INDEX
‘Note: Page numbers followed by “f” indicate figures and “t” indicate tables.’
A optimization opportunities, 143
Acid gas enrichment unit (AGEU), 21,
22f
Acid gas removal unit (AGRU), 9e10
chemical absorption processes, 10e12,
11f
mixed solvent processes, 15
physical solvent processes, 12e15, 13f
solvent absorption processes, 10
Adaptive control, 111e113
Advanced control methods, 108e115
adaptive control, 111e113
cascade control, 109
feedforward control, 108e109
interaction and decoupling, 110
internal model control (IMC), 113e114
model predictive control (MPC),
114e115
nonlinear control, 110e111
override control, 109
selective control, 109
Advanced process control (APC) systems,
65e66
Amine processes, 60e61
Amines, 90e91
Aquisulf process, 18, 18f
Autotune variation technique, 126e127
B on-off control, 104e105
Benzene, toluene, ethyl-benzene,
xylenes (BTEX), 88e89
Bespoke models, 79
Boilers, 139
air-limited and fuel-limited conditions,
141
combustion parameters, 140, 141f
drum level control, 142
feedforward control, 142
interlocks, 140
optimal allocation, 144
prime control, 139
secondary control, 139
steam pressure, 140
steam temperature, 142e143
three-element systems, 142
water blowdown, 144
Broyden’s method, 183
Butanes splitter, 203
C
Capacitance-type processes, 97e98
Carbon dioxide (CO2) removal, 37e38
Cascade control, 109
Caustic processes, 57e59
Centrifugal compressors, 153
capacity control, 153e154, 154f
compressor unit safeties, 157
surge, 154e157
Chemical absorption processes, 10e12,
11f
Chillers, 149e151
Claus sulfur recovery technology,
15e16, 17f
Closed-loop control systems, 104, 174
advanced control methods, 108e115
derivative control, 107
integral control, 105e106
proportional control, 105
proportional-integral-derivative (PID)
control, 107e108
Commercial models, 79
Composition control, 161
analyzers, 161, 162fe163f
inferentials-pressure-compensated
temperature, 162e163
Compressors
centrifugal compressors, 153e157
reciprocating compressors, 151e153
283
284 Index
Condensate stabilization, 7f
hydrocarbon liquids, 7e8
hydrotreater unit, 9
liquefied petroleum gas production, 8, 8f
organic sulfurs, 8
Conjugate gradient method, 176
Constant cycling methods, 125e126,
125t
Continuous optimization, 179
Control loop interaction, 160e161
Control loop tuning, 128e129
autotune variation technique, 126e127
constant cycling methods, 125e126,
125t
controller response, 117, 120
peak-related criteria, 118e119, 118f
time-related criteria, 119e120, 119f
error performance criteria, 121
first principles process relationships,
136e138
lambda tuning, 129e136
PID tuning software, 127e128
process reaction curve methods,
122e125
quality of control, 116e117
tuning methods, 121e127
Control system components, 103e104,
103f
Control valves
actuators and positioners, 226
control valve maintenance, 238e241
actuator diaphragm, 240
bench set, 241
grinding metal seats, 240e241
seat rings, 240
seat rings, replacing, 241
stem packing, 240
diagnosing problems, 230e233,
234fe235f
globe valves, 215e220
angle style, 218, 218f
balanced cage guided, 219e220, 220f
double ported, 216e218, 217f
high-capacity cage guided, 220, 221f
single port, 216, 216fe217f
three way, 219, 219f
performance, 224e226
actuator and positioner design, 225
dead band, 224e225, 224f
valve response time, 225
valve sizing, 226
valve type and characterization,
225e226
problems
cavitation, 230
leakage, 230, 231te233t
nonlinearities, 230
reliability, 235e238
smart valve technology, 236e238
rotary valves, 220e224
butterfly valves, 221, 222f
eccentric disk valves, 223, 223f
