Professional Documents
Culture Documents
Process Instrumentation and Control: Chemical Engineering Design
Process Instrumentation and Control: Chemical Engineering Design
and Control
Control valve location can create a need for additional pumps and
compressors, and must be decided in order to size the pumps and
compressors
Process instrumentation
Reading a P&ID
PV PAH PIC
Actuator PT
PAL
Controller
Process or
utility stream
Final control Sensing
element element
Disturbance
Input Output
Sensing Final control
element element
Measured variable Manipulated variable
Process
I: Integral
Output is proportional to integral of error
Eliminates offsets from P control, but makes response more sluggish
D: Derivative
Output is proportional to rate of change of error
Damps out instability and allows higher gain to be used
Controller Output = G e + (1 / Ti) e dt - Td
de
o dt
where: G = Controller gain
e = Error (set point minus measured variable)
Ti = Integral time constant
Td = Derivative time constant
stoichiometry
FFV
FT
Also used in some types of
distillation column control
to set reflux or boil-up
ratios
(secondary) to control TE
reactor temperature FT
FV
Coolant
Process instrumentation
Reading a P&ID
Pressure pH
Easy means cheap, reliable instrument with fast response time and
accurate measurement
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & SinnottChemical Engineering Design only. Do not copy
Chemical Engineering Design
Temperature Measurement:
Thermocouples
When a junction between dissimilar wires is heated, an
EMF (voltage) is developed, which can be read by a
millivolt transmitter
A A + Cu
MILLIVOLT
TRANSMITTER
B B - Cu
HOT JUNCTION (T1 )
COLD JUNCTION (T2 )
PD PD
Sensor element
PD
Process instrumentation
Reading a P&ID
The P&ID usually also indicates line sizes and pipe metallurgy
Actuators
S D M
*AH
*AL Shared display device with software alarms (* is measured variable)
F Flow R Radiation
L Level W Weight
Can you figure out what each of these ISA 5.1 codes
means and what the instrument does?
TRC
AR
PAH
PAHH
LI
PC
TSH
FFY
PT
JIAL
Process instrumentation
Reading a P&ID
PV Coolant
FIC FIC
FV
PI M PI FT
FT
LT
LV
Hence use level
Feed controller to actuate
Steam heat input to the
Trap
vaporizer and maintain a
Condensate
constant inventory
TV
Only one side of an
exchanger can be
temperature controlled
M M M M
TV
TO VARIABLE
TIC SPEED MOTOR TIC
TE TT TE TT
CONTROL CIRCUIT
FV
FT
FIC
TE
FIC TT FY
FT FV
Intermittent
Steam drain
Intermittent Trap
charge
Feed A
FIC TT
TIC FIC
FV FT
LAH LIC
LT
TE LAL
FV
FT
Feed B
Coolant Temperature
cascade control of
coolant flow
Product
Independent flow
control of feeds
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & SinnottChemical Engineering Design only. Do not copy
Chemical Engineering Design
Exercise: Gas Recycle Process
Make-up
gas Purge
Feed
Reactor
Product
Liquid feed is mixed with recycle gas, heat exchanged against reactor
effluent, heated to reactor temperature then passed over fixed bed of
catalyst. Product is cooled and liquid product is recovered. Unconverted gas
is recycled with purge to prevent accumulation of inerts
Feed
Reactor
Product
Process instrumentation
Reading a P&ID
Automatic
AutomaticSafety
SafetyShutdowns
Shutdowns
Basic
Basic Process
Process Control
Control
Other standards also recommend best practices for alarm levels, vessel
sizing to allow adequate control, etc.
LIC LIC
LT LT
LAL LAL
TRIP
LSL LAL
UC
A
UC
A
If there are too many alarms then they can become a distraction to
the operators
Increasing the chance of human error
Increasing the chance that the operator will ignore the alarm, switch it
off, or acknowledge it without taking action
Increased chance of an alarm flood
Process instrumentation
Reading a P&ID
Measured variable 1
Measured variable 2
Measured variable 3
Control Valve 1
Control Valve 2
Control Valve 3
FV
FT PT TT
Manual Control
Pneumatic Analog
Electronic Analog
Digital
?!?!?!?
Source: UOP
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & SinnottChemical Engineering Design only. Do not copy
Chemical Engineering Design
Fieldbus (ISA SP50)
Optimizer
User User
Plant DCS
Off-line Optimization
Users take plant data and run the optimizer then send
instructions to the plant operators to update the DCS
settings
Optimizer Optimizer
Optimizer Optimizer
Plant DCS
Closed Loop On-line Optimization
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & SinnottChemical Engineering Design only. Do not copy
Chemical Engineering Design
Real Time Optimization Models
Models and algorithms for RTO have very tough
requirements
Must be robust, i.e., always find a solution
Must solve quickly
Must converge to same solution whatever the starting point
Must allow for model error
Must reconcile data and filter out bad data
Must capture plant constraints
Must give reasonably good description of plant performance