CHAPTER VII

PROCESS CONTROL

7.1

Introduction

In recent year, the performance requirements for the process plants have become increasingly difficult to satisfy. Stronger competition, tougher environmental and safety regulations, and rapidly changing economic condition have been key factor in tightening of plant product quality specifications. A further complication is that modern processes have become more difficult to operate because of the trend toward larger, highly integrated plants with smaller surge capacities between the various processing units. Thus, process control has become increasingly important because without process control, it would not be possible to operate most modern processes safely and profitably while satisfying plant quality standards.

All processes are subject to disturbances that tend to change operating conditions, compositions, and physical properties of the streams. In order to minimize the effects that could result from such disturbances, our styrene plant is implemented with substantial amounts of instrumentation and automatic control equipment. The

227 instrumentation is computer monitored for convenience, safety and optimization. The primary objectives of the instrumentation and control schemes are:a) Safety of plant operation The safety of plant is key to keep the process variables within known safe operating limits. Other than this, it is use to detect dangerous situations as they develop and to provide alarms and automatic shutdown systems or interlocks system.

b) Production rate A plant should produce the desired amounts of the final products. Therefore, a control system is needed to ensure that the production level are satisfied. The purpose here is to achieve the desired product output at 100,000 MT styrene per year.

c) Product quality That is to maintain the product composition within the specified quality standard, which is 99.7%. The control system is designed to satisfied the purity specifications

d) Environment regulation. Various federal and state laws may specify that the temperature, concentration of chemicals and flow rate of the effluents from plant be within certain limits.

e) Operational constraints

228 The various types of equipments used in a chemical plant have constraints inherent to their operation. Such constraints should be satisfied throughout the operation of the plant. Control system are needed to satisfy all operational constraints.

f) Economic The operation of the plant must confirm to the market conditions, that is availability of raw material and the demand of the final product. All the requirement listed above dictate the need for continuous monitoring of the operation of a chemical plant and external intervention (control) to guarantee the satisfaction of the operational objectives. There are three general classes of need that a control system is called on to satisfy:

Suppressing the influence of external disturbances; Ensuring the stability of a chemical process; Optimising the performance of a chemical process.

7.2

Procedures for Control System Design

In developing a particular control scheme, control objectives are first defined. Then, critical controlled variables are identified, whereby measured variables, manipulated variables must be decided to conceptualize the control strategies. The following procedure is used to identify and locate the control instruments in the process: a) Identify and draw in those control loops that are obviously needed for steady plant operation, such as level control, flow control, pressure control, temperature control or composition control.

229 b) Identify the key process variables that to be controlled to achieve the specified product quality. Include controls loops using direct measurement of the controlled variable, where possible. c) Identify and include those additional control loops required for safe operation, not covered in steps 1 and 2. d) Decide and show those ancillary instruments needed for the monitoring of the plant operation by the operators and for trouble-shooting. Decide also on the alarms needed.

7.3

Control System Design for Individual Units

7.3.1

Reactor, R-5

The control system for the R-5 is designed to operate the reactor optimally and safely. The control objectives for the reactor are as follows: a) b) c) Control the feed to the reactor to maintain a constant flow rate. Control the temperature of the column to maintain it at desired level. Control the pressure of the column at a desired level.

230 Table 7.1: Control variables for Reactor, R-5 Control variable 1. Feed to the reactor (S15) 2. Reactor outlet pressure Measurable Variable Flow rate of S15 Outlet pressure Manipulated Variable Feed to the reactor, S15 Outlet flow rate Disturbances Temperat ure of the reactor Flow rate of S15 Flow rate of S10 Feed pressure Feed flow rate Feed temperature Feed flow rate Set Point 54198.7 kg/hr P = 1.15 bar
(If pressure exist 10% of set point, pressure alarm high/low will activated) (If temperature exist 10% of set point, temperature alarm high/low will activated)

3. Temperature of the reactor

T = 600 C

Alarm is set to ring when +10% (high alarm) or 10% (low alarm) exceeds the set point for all controllers.

231

H L

P IA

PIC

PT

S10

liquid sodium out

liquid sodium in
TT TIC T IA H L

FIC

FIA

H L

FT

S1 5

TITLE: CONTROL SYSTEM FOR REACTOR (R-5)

Fig. 7.1 : Process Control Diagram for Reactor, R-5

232 7.3.2 Flash Column, F-7

The control system for the flash column F-7 is designed to operate the column optimally and safely. The following are the control objective of a flash column: a) Control the feed to the flash to maintain a constant flow rate. b) Control the liquid level in the flash from flooding or from being too low. c) Control the pressure of the column at a desired level.

