Chemical Engineering 3P04 Process Control

Tutorial # 2
Learning goals
1. The feedback cause-effect principle

2. Key element in the loop: The control valve

WHAT DOES A FEEDBACK SYSTEM DO?

Desired value

CONTROLLER FINAL ELEMENT PROCESS Inputs Outputs

SENSOR

CONTROL (verb): To maintain desired conditions in a physical system by adjusting selected variables in the system.
FEEDBACK CONTROL makes use of an output of a system to influence an input to the same system. input = cause output = effect

2. The key elements and principles of a feedback loop Cause and Effect
Exercise: The key elements and principles of a feedback loop

What is being measured?

Is this a valid feedback control loop?

FC

cooling

2. The key elements and principles of a feedback loop Cause and Effect
Exercise: The key elements and principles of a feedback loop

What is being measured?

Is this a valid feedback control loop?

FC

cooling

2. The key elements and principles of a feedback loop Cause and Effect
Exercise: The key elements and principles of a feedback loop

What is being measured?

Is this a valid feedback control loop?
sensor valve pump

pump

valve

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop What is being measured? Is this a valid feedback control loop?
sensor

valve pump

pump

valve

2. The key elements and principles of a feedback loop Cause and Effect
Exercise: You want to control the level, but you can only measure the flow in. What is your strategy? Are you using feedback?
sensor

valve pump

pump

valve

2. The key elements and principles of a feedback loop Cause and Effect
Exercise: The key elements and principles of a feedback loop

What is being measured?

Is this a valid feedback control loop?
P

Gas stream

Gas stream

Empty vessel

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop

What is being measured?

Is this a valid feedback control loop?

v8
F2 F1 T1 T3

v3
T4

F5 T5 F3 L1 T6 F4 P1

v1 v2
T2

v5 v7
T8 T9

v6

T7

L2

Hot Oil

Hot Oil v4

F6

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop

What is being measured?

Is this a valid feedback control loop?
v8
F2 F1 T1 T3

v3
T4

F5 T5 F3 L1 T6 F4 P1

v1 v2
T2

v5 v7
T8 T9

v6

T7

L2

Hot Oil

Hot Oil v4

F6

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop
Hot process fluid into shell Cooling water into tubes

We want to control the hot outlet temperature.

Add a sensor and a valve to make this possible.

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop
Hot process fluid into shell

Cooling water into tubes

We want to control the hot outlet temperature.

TC

Add a sensor and a valve to make this possible.

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop
We want to control the hot temperature here.
Hot process fluid into shell
Cooling water into tubes

Add a sensor and a valve to make this possible.

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop
Hot process fluid into shell

We want to control the hot temperature here. T

Cooling water into tubes

We can measure this temperature, but the heat exchanger does not influence it. We cannot control the temperature using the flows in this figure! (We can look upstream to see if/how it can be controlled.)

Add a sensor and a valve to make this possible.

2. The key elements and principles of a feedback loop Cause and Effect Exercise: Typical disturbances Disturbances affect the important (controlled) variable, but we cannot influence disturbances
Identify disturbances that will affect the reactor temperature, T5
v8
F2 F1 T1 T3

v3
T4

F5 T5 F3 L1 T6 F4 P1

v1 v2
T2

v5 v7
T8 T9

v6

T7

L2

Hot Oil

Hot Oil v4

F6

2. The key elements and principles of a feedback loop Cause and Effect Exercise: The key elements and principles of a feedback loop

Now you can be original.

1. 2. 3. 4. sketch a process system that you have studied in your engineering courses, place a sensor and valve, and determine whether the sensor measurement can be controlled in feedback by adjusting the valve. Identify several disturbances that affect the controlled variable

Valves: How do we affect fluid flow? This control system requires a flow measurement, and we understand sensors well already. We also need equipment that we can adjust to achieve a desired flow rate.

Centrifugal pump (not positive displacement)

FC

The most common adjustable variable for the process industries is a valve. The valve provides an adjustable resistance to flow through the pipe.

cooling

Valves: How do we affect fluid flow? This control system requires a flow measurement, and we understand sensors well already. We need equipment that we can adjust to achieve a desired flow rate.

Other possibilities for affecting flow rate.

Variable speed centrifugal pump (lower energy that pump-valve) Variable speed positive displacement pump.
cooling

Valves: What types of fluids do we regulate with valves?

