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Chapter 1 Solutions • Braking Force

• Gear Selection
1.1
Input Variables – Disturbances:
i. Driving a car • Weather
Please see either jogging, cycling, stirred tank
• Path Conditions
heater, or household thermostat for a represen-
tative answer. • Other people, animals
(c) Output Variables – Measured:
ii. Two sample favorite activities:
• Speed
Jogging
• Direction
(a) Objectives: • Caloric Output (via electronic moni-
• Jog intensely (heart rate at 180bpm) tor)
for 30 min. Output Variables – Unmeasured:
• Smooth changes in jogging intensity • Level of enjoyment
and speed. • Mechanical integrity of person and bi-
(b) Input Variables: cycle
• Jogging Rate – Manipulated input • Aesthetics (smoothness of ride)
• Shocking surprises (dogs, cars, etc.)– (d) Constraints – Hard:
Disturbance • Turning radius
(c) Output Variables: • Mechanical limits of bike and person
• Blood Oxygen level – unmeasured • Maximum fatigue limit of person
• Heart beat – measured Constraints – Soft:
• Breathing rate – unmeasured
• Steering dynamics that lead to instabil-
(d) Constraints: ity before mechanical failure (i.e. you
• Hard: Max Heart Rate (to avoid heart crash, the bike doesn’t break)
attack → death) • Terrain and weather can limit enjoy-
• Hard: Blood oxygen minimum and ment level.
maximum (e) Operation: Continuous: Steering, weight
• Soft: Time spent jogging distribution, terrain selection within a path,
(e) Operating characteristics: Continuous dur- pedal force Semi batch: Gear selection,
ing period, Semi Batch when viewed over braking force Batch: Tire pressure, bike se-
larger time periods. lection, path selection

(f) Safety, environmental, economic factors: (f) Safety, environment, economics: Safety:
Potential for injury, overexertion Stability and mechanical limits prevent in-
jury to rider and others Environment: Trail
(g) Control: Feedback/Feedforward system. erosion, noise Economics: Health costs,
Oxygen level, heartbeat, fatigue all part of maintenance costs
determining action after the fact. Path,
weather are part of feedforward system (g) Control Structure: Feedback: Levels of ex-
ertion, bike performance are monitored and
Cycling ride is adjusted after the fact FeedForward:
Path is seen ahead and ride is adjusted ac-
(a) Objectives: cordingly.
• Ensure stability (don’t crash)
iii. A stirred tank heater
• Enjoy ride
• Prevent mechanical failure (a) Objectives
(b) Input Variables – Manipulated: • Maintain Operating Temperature
• Body Position • Maintain flow rate at desired level
• Steering (b) Input Variables:

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• Manipulated: Added heat to system • Soft: Max or minimum temperature for

• Disturbance: Upstream flow rate and comfort
conditions (e) Operating conditions: Continuous heating
(c) Output Variables – Measured: Tank fluid adjustment, continuous temperature read-
temperature, Outflow ing.
(d) Constraints: (f) Safety, Environmental, Economic consider-
• Hard: Max inflow and outflow as per ations: Safety: heater may be an electri-
pipe size and valve limitations cal or burning hazard Economics: Heating
costs Environmental: Energy consumption.
• Soft: Fluid temperature for operating
objective (g) Control System: Feedback; temperature is
(e) Operating conditions: Continuous fluid monitored, heating rate is adjusted after
flow adjustment, continuous heating adjust- the fact.
ment vii. Air traffic control
(f) Safety, Environmental, Economic consider- Please see either jogging, cycling, stirred tank
ations: Safety: Tank overflow, failure could heater, or household thermostat for a represen-
cause injury Economics: Heating costs, spill tative answer.
costs, process quality costs Environmental:
Energy consumption, contamination due to
spills of hot water
1.2
(g) Control System: Feedback: Temperature is a. Fluidized Catalytic Cracking Unit
monitored, heating rate is adjusted Feed-
forward: Upstream flow velocity is used to i. Summary of paper:
predict future tank state and input is ad- A fluidized catalytic cracking unit (FCCU) is
justed accordingly. one of the typical and complex processes in
petroleum refining. Its principal components are
iv. Beer fermentation a reactor and a generator. The reactor executes
Please see either jogging, cycling, stirred tank catalytic cracking to produce lighter petro-oil
heater, or household thermostat for a represen- products. The regenerator recharges the cata-
tative answer. lyst and feeds it back to the reactor. In this
v. An activated sludge process paper, the authors test their control schemes on
Please see either jogging, cycling, stirred tank a FCCU model. The model is a nonlinear multi-
heater, or household thermostat for a represen- input/multi-output (MIMO) which couples time
tative answer. varying and stochastic processes. Considerable
computation is needed to use model predic-
vi. A household thermostat tive process control algorithms (MPC). Stan-
dard PID control gives inferior performance. A
(a) Objectives:
simplified MPC algorithm is able to reduce the
• Maintain comfortable temperature number of parameters and computational load
• Minimize energy consumption while still performing better than a PID control
(b) Input Variables: method.
• Manipulated: Temperature setting ii. Familiar Terms: Constraint, nonlinearity, con-
• Disturbance: Outside temperature, en- trol performance, MPC, unmeasured distur-
ergy transmission between house and bance rejection, modeling, simulation.
environment
b. Reactive Ion Etching
(c) Output Variables: Please see FCCU for a representative answer.
• Measured: Thermostat reading
• Unmeasured: Comfort level c. Rotary Lime Kiln
Please see FCCU for a representative answer.
(d) Constraints:
• Hard: Max heating or cooling duty of d. Continuous Drug Infusion
system Please see FCCU for a representative answer.

