COMPETENCES



- Specific competences



The competences of this subject are defined by means of the specific module skills (TEQI) as follows:



(https://www.ehu.eus/es/web/graduak/grado-ingenieria-quimica-industrial-alava/verificacion-seguimiento-y-acreditacion?p_redirect=descargaFichero&p_cod_proceso=egr&p_tipo=MEMORIA&p_cod_titulo=88&p_anyo_acad=)



1. Know, understand, and apply the concepts and principles of control engineering applied to chemical process units and plants. (TEQI4)



2. Apply the strategies of the scientific methodology to analyze and solve problems related to the control of chemical processes. (TEQI8)



3. Communicate adequately the knowledge, procedures, and results, using the vocabulary and terminology of process control. (TEQI9)



4. Perform measurements, calculations, studies, and reports in feedback control systems. (TEQI12)





LEARNING OUTCOMES



The acquisition of these skills is expressed through the achievement of the specific learning outcomes of the subject:



- Theorical learning outcomes



1. Know the structure of a feedback control system of a chemical process, its components, and its representation by means of block diagrams.



2. Know and apply the concepts of transfer function and block diagram.



3. Relate the mathematical models of chemical processes with their respective transfer functions.



4. Describe the dynamics of first order, second order and dead time systems.



5. Know the different types of controllers applied in feedback control systems and the type of response of each control action.



6. Analyze the permanent response of the feedback control system of a chemical process.



7. Analyze the stability of closed-loop control systems.



8. Know the basic instrumentation used in the control systems related to chemical processes.



- Practical learning achievements



1. Study the regulation of the pH of a solution contained in a continuous stirred tank by means of an automatic feedback control system based on proportional control action. Analyze the effect of the controller gain constant and experimental estimation of the proportional band.



2. Apply the fundamentals of automatic chemical process control to the control of the level of a liquid contained in a tank using analog instruments. Establish a closed loop control configuration of a level control system with proportional (P), proportional + integral (PI) and proportional + integral + derivative (PID) control actions by means of analog instruments. Know the operation of the instrumentation used and the signal transmission of the control maneuvering circuit. To analyze the effects of the gain constant, integral time constant and derivative time constant.



3. Apply the fundamentals of automatic control of chemical processes to the control of the level of a liquid contained in a tank by means of digital controllers. To establish a closed loop control configuration of a level control system with proportional (P), proportional + integral (PI) and proportional + integral + derivative (PID) control actions by means of digital control. Know the operation of the instrumentation used and the signal transmission of the control maneuvering circuit. Analyze the effects of the gain constant, integral time constant, derivative time constant and sampling period.



4. Apply the fundamentals of automatic control of chemical processes to the control of the temperature inside a tank using an industrial digital controller. Establish a closed loop control configuration of an air temperature control system, with proportional (P), proportional + integral (PI) and proportional + integral + derivative (PID) control actions. Know the operation and programming of a commercial controller. Experiment with the tuning of a commercial controller using the Ziegler and Nichols limit cycle method. Analyze the effects of gain constant, integral time constant and derivative time constant.



5. Apply the fundamentals of automatic control of chemical processes to the control of the pressure in a compressed air tank by means of digital controllers. Model the dynamics of the system by obtaining the transfer function representing the process. Establish a closed-loop control configuration of a pressure control system with P and PI control actions. Analyze the effects of gain constant, integral time constant and disturbances.



6. Apply the fundamentals of automatic chemical process control to the temperature control of a water flow. Model the dynamics of the system by obtaining the transfer function representing the process. Establish a closed loop control configuration of a temperature control system with P, PI and PDI control action. Analyze the effects of gain constant, integral time constant, derivative time constant and disturbances.

The following is the list of topics corresponding to the theoretical contents and laboratory practices. These contents correspond to the learning results of the previous section:



Theorical contents



Topic 1. Introduction to chemical process control.



Topic 2. Mathematical fundamentals for the analysis and design of control systems.



Topic 3. Simplified representation of control systems. Graphical models.



Topic 4. First order dynamic systems.



Topic 5. Second order dynamic systems.



Topic 6. Feedback control: PID controllers.



Topic 7. Analysis of the response of steady-state systems.



Topic 8. Closed-loop transfer functions: concept of stability.



Topic 9. Instrumentation of chemical processes.





Practical contents to be developed in the laboratory



Activity 1. pH regulation in a continuous stirred tank reactor.



Activity 2. Regulation of the water level in a tank by controlling the opening degree of a servovalve at the process outlet.



Activity 3. Regulation of the level of the liquid contained in a tank by controlling the filling pump.



Activity 4. Regulation of the air temperature in a tank.



Activity 5. Regulation of the pressure in a compressed air tank.



Activity 6. Regulation of the temperature of a liquid flow.

