INSTRUMENTATION AND CONTROL IN PROCESS FLOW DIAGRAMS

MODULE 2 PART 5 – Process Design & Development

ChE 45 – Chemical Engineering Design 1
Lapeña, Don Kim S.

LEARNING OUTCOMES AUTOMATIC-CONTROL SCHEMES

Gain basic understanding on the process Things to know:
regulation concepts, objectives, and conventions - The detailed design and specification of
in identifying control and instrumentation the automatic control schemes for a large
elements product is usually done by specialists.
Trace the basic instrumentation sequence as - The process designer (the ChE), through
presented in a control & instrumentation diagram experience with similar plant and
Survey the basic control systems normally assessment of the process, can do the
encountered in a chemical process preparation of a preliminary scheme of
Draw simple instrumentation and control diagram instrumentation and control, developed
on our designed process from the process flowsheet.
- Many of the control loops will be
conventional and a detailed analysis of
CONCEPTS (PART 1) the system behavior will not be needed,
Over the life of a chemical processing plant, it is nor justified.
important to regulate operating conditions for - Judgement, based on experience, must
stable operations, and to produce quality be used to decide which systems are
products efficiently and economically. critical and need detailed analysis and
design.
Process Regulation – establishes the strategy
by which the process can be controlled
- Its other aspect, the study and control GUIDELINES FOR THE AUTOMATIC-
dynamic response or the transient CONTROL SCHEMES
behavior of the process to changes in Identify and draw in those control loops
operating variables that are obviously needed for steady-
state pant operation, such as
st
The regulation of process operations involves 1 - Level controls
understanding of the following: guide - Flow controls
- In most situations, processes are - Pressure controls
regulated, by the manipulation of the - Temperature controls
flowrates of utility and process
streams Identify the key process variables that
- Changes in the flowrates are achieved by need to be controlled to achieve the
opening or closing of valves specified product quality. Include control
2nd
loops using direct measurement of the
guide
controlled variable, where possible; if not
INSTRUMENTATION AND CONTROL practicable, select a suitable dependent
OBJECTIVES variable.
Safe plant operation Identify and include additional control
- To keep the process variables within 3rd loops required for safe operation which
known safe operating limits. guide may not be covered in the previous
- To detect dangerous situations as they steps.
develop and to provide alarms and Decide and show those ancillary
automatic shut-down systems. 4th instruments needed for monitoring,
- To provide interlocks and alarms to guide troubleshooting and development of
prevent dangerous operating procedures. plant operations.
5th Decide on the location of sample
Production rate guide points.
- To achieve the designed product output Decide on the need for recorded and the
6th location of the readout points. This step
Product quality guide would be done in conjunction with
- To maintain the product composition steps 1 to 4.
within the specified quality standards
Decide on the alarms and interlocks
7th
needed; this would be done in
Cost guide
conjunction with step 3.
- To operate at the lowest production
cost, commensurate with the other
objectives IDENTIFY CONTROL ELEMENTS IN PFDs

CONCEPTS (PART 2)
In a typical chemical processing plant, these
objectives are achieved by a combination of (1)
automatic control, (2) manual monitoring, and
(3) laboratory analysis
INSTRUMENTATION AND CONTROL IN PROCESS FLOW DIAGRAMS
MODULE 2 PART 5 – Process Design & Development
ChE 45 – Chemical Engineering Design 1
Lapeña, Don Kim S.

CONVENTIONS IN IDENTIFYING CONTROL UNDERSTANDING A SEQUENCEOF

ELEMENTS INSTRUMENTATION
For instruments – we identify/show
- Indicators
- Recorders
- Controllers
- Instrument lines

Conventions Used for Identifying

Instrumentation on P&IDs (ISA standard ISA-
S5-1)

Green arrow – a level sensing element (LE) is

located on the reflext drum V-104.

Yellow arrow – a level transmitter (LT) also

locaetd on V-104 sends an electrical signal
(designed by a dashed line) to a level indicator
and controller (LIC). This LIC is located in the
control room on the control panel or console (as
indicated by the horizontal line under LIC) and
can be observed by the operators

Blue arrow – from the LIC, an electrical signal is

sent to an instrument (LY) that computes
correct valve position and in turn sends a
pneumatic signal (indicated by a solid line with
cross-hatching) to active the control valve (LCV).

Purple arrow – high-level alarm (LAH) and low-

level alarm (LAL) are installed in the control room
Common examples of instrumentation and to warn operators
control indications encountered in process
flow diagrams
TYPICAL CONTROL SYSTEMS
Level Control – in any equipment where an
interface exists between two phases (e.g. liquid
vapor), some means of maintaining the
interface at the required level must be
provided.

A better representation indication

The control valve should be placed on the

discharge line from the pump.

Pressure control – necessary for most systems

handling vapor or gas. Alongside of this,
venting is the most common option. The method
of control will depend on the nature of the
process.
INSTRUMENTATION AND CONTROL IN PROCESS FLOW DIAGRAMS
MODULE 2 PART 5 – Process Design & Development
ChE 45 – Chemical Engineering Design 1
Lapeña, Don Kim S.

