Process and Instrumentation Diagram (PID) of Formaldehyde Production

Main Components of Control System

From the Process and Instrumentation Diagram above, there are three type of sensors
can be identified which is the level indicating controller (LIC), temperature indicating
controller (TIC) and the flow indicating controller (FIC). These sensors are used to detect any
changes throughout the process. The sensors detect the changes based on their type that is
level, temperature and flow. From the diagram, it can be observe that there is 3 units of level
indicating controller (LIC). Each is placed at Formaldehyde Reactor R-801, Formaldehyde
Tower T-802 and at Tower Reflux Drum V-801. These sensor functions to detect the changes
in level in each of the tank. Meanwhile for temperature indicating controller (TIC) and flow
indicating controller (FIC) there is one for each unit. The temperature indicating controller
(TIC) is installed at Formaldehyde Reactor R-801 while the flow indicating controller (FIC)
is placed at the Tower Reflux Pump P-802 A/B at the valve before entering Formaldehyde
Tower T-802. Each of the sensors provides the information on the temperature and flow rates
of the fluid processed in the equipment.

The type of controller used cannot be determined straight away. This due to the lack
of the response information on the process. But to deduce to all rational choices, the most
suitable controller in this process is the Proportional- Integral-Derivative Controller (PID).
This is because usually a big processing industrial system uses this type of controller. The
reason is because the production requires continuous modulated control. PID controller is
suitable in this kind of process as it used to maintain reactor temperature, level and flow
whenever the sensor detect any disturbance in the tanks. On the other hand, PID is only
capable on maintaining the control of the process but cannot optimize the process as in the
quality of the outcome. The control strategy components in this plant is not detected.
Therefore, there is no control strategy component used in this plant. This phenomenon brings
to the conclusion where the control strategy used is wholly auto with only the support of
sensors and final control element exist in the plant.

Lastly, for the final control element there is a total of 8 control valve in the plant.
These control valves are used to control the elements in the process. The elements controlled
are the capacity, range and pressure of the process when the plant is running. It is important
to have the final control element to provide the accurate quantity of feed or the process could
be disturbed. These valves also allow direct control on the equipment in case if the sensor and
controller shut down or having problem.
Insertion or Addition of Main Components Control System

In my opinion insertion of main components control system is a good idea in higher

levering the productivity of the process. Firstly, is the sensors. A few addition of sensors
would be suitable to the plant. Pressure indicating controller (PIC) should be added at the
Feed Air Compressor C-801. This is due to the compression of air needs surveillance on the
pressure of the fluid inside the tank. Inaccurate figure would give bad result on the process.
Other than that, a few temperature indicating controller (TIC) is suggested to be placed at the
Methanol Preheater E-801 and Air Preheater E-802. Addition of these sensor would give
good effect on the optimum temperature of the fluid that will be processed.

For the controllers, the addition of an automatic control would help so much in this
case. For first point, a feedback control system is the most fitting for this process. Feedback
control system can correct the Controlled Variable (CV) if it deviates from the set point
regardless of the type and source of disturbance. It also versatile as the knowledge required to
conduct it is not complicated. Automatic re-tuning of the system also turn out an acceptable
result. For the second point of control strategy, the adaptive controller is much likely
suggested. Adaptive controller can adapt to the situation of the process. It self-adapt the
controllers to fit the situation and adjust automatically to compensate for the change in
conditions or phase. The process will turn out smoother than before and the plant can run
optimally with higher efficiency. These controllers fit to be installed at the reactor that is
Formaldehyde Reactor R-801. Other than that, it also can be positioned at the Tower Reboiler
E-804 and Tower Condenser E-805 so that the process could be run easily.

Last but not least is the final control element. The final control element can be
determined by the type of reaction happened. In this case, the reaction occur is an
endothermic reaction where the heat is produced from the burning of hydrogen. Other than
that, production of formaldehyde also uses catalyst in order to lower the activation energy of
the reaction and in the same time promotes the reaction. For this reaction, gate valve is
suitable. The process is simple and does not need any more advanced valve. Using gate valve
is sufficient enough as in the plant above. Therefore, in my opinion the addition of valves is
no more required as the valves exist is already abundant.