Chapter # 10

INSTRUMENTATION AND CONTROL

10.1 Instrumentation
Instrumentation is the basis for process control in industry. However, it comes in
many sensed simultaneously. All of these can be interdependent variables in a
single process requiring complex microprocessor systems for total control. Due to
the rapid advances in technology, instruments in use today may be obsolete
tomorrow, as new and more efficient measurement techniques are constantly being
introduced. These changes are being driven by the need for higher accuracy,
quality, precision, and performance. To measure parameters accurately, techniques
have been developed that were thought impossible only a few years ago. In the
coming paragraphs a brief description about the instruments selection, installation
and calibration is given.forms from domestic water heaters and HVAC, where the
variable temperature is measured and used to control gas, oil, or electricity flow to
the water heater, or heating system, or electricity to the compressor for
refrigeration, to complex industrial process control applications such as used in the
petroleum or chemical industry.

10.2 Introduction to Distillation Control

All distillation columns have to be carefully operated in order to achieve the
required production rates and product quality. The 3 main objectives of column
control can be stated as:

 To set stable conditions for column operation

  To regulate conditions in the column so that the product(s) always meet the
required specifications

 To achieve the above objective most efficiently, e.g. by maximizing product

yield, minimizing energy consumption, etc

Process variables like temperatures, pressures, flow rates, levels and compositions
must be monitored and controlled in all distillation processes. These process
variables within a distillation system affect one another, whereby a change in one
process variable will result in changes in other process variables. Thus, in column
control one should be looking at the whole column and not focusing on any
particular sections only.

Each column has a control system that consists of several control loops. The loops
adjust process variables as needed to compensate for changes due to disturbances
during plant operation. Each of the process variables has its own control loop,
which typically consists of a sensor and transmitter, controller and control valve.
See the Figure below. Each control loop keeps track of the associated process
variable. An adjustment is made to a process variable by varying the opening of its
control valve. The stream flow rate is therefore adjusted and a desirable variable is
being controlled.
The sensor measures the process variable from the plant (i.e. plant data) and the
transmitter sends the information to the DCS (Distributed Control System)
controller located in the control room. The controller checks if the process variable
agrees with the set point. If not, it will send corrective signal to the control valve
that will make adjustment in the plant so as to match the process variable to the set
point. This goes on continuously, essentially in a loop - hence the term "control
loop".
There are several control loops associated with the distillation
column:

A:-Temperature:

1. Overhead condensation (Fin-fan)

2. Overhead column (Reflux)
3. Feed preheat
4. Column bottom (Reboiler steam)
Temperature Measuring Instruments

Application Considerations

Selection
In process control a wide selection of temperature sensors are available.
However, the required range, linearity, and accuracy can limit the selection. In the
final selection of a sensor, other factors may have to be taken into consideration,
such as remote indication, error correction, calibration, vibration sensitivity, size,
response time, longevity, maintenance requirements, and cost. The choice of
sensor devices in instrumentation should not be degraded from a cost standpoint.
Process control is only as good as the monitoring elements.

Range and Accuracy

Table gives the temperature ranges and accuracies of temperature sensors.
The accuracies shown are with minimal calibration or error correction. The ranges
in some cases can be extended with the use of new materials.

Table : Temperature Range and Accuracy of Temperature Sensors

Sensor Type Range ( ο C ) Accuracy (FSD)

Expansion Mercury in glass -35 to 430 ±1%

Liquid in glass -180 to 500 ±1%
Bimetallic -180 to 600 ±20%
Pressure–spring Liquid filled -180 to 550 ±0.5%
Vapor pressure -180 to 550 ±2.0%
Gas filled -180 to 550 ±0.5%

Resistance Metal resistors -200 to 800 ±5%

Platinum −180 to 650 ±0.5%
Nickel −180 to 320 ±1%
Copper -180 to 320 ±0.2%
 Thermistor 0 to 500 ±25%

Thermocouple -60 to 540 ±1%

-180 to 2500 ±10%
Semiconductor -40 to 150 ±1%
IC

Installation
Care must be taken in locating the sensing portion of the temperature sensor,
it should be fully encompassed by the medium whose temperature is being
measured, and not be in contact with the walls of the container. The sensor should
be screened from reflected heat and radiant heat if necessary. The sensor should
also be placed downstream from the fluids being mixed, to ensure that the
temperature has stabilized, but as close as possible to the point of mixing, to give
as fast as possible temperature measurement for good control. A low thermal time
constant in the sensor is necessary for a quick response. Compensation and
calibration may be necessary when using pressure-spring devices with long tubes
especially when accurate readings are required.

Calibration
Temperature calibration can be performed on most temperature sensing
devices by immersing them in known temperature standards which are the
equilibrium points of solid/liquid or liquid/gas mixtures, which is also known as
the triple point. Most temperature sensing devices are rugged and reliable, but can
go out of calibration due to leakage during use or contamination during
manufacture and should therefore be checked on a regular basis.
Protection
In some applications, temperature sensing devices are placed in wells or
enclosures to prevent mechanical damage or for ease of replacement. This kind of
protection can greatly increase the system response time, which in some
circumstances may be unacceptable. Sensors may need also to be protected from
over temperature, so that a second more rugged device may be needed to protect
the main sensing device. Semiconductor devices may have built in over
temperature protection. A fail-safe mechanism may also be incorporated for system
shutdown, when processing volatile or corrosive materials.

