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Process control
Adrie Huesman
Introduction I
• About me:
• 1984 – 1990 Student Chemical Technology (Delft University of
Technology).
• 1990 – 1996 Control technologist for Shell Nederland at
Pernis.
• 1996 – 1999 Senior control technologist for Shell Singapore at
Pulau Bukom.
• 1999 – now Assistant professor with DCSC, current research
area is “Economic dynamic process optimization”.
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Introduction II
• Content
1. Design and operation.
2. Safety.
3. Process and instrumentation diagrams.
4. Plantwide control
a. Degrees of freedom.
b. Objectives.
c. Decomposition.
Introduction III
• Content (continued)
4. Plantwide control
d. Production rate control.
e. Standard quality schemes.
f. Recycles.
g. Procedure.
h. Example.
2
Design and operation I
1. Operation mode
2. Process design
3. Control design
• Note that the process design is done before the control design.
This facilitates the control design; the process dynamics can be
used as a starting point for the control design. However the
process dynamics can severely limit the controlled behavior.
3
Design and operation III
4
Design and operation V
5
Design and operation VII
Advantages Disadvantages
Safety I
6
Safety II
cooling
water
safe
PC
location
SRV
IPF
PZ
steam
compressor or
turbine
heat exchanger
process line
7
Process and instrumentation diagrams II
• The letter-number combination “ABnn” is called a tag. The first
letter specifies the process variable type, the second the function.
SP FC OP
PV
t
KC d (SP − PV )
OP = K C (SP − PV ) +
τI ∫ (SP − PV ) dt + K τ
0
C D
dt
8
Process and instrumentation diagrams IV
Degrees of freedom
• The DOF also equal the number of inputs (typically flows that
can be manipulated). This is a more robust way to determine the
DOF since NV and NE are large while the DOF are small.
* Independent equations.
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9
Objectives
Decomposition
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Production rate control I
• The upper one is called a push scheme, the lower one a pull
scheme. Note that the level controllers automatically propagate
the production rate through the plant.
All rights reserved by Adrie Huesman 21
11
Standard quality schemes
Recycles I
12
Recycles II
V dC A2
⇒ vessel : + C A2 = C A1
10 dt
dC A2
⇒ total : V + C A 2 = C A0
dt
dy
Remember that : τ + y = Ku
dt
⇒ τ vessel = V / 10 and τ total = V
All rights reserved by Adrie Huesman 25
Procedure
13
Example I
Example II
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Example III
Example IV
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Example V
Number Equipment Description Remarks
16 Objectives
1 Plantwide Production rate Directly proportional to air
2 A1 Ratio air/methanol Related to maximum temperature
3 A1 Ratio steam/methanol Related to maximum temperature
4 A1 Level
5 E1 Outlet temperature Reaction temperature
6 R1 Pressure 1.5 bar
7 R1 Outlet temperature 145 °C
8 E2 Outlet temperature 100 °C
9 C1 Level bottom
10 C1 Pressure
11 C1 Ratio water/feed Related to quality bottom
12 C2 Pressure
13 C2 Level top
14 C2 Level bottom
15 C2 Ratio reflux/feed Related to quality top
16 C2 Ratio steam/feed Related to quality bottom
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