This question paper consists of 7 printed pages, each of which is identified by the Code Number PEME220001

UNIVERSITY OF LEEDS School of Process, Environmental and Materials Engineering May/June 2012 Examinations

PEME220001 PROCESS ENGINEERING SYSTEMS

Time allowed: 3 hours Answer five questions, at least one question from each Section PLEASE SHOW ALL WORKINGS IN ANSWERS TO NUMERICAL QUESTIONS. SECTION A 1 (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) 2 What is the turndown ratio of a flow meter? [2 marks] Express the instantaneous alternating voltage in trigonometric function. [2 marks] What are absolute pressure, gauge pressure and differential pressure? [2 marks] [2 marks] What is the difference between pressure and shear stress? State the major advantages and disadvantages of a venturi flow meter. [2 marks] What are the two basic methods of protection built into the design of equipment and devices used in an explosive environment? [2 marks] Summarise the advantages and disadvantages of a proportional controller. [2 marks] State the difference between feedback control and feedforward control. [2 marks] Estimate the viscosity values of air, water and olive oil. [2 marks] [2 marks] What are the installed characteristics of a control valve?

A process device can be modelled by an equivalent circuit of an electrical resistor (R = 30.0 ) in series connection with an inductor (XL = 40.0 ) as shown in Figure 1 on page 2. The effective value of an ac voltage (E = 240 V) is supplied to the device. (a) (b) (c) Determine the equivalent impedance of the device. Calculate the effective value of current supplied by the power. Calculate the effective value of voltage drop on the resistor. [4 marks] [2 marks] [2 marks] Continued over

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(d) (e) (f) (g) (h) (i)

Calculate the effective value of voltage drop on the inductor. Estimate the apparent power of the device. Estimate the actual power of the device. Determine the power factor of the device. Suggest a method to enhance the power factor to 1. Re-estimate the actual power of the device after the enhancement.

[2 marks] [2 marks] [2 marks] [2 marks] [2 marks] [2 marks]

R
Process device

Figure 1 SECTION B 3 The principle of differential flow meters can be described using Bernoullis ideal flow equation, which states that the sum of the static energy (pressure head), the kinetic energy (velocity head) and the potential energy (elevation head) of the fluid is approximately conserved in the flow across a constriction in a pipe. PA V2 + A + Z A = constant A g 2g where, at the cross section A of the flow, A is fluid density, ZA is elevation head, PA is pressure, VA is fluid flow velocity and g denotes the gravitational constant. Based on the Bernoulli principle and considering a horizontally installed pitot flow meter facing an incompressible fluid with the density , pressures Pt and Ps, as shown in Figure 2 below, derive the flow speed V2.

Pt, V1 Ps, V2 Figure 2 [20 marks]

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Considering a single feedback control for a liquid level control as shown below in Figure 3 and assuming a PI controller to be applied for the auto-control of the liquid level, (a) (b) (c) (d) identify the manipulated variable, controlled variable and possible disturbances; [5 marks] draw a block diagram to reflect the information flow of the control system; [5 marks] derive the input/output transfer functions of the control system; [5 marks] describe the steps of Ziegier-Nichols close-loop method for tuning of the control system. [5 marks]

fi

LT LC

LC

Pump

fo

Figure 3 SECTION C 5 (a) (i) (ii) (iii) (iv) Non-numerical question on temperature measurement: answer as briefly as possible. (Questions equally weighted at 0.4 marks)

Name a thermometer that relies on solid expansion upon heating. Name a thermometer that relies on phase change upon heating. Is the response time of liquid expansion thermometers small or large? Would you recommend using an alcohol liquid expansion thermometer in the temperature measurement of superheated steam? (v) Which physical law allows the temperature to be determined from pressure using a gas expansion thermometer? (vi) Name one property of liquid crystals that allows temperature measurement. (vii) Which electrical property of a single pure metal allows temperature measurement? (viii) Give one reason why platinum is used in thermometry that relies on thermoelectric effects. (ix) What is the treatment given to platinum wires and strips to increase their chemical and thermal stability for use in thermometers? Continued over 3

