Strictly Confidential

Process Controls
In PTA Plant
Industrial Revolution
1. 1760 to 1840 - Ushered in Mechanical production;
railways and steam engine.

2. 1870 to 1940 - Mass production; electricity and

assembly line

3. 1960 to 2010 - Computers; semi conductors, main 4. Industrial revolution

Based on cyber-physical-
frame computing, personal devices, internet systems

3. Industrial revolution
Through the use of electronics
and IT further progression in
autonomous production

2. Industrial revolution

Level of complexity
Introducingmass production
lines powered by electric
energy

1. Industrial revolution
Introducing mechanical
production machines powered
by water and steam

Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0

End of the Beginning of the Beginning of the Today
18th century. 20th century 70th

10-July-2022 Strictly Confidential 2

Introduction
In any industrial plant, the aim is to produce standard and quality products and sell
them at prices which make profit.
These purposes can be achieved in a successfully designed and controlled
processes.

Control Objectives:

– Safety

– Environmental Protection

– Equipment Protection

– Smooth Plant Operation and Production Rate

– Product Quality

– Profit Optimization

– Monitoring and Diagnosis

10-July-2022 Strictly Confidential 3

Purpose of Process Control & Automation
To achieve operational Excellence & Optimum Profitability

To Stay in business in a Competitive market

To OPTIMIZE A PLANT
Quality/ Economics  Steady State
Operation
&
For Safety of Assets

Continuous
Improvement
Quality Policy & Business Policy
10-July-2022 Strictly Confidential 4
Important Characteristics of Process Control

• The dynamic behavior of the individual unit operations/ unit

processes and combination of all unit operations/ all unit
processes, are to be understood completely.

• It is always the best to utilize the simplest control system that

will achieve the desired objectives.
• The design of control system of the plant, determines how it
will respond dynamically and how it can be controlled
automatically/ manually.

10-July-2022 Strictly Confidential 5

Set-Measure-Compare-Correct
It is for maintaining the desired conditions in a physical system by
adjusting selected variables in the system.

In control Systems:
• A specific value (Set Point) is used as a desired value for the
controlled variable.

• The conditions of the system are measured. (Detecting Element)

• Each system has a control calculation or algorithm. (Controller)
• The results of calculation are implemented by final control
element.

10-July-2022 Strictly Confidential 6

Process Control Strategies
• Feedback Control: uses direct measurements of the
controlled variables to adjust the values of the manipulated variables.
The objective is to keep the control variables at desired levels.

• Feed Forward Control: uses direct measurement of the

disturbances to adjust the values of the manipulated variables. The
objective is to keep the controlled output variables at desired levels.

• Cascade Control: different combinations of two types. One

controller (master controller) is dependent on the other controller (slave
controller)

• Ratio Control: One or more controllers are dependent on one

controller in Ratio only.

• Split Control: When one controller is controlling two control

elements, in reverse way, but not together/ at the same time.
10-July-2022 Strictly Confidential 7
Example:
Consider the tank heating system shown in the
figure.

Fi, Ti A liquid enters the tank with a flow

rate Fi (T/h) and a temperature of Ti
(0C). It is heated with steam having a
h flow rate of Fst (T/h). Let F and T be

the flow rate and temperature of the

F, T
stream leaving the tank.
Fst
The tank is considered to be well stirred, which
implies that the temperature of the effluent is

steam equal to the temperature of the liquid in the

tank.

10-July-2022 Strictly Confidential 8

 Example Contd.
Fi, Ti A thermocouple measures the temperature
of the fluid in the tank. Then this
temperature is compared with the desired
Thermocouple
value yielding a deviation

Set-point ε = Ts – T
F, T The value of deviation is sent to a control
Controller mechanism which decides what must be
done in order for the temperature to turn
Fi, Ti
back to the desired value.