eccentric plug valves, 223e224, 224f
V-notch ball valves, 221e223, 222f
sizing and selection, 226e229
cryogenic service valves, 229
flow characteristic selection, 228
Cryogenic service valves, 229
selecting, 229
D
Dead time, 98
Debutanizer, 202e203
Deethanizer, 202
Degrees of freedom, 115e116
Demethanizer, 201e202
Depropanizer, 202
Derivative control, 107
D’GAASS process, 18e19
Diethylene glycol, 23
Dimethylpolyethylene glycol (DPEG),
13e15
Discrete optimization, 174
Distributed models, 78e79
“Doctor treating” process, 57e58
Double-column nitrogen rejection,
32e33, 33f
Downhill simplex, 176
DPEG. see Dimethylpolyethylene glycol
(DPEG)
DRIZO process, 25e26
Drum level control, 142
Dual-column reflux process, 47e48, 47f
Dual composition control, 166e167

Dynamic models, 160
equation solver approach, 82
hybrid approach, 82
vs. steady-state model, 76
Dynamic process characteristics
capacitance-type processes, 97e98
combinations, 99
dead time, 98
inertia-type processes, 99
resistance-type processes, 97
simple systems
effects of variable conditions, 103
heat exchangers, 101e102
pipelines, 102
vessels and piping, 99e101
E Gas processing plant configurations
Equation of state (EOS), 74e75
Error performance criteria, 121
ExxonMobil, 20e21
F condensate stabilization, 7e9
Fans, 169
Feed composition compensation, 167
Feed enthalpy control, 168
Feedforward control, 108e109, 142
Feedforward systems, 166
Feed maximization, 168
Finger-type slug catcher, 5e6, 6f
First principles process relationships,
136e138
Flow rate measurement
orifice, 248e249, 248f
pitot tube and annubar, 249, 250f
positive displacement, 250, 251t
turbine meters, 250
venturi tube, 249, 249f
vortex shedding, 250
Fluor twin-column high absorption
process, 51e52
Fluor twin-reflux absorption process,
52e53, 52f
Furnaces, 169e171
G recovery and LNG production plants,
Gas dehydration
with triethylene glycol (TEG), 88
modeling, 89e90
Index 285
thermodynamic model selection,
88e89
units
absorption processes, 22
adsorption processes, 22
conventional TEG dehydration
process, 24e25, 24f
direct cooling method, 22
enhanced TEG dehydration process,
25e27, 26f, 27t
glycols, 23
purposes, 23
Gas plant support systems
process control systems, 65e66
safety systems, 66
utility and off-site, 64e65
“fit-for-purpose” design, 4
hydrocarbon dew pointing
acid gas removal unit (AGRU),
9e15
deep hydrocarbon dew pointing,
29e30, 30f
gas compression and transmission,
35e36
gas dehydration unit, 22e27
inlet separation facility, 5e7
JouleeThomson cooling, 27e28, 28f
lean gas, 4e5
nitrogen rejection, 4e5, 30e35
process units, 4e5, 4f
propane refrigeration, 29, 29f
sulfur recovery and handling unit,
15e22
natural gas liquids (NGLs) production
carbon dioxide (CO2) removal,
37e38
dehydration, 38e40
fractionation, 55e61
liquid facility, 37
mercaptan removal, 38e40
mercury removal, 40e43
process units, 37, 37f
43e55, 61e64
residue gas, 3e4
two different schemes, 3e4, 3f
286 Index

Gas subcooled process (GSP), 48e49, Lambda tuning

48f overdamped response, 135
Genetic algorithms, 189 reaction curve method, 132
Glycols, 23 relay method, 133
Gradient descent, 175e176 self-regulating processes, 130, 133
unification, 131
H Lean oil absorption, 43e44, 44f
Heat exchangers, 148 LeeeKesler method, 92
Hessian matrix, 178 Linear programming, 179e180
Hydrocarbon dew pointing Liquid distillate/inerts, 164
acid gas removal unit (AGRU), 9e15 Load sharing, 156
condensate stabilization, 7e9 Lumped parameter, 78e79
deep hydrocarbon dew pointing,
29e30, 30f M
gas compression and transmission, Measurement
35e36 analyzers, 264e266