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(x) (xi) (xii) (xiii) (xiv) (xv) (xvi) (xvii) (xviii) (xix) (xx) (xxi) (xxii) (xxiii) (xxiv) (xxv)

Draw a simple diagram of R vs. T for a negative temperature coefficient thermistor. What type of materials do thermistors rely on for temperature measurement? Can thermistors be used in sub-zero C temperature measurements? Name the appropriate law of physics that allows thermocouples to generate a temperature difference output. Name the appropriate law of thermocouples allowing them to give an accurate temperature output when their cold junction is at a temperature other than zero C. Name the appropriate law of thermocouples allowing operating them with cheap metal leads at the cold junction. What is the term used when a thermocouple measurement requires a correction because its cold junction is not at 0 C? Does this correction become relatively larger or smaller as the hot junction temperature increases? What type of heat transfer (convection/conduction/radiation) do thermocouples rely on to accurately measure the temperature of a non-moving solid? Does the response time of a thermocouple increase or decrease with increasing the diameters of the thermocouples wires? What does the voltage generated by a thermocouple do when doubling the thermocouples wires length? (halves/doubles/remains the same). What protective measure can be taken to carry out accurate gas temperature measurements with thermocouples in highly radiative environments? Cite a circumstance when a pyrometer would be the only practical device allowing temperature measurement. Give an example of a partial radiation pyrometer. What type of correction is usually associated with the use of pyrometers? If a thermal radiation thermometer is pointed at a target that is opaque, and considered a grey body with reflectivity of 0.1, what is its emissivity? [10 marks] Gas composition measurement: answer the following questions as briefly as possible (usually one word, one reaction). (Questions equally weighted 0.5 marks) Which of the following gases is commonly measured using non-dispersive infrared (NDIR) absorption: Oxygen, nitrogen, carbon dioxide? Increasing the path length in a NDIR analyser would have which effect on the accuracy of the gas concentration measurement (increase/decrease/no effect)? In a NDIR analyser, what would increasing the intensity of the infra red source do? Increase or decrease absorption? In gas composition measurements of combustion exhausts by NDIR absorption, give an example of a component in the sample that may typically cause an error in the readings. Is NDIR a destructive or non destructive method of analysis? Would you place a NDIR absorption analyser at the beginning or at the end of a series of online analysers for the same sample line? Name one gas species that may be measured by UV absorption. Continued over 4

(b)

(i) (ii) (iii) (iv) (v) (vi) (vii)

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(viii) In gas chromatography, what is the output of the analyser called? (ix) Which of the following parameters allows the identification of a sample species in gas chromatography: peak height, retention time, peak area? (x) Which of the following gases would elute first from a gas chromatograph column: oxygen, nitrogen, hydrogen? (xi) In a flame ionisation detector, which reaction allows quantification of the gas species? (xii) Name one hydrocarbon that is suited to GC-FID analysis. (xiii) What does TCD in GC-TCD mean? (3 word answer) (xiv) Name which of the GC detectors (FID or TCD) you would use to analyse N2 content? (xv) Name which type of GC detector (FID or TCD) you would use to analyse butane content? (xvi) What online technique would you recommend to measure nitrogen oxide gas concentration online with a response time of around 20s? (xvii) What online technique would you use to analyse O2 content? (xviii) Complete the sentence with two words: a mass spectrometer allows the measurement of species according to their .. to .. ratio. (xix) Which two forces does the MS rely on for separation of the sample components? (xx) Name one component that makes up the three essential stages of a mass spectrometer. [10 marks] 6 (a) Two type C thermocouples (Tungsten-5% Rhenium vs. Tungsten-26% Rhenium) are used to measure local temperatures in a vacuum reactor. A chart recorder with a calibration setting of 40 mV for the full scale of 100 divisions reads 84.15 and 91.5 divisions respectively. The thermocouples cold junctions are exposed to the ambient temperature of 35 C. Using the table of calibration for type C thermocouples (on page 6), and providing the details of the calculation step by step, determine: (i) The two reactor temperatures given by the chart recorder without correction. [3 marks] (ii) The two corrected reactor temperatures. [3 marks] (i) A total radiation thermometer (calibrated with a black body) is used to measure the wall temperature of a reactor. It reads 677C on a section of the wall which is assumed to have a grey body emissivity of 0.7. [3 marks] Determine the wall sections true temperature Tt1. A disappearing filament pyrometer is used for a measurement on another part of the reactor as in b(i). The pyrometer has also been calibrated with a black body and reads a brightness temperature of 677 C. The walls emissivity is 0.7. The pyrometer uses a tungsten filament and a filter that transmits the wavelength at 0.5 m. Determine the true temperature Tt2 of this section of the reactor wall. (Data: C2 = 0.01439 mK). [3 marks] Continued over