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e. Anaerobic Digester sentative answer.

Please see FCCU for a representative answer.
g. pH
f. Distillation Please see vortex–shedding flow meters for a repre-
Please see FCCU for a representative answer. sentative answer.

g. Polymerization Reactor
1.4
Please see FCCU for a representative answer.
No solutions are required to work through Module 1
h. pH
Please see FCCU for a representative answer.
1.5
i. Beer Production a.
Please see FCCU for a representative answer. The main objective is to maintain the process fluid
outlet temperature at a desired setpoint of 300 C.
j. Paper Machine Headbox
Please see FCCU for a representative answer. b.
The measured output is the process fluid outlet tem-
k. Batch Chemical Reactor perature.
Please see FCCU for a representative answer.
c.
1.3 The manipulated input is the fuel gas flowrate, specif-
ically the valve position of the fuel gas control valve.
a. Vortex–shedding flow meters
The principal of vortex shedding can be seen in the d.
curling motion of a flag waving in the breeze, or the Possible disturbances include: process fluid flowrate,
eddies created by a fast moving stream. The flag process fluid inlet temperature, fuel gas quality, and
outlines the shape of air vortices as the flow past the fuel gas upstream pressure.
pole. Van Karman produced a formula describing the
phenomena in 1911. In the late 1960’s the first vortex e.
shedding meters appeared on the market. Turbulent This is a continuous process.
flow causes vortex formation in a fluid. The frequency
f.
of vortex detachment is directly proportional to fluid
This is a feedback controller.
velocity in moderate to high flow regions. At low
velocity, algorithms exist to account for nonlinearity. g.
Vortex frequency is an input, fluid velocity is an out- The control valve should be fail-closed. Increasing
put. air pressure to the valve will then increase the valve
position and lead to an increase in flowrate. Loss of
b. Orifice–plate flow meters
air to the valve will cause it to close. The gain of the
Please see vortex–shedding flow meters for a repre-
valve is positive, because an increase in the signal to
sentative answer.
the valve results in an increase in flow.
c. Mass flow meters
h.
Please see vortex–shedding flow meters for a repre-
It is important from a safety perspective to have a
sentative answer.
fail-closed valve. if the valve failed open, there might
d. Thermocouple based temperature measurements not be enough combustion air, causing a loss of the
Please see vortex–shedding flow meters for a repre- flame - this could cause the furnace firebox to fill with
sentative answer. fuel gas, which could then re-ignite under certain con-
ditions. Although the combustion air is not shown, it
e. Differential pressure measurements should be supplied with a small stoichiometric excess.
Please see vortex–shedding flow meters for a repre- If there is too much excess combustion air, energy is
sentative answer. wasted in heating up air that is not combusted. If
there is too little excess air, combustion will not be
f. Control valves complete, causing fuel gas to be wasted and pollu-
Please see vortex–shedding flow meters for a repre- tion to the atmosphere. The process fluid is flowing

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to another unit. If the process fluid is not at the 1.8

desired setpoint temperature, the performance of the
We know from the problem statement that the inlet
unit (reactor, etc) may not be as good as desired, and
(Fin ) and outlet (Fout ) flowrates can be represented
therefore not as profitable.
with the following equations:
i.
Fin = 50 + 10 sin(0.1t)
The control block diagram for the process furnace is
shown below in Figure 1. Where the the signals as Fout = 50
The change in volume as a function of time is
dV
= Fin − Fout
dt
substituting what we know:
dV
= 50 + 10 sin(0.1t) − 50
dt
Figure 1-1: Control block diagram of process furnace Simplifying
dV
follows: = 10 sin(0.1t)
dt
• Tsp : Temperature setpoint Rearranging the equation

• pv : Valve top pressure dV = 10 sin(0.1t)dt

• Fg : Fuel gas flowrate Taking the integral of both sides

Z Z
• Fp : Process fluid flowrate dV = 10 sin(0.1t)dt
• Tp : Process fluid inlet temperature
Using basic calculus to solve
• T: Temperature of process fluid outlet
−10
V − V0 = cos(0.1t)|tt=0
• Tm : Measured temperature 0.1
We know the initial tank volume is 500 liters
1.6
V − 500 = −100 cos(0.1t) − 100 cos(0)
The problem statement tells us that the gasoline is
worth $500,000 a day. A 2% increase in value is: V − 500 = −100 cos(0.1t) + 100