gas dehydration unit, 22e27 defined, 243
inlet separation facility, 5e7 elements, 243e246, 245f
JouleeThomson cooling, 27e28, 28f instrument
lean gas, 4e5 calibration necessity, 262e263
nitrogen rejection, 4e5, 30e35 sensors and instruments calibration,
process units, 4e5, 4f 263e264
propane refrigeration, 29, 29f types, 261e262
sulfur recovery and handling unit, process controllers, 266e272
15e22 distributed control systems, 267
humanemachine interfaces, 269e270
I programmable logic controllers,
Inertia-type processes, 99 268e269
Inlet separation facility security, 272
finger-type slug catcher, 5fe6f supervisory control and data acquisi-
monoethylene glycol (MEG), 7 tion (SCADA), 270e272
sour water, 7 safety instrumentation, 272e282
three-phase separator, 6 regulations and standards, 276e282
vessel-type slug catcher, 5e6, 5f relief valves and relief systems,
Integral control, 105e106 272e275
Interlocks, 140 safety instrumented systems (SIS),
Internal model control (IMC), 113e114 275e276
Internal reflux, 167 system applications, 243
variables, 246e261
J flow rate, 246e250
JouleeThomson cooling, 27e28, 28f liquid level, 256e258, 258t
pressure, 255e256, 257t
K speed, 258e259
KarusheKuhneTucker (KKT), 182 temperature, 250e255
vibration, 260e261
L Membrane separation, 54, 54f
Lagrange multipliers, 180e181 Mercaptans, 57e58

Merox process, 58
Metaheuristics, 188
MetropoliseHastings algorithm, 188
Mixed-integer linear programming
(MILP), 185e186
Mixed-integer nonlinear programming
(MINLP), 186e187
Mixed solvent processes, 15
Model predictive control (MPC),
114e115
Modern NGL recovery processes, 47
dual-column reflux process, 47e48, 47f
Fluor twin-column high absorption
process, 51e52
Fluor twin-reflux absorption process,
52e53, 52f
gas subcooled process (GSP), 48e49,
48f
Ortloff SCORE, 49, 50f
residue gas recycle, 49, 50f
Molecular sieve technology, 59e60
Monoethylene glycol (MEG), 7, 23,
94e96
Multistream exchanger, 92e93, 92fe94f
N Newton’s method, 181e182
National Institute of Standards and
Technology, 75
Natural gas liquids (NGLs), 2
carbon dioxide (CO2) removal,
37e38
dehydration, 38e40
fractionation, 55e56, 55f
column design and operation, 56
liquid products processing, 56e61
liquid facility, 37
mercaptan removal, 38e40
mercury removal, 40e43
process units, 37, 37f
recovery and LNG production plants,
43e55, 62fe64f
Natural gas processing plants
configurations, 3e64
objectives
natural gas liquids (NGLs), 2
pipeline gas specifications, 1e2, 2t
Y-Grade, 2, 3t
Index 287
optimal design and operations
process control, 67e68
process modeling and simulation,
66e67
process optimization, 68
NeldereMead method, 176
Newton’s method, 176
Nitrogen rejection unit (NRU), 4e5
cryogenic separation, 31
double-column nitrogen rejection,
32e33, 33f
membrane separators and molecular
sieves, 31
single-column nitrogen rejection, 31,
32f
South China Sea, 30
three-column nitrogen rejection,
33e34, 34f
two-column nitrogen rejection, 34e35,
35f
Nonlinear control, 110e111
Nonlinear programming (NLP)
function values, 184
gradient methods, 183e184
Hessian methods, 182
quadratic programming, 184e185
Nonregenerative mercury sorbents,
41e42
O
On-off control, 104e105
Ortloff SCORE, 49, 50f
Override control, 109
P
Pharmaceutical plant, 81e82
Physical solvent processes, 12e15, 13f
PID. see Proportional-integral-derivative
(PID) control
Predominate lag, 116e117
Pressure control, 164
Process control, 266e272
closed-loop control, 104
advanced control methods, 108e115
derivative control, 107
integral control, 105e106
288 Index
Process control (Continued)
on-off control, 104e105