(b)

(ii)

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(iii)

A two colour radiation thermometer is now used on another section of the reactor wall. The thermometer reads brightness temperatures of 677C and 665C using the wavelengths 0.45 m and 0.55 m (indigo and yellow-green respectively). Determine the true temperature Tt3 of this section of the reactor wall. [3 marks]

(c)

Exhausts from a combustion process fuelled with propane (C3H8) are sampled and cooled down to near 0oC by flowing the exhaust flow through an ice bath, and once dry, are analysed by gas chromatography (GC). The CO2 vol % is 11.9%, O2 is 3.68% and N2 is 83.25%. Determine the wet composition of the exhausts (CO2, O2, N2 and H2O). [5 marks]

Table of calibration of type C thermocouple. Voltages in mV, temperatures in Celsius. Reference junction at 0C.
0.000 0.013 0.026 0.040 0.053 0.067 0.080 0.094 0.107 0.121 0.135 0 0.135 0.148 0.162 0.176 0.189 0.203 0.217 0.231 0.244 0.258 0.272 10 0.272 0.286 0.300 0.314 0.328 0.342 0.356 0.370 0.384 0.398 0.412 20 0.412 0.426 0.440 0.454 0.469 0.483 0.497 0.511 0.525 0.540 0.554 30 0.554 0.568 0.583 0.597 0.612 0.626 0.640 0.655 0.669 0.684 0.698 40 - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2000 33.660 33.672 33.684 33.697 33.709 33.721 33.733 33.745 33.757 33.769 33.782 2000 2010 33.782 33.794 33.806 33.818 33.830 33.842 33.854 33.866 33.878 33.890 33.902 2010 2020 33.902 33.914 33.926 33.938 33.950 33.962 33.974 33.986 33.998 34.010 34.022 2020 2030 34.022 34.034 34.046 34.058 34.070 34.082 34.094 34.106 34.118 34.130 34.142 2030 2040 34.142 34.153 34.165 34.177 34.189 34.201 34.213 34.225 34.236 34.248 34.260 2040 2050 34.260 34.272 34.284 34.295 34.307 34.319 34.331 34.342 34.354 34.366 34.378 2050 2060 34.378 34.389 34.401 34.413 34.424 34.436 34.448 34.459 34.471 34.483 34.494 2060 2070 34.494 34.506 34.518 34.529 34.541 34.552 34.564 34.576 34.587 34.599 34.610 2070 2080 34.610 34.622 34.633 34.645 34.656 34.668 34.679 34.691 34.702 34.714 34.725 2080 2090 34.725 34.737 34.748 34.760 34.771 34.782 34.794 34.805 34.817 34.828 34.839 2090 2100 34.839 34.851 34.862 34.874 34.885 34.896 34.908 34.919 34.930 34.942 34.953 2100 2110 34.953 34.964 34.975 34.987 34.998 35.009 35.020 35.032 35.043 35.054 35.065 2110 2120 35.065 35.077 35.088 35.099 35.110 35.121 35.132 34.144 35.155 35.166 35.177 2120 2130 35.177 35.188 35.199 35.210 35.221 35.232 35.243 35.254 35.265 35.277 35.288 2130 2140 35.288 35.299 35.310 35.321 35.332 35.343 35.353 35.364 35.375 35.386 35.397 2140 2150 35.397 35.408 35.419 35.430 35.441 35.452 35.463 35.474 35.484 35.495 35.506 2150 2160 35.506 35.517 35.528 35.539 35.549 35.560 35.571 35.582 35.592 35.603 35.614 2160 2170 35.614 35.625 35.635 35.646 35.657 35.668 35.678 35.689 35.700 35.710 35.721 2170 2180 