Table 7.2: Control Variable For Flash Column, F-7 Control Variable 1. Feed to flash 2. Liquid level in flash 3. Column top pressure Measured Variable Flow rate of stream S42 Level of liquid in the flash Pressure in the column Manipulated Variable Flow rate of S42 Flow rate of output liquid, S28 Column to pressure

Disturbances S19 flow rate S28 flow rate S42 flow rate S42 flow rate

Set point 54198.7 kg/hr Avoid flooding 1.15 bar

233
S19

FIC

FT

PT

PIC

S42
LT LIC LIA H L

S28

T IT LE : CO NT RO L SYSTE M FO R FLAS H, F-7

Fig 7.2 : Process Control Diagram for Flash, F-7

7.3.3

Mixer, M-1

234

The control objective of the mixer is: a) To mix the feed of fresh water and the recycle water. Table 7.3: Control Variable For Mixer, M-1 Control Variable 1. Feed to mixer, S2 Measured Variable Flow rate of the stream S2 Manipulated Variable Flow rate of S2 Disturbances S5 flow rate S33 flow rate Set point 54189.7 kg/hr

S2

FT

FIC

S5

S 33

T IT LE : CO NTRO L SYST EM FO R MIXER, M-1

Fig 7.3 : Process Control Diagram for Mixer, M-1 7.3.4 Mixer, M-3

235 The control objective of the mixer is: b) To have constant ratio feed of ethlybenzene to steam into the reactor. Table 7.4: Control Variable For Mixer, M-3 Control Variable 1. Feed to mixer, S9 Measured Variable Flow rate of the stream S9 Manipulated Variable Flow rate of S9

Disturbances S39 flow rate S7 flow rate

Set point 54198.7 kg/hr

S39

S7

S 14
FT FIC

S9

T IT LE : CONT ROL SYSTEM FO R MIXER, M-3

Fig. 7.4 : Process Control Diagram for Mixer, M-3 7.3.5 Distillation Column, T-9

236

The control system for this column is designed with following control objectives:a) Maintain a constant feed flow rate to the column. b) Control the liquid level in the column from flooding or from being too low. c) Control the temperature at a desirable level. d) Control the pressure of the column at a desired level. e) Control the liquid level in the reflux drum at a desired level. f) Control the liquid level in the reboiler at a desired level. g) Control the composition of the bottom stream at a desired level. h) Control the flow rate of bottom product at a desired level.

Table 7.5: Control System For Distillation Column, T-9 Control Variable 1. Liquid level in column Measured Variable Level of liquid in the column Manipulated Variable Flow rate of inlet stream of the column, S12 Disturbances Set point

2.

Temp. of top column

Temp. in the column

Flow rate of S34 by-pass

3. Column top pressure 4. Liquid level in reflux drum 5. Liquid level in kettle reboiler 6. Composi

Pressure in the top of the column Level of liquid in the reflux drum Level of liquid in the reboiler Comp. of

Flow rate of the overhead stream of the column Reflux flow rate

Avoid Flow rate of flooding bottom stream of the column Reflux flow rate S12 flow 108.75C (If temperature rate exist 10% of S12 set point, pressure temperature Tempera alarm high/low will activate) ture of S34 1.1 bar S12 pressure S12 flow rate Flow rate of S6 Flow rate of S36 Flow rate S13 Flow rate S20 Bottom Avoid flooding

Flow rate of S6

Avoid flooding

Flow rate of

64.67%

237 tion of bottom product the bottom product S20 by-pass product flow rate styrene

238

S34

H TIA L

T IC

TT

H PIA L

PIC

S40

PT

S36

S12

LIC

LT

H LIA L

LIC

LT

S20 kettle reboiller

LT

L IC

S13 S6
CC CT

CO NT RO L SYSTEM

TITLE : FOR DIST ILLATIO N CO LUMN, T -9

Fig. 7.5 : Process Control Diagram for distillation column, T-9

239 7.3.6 Distillation Column, T-10

The control objective for this column is same with distillation column T-9.

Table 7.6: Control System For Distillation Column, T-10 Control Variable 1. Liquid level in column Measured Variable Level of liquid in the column Manipulated Variable Flow rate of bottom stream of the column Disturbances Flow rate of inlet stream of the column, S6 Reflux flow rate S6 flow rate S6 pressure S40 temperature S6 pressure S6 flow rate Flow rate of S35 Flow rate of S8 Flow rate S18 Flow rate S20 Flow rate of bottom product Set point Avoid flooding

2.

Temp. of top column

Temp. in the column

Flow rate of S40 by-pass

139.33C
(If temperature exist 10% of set point, temperature alarm high/low will activate)

3. Column top pressure 4. Liquid level in reflux drum 5. Liquid level in kettle reboiler 6. Composi tion of bottom product

Pressure in the top of the column Level of liquid in the reflux drum

Flow rate of the overhead stream of the column Reflux flow rate

1.1 bar

Avoid flooding

Level of liquid in the reboiler Comp. of the bottom product

Flow rate of S35

Avoid flooding

Flow rate of S18 by-pass

99.7% styrene

240

S 40

H TIA L

T IC

TT

H PIA L

PIC

S7

PT

S8

S6

LIC

LT

LT

H LIA L

LIC

S 18 kettle reboiller

LT

LIC

S20 S 35
CC CT

CO NT RO L SYST EM

TIT LE : FO R DISTILLATION COLUMN, T -10

Fig. 7.6 : Process Control Diagram for distillation column, T-10

241 7.3.7 Heat Exchanger, X-1

The control system for heat exchanger, X-1 is designed to operate optimally and for safety purposes. The following are the control objectives for this heat exchanger:a) Control the temperature of the process stream at a desired level.