CO2, N2, H20 + little catalyst
Reacts (cracks) petroleum to more valuable products; by-product is carbon on catalyst

FCC
Fluid Catalytic Cracker
Burns carbon to regenerate catalyst
regenerator

riser

Hot oil

air Catalyst & steam

Feed oil

Other fluids: water, nitrogen, tree pulp and water, blood,

sewage, food products (yogurt), highly pure pharma products, hazards (isocyanates) and just about anything else that flows!

Adjusting valves: Do you believe in automation?

Do we run around the plant to adjust the valves when required?

Process pictures courtesy of Petro-Canada Products

Adjusting valves: Do you believe in automation?

Central control room

Overview of entire process Make immediate adjustment anywhere Safe location

History of past operation

Process pictures courtesy of Petro-Canada Products

Valves: How to we actuate or open and close valves?

Name Block Table 3.1.1. Most common applications of valves in the process industries. Symbol Power Typical process application Manual These valves are usually fully opened or closed, (by person) although they can be used to regulate flow over short periods with a person by the valve. Self-actuated (the difference between process and external pressures results in opening when appropriate) Electric motor
(fully open or closed)

Safety Relief

These are located where a high (low) pressure in a closed process vessel or pipe could lead to an explosion (implosion).

On-off

Throttling control

Usually pneumatic pressure

These valves are normally used for isolating process equipment by ensuring that flows are not possible. They can be operated by a person in a centralized control room, who can respond quickly regardless of the distance to the valve. These valves are typically used for process control, where the desired flow rate is attained by changing the opening of the valve.

We will concentrate on control valves used to modulate the flow, i.e., achieve value of flow between maximum (fully opened) and minimum (fully closed)

Valves: What are the two main features? Sampson Valves

The actuator provides the ability to change the flow resistance, i.e., the size of the opening for flow. The most common actuator is a pneumatic diaphragm. The body of the valve defines the flow path and is selected to achieve the desired fluid flow behavior.

Valves: What are important features for process control? Capacity Range Failure position Gain Pressure drop Precision Linearity Consistency with process environment Dynamics Cost

These are explained in the pc-education site. Most engineers select valves, do not design them.

Valves: What are important features for process control? Capacity =

Range =

Pressure drop =

Valves: What are important features for process control? Capacity = The maximum flow rate through the flow system (pipes, valves, and process equipment) must meet operating requirements.

Range = The range indicates the extent of flow values that the valve can reliably regulate; very small and large flows cannot be maintained at desired values. Range is reported as ratio of largest to smallest.
Pressure drop = The purpose of the valve is to create a variable pressure drop in the flow system. However, a large (non-recoverable) pressure drop wastes energy.

Valve Actuator: Why is the failure position important? The failure position is the position of the valve plug when the air pressure is zero (atmospheric). This is typically either (fully) open or (fully) closed.
What are the best failure positions? Vapor product

best = safest
T5

T6

P1

v5

v3

Feed

T1

T2

P 1000 kPa T 298 K

Methane Ethane (LK) F1 Propane Butane Pentane F2

T4

T3

L1

v1
F3

v2 v4
A1 L. Key Liquid product

Process fluid

Steam

Valve Actuator: Why is the failure position important? The failure position is the position of the valve plug when the air pressure is zero (atmospheric). This is typically either (fully) open or (fully) closed.
fo
What are the best failure positions? T6 P1 Vapor product

best = safest
T5

v5

v3

Feed

T1

T2

Methane Ethane (LK) F1 Propane Butane fc Pentane F2

Must consider upstream and downstream processes L1

T4

T3

fc
v1
F3 A1 Steam

v2 v4
L. Key Liquid product

Process fluid

Valve Body: We match the valve body to the fluid type and process needs?

http://www.tycoflowcontrol-pc.com/products_results.asp?Selection=Double+Flanged+Butterfly+Valve&m=1

Fluids: water, nitrogen, tree pulp and water, blood, sewage, food products (yogurt), highly pure pharma products, hazards (isocyanates), polymer melts, and just about anything else that flows!

http://images.google.ca/imgres?imgurl=http://www.ckit.co.za/Secure/Catalogues/mac%2520steel/fluid%2520control/MS%2520image%2520 24%25202520thumb.jpg&imgrefurl=http://www.ckit.co.za/Secure/Catalogues/Mac%2520steel/Fluid%2520control/MS%2520fluid%2520control.htm &h=150&w=113&sz=5&hl=en&start=83&tbnid=3ZKYixrpLJ5wTM:&tbnh=96&tbnw=72&prev=/images%3Fq%3Dball%2Bvalves,%2Bpr ocess%2Bcontrol%26start%3D80%26ndsp%3D20%26svnum%3D10%26hl%3Den%26sa%3DN

Valve Body: We match the valve body to the fluid type and process needs?

http://www.tycoflowcontrol-pc.com/products_results.asp?Selection=Double+Flanged+Butterfly+Valve&m=1

Question: Would a globe valve be a good choice for affecting yogurt flow?

