16 Chemical Process Control Fundamentals

CHEMICAL PROCESS CONTROL
FUNDAMENTALS
CONTROL CATEGORIES
OPERATING MODE
CONTINUOUS BATCH SEMI-BATCH
OPERATING CONDITIONS
START-UP http://www.synergySTEADY-STATE OPERATION ergs.com/images/FM%20 CONTROLLED SHUTDOWN operator%20desk.jpg EMERGENCY SHUTDOWN
MONITORING
MAINTENANCE OPTIMIZATION
SEE PERRYS 7TH ED., CHAPTER 8
CONTROL DESIGN

OPERATOR CONTROL AUTOMATIC CONTROL ALARMS INTERLOCKS DATA LOGGING AUTOMATIC TUNING SEQUENCING PROGRAMMABLE LOGIC CONTROLLERS FIELD MONITORS
http://www.tpub.com/content/draftsman/14276/css/1427 6_255.htm
STEADY STATE OPERATION
SYSTEM SHOULD RUN RELIABLY WITH MINIMAL SUPERVISION SYSTEM SHOULD MAKE ON-SPECIFICATION PRODUCT ROUTINELY MONITORED BY OPERATOR WITH A MINIMUM NUMBER OF VARIABLES CONTROL LOOP INTERACTIONS AUTOMATIC
http://www.historicphotoa rchive.com/images11/007 00.jpg
START UP
SYSTEM SHOULD BE ABLE TO SAFELY REACH PRODUCTION AND QUALITY LEVELS THROUGH A STANDARD SEQUENCE OF EVENTS CONTROL SYSTEM SHOULD INCLUDE ASSESSMENT (CHECKS TO CONFIRM STEPS IN THE START UP SEQUENCE HAVE BEEN CORRECTLY COMPLETED) EFFFECTS OF CHANGES SHOULD BE http://www.malvern.com/ProcessEng/process ANTICIPATED es/milling/milling_startup_offline.gif
START UP PROCEDURES
REACTORS CONTINUOUS MAY BE STARTED WITH A HEEL OF MATERIAL FROM THE PREVIOUS SHUTDOWN OR SOME PRODUCT RECYCLED TO THE REACTOR TO APPROXIMATE STEADY STATE CONDITIONS BATCH FOLLOW NORMAL START UP SEQUENCE
START UP PROCEDURES
SEPARATION PROCESSES
TYPICALLY ARE STARTED ON TOTAL RECYCLE UNTIL SPECIFICATION QUALITY MATERIAL IS PRODUCED. THIS MAY REQUIRE DELAYING START UP OF REACTION SYSTEM OR ADDING A SURGE TANK TO COLLECT PRODUCT DURING SEPARATION START UP.
CONTROLLED SHUT DOWN

CAN BE PARTIAL OR COMPLETE PARTIAL
PUT SYSTEM IN STANDBY MODE TO ALLOW RAPID AND SAFE RESTART DISTILLATION COLUMNS ON TOTAL RECYCLE
COMPLETE
SHUT DOWN PROCESS WITHOUT CREATING OFF-SPEC PRODUCT OR PRODUCING A HAZARDOUS SITUATION
STANDARD PROTOCOLS FOR BOTH
TYPICAL SHUTDOWN DESIGNS

REACTORS
SHORT TERM
STOP FEEDS MAINTAIN COOLING, BUT KEEP MATERIALS FROM CRYSTALLIZING MAINTAIN AGITATION. POSSIBLY DRAIN REACTANTS TO A SEPARATE VESSEL IF REACTION CANNOT BE STOPPED AT THE STEADY STATE CONDITIONS OTHERWISE, SAME AS SHORT TERM
SUPERPRO
LONG TERM
TYPICAL SHUTDOWN DESIGNS

SEPARATION PROCESSES
SHORT TERM - PLACE SYSTEM ON TOTAL RECYCLE AND MAINTAIN OPERATION. LONG TERM - DRAIN SYSTEM TO SAVE UTILITIES. DEPEND ON NEEDS OF PROCESS WHILE SHUTTING DOWN COOLING AND AGITATION ARE TYPICALLY MAINTAINED.
ROTATING EQUIPMENT

