CHAPTER 3
3.0 Design and Calculation of a Pressure Controller for a Batch
Crude Oil Distillation Column
3.1 Design Considerations for Pressure Control
- Operating Pressure Range: Define normal (e.g., 1–2 atm), maximum,
and minimum pressures.
- Key Disturbances: Feed composition variability, temperature fluctuations,
and vapor load changes during batch progression.
- Control Objectives: Maintain pressure within ±0.05 atm of set point,
ensure safety, and adapt to dynamic batch phases.
3.2 .Steps in Designing a Pressure Controller
3.2.1 Process Analysis and Requirements
- System Characterization: Identify critical phases in the batch cycle
where pressure control is most challenging.
- Disturbance Analysis: List potential disturbances (e.g., sudden vapor
generation during heating) and their impacts.
3.3 Selection of Control Strategy
- Feedback Control (PID): Primary strategy due to simplicity and
effectiveness. Reverse-acting controller (pressure ↑ → coolant ↑).
- Manipulated Variable: Coolant flow to the condenser (adjusts
condensation rate to stabilize pressure).
- Alternative Strategies: Feedforward control for measurable disturbances
(e.g., feed rate changes).
3.4 Instrumentation Selection
3.4.1 Pressure Transmitter:
- Range: 0–2.5 atm (gauge for a 0.5–2 atm operating range.
- Accuracy: ±0.1% of full scale.
- Type: Absolute or gauge pressure sensor based on process needs.
3.4.2 Control Valve:
- Type: Globe valve (linear characteristics for proportional control).
The basic formula for calculating the flow coefficient (Cv) for a liquid is:
- Sizing: Calculate using
- Example:
- Actuator: Pneumatic, fail-open (air-to-close) for safety.
3.5 Control Loop Configuration
- P&ID Diagram: Illustrate the loop with transmitter, PID controller, and
control valve on the coolant line.
- Signal Types: 4–20 mA signals for pressure measurement and valve
positioning.
- Controller Action: Reverse-acting (output ↑ → valve opens ↑ → pressure
↓).
3.6 Controller Tuning
-Ziegler-Nichols Method:
- Ultimate gain (\( K_u \)) and period (\( P_u \)) from step tests
In this method, you analyze the open-loop step response of the system to
determine the time delay (L), time constant (T), and steady-state gain (K).
The “equations” for calculating the PID controller parameters are given by
this table:
Here, these tables represent the “equations” of the Ziegler-Nichols ultimate
cycle tuning method. They provide direct formulas to calculate the controller
parameters based on the experimentally found K_u and P_u.
-Empirical Tuning: Start with conservative settings (e.g.,
3.7 .Safety and Redundancy Measures
- Overpressure Protection: Safety relief valve set at 2.2 atm.
- Fail-Safe Design: Valve fails open to maximize cooling.
- Alarms: High/low pressure alerts with shutdown protocols.
3.8 Calculations for Control Valve Sizing and Controller Parameters
- Control Valve Sizing (Example)
- Transmitter Range: 0–2.5 atm (covers operating range with margin).
- PID Tuning:
3.9 Conclusion
-Design Summary: The controller maintains pressure via coolant flow
adjustments, with fail-safe mechanisms for safety.
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