B:-Level:

1. Overhead accumulator (Distillate product)

2. Column bottom (Bottoms product)

Flow Measuring Devices

Application Considerations
Many different types of sensors can be used for flow measurements. The
choice of any particular device for a specific application depends on a number of
factors such as- reliability, cost, accuracy, pressure range, temperature, wear and
erosion, energy loss, ease of replacement, particulates, viscosity, and so forth.

Selection
The selection of a flow meter for a specific application to a large extent will
depend on the required accuracy and the presence of particulates, although the
required accuracy is sometimes down graded because of cost. One of the most
accurate meters is the magnetic flow meter which can be accurate to 1 percent of
full scale reading or deflection (FSD). The meter is good for low flow rates, with
high viscosities and has low energy loss, but is expensive and requires a
conductive fluid.

The turbine gives high accuracies and can be used when there is vapor
present, but the turbine is better with clean low viscosity fluids. Table 8.3 gives a
comparison of flow meter characteristics.

The general purpose and most commonly used devices are the pressure
differential sensors used with pipe constrictions. These devices will give accuracies
in the 3 percent range when used with solid state pressure sensors which convert
the readings directly into electrical units or the rotameter for direct visual reading.

The Venturi tube has the highest accuracy and least energy loss followed by
the flow nozzle and the orifice plate. For cost effectiveness the devices are in the
reverse order. If large amounts of particulates are present, the Venture tube is
preferred. The differential pressure devices operate best between 30 and 100
percent of the flow range. The elbow should also be considered in these
applications. Gas flow can be best measured with an anemometer. Solid-state
anemometers are now available with good accuracy, are very small in size, and are
cost effective.

For open channel applications the flume is the most accurate and best if
particulates are present, but is the most expensive. Particular attention should also
be given to manufacturer’s specifications and application notes.
Installation
Because of the turbulence generated by any type of obstruction in an
otherwise smooth pipe, attention has to be given to the placement of flow sensors.
The position of the pressure taps can be critical for accurate measurements. The
manufacturer’s recommendations should be followed during installation. In
differential pressure sensing devices the upstream tap should be one to three pipe
diameters from the plate or constriction and the down stream tap up to eight pipe
diameters from the constriction.

To minimize the pressure fluctuations at the sensor, it is desirable to have a straight

run of 10 to15 pipe diameters on either side of the sensing device. It may also be
necessary to incorporate laminar flow planes into the pipe to minimize flow
disturbances and dampening devices to reduce flow fluctuations to an absolute
minimum.

Flow nozzles may require a vertical installation if gases or particulates are

present. To allow gases to pass through the nozzle, it should be facing upwards and
for particulates, downwards.

Calibration

Flow meters need periodic calibration. This can be done by using another
calibrated meter as a reference or by using a known flow rate. Accuracy can vary
over the range of the instrument and with temperature and specific weight changes
in the fluid, which may all have to be taken into account. Thus, the meter should be
calibrated over temperature as well as range, so that the appropriate corrections can
be made to the readings. A spot check of the readings should be made periodically
to check for instrument drift that may be caused by the instrument going out of
calibration, particulate build up, or erosion.
 Summary of Flow Meter Characteristics
Meter Type Range Accuracy Comments
Percent
Orifice plate 3 to 1 ± 3 FSD Low cost and
accuracy
Venturi tube 3 to 1 ± 1 FSD High cost, good
accuracy, low
losses
Flow nozzle 3 to 1 ± 2 FSD Medium cost,
accuracy
Dall tube 3 to 1 ± 2 FSD Medium cost,
accuracy, low
losses
Elbow 3 to 1 ± 6 −10 FSD Low cost, losses,
sensitivity
Pilot static tube 3 to 1 ± 4 FSD Low sensitivity

Rotameter 10 to 1 ± 2 of rate Low losses, line

of sight
Turbine meter 10 to 1 ± 2 FSD High accuracy,
low losses
Moving vane 5 to 1 ± 10 FSD Low cost, low
accuracy
Electromagnetic 30 to 1 ± 0.5 of rate Conductive fluid,
low losses, high
cost
Vortex meter 20 to 1 ± 0.5 of rate Poor at low flow
rates
Strain gauge 3 to 1 ± 2 FSD Low cost,
accuracy
Nutating disc 5 to 1 ± 3 FSD High accuracy,
cost
Anemometer 100 to 1 ± 2 of rate Low losses, fast
response

Distillation Control Philosophy

Some of the general guidelines are noted below:

 Column pressure normally controlled at a constant value

 Feed flow rate often set by the level controller on a preceding column
 Feed flow rate is independently controlled if fed from storage tank
 Feed temperature controlled by a feed preheater. Prior to preheater, feed may
be heated by bottom product via feed/bottom exchanger
 Top temperature usually controlled by varying the reflux
 Bottom temperature controlled by varying the steam to reboiler

Control Scheme:
REFERENCE:-
www.separationprocesses.com , chap-2