This is a real process with real data. Consider the heater shown in Fig. P10-2. In this process,…

This is a real process with real data. Consider the heater shown in Fig. P10-2. In this process, the heater is actually a reactor where the catalytic reaction of C,H, and steam takes place to form H, and C02. The temperature of the product gas is controlled by manipulating the flow of fuel. It was suspected that the controllers were not correctly tuned. This suspicion was confirmed by looking at the unstable response, shown in Fig. P10-3, of the reactor after an upset (a change in feed flow) entered the reactor. On the basis of this response, it was decided to re-tune the controllers. Both controllers were set in manual, and after the process reached a steady condition, shown in Fig. P10-3, the output from the flow controller to the valve was changed by – 5%. The flow and temperature responses are given in Table P10-1. Interestingly, although the plant personnel were expecting a 20°F change in temperature, the actual change was about 230°F. Figure P10-3 also shows this temperature response. After the temperature reached bottom, the flow controller output was changed by + 5% to bring the temperature back to its

desired operating condition. On the basis of the process response, both controllers were tuned and set in automatic. Figure PlO-3 shows the response under automatic control with the new settings and for the same upset. Obtain the settings for the controllers using Austin’s method, which is outlined in this chapter. The temperature transmitter range is 0 to 2000”F, and that of the flow transmitter is 0 to 24 mscfh



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