Table 7.7 : Control Variable for X-1 Control Measured Manipulated Variable Flow rate of S13 by-pass Flow rate of S5 by-pass Disturbances S13 Temperature S5 temp. Set point 64.14C 40.976C

Variable Variable 1. Temp. of Temperatur S34 e of the stream S34 2. Temp. of Temp. of S17 S17

242

T IA

H L

TIC

TT

S17

S5

H EAT EX C HA NGE R X -1

S 34

TT

TIC

T IA

H L

S13

CO NT RO L SYST EM FO R HEA T EXCHANG ER, X-1

Fig. 7.7 : Process Control Diagram for Heat Exchanger, X-1

243 7.3.8 Heat Exchanger, X-6

The control system for heat exchanger, X-6 is designed to operate optimally and for safety purposes. The following are the control objectives for this heat exchanger:a) Control the temperature of the process stream at a desired level.

Table 7.8: Control Variable for X-6 Control Variable 1. Temp. of the S16 2. Temp of S18 Measured Variable Temp.of S16 Temp. of S18 Manipulated Variable Flow rate of S10 bypass Flow rate of S14 bypass Disturbances Temp. of S10 Temp. of S14 Set point 545.56C

381.727C

244

S 10

T IA

H L

T IC

TT

S 14

HEAT E X C HA N G ER X -6

S 16

TIC

TT

S18

CO NT RO L SYST EM FO R HEAT EXCHAG ER, X-6

Fig. 7.8 : Process Control Diagram for heat exchanger, X-6

245 7.3.9 Heater, X-7

The control system for heater, X-7 is designed to operate optimally and for safety purposes. The following are the control objectives for this heat exchanger:a) b) Control the temperature of the process stream at a desired level. Control flow rates of process fluid into heat exchanger.

Table 7.9: Control Variable for X-7 Control Measured Manipulated Variable Sodium flow rate Disturbances S16 flow rate Set point 600.0C

Variable Variable 1. Temp. of Temperatur the e of the process stream S15 stream

246

Liquid Sodium In

T IC

TT

S 16

Heater X-7

S15

Liquid Sodium O ut

CO NT RO L SYST EM FO R HEAT ER, X-7

Fig. 7.9: Process Control Diagram for Heater, X-7

247 7.3.10 Cooler, X-8

The control system for cooler, X-8 is designed to operate optimally and for safety purposes. The following are the control objectives for this heat exchanger:a) Control the temperature of the process stream at a desired level.

Table 7.10: Control Variable for cooler, X-8 Control Measured Manipulated Variable Cooling water in Disturbances S17 flow rate Hot water out Set point 31.0C

Variable Variable 1. Temp. of Temperatur the S42 e of the stream S42

248

Cooling w ater In

T IC

TT

S17

cooler

X-8

S42

Hot W ater O ut

CO NTRO L SYST EM FO R CO O LER, X-8

Fig. 7.10 : Process Control Diagram for cooler, X-8

249 7.3.11 Decanter, S-8

The control system for decanter, S-8 is designed to ensure the operation run optimally and for safety purposes. The following are the control objectives for this heat exchanger:a) b) Control the composition of the bottom product at a desired level. Control flow rates of process fluid into heat exchanger. Table 7.11: Control Variable for Decanter, S-8 Control Variable 1. Level of fluid in the decanter 2. Flow rate of the fluid into the decanter Measured Variable Level of fluid in the decanter Manipulated Variable Level of fluid in the decanter Disturbances S28 flow rate S12 flow rate S12 flow rate S21 flow rate Set point Level between the heavy liquid and the light liquid 52426.8 kg/hr

Flow rate of S28

Flow rate of S28

250

S12

Decanter
LT

S28

LC

S21

CONTROL SYSTEM FOR DECANTER, S-8

Fig. 7.11 : Process Control Diagram for Decanter, S-8

251 Abbreviation:

PC

PRESSURE INDICATOR AND CONTROLLER

PT

PRESSURE DETECTOR

TT

TEMPERATURE TRAMSMITTER
TIC

TEMPERATURE INDICATOR AND CONTROLLER

TIA

TEMPERATURE INDICATOR AND ALARM

FIC

FLOW INDICATOR AND CONTROLLER

FIA

FLOW INDICATOR AND ALARM

FT

FLOW TRANSMITTER

ELECTRICAL LINES

PNEUMATICS LINES

VALVE

RELIEF VALVE

HEAT EXCHANGER

LT

LEVEL TRANSMITTER

LIC

LEVEL INDICATOR AND CONTROLLER

LIA

LEVEL INDICATOR AND ALARM

CT

COMPOSITION TRANSMITTER

CIC

COMPOSITION INDICATOR AND CONTROLLER