SIMSCI PROSIM II
EMERGENCY SHUT DOWN

ONE BUTTON SHUT DOWN BY OPERATOR
PROCESS SHOULD BE PROTECTED AGAINST CATASTROPHIC FAILURE DURING AN UNMONITORED SHUT DOWN PROCESS SHOULD BE FAIL-SAFE
ALARMS AND INTERLOCKS SHOULD PROTECT LOCAL PROCESSES
FIRST LEVEL ALARMS ALERT THE OPERATOR TO TAKE ACTION SECOND LEVEL ALARMS AUTOMATICALLY INTITIATE PROTECTIVE ACTION
http://ridetheclock.com/
http://www.plastomatic.com/fails afe-explanation.gif
MONITORS
INSTRUMENTATION THAT IS NOT REQUIRED FOR NORMAL OPERATION
USED FOR FIELD OBSERVATION USED FOR START-UPS USED FOR MAINTENANCE USED FOR OPTIMIZATION
P T
HEAT EXCHANGER P T P T
SAFETY & ALARM SYSTEMS

OPERATOR ALARMS AND INTERLOCK ALARMS
(LO, LOLO, HI, HIHI) SHOULD BE ON LOOPS THAT ARE INDEPENDENT FROM CONTROL LOOPS
RELIEF SYSTEMS NEED TO BE DIRECTED TO FACILITIES TO SAFELY PROCESS THE RELEASE SAFETY SYSTEMS SHOULD BE INTERLOCKED TO SHORT OR LONG TERM SHUTDOWN LOOPS, AS APPROPRIATE.
CONTROL DESIGN
REQUIRES PFDS P&IDS ARE THE PRIMARY DOCUMENT
SHOW LOOPS SHOW INTERLOCKS SHOW PLCs
STANDARD DIAGRAMS CAN BE USED FOR SOME SYSTEMS SPECIAL CONTROL DIAGRAMS LADDER LOGIC, AND INTERLOCKS ARE ALSO DEVELOPED
http://www.cbu.edu/~rprice/lectures/figures/loop.gif
CONTROL LOOPS
CONTROL STATION
SENSORS - TO MEASURE CONTROL VARIABLE AND ADJUSTED VARIABLE THERMODYNAMIC PROPERTIES

PRESSURE TEMPERATURE FLOW
VOLUMETRIC MASS
TRANSPORT PROPERTIES
DENSITY VISCOSITY
SYSTEM INVENTORY - LEVEL ANALYTICAL SENSORS MEASURE SPECIFIC CHEMICAL PROPERTIES
CONTROL CONFIGURATION
FEED BACK CONTROL
SET POINT CONTROL ELEMENT CONTROLLER
Cont. Var. SENSOR PROCESS
CONTROL CONFIGURATION
FEED FORWARD CONTROL
CONTROL ELEMENT CONTROLLER
Input Var. SENSOR PROCESS
Cont. Var. SENSOR
PROCESS MODEL
SET POINT
CONFIGURATION COMPARISON
FROM PERRYS CHAPTER 8 STEAM TO HEAT EXCHANGER FEEDBACK BASED ON PROCESS EXIT FLOW TEMPERATURE FEEDFORWARD BASED ON PROCESS FEED FLOW
LOOP RESPONSE
DYNAMIC RESPONSE IS MEASURED BY HOW QUICKLY A SYSTEM RETURNS TO CONTROL AFTER A PERTURBATION.
CONVERGENT DIVERGENT CYCLING AT STEADY STATE, THE IDEAL CONTROL PATTERN IS LINEAR
ANALOG AND DIGITAL SIGNALS

CONTINUOUS SENSORS AND CONTROLLED DEVICES TYPICALLY ARE ANALOG CONTROLLERS ARE TYPICALLY DIGITAL DISTRIBUTED CONTROL
USES LOCAL I/O PANELS DATA HIGHWAY IS USED TO CONVEY ACTUAL AND SET POINT CONDITIONS TO AND FROM THE CONTROL ROOM PANEL
DATA HIGHWAY DESIGN

SENS 1 C. ELEM. 1 SENS 2 C. ELEM. 2 SENS 3 C. ELEM. 3 AL 1 INTR. 1 AL 2 INTR. 2 AL 3 INTR. 3 INTERLOCK I/O PANEL CONT. I/O PANEL
CONT. SIG. PANEL
DATA HIGHWAY
BACKUP CRT CONTROL CRT ALARM CRT TREND CRT CONTROL COMPUTER DATA STORAG E
MUX BOX
LOCAL MUX
COMPUTER INTEFACE
SYSTEM CAN ALSO BE CONNECTED TO PROGRAMMABLE LOGIC CONTROLLERS FOR BATCH OPERATION AND INTERLOCK FUNCTIONS SYSTEM CAN HAVE PARALLEL DATA HIGHWAYS
INSTRUMENTATION SYMBOLS
ISA SYMBOLISM IS TYPICALLY USED

