200
374
6
7
2
428
851
8
8
2
631
1200
(Gas)
8
8
3
867
1880
1-5/16
1-1/2
J/4
40.6
"S8.0
-2
1-5/16
32JS
3/4
*49.0
v562
.2-1/2
1-7/8
3/4
.89.4
-68.0
3
-2-5/16
1-1/8
114
4
2-7/8
1-1/2 132
2S6
6
4-3/8
219
2
369
"
J & 1-1/4 1-5/16
3/4
1.56
2 42
1-1/2
3/4
1-7/8
2.69
4 51
2
1-1/B
2-5/16
3.02
5.35
1-1/2
2-1/2
2-7/8
6.05
12.0
1-1/2
3
3-7/16
7.60
12.7
4
4-3/8
2
10.0
18.7
6
7
2
21.4
42.6
8
31 6
8
2
60.0
(Steam)
43.4
8
8
3
94.0
1-1/2
1-5/18
2.03
3/4
2.90
2
1-S/lff
1.63
3/4
2.45
2-1/2
2.81
1-7/8
3/4
447
.3.40
3
2-5/16
1-1/8
5.70
6.60
-4
1-1/2
2-7/8
12.8
6
4-3/8
.2
11.0
183
Coefficients

Valve OpeningPercent of Total Travel

30

40

2.20
2.89
3.87
5.41
4.66
6.98
10.8
15.1
10.9
17.1
18.3
30.2
43.3
67.4
58,4
86.7
105
188
=2223JO
-2M9.
_a-ays M&44-".*77=7J07.
TX1A -16J9~ :
26.7
.taa
67.4
94.4
131
183
238
164
359
497
360
545
587
970
1430
2270
2660
1810
5880
3350
~BOv4- 104
723
;953
179
129
-171
- -246
553
380
*42
884
3.37
4.72
6 55
9,15
820
11.9
18.0
24.9
18.0
27.3
29.4
48 5
71.5
114
90.6
133
168
294
4.02
520
3.S0
4.78
-6.45
895
8.55
12.3
19.0
27.7
27.1
432

50
4.21
7.45
10.8
22.4
272
49.7
104
130
307
<*"*27- '"7.64tO.7*
253 I
452
138
256
358
727
854
1580
3480
3960
9850
-345
139
246
367 "
-816
1430
6.90
12.8
17.9
36.4
42.7
79.0
174
198
493
7.25"
6.95
12.3
18.4
40.8
71.5

60
5.76
112
16.5
,,33.7

70
7.83
174
25.4
492
66.0
79.7
125
162
239
189
268
478
605
9.01
f *6:17 .
3.63 - - -8:68
Tt5 ' 1 * 2
nxo . 527.9
60.5
371.2
t C 2 - 111
270
191
578
382
546
851
1090
1600
2150
1350
2520
4100
8200
5500
5790
8300
15.000
20.600
206
.294
197
.290
377
-677
545
S13
1210
^ I860
2230
3480
13 5
9 55
28.9
19 1
42.6
27.3
80.0
54 5
108
67.5
126
205
275
410
290
415
750
1030
103
14.7
9.85
14.5
189
28.9
27.3
40.7
60.5
93.0
174
112

80
10.9
24.5
37.3
71.1
97.0
171
316
371
695
-13.1 "123
28.7
41.5
-85.7
169
380
811
1280
2320
3230
5890
10.900
11.600
25.000
=419
41 a
351
1300
2750
5280
190
40 6
64.0
116
162
295
545
580
1250
21.0
203
42.6
65.0
137
264

90
V4 1
30 8
50.7
89.5
120
205
368
476
761
182
183
35.1
58.0
105
232
483
1020
1680
2910
3930
7040
13.000
15.600
27,300
587
383
1130
1840
3600
7360
242
51 0
84.0
146
197
352
650
780
1370
29.4
292
59.0
32.0
180
368
-

100
17.2
59 7
99.4
136
224
394.
567
818
-23.1
24.3
43.9
70.7
112
274
562
1180
19B0
3230
4470
7S80
13.900
19.300
29.400
773
783
1480
2370
4040
-9T40
28.1
59.0
99.0
162
224
379
695
965
1470
38-7
392
74.0
119
202
457

- T I M S column hsts the K . vilues for the C . coefficients and tho C, vetoes for the C . end C,
coefficients i t 100% travel
Restricted Trim

Hak Cipta Universiti Teknologi MARA

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