35.721 35.731 35.742 35.753 35.763 35.774 35.784 35.795 35.806 35.816 35.827 2180 2190 35.827 35.837 35.848 35.858 35.869 35.879 35.890 35.900 35.911 35.921 35.932 2190 2200 35.932 35.942 35.953 35.963 35.973 35.984 35.994 36.004 36.015 36.025 36.036 2200 2210 36.036 36.046 36-056 36.067 36.077 36.087 36.097 36.108 36.118 36.128 36.138 2210 2220 36.138 36.149 36.159 36.169 36.179 36.189 36.200 36.210 36.220 36.230 36.240 2220 2230 36.240 36.250 36.260 36.271 36.281 36.291 36.301 36.311 36.321 36.331 36.341 2230 2240 36.341 36.351 36.361 36.371 36.381 36.391 36.401 36.411 36.421 36.431 36.441 2240 2250 36.441 36.451 36.460 36.470 36.480 36.490 36-500 36.510 36.520 36.529 36.539 2250 2260 36.539 36.549 36.559 36.569 36.578 36.588 36.598 36.608 36.617 36.627 36.637 2260 2270 36.637 36.646 36.656 36.666 36.675 36.685 36.695 36.704 36.714 36.723 36.733 2270 2280 36.733 36.743 36.752 36.762 36.771 36.781 36.790 36.800 36.809 36.819 36.828 2280 2290 36.828 36.838 36.847 36.857 36.866 36.875 36.885 36.894 36.903 36.913 36.922 2290 2300 36.922 36.932 36.941 36.950 36.959 36.969 36.978 36.987 36.997 37.006 37.015 2300 2310 37.015 37.024 37.033 37.043 37.052 37.061 37.070 37.079 37.088 37.097 37.107 2310

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SECTION D 7 (a) Hydraulic and pneumatic systems are both concerned with the flow of a fluid (liquid or gas) through a system. Flow is a general term used but has three distinct meanings: Give the three terms used and describe each. [10 marks] State the S.I. units that are used for the following measurements of: (i) Force (ii) Area (iii) Volume (iv) Flow rate (v) Pressure [1 mark each] What is the value of pressure (in bar) resulting when a force of 100,000 Newtons acts upon an area of 1 square metre? [2.5 marks] If the absolute pressure of 2 m3 of air is increased from 2.4 bar to 2.75 bar, find the new volume, given that the temperature remains constant. [2.5 marks] Bar litre calculations are used to determine the category of a system being used under the pressurised systems regulations and is determined by volume x bar pressure in the system. Calculate the bar litres for the following storage cylinder (Figure 4) containing gas at a pressure of 18 bar and determine the type of system in operation. [10 marks] Within industry there are 10 principle advantages and distinguishing characteristics when using pneumatics and hydraulics for measurement and control systems. List five of those characteristics and describe each. [1 mark each] There are five main limitations when applying hydraulics or pneumatics within industrial systems. Name all five and describe each one. [1 mark each]

(b)

(c) (d)

(a)

(b)

(c)

Dia. = 750mm Internal

2000 mm Internal Length Figure 4

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