proportional control, 105
proportional-integral-derivative (PID)
control, 107e108
control loop tuning, 116
autotune variation technique,
126e127
constant cycling methods, 125e126,
125t
controller response, 117e120
error performance criteria, 121
process reaction curve methods,
122e125
quality of control, 116e117
control system components, 103e104,
103f
degrees of freedom, 115e116
distributed control systems, 267
dynamic process characteristics
capacitance-type processes, 97e98
combinations, 99
dead time, 98
inertia-type processes, 99
resistance-type processes, 97
simple systems, 99e103
humanemachine interfaces, 269e270
individual unit operation control/
optimization strategies, 138
blending, 138e139
boilers, 139e145
chillers, 149e151
compressors, 151e157
distillation, 159e168
heat exchangers, 148
steam turbines, 145e148
turboexpanders, 157e158
utility steam systems, 145
programmable logic controllers,
268e269
security, 272
supervisory control and data acquisition
(SCADA), 270e272
Process optimization, 209e210
continuous optimization, 179
conventional optimization techniques
gradient-based methods, 175
NeldereMead method, 176
Newton’s method, 176
sequential quadratic programming
(SQP), 177
trust region methods, 177
discrete, 185e187
dynamic optimization
linear quadratic control, 190e192
numerical methods, 192e193
Pontryagin’s maximum principle, 190
genetic algorithms, 189
Hessian matrix, 178
Lagrange multipliers, 180e181
limitations, 177
linear, 179e180
metaheuristics, 188
nonlinear programming (NLP)
function values, 184
gradient methods, 183e184
Hessian methods, 182
Newton’s method, 181e182
quadratic programming, 184e185
real-time optimization (RTO), 173,
193
absorbers and strippers, 198
advanced process control (APC)
system, 194
compression model, 198e200
custom models and fractionators,
197e198
demethanizer feed chilling models,
203e204
distillation calculations, 200e203
model fidelity and measurement
errors, 207e209
optimization models, 197
optimization objective function, 197
physical properties, 195
plant model integration, 206e207
real-time optimization configuration
interface, 194e195, 196f
real-time optimization interactive
model, 194e195, 195f
real-time optimization real-time
scheduling interface, 194e195,
196f
refrigeration models, 203

steam and cooling water system
models, 204
turbines, 204e206
simulated annealing, 188e189
stochastic optimization methods, 187
threshold acceptance, 189
types, 174e175
unconstrained problems, 177e178
Process reaction curve methods,
122e125
CoheneCoon tuning method, 124
internal model control tuning rules,
124e125
ZieglereNichols open-loop procedure,
122e124
Process simulation model
benefits, 73e74
component lists, 83
defined, 73
simulation model, 84
model robustness, 86e88
model speed and iterations, 85e86
solution order, 86, 87f
steady-state models
combined approach, 81
equation solver approach, 80e81
modular approach, 79e80
thermodynamic model selection, 83e84
Propane refrigeration, 29, 29f
Proportional (P) control, 105
Proportional-integral-derivative (PID)
control, 107e108
PURASPEC process, 21
R 272e275
Real-time optimization (RTO), 173,
193
absorbers and strippers, 198
advanced process control (APC) system,
194
compression model, 198e200
custom models and fractionators,
197e198
demethanizer feed chilling models,
203e204
distillation calculations, 200e203
Index 289
model fidelity and measurement errors,
207e209
optimization models, 197
optimization objective function, 197
physical properties, 195
plant model integration, 206e207
real-time optimization configuration
interface, 194e195, 196f