Notice that feed forward control does not

Thermocouple
wait until the effects of the disturbances
has been felt by the system, however, acts
Set-point appropriately before the external
F, T disturbance affects the system anticipating
Controller what its effect will be.
10-July-2022 Strictly Confidential 9
Example Contd.
Fi, Ti
To keep the volume at Level Measuring
Device
its set point or the liquid
hs
level hs we measure the
Controller
level of the liquid in the
tank, and we open or F, T

close the effluent flow

rate.
Controller

hs
Fi, Ti Level Measuring
Device

F, T
10-July-2022 Strictly Confidential 10
What To control
• Pressure
• Temperature
• Flow
• Level
• pH
• Speed
• Compressor Surge
• Slurry Concentration
• Weight ETC
10-July-2022 Strictly Confidential 11
Recapitulation
Recapitulation: Process Flow Diagram
WWT
Atmosphere
Atmosphere
Comp. train

Atmospheric
Absorber
High
Pressure
Absorber

WWT

AIR
PX F/C

Rotary
Crystallizer Vacc. Filter
Post Hydrogenation
Oxidation Reactor
Oxidation Reactor
CTA Dryer Crystallizer PTA Silo&
Reactor Buffer/
CTA Silo 1st Decanter Packing
Conventional Distillation Slurry Tank
2ndDecanter

The Major Processing Steps:

• pX Oxidation (CTA Synthesis)
• CTA crystallization
• CTA filtration
• CTA Drying
• Hydrogenation (CTA purification to PTA)
• PTA Crystallization
• PTA Filtration
• PTA Drying
• PTA Conveying
10-July-2022 Strictly Confidential 13
Common
Controllers
FEEDBACK CONTROL
CONTROLLER Disturbance

SV DV Computation MV Control
Block PROCESS
Valve
PV

Transmitter Sensor

CONTROLLED VARIABLE : TEMPERATURE

PV SV
OPERATION VARIBLE : HEATING STEAM
TCE TC
840 840 DETECTING ELEMENT : TCE840
TCV
MV 840
FINAL CONTROL ELEMENT : TCV840
HOT Water Out

Steam Similarly,
Several applications of

• Level Control
• Flow Control
• Pressure Control
ST Condensate • pH Control
10 -J uly -2022
Cold W ate r In
Strictly Confidential 15
ETC.
CASCADE CONTROL
L1 L2
DV PRIMARY/
MV DV SECONDARY/
SV CONTROL SECONDARY PRIMARY
MASTER SLAVE
CONTROL SV CONTROL VALVE PROCESS PROCESS
PV
PV
SECONDARY
TRANSMITTER
SENSOR

PRIMARY
TRANSMITTER
SENSOR
MV TC SV
802
A CASCADE CONTROL SYSTEM CONSISTS OF
PV
PRIMARY AND SECONDARY CONTROL LOOP.
TCE
DISTURBANCES OCCURING IN THE SECONDARY Master 802
(Primary)
(or SLAVE) CONTROLLER BEFORE THEY CAN AFFECT THE
Cold Oil Hot Oil
CONTROLLER VARIABLE OF THE PRIMARY LOOP.
SV
THE LATER IS CONTROLLED BY THE PRIMARY
PV FC
801
(or MASTER) CONTROLLER.
FCT
801
MV
Slave
(Secondary)
Furnace
10-July-2022 Fuel Strictly Confidential 16
RATIO CONTROL

Fa

K=Fa/Fb

FC
Fb

10-July-2022 Strictly Confidential 17

Process Flow Diagram

10-July-2022 Strictly Confidential 18

RATIO CONTROL
RATIO CONTROL IS DEFINED AS A MEAN OF HOLDING TWO OR MORE DISTURBANCES IN A CONSTANT RATIO
TO EACH OTHER.
THE FLOW RATE OF ONE PARTICULAR STREAM IS MEASURED AND THIS MEASUREMENT IS USED TO ADJUST THE
SET POINT OF A FLOW CONTROLLER WHICH IN TURN REGULATES THE FLOW OF ANOTHER STREAMS (THE CONTROLLED
STREAM) SUCH THAT THE FLOW RATE S OF THE TWO STREAMS MAINTAIN A FIXED RATIO TO EACH OTHER.

