Instrumentation and Process Control :-

Measurement is a fundamental requisite to process control. Either the control can be affected
automatically, semi automatically or manually. The quality of control obtainable also bears a
relationship to accuracy, reproducibility and reliability of measurement methods, which are employed.
Therefore, selection of the most effective means of measurements is an important first step in design
and formulation of any process control system. Design of control system involves large number of
theoretical and practical consideration such as quality of controlled response, stability, the safety of
operating plant, the reliability of control system, the range of control, easy of startup, shutdown or
changeover, the ease of the operation and cost of control system. Traditionally one under takes the
design of control system for chemical plant only after the process flow sheet has been synthesized and
designed. This allows the
control designer to know
1. What units are in plant and their sizes
2. How they are interconnected
3. The range of the operating conditions
4. Possible disturbance, available measurements and manipulations
5. What problem may arise during shutdown and start up

Heat exchanger control:-

The control objective is to maintain the temperature at desired value and to allow particulate heat
exchange. The manipulated variable is flow rate of utility stream.The external disturbance that will
affect the operation of heat exchanger is surrounding temperature,inlet temperature and steam pressure
and steam temperature or its flow rate in case when utility is steam. The output variable is the
temperature of outlet process stream and temperature of outlet utility stream.The above is feedback
control scheme for heat exchanger.The control system of complete plant must permit smooth, safe and
relatively fast startup and shutdown of plant operation.

Control on reactor:-
In PFR control any of following may be the goals to achieve
1. Constant temperature inside the reactor.
2. High Quality Product.
Reactor Variable
The independent variable for PFR may be divided into following categories
1. Uncontrolled variable.
2. Manipulated variable.
3. Controlled variable.
Uncontrolled Varaibles
The variable which cannot be controlled by the controller, are called uncontrolled variable. The
uncontrolled variable included
1. Vent gas rate
2. Temperature of feed
Manipulated variables
The independent manipulated inputs are variables, which are adjusted to control the chemical reaction
. Any one or the combination of following may be the manipulated variables.
1. Flow rate of cooling water.
2. Flow rate of feed.
3. Flow rate of product.
Controlled variables
Any process variable that is selected to e manipulated by a control system is called a controlled
variable. Following are the controlled variables.
1. Inside reactor temperature.
2. Inside reactor pressure.
Temperature control scheme
The simplest method of cooling a PFR is shown in figure . Here we measure the reactor temperature
and manipulated variables to the flow of cooling water to the shell side in shell. Using a shell side for
cooling water has two advantages.
1. First it minimize the risk of leaks and therevy cross combination between the cooling system
and process .
2. Second , Heat transfer rate is increased by using baffles.
A temperature sensor measures the inside reactor temperature and transfer signal to the temperature
transducer , transducer converts the signals in other form and the output of transducer is accepted by
controller and controller transfer its signal to final control element .Final control element takes step to
overcome these disturbances.
PFR Control Configuration:
TT

TC

Figure: Control scheme on PFR

Control scheme of distillation column:-

Objectives
In distillation column any of following may be the goals to achieve.
1. Overhead composition
2. Bottom composition
3. Constant over head product rate
4. Constant bottom product rate

Manipulated variables
Any one or any combination of following may be the manipulated variables.
1. Steam flow rate to reboiler
2. Reflux rate
3. Overhead product with drawn rate
4. Bottom product withdrawn rate

5. Water flow rate to condenser

Loads or disturbances
Following are typical disturbances.
1. Flow rate of feed.
2. Composition of feed.
3. Temperature of feed.
4. Pressure drop of steam across reboiler.
5. Inlet temperature of water for condenser.

Control scheme
Here is control scheme on acrolein distillation column. Consider the
feed to this column as binary mixture composed of acorlein and water.
We can specify four control variable for this distillation column are
 Acrolein product quality
 Fractional recovery of acroelin in overhead product (distillate rate)
 Liquid level in overhead accumulator
 Liquid level at bottom of column