As shown in figures (a and b), a by-pass control

would be used.

In figure A – discrepancies in the volume of gas

flow from the set point is controlled by allowing a
portion of the gas stream to by-pass the pump
or the compressor if the flowrate becomes higher
than the set point.
- The degree of the control valve opening
depend on how far the actual flow rate
The scheme shown would not be used where the to that of the set point.
vented gas was toxic, or valuable. In these
circumstances thevent should be taken to a In figure B – the centrifugal flow of the
vent recovery system, such as a scrubber. equipment allows flow control by degree of
control valve opening.
Other schemes of pressure control - The pressure control in a process is
similar shown in figure a.

HEAT EXCHANGER CONTROL

Figure a shows the simplest arrangement, the
temperature being controlled by varying the
flow of the cooling or heating medium.

Figure b is the scenario if the exchange is

between two process streams whose flows are
At b – This happens at the top of the column fixed, by-pass control will have to be used.
wherein there is a sitpoint for the pressure that
should apply. If the certain pressure already
exceed, the system will allow some of the non-
condensable to go out, therefore the pressure of
the column will go down.

At c – The amount of coolant would correspond

to the amount of vapor that is being condensed
that will also affect the pressure in the
condenser.

At d – If we control the amount of the condensed

vapor that goes out of this condenser therefore,
the heat transfer area is also being controlled
and it will directly affect the pressure inside of the As with condensers, temperature control is not
condenser. effective in vaporizes since saturated vapor
temperature is constant at constant pressure.
- The amount of liquid feed present in the
FLOW CONTROL vaporizer directly corresponds to the
Usually associated with inventory control in a level. This is often used for controlling
storage tank or other equipment that will provide the steam supply to the heating surface.
flow control on a compressor or pump running
at a fixed speed and supplying a near constant The liquid feed to the vaporizer is on flow
volume output. control. Thus, an increase in the feed results
in an automatic increase in steam to the
vaporizer to vaporize the increased flow and
maintain the level constant.
INSTRUMENTATION AND CONTROL IN PROCESS FLOW DIAGRAMS
MODULE 2 PART 5 – Process Design & Development
ChE 45 – Chemical Engineering Design 1
Lapeña, Don Kim S.

CASCADE CONTROL Examples of Distillation column control

With this arrangement, the output of one
controller is used to adjust the set point of
another.
Cascade control can give smoother control in
situations where direct control of the variable
would lead to unstable operation.
- The “slave” controller can be used to
compensate for any short-term
variations in, say, a service stream flow,
which would upset the controlled variable;
the primary (master) controlling long-
term variations.

REACTOR CONTROL
In chemical reactors, the product is the most
important parameter to control.
Reliable on-line analyzer available – the
product composition can be monitored
continuously and the reactor conditions and feed
flows controlled automatically to maintain the
desired product composition and yield.
RATIO CONTROL - Reactor temperature will normally be
Used where it is desired to maintain two flows at controlled by regulating the flow of the
a constant ratio; for example, reactor feeds heating or cooling medium.
and distillation column reflux. - Pressure is usually held constant.
- Material balance control will be necessary
to maintain the correct flow of
reactants to the reactor and the flow of
products and unreacted materials from
the reactor.

The ratio control is sometimes called the flow

fraction controller (FFC)

DISTILLATION COLUMN CONTROL

A complex unit operation that requires more ALARMS AND SAFETY TRIPS, AND
control. INTERLOCKS
The primary objective is to maintain the Alarms are used to alert operator of serious,
specified composition of the top and bottom potentially hazardous, deviations in process
products, and any side streams, correcting for conditions.
the effects of disturbances in:
- Feed flow-rate, composition and
Key instruments are fitted with switches and
temperature relays to operate audible and visual alarms on
- Steam supply pressure
the control pane and annunciator panels
- Cooling water pressure and header
temperature
Where delay, or lack of response, by the operator
- ambient conditions, which cause changes is likely to lead to the rapid development of a
in internal reflux hazardous situation, the instrument would be
INSTRUMENTATION AND CONTROL IN PROCESS FLOW DIAGRAMS
MODULE 2 PART 5 – Process Design & Development
ChE 45 – Chemical Engineering Design 1
Lapeña, Don Kim S.

fitted with a trip system to take action

automatically to avert the hazard; such as
shutting down pumps, closing valves, operating
emergency systems.

The basic components of an automatic trip

system are:
- A sensor to monitor the control variable
and provide an output signal when a
preset value is exceeded (the
instrument).
- A link to transfer the signal to the
actuator, usually consisting of a system of
pneumatic or electric relays.
- An actuator to carry out the required
action; close or open a valve, switch off a
motor.

A safety trip can be incorporated in a control

loop

In this system, the high-temperature alarm

operates a solenoid valve, releasing the air on
the pneumatic activator, closing the valve on high
temperature.