Answer: No! The globe valve has many small dead ends where food could collect and not be removed by cleaning fluid.
http://images.google.ca/imgres?imgurl=http://www.ckit.co.za/Secure/Catalogues/mac%2520steel/fluid%2520control/MS%2520image%2520 24%25202520thumb.jpg&imgrefurl=http://www.ckit.co.za/Secure/Catalogues/Mac%2520steel/Fluid%2520control/MS%2520fluid%2520control.htm &h=150&w=113&sz=5&hl=en&start=83&tbnid=3ZKYixrpLJ5wTM:&tbnh=96&tbnw=72&prev=/images%3Fq%3Dball%2Bvalves,%2Bpr ocess%2Bcontrol%26start%3D80%26ndsp%3D20%26svnum%3D10%26hl%3Den%26sa%3DN

Valve Body: We match the valve body to the fluid type and process needs?

http://www.tycoflowcontrol-pc.com/products_results.asp?Selection=Double+Flanged+Butterfly+Valve&m=1

Question: Would a butterfly valve be a good choice when tight closing is required?

Answer: No! The manufacturing would almost never provide a perfect fit.
http://images.google.ca/imgres?imgurl=http://www.ckit.co.za/Secure/Catalogues/mac%2520steel/fluid%2520control/MS%2520image%2520 24%25202520thumb.jpg&imgrefurl=http://www.ckit.co.za/Secure/Catalogues/Mac%2520steel/Fluid%2520control/MS%2520fluid%2520control.htm &h=150&w=113&sz=5&hl=en&start=83&tbnid=3ZKYixrpLJ5wTM:&tbnh=96&tbnw=72&prev=/images%3Fq%3Dball%2Bvalves,%2Bpr ocess%2Bcontrol%26start%3D80%26ndsp%3D20%26svnum%3D10%26hl%3Den%26sa%3DN

Valve Body: We match the valve body to the fluid type and process needs?

http://www.tycoflowcontrol-pc.com/products_results.asp?Selection=Double+Flanged+Butterfly+Valve&m=1

Question: Would a ball valve be a good choice for low non-recoverable pressure drop?

Answer: No! The flow follows a tortuous path and experiences extreme turbulence.
http://images.google.ca/imgres?imgurl=http://www.ckit.co.za/Secure/Catalogues/mac%2520steel/fluid%2520control/MS%2520image%2520 24%25202520thumb.jpg&imgrefurl=http://www.ckit.co.za/Secure/Catalogues/Mac%2520steel/Fluid%2520control/MS%2520fluid%2520control.htm &h=150&w=113&sz=5&hl=en&start=83&tbnid=3ZKYixrpLJ5wTM:&tbnh=96&tbnw=72&prev=/images%3Fq%3Dball%2Bvalves,%2Bpr ocess%2Bcontrol%26start%3D80%26ndsp%3D20%26svnum%3D10%26hl%3Den%26sa%3DN

Valve Body: We match the valve body to the fluid type and process needs?

http://www.tycoflowcontrol-pc.com/products_results.asp?Selection=Double+Flanged+Butterfly+Valve&m=1

Typical purchase cost ~ $2000-3000 for a 4pipe globe or ball valve with actuator (installation extra)
http://images.google.ca/imgres?imgurl=http://www.ckit.co.za/Secure/Catalogues/mac%2520steel/fluid%2520control/MS%2520image%2520 24%25202520thumb.jpg&imgrefurl=http://www.ckit.co.za/Secure/Catalogues/Mac%2520steel/Fluid%2520control/MS%2520fluid%2520control.htm &h=150&w=113&sz=5&hl=en&start=83&tbnid=3ZKYixrpLJ5wTM:&tbnh=96&tbnw=72&prev=/images%3Fq%3Dball%2Bvalves,%2Bpr ocess%2Bcontrol%26start%3D80%26ndsp%3D20%26svnum%3D10%26hl%3Den%26sa%3DN