FACE-TO-FACE ACTIVITIES



The methodology planned for the development of the contents of the previous section, and, consequently, for the achievement of the corresponding learning results, is summarized as follows:



Theoretical Classes (M) (18 h)



Development of the concepts related to the feedback control theory applied to chemical processes.



Classroom Practices (PA) (18 h)



Resolution of exercises and practical activities regarding the feedback control theory taught in theoretical classes.



Laboratory practices (PL) (24 h)



Each practical activity corresponds to an experimental equipment and the realization of the practices is carried out in such a way that the students, distributed in groups of 2 or 3 people, rotate through them. Each activity includes:



• Study of the practical procedure, clarification of doubts, review of the theoretical concepts and guidance on the experimentation to be performed.



• Carrying out the experimental part of the practical, including calculations and data processing, as well as the discussion of results and conclusions.



• Preparation of the report and presentation of the practical. Activities of sharing of results and conclusions.



TUTORIALS



The tutorials are used to solve doubts, to guide work and problems, to situate the evolutionary state of the students within the subject, to propose improvements to increase academic performance, etc. In general, it is a voluntary activity (individual or in groups) and is carried out at the students' request.



NON-FACE-TO-FACE ACTIVITIES (90 h)



Continued work of student is essential to develop the competences of the subject. In addition to preparing the written exams, students should devote the hours of non-presential teaching to:



o Complete notes, consult bibliography and solve questions and/or problems, including voluntary deliverable tasks (a time commitment of approximately 3-4 h per week).



o Prepare the laboratory sessions and complete the corresponding report and presentation.



*If healthcare circumstances (e.g., COVID-19) oblige to develop an online evaluation, all media available in the UPV/EHU (Teams, eGela, etc.) will be used. The characteristics of this new evaluation mode will be published in eGela.

CONTINUOUS ASSESSMENT



• Written exam (60 % of the final grade)



• Laboratory practicals (40 % of the final grade):



- Oral exam (presentations): 40 %

- Written test: 25 %

- Laboratory reports: 25 %

- Laboratory work: 10 %



REQUIREMENTS TO PASS THE SUBJECT



- Obtain a mark ≥4 out of 10 in both parts (written exam and laboratory practicals).



- Complete all the laboratory practicals and deliver all the lab-reports required.



- Obtain a mark ≥4 out of 10 in all the parts related to the laboratory practicals: oral exam, written test, laboratory reports and laboratory work.



- Obtain a mark ≥5 in the final grade (obtained as a weighted average of the marks corresponding to the written exam and laboratory practicals).



Those students who do not meet any of these requirements will be marked with a 4.0 (maximum) in the Ordinary Call regardless of the final grade obtained.



*If healthcare circumstances (e.g., COVID-19) oblige to develop an online evaluation, all media available in the UPV/EHU (Teams, eGela, etc.) will be used. The characteristics of this new evaluation mode will be published in eGela.



CALL RESIGNATION



Those students who do not appear for the written test will be recorded as "Not Presented" in the Ordinary call.



FINAL TEST



Students who meet the conditions established in the UPV/EHU regulations and request to take a final test within the deadline set for that purpose (Chapter II, Article 8 of the Agreement of December 15, 2016, of the Governing Council of the University of the Basque Country/Euskal Herriko Unibertsitatea, which approves the Regulations governing the students’ Evaluation in official Bachelor's degrees), they need to implement the following activities:



- A written exam related to the theoretical-practical contents of the subject (100 % of the final grade).





REQUIREMENTS to pass the subject (FINAL TEST)



- Obtain a mark ≥5 in the final grade (obtained as the weighted average of the marks corresponding to the written test and the practical exam).



*If healthcare circumstances (e.g., COVID-19) oblige to develop an online evaluation, all media available in the UPV/EHU (Teams, eGela, etc.) will be used. The characteristics of this new evaluation mode will be published in eGela.



CALL RESIGNATION



Those students who do not appear for the written test will be recorded as "Not Presented" in the Ordinary call.

Compulsory material for laboratory practicals:

• Laboratory coat.

• An electronic lab notebook (or similar device)

• Laboratory practical scripts provided by the professor, which includes the following information:
o Objectives.
o Description of the equipment used.
o Procedure for the development of the practical and notes for the corresponding report (including questions related to the practical).

Basic bibliography

o Control Automático de Procesos; Smith, C. A. y Corripio, A. B. Ed. Limusa México, 1995.



o Control e Instrumentación de Procesos Químicos; Ollero de Castro, P. y Fernández Camacho, E. Ed. Síntesis, Madrid, 1997.



o Chemical Process Control; Stephanopoulos, G; Ed. Prentice Hall. New Jersey, 1987.

In-depth bibliography

o Process Modeling, Simulation and Control for Chemical Engineers; Luyben, W.L. Ed. McGraw-Hill, New York, 1990.