Faculty of Chemical Engineering

Universiti Teknologi MARA CGE 666 PROCESS DESIGN

TUTORIAL
CHAPTER 7 – PROCESS CONTROL

Question 1
a) Describe the importance of process control in the aspect of variability, efficiency and
safety.

b) Figure 1 shows a “free-water knockout” (FWKO), a low-pressure vertical three-phase

separator type that is designed to separate the free water from the oil and emulsion, as
well as separate gas from liquid. This FWKO receives feed from low-pressure (LP) well
and intermediate pressure (IP) separator

Figure 1 Vertical free-water knockout

Propose and sketch the control strategies that should be applied to this system. Explain the
control strategies applied.
Question 2

a) Figure 2 and Figure 3 show the results of real-time process control simulation by using
Delta-V software/system. By using the information from the figures, demonstrate the
concept of open and closed loop control.

b) Figure 4 shows a drilling circulation system. Working scenario of circulating system is

the drilling mud will be pumped into the drill pipe from the mud reservoir, we called it
 mud tank. After mud reached the bottom the well, it brings rock cuttings to the surface
through the annulus between drill pipe and well wall. The mud with rock cuttings will be
separated through surface solid control system, such as screens, desanders or
centrifuges. After these, clean drilling mud will be retreated with certain chemicals and
again pumped into the wellbore. Propose 2 (two) possible control objectives for the
system and justify your answers. Next draw the control strategies complete with the
signal types.

Figure 4 Drilling mud circulation

Question 3

Process control and instrumentation plays a significant role in order to ease the operational
part of the plant or any other related facilities. In addition the feature of controlling the
process via network (such as Supervisory Control and Data Acquisition, SCADA and
Distributed Control System, DCS) and automation contribute to the widely use of the
technology.

a) List out the elements in a typical process control loop. Next explain in details the role
of each element in the process control.

b) Figure 5 shows a bulk treater to separate oil-water system. Sketch the feedback
control strategies that can be applied to this system as to control the following: 1)
level of the vessel and 2) inlet flow to the vessel.
 Figure 5 Horizontal Bulk Treater

c) Propose an alternative control strategies that can be applied to the system in b) and
briefly explain the control strategies applied.

Question 4

a) Consider an example of utility line. The line is equipped with Pressure Relieve Valve
(PRV1), Pressure Safety Valve (PSV1) and Temperature Control Valve (TCV1). The
pressure and temperature profile for the line are depicted in Table 2. Determine the
set point for PSV1. Next calculate the value of test pressure needed for Line 1.
Explain the reason for your answer for both set point and test pressure.

Figure 6 Utility line

Table 2: Pressure and Temperature Profile for Line 1