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Control Valves
Safety Aspects
Fail Open, Fail Closed
Pressure Transducer PT
Pieziolelectric, diaphragm displacement
Alarm High
Alarm Low
pump
Alarm High
Alarm Low
Pump may dead head
Interlock or gain schedule valve to never go to zero
Flow Control
Flow
Ratio
Centrifugal Pump
Flow Control Valve Fail ??
Flow Transducer
Orifice, venture, v-cone, many others
Note, check valve to prevent back flow and by-pass loop to prevent
dead-heading pump
VFD can be costly
Missing Alarms on Pressure Indicator (PI)
Ratio Control
Ratio Control Valve FFV fail Closed
May have two control valves one for each stream
2 Flow Transducers
Orifice, venture, v-cone, many others
CV1 SP=Ratio*SPLC
CV2 SP=(1-Ratio)*SPLC
Vaporizer Control
Pressure Control
PID, gain scheduling = on/of
Valve Fail ???
Level Control
PID, gain scheduling if non-linear Valve
Valve Fail??
Kc=(Kp)-1*(Tr)/(+Td)
Tr=, =0.5 to 4 (typically 3) times Max(Td, Tr)
Cascade Control inner loop 5x to 10x faster than outer
loop
Profit Optimizer
Provide inputs for Active Control System
Heat Exchanger
Network Control
Hot Stream
Distillation Control
with Total
Condenser
Control Valves ????
Degrees of Freedom Analysis DoF= Nv-NDef-Neq
Variables, Nv= 4 NT+13, NDef=2 (Feed Flow and
Composition)
Additional Control
Valve on Feed is
Possible which is
used for Production
Rate Control
Equations = 4 NT+6,
Valves)
DoF=5 (# Control
Distillation Control
What measurements?
What should be the pairings
of measurements to control
valves?
PD controlled with CV QC
LR controlled by CV B
LD controlled by
CV L if so what does CV D
control??
CV D if so what does CV L
control??
Distillation Control
Material Balance Control
4 Control Schemes
Inferred Composition Analysis = Temp. of Stage
Top CA or Bottom CA
With
Composition
Analysis
LV control
DV control
L/F V control
D/F V control
Acrylic Process
AB
Objectives
Production Rate of B high
& constant
Conversion in reactor
highest possible
Constant Composition for
B
On-demand Product or
Feed Flow Control
System
20.13
FC on Product B
Feed of A controlled as needed by
reactor
20.14
FC on Feed A Flow
Level Controls Product B Flow Rate
Reactor Temp is controlled with
Cascade Controller
To meet Composition Requirements
Note:
Trim steam heater for Feed A for accurate
temperature control at reactor
Determine all manipulated variable. Number of manipulated variables MAY be equal to the number of control valves.
Determine how production rate is set: (a) upstream process; (b) downstream process; (c) free to vary. Determine the best way to control the
production rate: (a) valve selection; (b) setpoint on temperature, recycle, etc. can sometimes be used to control production rate.
The closed loop system for product quality control should have adequately small time constant, time delays, and sufficiently large gains.
Consider interaction between diferent loops and decide if multivariable control is needed.
Make sure that flows are not too small to achieve the objective (i.e. it is difficult to control condenser level using small flow rate of distillate in the column with high internal
flows).
Develop component balance control loops (control of makeup streams of reactants, makeup gaseous streams to maintain pressure, liquid makeup to
control level, etc.).
Be careful with recycle loops: They introduce feedback (positive or negative), which makes it difficult to analyze the consequences of the particular
control design on the overall performance. For instance, it was found that unless one flow somewhere in the recycle loop is fixed, the recycle flow
might grow to very high rate when disturbance occurs or when throughput is increased (snowball efect).
Heat integration saves cost but can make plantwide control more difficult because integrating loops also spread disturbances.
Using steady state simulations to study controllability of the designed system in face of disturbances. For example, perturb the feed flow rate or
composition and study how flows and other process variables change to compensate for the disturbances. If small disturbance requires large changes
in flow rate or other manipulated variables to compensate for its efect, the control system must be redesigned.
Using steady state simulations, determine the ranges of acceptable disturbances, which can be taken care of while maintaining the production goals.
Use dynamic simulation to determine dynamic response of the designed system. Redesign as needed. For instance, redesign to eliminate inverse
response, if at all possible.
Use dynamic simulation to find the range of disturbances, which can be compensated for using the designed control system.
Use dynamic model to determine the range of stability of the closed-loop system when diferent model parameters change.
Use the remaining degrees of freedom (manipulated variables) for steady state optimization (maximize the profit, etc.) and/or to improve
controllability of the plant (disturbance rejection, flexibility in changing operation point or product mix, etc).
Approach to Optimizer
DoF Analysis for Optimizer
Levels are not important in Optimization
Constraint Analysis
Optimization Itself
4
1
2
GivenfeedrateF0and
columnpressure:
Nm=5
N0y=2Levels
DoF=Nss=52=3
Constraints:
Maximizereactorvolume(residence
timeandthusconversion)
Productspec:xB>0.98
Recycle process:
Selection of controlled variables
Step 3.1 J=V (minimize energy with
given feed)
Step 3.1 DOFs for optimization: Nss = 3
Step 3.3 Most important disturbance:
Feedrate F0
Step 3.4 Optimization: Constraints on
max. Mr and xB always active
Step 3.5 1 DOF left, candidate controlled
variables: F, D, L, xD, ...
Recycleprocess:Losswithconstantsetpoint,cs
Largelosswithc=F
Negligiblelosswithc=L/F
Activeconstraint
Mr=Mrmax
Activeconstraint
xB=xBmin=98%
2 Active Constraints for Optimization
Reactor Full
Min Composition Required
Recycle process:
Selection of controlled variables
Step 3.1 J=V (minimize energy with
given feed)
Step 3.1 DOFs for optimization: Nss = 3
Step 3.3 Most important disturbance:
Feedrate F0
Step 3.4 Optimization: Constraints on
max. Mr and xB always active
Step 3.5 1 DOF left, candidate controlled
variables: F, D, L, xD, ...
MAX
HW 5 Heat Integration
Cequipment
Cost of HX
E1+E2+E3
Tthres