$500, 000 $10, 000 V (t) = 600 − 100 cos(0.1t)

x 0.02 =
day day The equation above tells us how the volume of the
tank will vary with time. This can also be seen visu-
We are also given that the revamp will cost ally in Figure 2 below.
$2,000,000. We can now calculate the time required
to payback the control system investment.
1.9
$2, 000, 000
= 200days a.
$10,000
days The objective is to maintain a desired blood glucose
concentration by insulin injection. Insulin is the ma-
Therefore, we know it will take 200 days to pay off nipulated input and blood glucose is the measured
the investment. output. As performed by injection, the input is re-
ally discrete and not continuous. Also, glucose is
1.7 not continuously measured, so the measured output
is discrete. Disturbances include meal consumption
and exercise. Feedforward action is used when a di-
2yrs · 4.4 million $/yr · 0.2% = $176, 000 abetic administers an injection to compensate for a

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Liquid volume as a function of time

700

650
V(t)

600

Figure 1-4: control block diagram of closed-loop in-

sulin infusion
550

gain is positive. A fail-closed valve should be speci-

500 fied. If the valve failed-open, the cold stream outlet
0 50 100 150
temperature could become too high.
time

b.
Figure 1-2: Liquid volume as a function of time An increase in the hot by-pass flow leads to a decrease
in the cold stream outlet temperature, so the gain is
negative. A fail-open valve should be specified.
meal. Feedback action occurs when a diabetic admin-
isters more or less insulin based on a blood glucose c.
measurement. It is important not to administer too An increase in the cold by-pass flowrate leads to a
much insulin, because this could lead to too low of a decrease in the outlet temperature, so the gain is neg-
blood glucose level, resulting in hypoglycemia. ative. A fail-open valve should be specified, so that
the outlet temperature is not too high or the air pres-
b. sure is lost.
A process and instrumentation diagram of an auto-
mated closed-loop system is shown in Figure 3 below. d.
For simplicity, this is shown as a pump and valve Strategy (c), cold by-pass, will have the fastest dy-
namic behavior because the effect of changing the by-
pass flow will be almost instantaneous. The other
strategies have a dynamic lag through the heat ex-
changer.

1.11
The anesthesiologist attempts to maintain a desired
setpoint for blood pressure. This is done by manipu-
lating the drug flowrate. A major disturbance is the
effect of an anesthetic on blood pressure.

The control block diagram for the automated system

is show below in Figure 5, where, for simplicity, the
drug is shown being changed by a valve.
Figure 1-3: P&ID of closed-loop insulin infusion

arrangement. In practice, the pump speed would

be varied. The associated control block diagram is
shown in Figure 4 below.

1.10
a. Figure 1-5: Control block diagram of drug delivery
An increase in the hot stream flowrate leads to an in-
crease in the cold stream outlet temperature, so the

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Chapter 2 Solutions 40.8

Euler integration vs. ode45

2.1 40.7

40.6
The modeling equation is

Outlet Temperature − C
RT

40.5

°
dP RT
= qi − β P − Ph
dt V V 40.4

At steady state 40.3

RT

40.2
dP RT
= qi − β P − Ph = 0
dt V V 40.1

RT
RT ode45
β Ps − Phs = qis 40
Euler

V V 0 0.2 0.4 0.6 0.8 1

Time − min
1.2 1.4 1.6 1.8 2

q2
Ps = Phs + is2
β Figure 2-2: Plot for 2.2
Thus we can conclude that it is a self–regulating sys-
tem, as for a change in input it will attain a new the inlet and outlet flow rates are the same. Thus
steady–state. Fi
The sketch of the steady–state input–output curve (Ti − T ) + Q = 0
V
should look like figure 2-1. 100
(20 − 40) + Q = 0
500
Q = 4◦ C/min
Steady−state input−output curve
30

25 b. For this part we need to integrate

dT 100
20 = (22 − T ) + 4
dt 500
from an initial state of T = 40◦ C. The Euler
Ps

15
formula is
10
xk+1 = xk + ∆txk
xk = f (xk )
5

where f (·) is the right hand side of the differen-

0
tial equation, and x is the state, in this case T .
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
q
is Using ∆t = 0.5, and for a total of 2 minutes, we
have
Figure 2-1: Plot for 2.1
x0 = 40
 
1
x1 = 40 + 0.5 (22 − 40) + 4 = 40.2
5
2.2  
1
x2 = 40.2 + 0.5 (22 − 40.2) + 4 = 40.38
The model equations are 5
 
1
dV x3 = 40.38 + 0.5 (22 − 40.38) + 4 = 40.542
= Fi − F 
5

dt
1
dT Fi x4 = 40.542 + 0.5 (22 − 40.542) + 4 = 40.6878
= (Ti − T ) + Q 5
dt V
Figure 2-2 shows the curve of the solution found
using matlab’s ode45, with the circles marking
a. At steady–state, the volume will not change, as the points of the Euler solution.

2-1