PX IN PV
FC724

OUT
SV PID
MV
ML IN PV1’
FR725 FC726
SV1 IN OUT SET

RATIO MV1 SV1’ PID

OUT

MV1’ To Reactor
AA (Start Up
IN PV2’
IN
FR726
OUT SET
FC725
Sequence)
SV2
OUT
RATIO MV2 SV2’ PID

MV2’
CAT IN PV3’
FR721 FC721
IN OUT SET
SV3
OUT
10-July-2022
RATIO MV3 SV3’ Confidential
Strictly
PID
19
MV3’
Purpose of Process Control & Automation
To achieve operational Excellence & Optimum Profitability

To Stay in business in a Competitive market

To OPTIMIZE A PLANT
Quality/ Economics  Steady State
Operation
&
For Safety of Assets

Continuous
Improvement
Quality Policy & Business Policy
10-July-2022 Strictly Confidential 20
CASE STUDY: Loss Optimization
PI764
Condenser
FC769
Top Press. FC769 Fluctuates
Reflux Top Product
Water + Trace RR
FC767
of AA (Loss) Fluctuates

Bottom Temp.
Fluctuates

Feed: REFLUX Distillation

AA +
Water
RATIO = Disturbance
(FC767-FC769)/
FC769
System
UNSTABLE

TC764
Steam High AA loss
Bot.
Temp.
Normally AW contains
Bottom Product 0.8% AA; it reached
Stric tlAy +CoTnrafcideeonftW
A i alater
10-July-2022
up to 1.2% 21
 •If D-1764 Stable
TC764, FC769,FC767 Stable
•PI764B Stable

P=450 P=250
I=40 I=5
D=0 D=0

AA concentration reduced
from 1.2% to 0.8%.
 (1.2%-0.8%)*16.5T/h*8000h/Y
*1264$/T*75Rs/$

 Loss Prevention: 5 Cr.

INR/Y
10-July-2022 Strictly Confidential 22
Special
Controller
Purpose of Process Control & Automation
To achieve operational Excellence & Optimum Profitability

To Stay in business in a Competitive market

To OPTIMIZE A PLANT
Quality/ Economics  Steady State
Operation
&
For Safety of Assets

Continuous
Improvement
Quality Policy & Business Policy
10-July-2022 Strictly Confidential 24
Process Flow Diagram
WWT
Atmosphere
Atmosphere
Comp. train

Atmospheric
Absorber
High
Pressure
Absorber

WWT

AIR
PX F/C

Rotary
Crystallizer Vacc. Filter
Post Hydrogenation
Oxidation Reactor
Oxidation Reactor
CTA Dryer Crystallizer PTA Silo&
Reactor Buffer/
CTA Silo 1st Decanter Packing
Conventional Distillation Slurry Tank
2ndDecanter

The Major Processing Steps:

• pX Oxidation (CTA Synthesis)
• CTA crystallization
• CTA filtration
• CTA Drying
• Hydrogenation (CTA purification to PTA)
• PTA Crystallization
• PTA Filtration
• PTA Drying
• PTA Conveying
10-July-2022 Strictly Confidential 25
Compressor
Train &
Theory of Surge
Centrifugal Compressor Working Principle &
Anti-Surge Control
 The purpose of “Compressor” is to supply compressed air to CTA reactor for

the oxidation process from PX  TA.

 The Process Air Compressor train (PAC train): (a) Gas Turbine, (b)

Motor/Generator, (‘c) Air Compressor, (d) Intermediate Gear, (‘e) Steam

Turbine (f) Condenser.

 All components are fixed coupled and therefore rotating always at the same

time.
10-July-2022 Strictly Confidential 27
Schematic Of Compressor Train

Steam Turbine

Gas Expander
Compressor
+30.6 MW
-27.8 MW

-14.0 MW
Motor/
Gear
Condenser Box
Genera
tor

10-July-2022 Strictly Confidential 28

Schematic Of Compressor Train
3rd stage out

Inlet Guide Vane

(IGV) location

10-July-2022 Strictly Confidential 29

Working Principle: Performance Curve
 A Centrifugal compressor is a machine that imparts energy to the gas flowing through it. This energy is
in the form of velocity and is imparted from compressor impeller to the gas. Kinetic energy of the gas is
then converted to pressure head when gas is diffused, slowed down.

