ME503: Industrial Process Control Systems Assessment

Task:

The project is to design a controller for a mixer. A black dye for making shirts is injected into a stream of water. The injected dye is blended into the water flow with constant speed mixers. A detector is used to monitor the dye/water concentration. The output of the detector is sent to a controller, which then sends a signal to the dye-injection valve. One needs to be careful with the location of the detector. The sensor has to be far enough away to ensure a well-mixed stream. However, if the detector is too far away, the transport lag can destabilize the process. The regulating valve is especially designed so that the dye input rate, in milliliters per second, varies linearly with the valve position. The regulating valve thus is a first order with a time constant of Tv (seconds) and a steady state gain of K_v (mL/sec.mV). The mixing process itself can be modeled as first order with a steady-state gain of Kp (ppm.sec/mL) and a time constant of Tp (seconds).

CT = Controller

CC = Control Valve

Q = Water flow rate

L = Distance from Dye injection to optical sensor

Consider/discuss the following in the report:

• Control objective(s).
• Input variables— classify these as (a) manipulated or (b) disturbance variables.
• Output variables — classify these as (a) measured or (b) unmeasured variables.
• Modelling – discuss how you could obtain the different models and transfer functions.
• Safety, environmental, and economic considerations.
• Control structure:
  • Discuss which type of controller should be used, P, PI or PID, and give your reasons why.
  • Discuss the advantages and disadvantages of each type of controller.
  • Would it be beneficial to use a cascade architecture?
  • Draw the block diagram using your chosen controller.

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