Overall product rate is fixed and any change in feed must be absorbed
by changing bottom product rate. The change in product rate is
accomplished by direct level control of reboiler if the stream rate is
fixed, feed rate increases then vapor rate is approximately constant
and the internal reflux flow must increase.
Trying to control the liquid level at the bottom of column with reflux
flow or distillate flow rate involves very long time response because
action of manipulated variable must travel the whole length of
distillation column before it is felt by the controller variable so it
cannot be done.
A long time response is involved when we try to control the level in
the overhead accumulator by manipulating the bottoms flow rate &
stream flow rate. It is quite complicated to control the distillate
composition or flow rate with bottom flow
rate. Since an increase in feed rate increases
reflux rate with vapor rate being approximately
constant, then purity of top product increases.
Explanation
First on the cold day or in rainstorm the
temperature of cold water in overhead condenser
drops and overhead vapors passing through
condenser produces sub cooled liquid. When sub
cooled liquid returns back from reflux to the top
tray of distillation column it causes less vapors to
go overhead. Low vapors in overhead causes less
liquid level in accumulators. If the accumulator
level is controlled by reflux flow the latter will
decrease thus the disturbance causes by the cooling
water temperature drop does not

Control scheme of distillation column

propagate down the column in terms of increased
 liquid level overflow. The acrolein product
composition is controlled by distillate flow. The
scheme shown is cascade scheme for distillation
column.

Instrumentation and Control on

Adsorber:-

Absorption Operation
Absorption column is a unit operation where the solute of a gas are removed by
being placed in contact with a nonvolatile liquid solvent that removes the
components from the gas.
Changing the conditions of the absorption column can influence the effectiveness
and efficiency of absorption. Some important controlled variables are as follows:
• Pressure of the column.
Raising the total pressure of the column may increase the efficiency of the
separation because increasing the pressure decreases the liquid flowrate and
increases the concentration of the gas
• Temperature of entering liquid and gas streams.
The temperature of entering liquid affects absorption in that it affects the flow rate
of liquid required for the separation with a given number of stages.
• Humidity of the gas stream.
Inlet gases of the absorber with high humidity at a high temperature affect the
capability of the gas to consume latent heat hindering the absorption process.
Therefore, dehumidification of the inlet gas should be considered for absorbers
with large heat effects
• Ratio of the liquid and gas stream rates.
The ratio of the liquid to gas stream rates has effect in that if the ratio is too low,
the solute builds in the upper portion of the column 2 causing a higher temperature
profile in the top of the column. As a result, internal cooling maybe necessary for
lower liquid to gas ratios.

The Control Strategies

In this work different control strategies both conventional and advanced are used to
show its effect on the system. Feed control in general is used to achieve and
maintain the desired condition using an actual value of this condition it compares it
to a reference value (set point), using differences between those values to eliminate
any difference between them. Most controllers use negative feedback, which
measures process output (controlled variable), subtracted from a desired value (set
point) to generate an error signal. The controller recognizes the error signal and
manipulates a process input (control element), to reduce the error. The most
important types of industrial feedback controllers; include P, PI, and PID
controller.

Proportional Control (P)

In this type of control the output of proportional controller changes only if the error
signals changes. Since a load change requires a new control valve position, the
controller must end up with a new error signal; this means that proportion
controller usually gives a steady state error off set.
Proportional Integral Controller (PI)
Most control loops use PI controller. The integral action eliminates steady state
error. The smaller τI then the faster the error is reduced, but the system becomes
more under damped as τI is reduced, if it is made too small, the loop becomes
unstable. τI is the integral time constant.
Proportional Integral Derivatives Controller (PID)
PID controller is used in loops where signals are not noisy and where tight
dynamic response is important. The derivative action helps to compensate for lags
in the loop.
Response of Absorption Column without Controller:
Response of Absorption with P controller

Response of Absorption with PI controller

Response of Absorption with PID controller

In the P, PI and PID controller when it is applied to the Cohen-Coon tuning, we get
the above diagrams.
Conclusion:
The response Figure for the system without controller is unstable.
but when controller is used the system is more stable as showed in Figures .
These Figures show that the Cohen-Coon tuning with PI controller is more stable
and the controlled variable ultimately returns to the original value.

Instrumentation
The Concentration Cell is used to measure the concentration of the Acrolein in the
outlet liquid stream. It show that how much Mass transfer is occurring in the
absorber. The separation of the acrolein is will be stable at required temperature
and pressure. If the pressure is changed it means the flow rate will be changed and
time of interaction between liquid and mass phase will be changed so it will affect
the separation of Acrolein.
Concentration measuring sensor Refractometer will detect the amount of Acrolein
and give signal to the controller. If there will be change in Set point it will check
the temperature , pressure and flow rate of Input streams and will make changes…
This will be Feedback Control System.
By this Control system Channeling and Flooding will also controlled by
controlling Flow rate of Water entering from top.