INSTRUMENTATION FOR P&IDs

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/

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

Instrumentation Cookbook Control Loop

A Simple Feedback Control Loop
Set Point Often not shown

Measured Variable (temp, pressure, flow...)

FE FIT

Controller

Manipulated Variable

FIC FV

Controllers

Initiating or First Measured Variable Letter Analysis A Burner, Combustion B Users Choice C Users Choice D Voltage E Flow Rate F Flow Quantity FQ Flow Ratio FF Users Choice G Hand H Current (Electrical) I Power J Time K Level L Users Choice M

Instrumentation Naming
ERC FRC FQRC FFRC EIC FIC FQIC FFIC HIC IIC JIC KIC LIC EC FC FCV FICV FFC HC ER FR FQR FFR HR IR JR KR LR EI FI FQI FFI HI II JI KI LI ESH FSH FQSH FFSH ESL FSL FQSL FFSL ESHL FSHL IRC JRC KRC LRC KC LC KCV LCV ISH JSH KSH LSH ISL JSL KSL LSL HS ISHL JSHL KSHL LSHL

Recording Indicating blind ARC AIC AC BRC BIC BC

Readout Devices Switches and Alarm Devices Self Actuated Control Valves Recording Indicating High Low Comb AR AI ASH ASL ASHL BR BI BSH BSL BSHL

Transmitters

Recording Indicating Blind ART AIT AT BRT BIT BT

ERT FRT

EIT FIT FQIT

ET FT FQT

Instrument Society Of America (ISA)

HRT IRT JRT KRT LRT

HIT IIT JIT KIT LIT

HT IT JT KT LT

Initiating or First Measured Variable Letter Analysis A Burner, Combustion B Users Choice C Users Choice D Voltage E Flow Rate F Flow Quantity FQ Flow Ratio FF Users Choice G Hand H Current (Electrical) I Power J Time K

Solenoids, Relays, Computing Primary Devices Element AY AE BY BE

Well Of Test Point Probe AP AW BW

Viewing Device, Glass BG

Safety Device

Final Element AV BV

EY FY FQY

EE FE FQE FE

FP

FG

EZ FV FQV FFV HV IZ JV KV

HY IY JY KY

IE JE KE

ISA Typical Letter Combinations.xls

Instrumentation Cookbook P&IDs - Symbology

Equipment Symbology Instrumentation Symbology See the document P&ID Symbols and Photos.DOC

Instrumentation Cookbook Signal The Control Valve Elec To valve

(4-20 mA DC signal) Actuator driven by Compressed Air

Valve

Instrumentation Cookbook P&IDs - Symbology

LIC

Located in DCS (process control computer) Software Signal Physically located in field Physical wire hardwired

LT

LIC

LIC

DCS cabinet

FIT

PIT

PI

PC

HS

Power Multivariable Level Indicating Analysing User

JULIAN

SIC

Instrumentation Cookbook The Control Valve

Control Valve Sizing CV vs % Opening Characteristic
CV Volumetric_Flow gal min psi
Flow Rate

Spec_Gravity Pressure_Differential
Pressure Drop

Volumetric_Flow

Pressure_Differential

Instrumentation Cookbook The Control Valve

CV vs % Opening Characteristic
Cv % open

Instrumentation Cookbook Typical Controls

Level Flow Pressure Temperature Composition

Instrumentation Cookbook Level Control

Purpose Prevent the tank from overfilling / running dry

LT
LIC

LV

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Instrumentation Cookbook Level Control

Purpose Hold a liquid Seal

LT
LIC

No Gas! LV

Instrumentation Cookbook 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

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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 Say > few seconds Reducing Pressure by Opening a valve on a large gas filled tank Measure Composition (analysers) Change Level In Large Tank Fast Things Less than a second Measure Pressure Measure Flow (Diff Press) Measure Temp (?)

But. Its all RELATIVE !!

