CONTROL PHILOSPHY

A Issued for Approval 22/03/2020 Muhammad Usman

Client
Rev Description Date Prepared by
Approval

CONTROL PHILOSPHY

FOR

PROCESS AND INSTRUMENTATION DIAGRAM

ISSUED FOR
APPROVAL
Mar 22, 2020

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CONTROL PHILOSPHY

Process Control System Hardware

According to Stephanopoulos (1984), the hardware elements that can be established in control
configuration include:

i. Chemical Process:

It indicates the material equipment together with the physical or chemical operations that occur there.

ii. Sensor:

These type of measuring instruments are usually used for the measurement of the disturbances, the
controlled output variables, or secondary output variables. It represents the behavior of the process. For
instance, thermocouple, venture meter and gas chromatographs.

iii. Transducer:

It used to convert measurement to physical quantities (such as electrical voltage or pneumatic signal)
which can be transmitted easily

iv. Transmission line:

The line is used to carry the measurement signal from the measuring device to the controller.
Sometimes it is equipped with amplifier due to weak signal coming from a far measuring device.

v. Controller:

It is usually a hardware element of an instrument which has “intelligence” features. It accepts the facts
and decides what action should be taken.

vi. Final Control Element:

It implements in real life the decision taken by the controller. For example control valve.

vii. Recording Elements:

They are used to provide a visual demonstration of how a chemical process behaves.

7.1.7 Valve Selection

Valves used in chemical plants can be divided into two categories depending on their function:

1. Shut off valves – The main purpose of shut off valves is to close off the flow.
2. Control valves – They can be either automatic or manual and their objective is used to regulate
the flow.

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CONTROL PHILOSPHY

Control Valves

Selection of control valves is an important factor. It is important that good flow control is achieved
whilst the pressure drop is kept low as possible. Control valves may fail open this is the position the
valves take when power supply failure occurs. Diaphragm valves are commonly used and this is the type
used in this case. This type of valve can be seen from figure 51 below.

Instruments and Controllers

There are various locations of instruments in a chemical plant, for example local, mounted on a central
control panel. Within the P&ID there are many different shapes on instruments which are used. A circle
symbol represents a device which is field mounted. A circle which has a line through the middle
indicates a device which can be easily accessible by the operators.

Figure xx: Diagram to show Instrument type and location

Control Schemes
Feed Backward Control Loop
A feedback system measures a value in a process and reacts to the change in the value measured.

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CONTROL PHILOSPHY

The output of the process is measured with the help of a sensor and the sensor value is given to the
controller to take a proper controlling action. A controller compares this sensor signal with a set point
and generates a control signal. Actuators are the controlling devices used in a process so that the
controller output is the actuator input signal. Actuators effect the plant directly by varying the
manipulating variable. Controller action will be zero until the process variable meets setpoint.

In a feedback control system controller takes control action only after the process variables and
disturbance effects the process and the control action is also given to the process directly, which is
different in feedforward control.

Feedforward control system:

A feedforward controller avoids the slowness of the feedback control.

Using feedforward control the performance of control systems can be enhanced greatly.

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CONTROL PHILOSPHY

Process variables such as pressure, level, flow, temperature are interrelated and so one variable may
affect another as a disturbance in the process. Feedforward system measure important disturbance
variables and take corrective action before they upset the process.

Here the setpoint is fixed in the feedforward controller after doing little complex mathematical
derivations. The feedforward controller determines the needed change in the manipulated variable, so
that, when the effect of the disturbance is combined with the effect of the change in the manipulated
variable, there will be no change in the controlled variable at all. The disturbance is measured at the
input side of the process and the manipulating variable also, so the controlling process is done before a
disturbance affects the process.

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CONTROL PHILOSPHY

Control Scheme on Scrubber

The major control loop on the scrubber vessel is level control and temperature control.

Level Control

It’s the feedback control scheme As the level is increase and decreases from the set point the controller
take action and adjust the final control element (Control Valve). So that the desired level is remain in the
vessel.

Note: Typical Level control scheme on other vessels as well.

Temperature Control:

It’s a feedback control scheme, TI is the Temperature indicator and transmitter which send signal to the
controller. The controller create error by subtracting set point and current value and this error is used to
adjust the final control element (temperature Control Valve). Suppose if the temperature of stream
decreases then the control valve will open and send more steam flow so that it increase its temperature
to desirable set point.

Note: Typical Temperature scheme on other vessels as well

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Control Scheme on Reactor

Inlet Stream Flow control:

It’s the Feed forward control loop, FI detect the flow before disturbance and control it by final control
element which is flow control valve. Flow indicator send the electric signal to the controller and then
controller send the pneumatic signal to control valve.

Two Gate valves is used to isolate the control valve in case of Failure and by pass the flow with globe
valve.

Temperature Control:

It’s a feedforward control scheme, TI is the Temperature indicator and transmitter which send signal to
the controller. The controller create error by subtracting set point and current value and this error is
used to adjust the final control element (temperature Control Valve). Suppose if the temperature of
stream decreases then the control valve will open and send more steam flow so that it increases its
temperature to desirable set point. It take action before its disturb the system.

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Motor Control

Symbols:

XI is the only indication of motor running and stop condition on Digital Control System (DCS).

Variable frequency drive to adjust the RPM of the motor

These are the field mounted hand switches which is used to start and stop the motor from the filed or in
other words it’s a local access to operator on filed.

This is the start and stop command on the DCS System

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