Instrumentation FOR P&ID's: Peer Evaluation

INSTRUMENTATION
FOR
P&ID’s
Peer Evaluation
Phase 1 (not confidential to your peers) – ends Nov 13 5pm
You provide the feedback
Distribute 100 marks among your group based on how you feel their
contribution to the project has been (see instructions on website).
Provide any additional comments
I will send comments to any people with low peer assessments to
warn them of impending doom
Phase 2 (confidential) – opens Dec 1, closes Dec 7
You provide the feedback (same as above)
The peer assessment is worth approx 10%
Very low peer assessments will result in an exam being written
Failure to ‘provide’ a peer assessment (both Phases) will result in you

receiving 0 of 10% for that part of the course.
http://www.chemeng.queensu.ca/undergraduate/evalu
ations/2006-2007/CHEE470/peer/
1
Learning Objectives
Be Able to Interpret Controls Symbology
Know what the physical manifestation of the
symbology is
Know the parts of a ‘control loop’
Know what a Control Valve looks like and
how it works
Be able to look at a control scheme and
understand how it works
Be able to design some basic control schemes
Instrumentation Cookbook
Instrumentation
Why Are We Doing This For this Project
ChemEcon – Includes Controls in ‘factors’
ChemEcon – To Size The Pumps We Need
To Include “Inline” Instrumentation
Anything that generates pressure drop
FE PI
2
Control Loop
A Simple Feedback Control Loop
Set Point Often not shown
Measured Manipulated
Variable (temp, Controller Variable
pressure, flow...)
FE FIT FIC
FV
Controllers Readout Devices Switches and Alarm Devices Transmitters

Self
Actuated
Initiating or First Control
Measured Variable Letter Recording Indicating blind Valves Recording Indicating High Low Comb Recording Indicating Blind
Analysis A ARC AIC AC AR AI ASH ASL ASHL ART AIT AT
Burner, Combustion B BRC BIC BC BR BI BSH BSL BSHL BRT BIT BT
Instrumentation Naming
Users Choice C
Users Choice D
Voltage E ERC EIC EC ER EI ESH ESL ESHL ERT EIT ET
Flow Rate F FRC FIC FC FCV FICV FR FI FSH FSL FSHL FRT FIT FT
Flow Quantity FQ FQRC FQIC FQR FQI FQSH FQSL FQIT FQT
Flow Ratio FF FFRC FFIC FFC FFR FFI FFSH FFSL
Users Choice
Hand Instrument Society Of America (ISA)
Current (Electrical)
G
H
I IRC
HIC
IIC
HC HR
IR
HI
II ISH ISL
HS
ISHL
HRT
IRT
HIT
IIT
HT
IT
Power J JRC JIC JR JI JSH JSL JSHL JRT JIT JT
Time K KRC KIC KC KCV KR KI KSH KSL KSHL KRT KIT KT
Level L LRC LIC LC LCV LR LI LSH LSL LSHL LRT LIT LT
Users Choice M
Solenoids,
Relays, Viewing
Initiating or First Computing Primary Well Of Device, Safety Final
Measured Variable Letter Devices Element Test Point Probe Glass Device Element
Analysis A AY AE AP AW AV
Burner, Combustion B BY BE BW BG BV
Users Choice C
Users Choice D
Voltage E EY EE EZ
Flow Rate F FY FE FP FG FV
Flow Quantity FQ FQY FQE FQV
Flow Ratio FF FE FFV
Users Choice G
Hand H HY HV
Current (Electrical) I IY IE IZ
Power J JY JE JV
Time K KY KE KV
ISA Typical Letter Combinations.xls
3
P&ID’s - Symbology
Equipment Symbology
Instrumentation Symbology
See the document “P&ID Symbols and