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Instrumentation Cookbook 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 its 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

Instrumentation Cookbook Flow Control

FT
FIC

FE FT FV
M I

FIC

FE

SIC Variable Speed Drive

Mount FE upstream in vapour systems to minimize pressure/density effects

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Instrumentation Cookbook - Ratio Flow Control

FIC
SP

FT FV
FIC
SP

FRIC

SP

FE FT

Set one flow rate Other flow is proportionally controlled to first flow
Ensure correct mixture / recipes

FE

FV

Instrumentation Cookbook 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

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Instrumentation Cookbook Pressure Control

Control Upstream | Control Downstream
PIC PT PV PV PIC PT

Need to control vessel pressure

Need to downstream (header or process) pressure

Instrumentation Cookbook Pressure Control

Condensable Gas

PIC PV PT
Need to control vessel pressure Fast or slow?

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Instrumentation Cookbook Pressure Control

Liquid Pressure Control

PIC PT PV
Control pump discharge pressure - not very useful

Instrumentation Cookbook Pressure Control

Liquid Pressure Control

PIC PT FT PV
Control pump discharge pressure - ensure constant feed pressure to FV

FIC

FE

FV

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Instrumentation Cookbook Temperature Control

Normally control the flow of one fluid to change the temperature of another In Reality its an LMTD change that affects the exchanger duty Q = U A Tln

Instrumentation Cookbook Temperature Control

Liquid / Liquid - control on cooling media

C/w

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Instrumentation Cookbook Temperature Control

Liquid / Liquid - control on process

C/w

Instrumentation Cookbook Temperature Control

Steam Pressure Control

Increase Stm Pressure

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Instrumentation Cookbook 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

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Instrumentation Cookbook Cascade Control

Example - Driving to Montreal Youre driving / steering the car Someone else is telling you which roads to drive on and when to turn

Instrumentation Cookbook Cascade Control

One Control Loop Determines Setpoint of a Second Loop
FT
-Using the flow through the pump to control the rotational speed of the pump

FE
High Speed

M I

FIC

SP

P
Low Speed

SIC

SP

Flow

Variable Speed Drive

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Instrumentation Cookbook Cascade Control

PIC FIC

FT

FE PT

FV

Common Around Distillation Columns Where There Are Slow Loops

Instrumentation Cookbook 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)

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Instrumentation Cookbook Controller Interaction

Duelling Control ?

LT
LIC

FIC

FT FE

LV

Instrumentation Cookbook Controller Interaction

Duelling Control ?

LIC

LT

FIC

FT FE
LV

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Instrumentation Cookbook Controller Interaction

Duelling Control ?
SP= 75 psig SP= 35 psig

PIC PT
100 psig Compressed Air

PIC PT PV

PV
User 1

User 2 User 3

User 1

User 2 User 3

P&ID Cookbook -By Equipment

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P&ID Cookbook - Pumps

PRV

PI

PI

HS HS

Pump - Min Flow Bypass

RO

PI

LT

PI

LIC

LV
HS HS

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Reflux Tanks
Set@ From Condenser
PI

Vent to Safe Locn From Pump

TI

LSLL

HLL = 4-6 NLL = 3-6 LLL = 2-0 LLLL = 2-0

LIT

LAHL LIC

TO LV

LALL

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 reqd (lube system...) CWS Control From ? CWR

SIC

M By Vendor By Owner

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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 Pressure control Provide a control scheme to ensure Feed rate is constant or is slowly changing Level control

Level control

Treat the top and bottom independently of each other

Composition control

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Columns Bottoms

Put level control on bottoms outflow when 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

LIT

HLL NLL LLL LLLL

Low P Cond

TE
LAHL

LIC

TIC

TE

XIC

Columns - Overhead
PIC
CWS

PT

FV

CWR

FIC
FT
TI

Set@

PI

PV RO

LSLL

HLL = 4-6 NLL = 3-6 LLL = 2-0 LLLL = 2-0

LIT

LAHL LIC PI PI

LALL

Pump S/D HS HS

LV I M

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Instrumentation Cookbook 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

Instrumentation Cookbook 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

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Instrumentation Cookbook Tanks - Storage

PRV
LAHH

LSHH

LY

TI

LSHH

Temperature Control May Be Required -does material freeze / boil?

LI
LAHL

LSLL

LIT
LV

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

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END

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