FOR LABELING DEVICES FOR LABELING LOOPS POSITION 1 - VARIABLE CONTROLLED
P, V, T, F, L, , , ETC.
POSITIONS
POSITION 2 - FUNCTION
INDICATION, GAUGE, CONTROLLER, ALARM, CAN BE SAME AS POSITION 1 FOR RATIO DEVICE.
POSITION 3 - FUNCTION
CONTROL, RANGE (HIGH OR LOW FOR ALARMS) , RATIO FOR RC
POSITION 4 - FUNCTION AGAIN

FFRC, e.g.
CHARACTERISTICS OF CONTROL MODES

STEADY STATE CAN BE DIRECT OR INDIRECT
FRC DIRECT FLOW CONTROL
FCV INDIRECT FLOW CONTROL LRC
FCV
CASCADE EFFECTS
FOR THIS EXAMPLE THE FEEDS TO THE REACTOR ARE SET BY ONE MASTER FLOW WITH THE SECOND FLOW FED BY RATIO.
CASCADE EXAMPLE
USING A FLOW CONTROL TO THE FLASH TANK
WOULD REQUIRE THAT IT CHANGE ACCORDING TO THE MASTER FEED THE EXTENDED LAG TIME WOULD MAKE THIS CONTROL INEFFECTIVE.
USING A FLASH FEED BASED ON LEVEL CONTROL

PROVIDES A MORE IMMEDIATE RESPONSE TO CHANGES IN THE REACTOR FEED THE GAIN WOULD NEED TO BE ADJUSTED TO ALLOW FOR THE CAPACITANCE OF THE SYSTEM.
GENERAL INSTRUMENTATION DESIGN COMMENTS

CONTROL LOOP SENSORS - LOCATE AT THE POINT OF CONTROL ON ALL DIAGRAMS CONTROL VALVES - LOCATE ON PUMP DISCHARGE LINES PUMP TANKS AND SUMPS - SHOULD BE PROVIDED WITH LEVEL CONTROL, HI/HIHIH/LO/LOLO ALARMS AND RELIEF SYSTEMS.
http://www.advantageengineeri ng.com/pumpTankStations/ind ex.php

STORAGE, SURGE AND OTHER PROCESS TANKS - SHOULD BE PROVIDED WITH LEVEL CONTROL, HI/HIHIH/LO/LOLO ALARMS AND RELIEF SYSTEMS. HEAT EXCHANGER CONTROL - SHOULD TYPICALLY CONSIST OF A CONTROL VALVE ON THE HEATING/COOLING MEDIA WITH A SENSOR ON THE TEMPERED FLOW DISCHARGE. SOLIDS FLOW CONTROL - GENERALLY OBTAINED BY VARIABLE SPEED DRIVES FOR CONVEYING EQUIPMENT, CONNECTED TO A WEIGHING DEVICE; BELT SCALE OR WEIGH TANK.

CONTROL ROOM DISPLAY - ALL PROCESS VARIABLES AND ALL ALARMED POINTS SHOULD BE ON THE CONTROL ROOM PANELS. ONLY LOCAL GAUGES AND NONPROCESS ITEMS SHOULD BE EXCLUDED.
http://www03.ibm.com/ibm/hist ory/exhibits/tucson/i mages/5403PH15.j pg

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CHEMICAL PROCESS CONTROL

SEE PERRYS 7TH ED., CHAPTER 8

STEADY STATE OPERATION

http://www.historicphotoa rchive.com/images11/007 00.jpg

CONTROLLED SHUT DOWN

STANDARD PROTOCOLS FOR BOTH

TYPICAL SHUTDOWN DESIGNS

TYPICAL SHUTDOWN DESIGNS

EMERGENCY SHUT DOWN

ALARMS AND INTERLOCKS SHOULD PROTECT LOCAL PROCESSES

SAFETY & ALARM SYSTEMS

SENSORS - TO MEASURE CONTROL VARIABLE AND ADJUSTED VARIABLE THERMODYNAMIC PROPERTIES

SYSTEM INVENTORY - LEVEL ANALYTICAL SENSORS MEASURE SPECIFIC CHEMICAL PROPERTIES

Cont. Var. SENSOR PROCESS

Input Var. SENSOR PROCESS

Cont. Var. SENSOR

ANALOG AND DIGITAL SIGNALS

DATA HIGHWAY DESIGN

ISA SYMBOLISM IS TYPICALLY USED

POSITION 4 - FUNCTION AGAIN

CHARACTERISTICS OF CONTROL MODES

FCV INDIRECT FLOW CONTROL LRC

USING A FLASH FEED BASED ON LEVEL CONTROL

GENERAL INSTRUMENTATION DESIGN COMMENTS

GENERAL INSTRUMENTATION DESIGN COMMENTS

GENERAL INSTRUMENTATION DESIGN COMMENTS

http://www03.ibm.com/ibm/hist ory/exhibits/tucson/i mages/5403PH15.j pg

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