Photos.DOC”
The “Control Valve” Elec Signal
To valve
(4-20 mA
DC signal)
Actuator -
driven by
Compressed
Air
Valve
4
P&ID’s - Symbology
Located in DCS
LIC (process control
computer)
Software Signal
Physically
LT located
‘in field’
Physical wire
“hardwired”
LIC
5
LIC
DCS cabinet
FIT
PIT
6
PI PC
HS
7
Power
Multivariable
Level
Indicating
Analysing
User
JULIAN
I M
SIC
I M
8
The “Control Valve”
Control Valve Sizing
CV vs % Opening Characteristic
Spec_Gravity
CV Volumetric_Flow⋅
Pressure_Differential
gal Pressure
Volumetric_Flow
min Drop
Pressure_Differential psi
Flow Rate
The “Control Valve”
CV vs % Opening Characteristic Cv
% open
9
Typical Controls
Level
Flow
Pressure
Temperature
Composition
Level Control
Purpose
Prevent the tank from overfilling / running
dry
LT
LIC
LV
10
Level Control
Purpose
Hold a liquid “Seal”
LT
LIC
No Gas!
LV
Level Control
Purpose
Prevent pump from running dry and thus
being destroyed
RO
LT
LIC
LV
Note: - valve always on disch to prevent flashing on pump suction
- pump may also require a minimum flow bypass
11
Control Systems
Aside - Speed
Measured Variable can be slow to measure
(i.e. the composition using an analyser) or,
fast (i.e. pressure)
The Manipulated Variable can be slow too
i.e. adjusting the hot water tap in your
shower
The level in a tank can take hours to
change (slow)
Control Systems
Aside - Speed
Slow Things Fast Things
Say > few seconds Less than a second
Reducing Pressure Measure Pressure
by Opening a valve Measure Flow (Diff
on a large gas filled Press)
tank Measure Temp (?)
Measure Composition
(analysers)
Change Level In
Large Tank
But…. It’s all RELATIVE !!
12
Flow Control
Purpose: Ensure steady material flow rate
Smooth feed to columns
Set Production rate
Fast to Measure
Flow Changes usually require a control valve
to change it’s position which can take
seconds.
Vapour systems have a ‘capacitance’ that
need to be overcome before the flow changes
are experienced everywhere in the system
Flow Control
FT
FIC
FE FIC
M
FT
I
FV SIC
FE
Variable Speed Drive
Mount FE upstream in vapour systems to minimize pressure/density

effects
13
- Ratio Flow Control
SP
FIC
FT FRIC SP Set one flow

rate
FV Other flow is
FE proportionally
FIC
SP
controlled to
FT first flow
Ensure correct
mixture / recipes
FV
FE
Pressure Control
Similar to Level (control of material inventory)
Very fast for incompressible fluids
Hard to say for compressible fluids, depends
on system volume but probably slow
14
Pressure Control
Control Upstream | Control Downstream
PIC PIC
PT PT
PV PV
Need to downstream (header or

Need to control vessel pressure
process) pressure
Pressure Control
Condensable Gas
PIC
PV
PT
Need to control vessel pressure
Fast or slow?
15
Pressure Control
Liquid Pressure Control
PIC
PT
PV
Control pump discharge pressure - not very useful
Pressure Control
Liquid Pressure Control
PIC FIC
PT
FT
PV
Control pump discharge pressure - ensure FV

constant feed pressure to FV FE
16
Temperature Control
Normally control the ‘flow’ of one fluid to
change the temperature of another
In Reality it’s an LMTD change that affects
the exchanger duty
Q = U A ∆Tln
Temperature Control
Liquid / Liquid - control on cooling media
C/w
17
Temperature Control
Liquid / Liquid - control on process
C/w
Temperature Control
Steam Pressure Control
T Increase Stm
Pressure
18
Temperature Control
Condensate Level Control
Reduce flooded
Area
Rookie Mistake
- Temperature Control
Controlling an outlet temperature on a 2
phase exchanger
TIC
TE
Horiz Reboiler
19
Cascade Control
Example - Driving to Montreal
You’re driving / steering the car
Someone else is telling you which roads to
drive on and when to turn
Cascade Control
One Control Loop Determines Setpoint of a
Second Loop
FT
-Using the
FE FIC
M SP flow through
High Speed
the pump to
∆P I
control the
rotational
Low Speed
SIC SP speed of the
Variable Speed Drive pump
Flow
20
Cascade Control
PIC FIC
FT
FE FV
PT
Common Around Distillation