Pe/Pa

10-July-2022 Strictly Confidential 30

Centrifugal Compressor Surge
 Surge:
 Cyclic pressure and volume fluctuations.
 Reversal of the volume flow may even take place. (cause of flow stall at
the blade profile)

 Surge is a very dangerous phenomenon as the

compressor to vibrate, and
 Detrimental because it causes damage to the
expensive compressor parts and also can lead to a
long time shut down of the plant, which is not at
all desirable.

10-July-2022 Strictly Confidential 31

Centrifugal Compressor Surge (1/2)
 Surge can be understood by the help of impeller Air
OUT
schematic diagram. At point (1), suction end of an
impeller, fluid has the lowest energy. As the gas
moves to point (2), energy of the fluid increases due
to kinetic energy imparted by impeller. Energy
reaches a maximum at point (3). Air
 When the compressor is imparting maximum energy, IN

if any backpressure at the discharge is too high to be

overcome, the fluid flow stalls near point (3). This
means the pressure at point (3) increases because
the kinetic energy changes to pressure as it slows to
a stop.
 Thus the flow reverses and flows backward through
the impeller.
10-July-2022 Strictly Confidential 32
Centrifugal Compressor Surge (2/2)
 When the flow reverses, energy and pressure at Air
point (3) is relieved and drops down. OUT
 Now the compressor can compress fluid, which it
does and with the increase of pressure the backflow
occurs again and this is the reason why compressor
surge is a cyclic phenomenon.
 Compressor surge puts strain on many of the Air
compressors parts such as the bearings, seals and IN
the impeller itself and thus damage can occur if the
compressor is left to surge.
 The vibration caused by the surging can severely
damage the motor compressor coupling and also the
baseplate.

 To protect Compressor an “ANTI SURGE

CONTROL” logic is being developed with installation
of an “ANTI SURGE VALVE (ASV)”.
10-July-2022 Strictly Confidential 33
Anti-Surge Control System
 Anti-Surge control systems detect when a process
compression stage is approaching to surge and
subsequently take action to reverse the movement of
the operating point towards the surge line (SL).
 This systems keep the plenum pressure constant and
increases the flow through the compressor, resulting
in stable working conditions.
 It is normally achieved by opening a control valve in
a recycle line (Anti-Surge Control Valve or
ASCV/ASV), returning the discharge gas to the inlet
of the compressor/ by venting the air in the
atmosphere if the compressing fluid is Air.
 The resulting increase in compressor inlet volume
flow moves the operating point away from surge.

10-July-2022 Strictly Confidential 34

Compressor Performance Curve:

IGV IGV
Min. Max.
Explanation

10-July-2022 Strictly Confidential 35

Anti-Surge Control System

3
1. Inlet Guide Vane
(IGV) 2
2. Power Recovery
Valve (PRV)
3. Anti Surge Valve
(ASV)

10-July-2022 Strictly Confidential 36

Anti-Surge Control System
3
1. Inlet Guide Vane
(IGV)
2. Power Recovery
Valve (PRV)
3. Anti Surge Valve
(ASV)
1

10-July-2022 Strictly Confidential 37

Anti Surge Control System

2FC 2PC 2HC 2PC 2ZC

DCS

Remote Local Local Remote Local Remote PLC

Atmosphere

3 Anti Surge
Switching over Switching over
Switching over

2HC 2ZC Controller is

Max Value
ASV
selector 2FV111402 (ASV)
conceptualized &
designed in such
2PC
away, that it can
2FC 2PC IN 1 111404

Anti Surge take care of the

Controller IGV
SAFETY &
IN 2

2TE

1. Inlet Guide Vane Compressor Economics of

T/P
compensation 2PT
plant operation
(IGV) 2FT
1 together, with
2. Power Recovery PRV
keeping Safety as
2HV

Valve (PRV) AIR

1st priority.
2
3. Anti Surge Valve
10-July-2022 Strictly Confidential 38
(ASV)
Happy Learning

10-July-2022 Strictly Confidential 39