real-time optimization interactive
model, 194e195, 195f
real-time optimization real-time
scheduling interface, 194e195,
196f
refrigeration models, 203
turbines, 204e206
Reciprocating compressors, 151e153
RefProp model, 75
Regenerative mercury adsorbents, 42
Residue gas recycle, 49, 50f
Resistance-type processes, 97
Rich amine, 90
Rigorous models, 77e78
S
Safety instrumentation, 272e282
regulations and standards, 276e282
high-integrity pressure protection
system (HIPPS), 280e282, 281f
International Electrotechnical
Commission 61508, 279
International Electrotechnical Com-
mission 61511, 277e279, 277f
safety integrity level, 279, 280t
relief valves and relief systems,
safety instrumented systems (SIS),
275e276
Selective control, 109
Sequential quadratic programming
(SQP), 177
Shortcut models, 77e78
Simplified Internal Model Control
(SIMC) equation, 131
Simulated annealing, 188e189
Simulation objectives, 82e88
vs. modeling effort
290 Index
Simulation objectives (Continued)
commercial models vs. bespoke
models, 79
lumped parameter vs. distributed
models, 78e79
shortcut vs. rigorous models, 77e78
Simultaneous perturbation stochastic
approximation (SPSA) method,
184
Single-block multistream exchanger,
93, 93f
Single-column nitrogen rejection, 31,
32f
Single input/single output (SISO)
control, 165e166
Slug catcher, 5e6, 5fe6f
Smart valve technology
in-service friction and friction trending,
238
instrument air leakage, 237
instrument air quality, 238
other examples, 238
supply pressure, 237
travel deviation and relay adjustment,
237e238
Snap acting, 104e105
Solid bed adsorption, 53e54, 53f
Sour gas sweetening process, amines
absorption and regeneration, 90e91
rich amine, 90
thermodynamic model selection, 90
Split block multistream exchanger, 93,
94f
SQP. see Sequential quadratic program-
ming (SQP)
Steady-state models, 79e80
combined approach, 81
vs. dynamic models, 76
equation solver approach, 80e81
modular approach, 79e80
Steam turbines
condensing, 146
configurations, 145e146
low-pressure steam, 147
noncondensing, 146
safety systems, 146
two-stage extraction turbine, 147, 147f
Suboptimization, 168
Sulfur degassing
agitation, 16
Aquisulf process, 18, 18f
D’GAASS process, 18e19
Sulfur recovery unit (SRU), 15e22
Sulfur scavenger unit, 21e22
Sulfur storage/handling, 19
Supervisory control, 167e168
Surge limit line (SLL), 154e155
T
Tail gas treating unit, 19e21, 20f
TCHAP. see Twin column high
absorption process (TCHAP)
Temperature measurement, 250e255
resistance temperature detectors (RTD),
250e252, 252t
sensor, 254e255
thermocouples, 252e253, 254t
Tetraethylene glycol, 23
Thermodynamics, 74e75
Three-column nitrogen rejection,
33e34, 34f
Three-element systems, 142
Threshold acceptance, 189
Transportation lag, 98
Tray-to-tray distillation method,
200e201
Triethylene glycol (TEG), 23, 88e90
Trust region methods, 177
Tuning methods, 121
autotune variation technique,
126e127
constant cycling methods, 125e126,
125t
process reaction curve methods, 122
CoheneCoon tuning method, 124
internal model control tuning rules,
124e125
ZieglereNichols open-loop
procedure, 122e124
Turboexpander NGL recovery processes,
44e47, 45fe46f, 91
modeling, 93e94, 95f
multistream exchanger, 92e93, 92fe94f
thermodynamic model selection, 92
 Index 291

Twin column high absorption process Vapor recompression, 165

(TCHAP), 51 Vessel-type slug catcher, 5e6, 5f
Twister supersonic separation, 55
Two-column nitrogen rejection, 34e35, Y
35f Y-Grade, 2, 3t

U Z
Utility steam systems, 145 Ziegler-Nichols closed-loop method,
125e126, 125t
V
Vapor distillate/inerts, 164e165