Columns Where There Are
Slow Loops
Controller Interaction
Many Controllers Interact but some
configurations Interfere with each other
I.e.
the control of reflux flow interacts with the
column bottom level control
but two flow controllers on the same pipe
will interfere with each other (they duel for
control of the flow)
21
Duelling Control ?
LT
LIC
FIC
FT LV
FE
Duelling Control ?
LIC
LT FIC
FT
FE
LV
22
Duelling Control ?
SP= 75 psig SP= 35 psig

PIC PIC
PT PT
100 psig
Compressed
Air PV PV
User 2 User 2
User 1 User 1
User 3 User 3
P&ID Cookbook
-By Equipment
23
P&ID Cookbook
- Pumps
PRV PI PI
HS
I M
HS
Pump - Min Flow Bypass

RO
PI
LT PI LIC
LV
HS
I M
HS
24
Reflux Tanks Vent to Safe Locn
Set@ PI
From Condenser From Pump
LAHL
TI HLL = 4’-6”
NLL = 3’-6” LIT LIC TO
LLL = 2’-0” LV
LSLL
LLLL = 2’-0”
LALL
I Pump
S/D
To Pump
Compressors - Centrifugal
For our purposes treat controls as a black box
But... Provide an input control signal (cascade)
Remember cooling water req’d (lube system...)
CWS CWR
Control
SIC
From ?
M
By Vendor
By Owner
25
Requirements for Column Control
Feed rate control, as best as possible
Level control for reboiler and condensate
receiver
Column pressure control
Two controllers, corresponding to the two
degrees of freedom, to deal with the
specifications in PRO/II
This is a very complex topic and can only be
dealt with superficially in this course
Columns
Composition control
Level control
Pressure control
Provide a
control scheme
Treat the
to ensure
top and bottom
Feed rate is
independently
constant or is Level control of each other
slowly
changing
Composition
control
26
Columns - Put level control on bottoms outflow
when
Bottoms
outflow rate > 10 x boil up rate
Put level control on Steam control
boilup rate > 10 x outflow rate
otherwise either scheme okay
FIC
HHLL FT
5 bar
Stm
HLL
LIT NLL
LLL
LLLL Low
T P Cond
TE
LAHL
LIC TIC
TE XIC Columns - Overhead

PT PIC
CWS
FV
CWR
Set@ PI PV
FIC
RO
FT
LAHL
TI HLL = 4’-6”
NLL = 3’-6” LIT LIC
LLL = 2’-0” PI
LSLL
LLLL = 2’-0”
PI
LALL
I Pump
S/D LV
HS
I M
HS
27
Column Control
How to Choose the Stream that will control
Level in the reflux tank
Column Overhead Control - Scheme 1

when the draw rate is 10 x > reflux rate
Manipulate Distillate draw rate to control Reflux
level
Manipulate reflux rate to control Column
Composition
Column Control
Column Overhead Control - Scheme 2
when the reflux rate is 10 x > draw rate
Manipulate Distillate draw rate to Manipulate
Column Composition
Manipulate reflux rate to control control Reflux
Drum level
28
Tanks - Storage
PRV
LAHH Temperature
Control
LSHH
I May Be
Required
-does material
LY LSHH
freeze / boil?
TI
s LI LSLL
LAHL
LIT
LV
I M
Workshop
Add the composition control to the overhead
Hint: use the pressure and temperature
420 kg/hr, 113 °C
33,316 kg/hr, 113 °C
29
END
30

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INSTRUMENTATION

Failure to ‘provide’ a peer assessment (both Phases) will result in you

Set Point Often not shown

Controllers Readout Devices Switches and Alarm Devices Transmitters

ISA Typical Letter Combinations.xls

See the document “P&ID Symbols and

Mount FE upstream in vapour systems to minimize pressure/density

FT FRIC SP Set one flow

Need to downstream (header or

Need to control vessel pressure

Control pump discharge pressure - not very useful

Control pump discharge pressure - ensure FV

Common Around Distillation

SP= 75 psig SP= 35 psig

Pump - Min Flow Bypass

TE XIC Columns - Overhead

Column Overhead Control - Scheme 1

420 kg/hr, 113 °C

33,316 kg/hr, 113 °C

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