Virtual Unit Operations

pH Control
Lesson #6: “Comparing Three Control Techniques”
In this lesson trainees will run a brief introduction experiment. Then trainees will run three separate
experiments where various control techniques for the pH Control unit will be explored. Trainees will
have the same bottoms pH stream specifications in each of the three experiments. In the first
experiment trainees will try to reach this goal by adjusting acid and alkali control valves in the Outside
Operator. In the second experiments trainees will control the Setpoints of the acid and alkali flow
controllers. In the third experiment the “design” process control will be engaged, and trainees will
simply adjust process feed flow and collect data on the control performance.

A. Introduction to New Process Specifications

1. In the following 3 experiments (Sections B, C, and D) there is a new process

specification for the pH Control process. The new target process feed flow and
bottoms flow have the following specifications:
i. Process feed flow (FIC-101): 25.71 m3/h (gradual increase)
ii. Bottoms outlet pH (AG-106): 7.0pH (to be maintained the entire run)
2. The process feed flow controller Setpoint (FIC-101) is to be steadily increased
while maintaining the bottoms pH (AG-106) as close to the design specification
(7.0 pH) as possible. It is of great importance to the downstream unit that AG-
106 is maintained at the desired 7.0 pH.
3. Launch the pH Control simulator. You will have to load in an Exercise before
beginning this procedure. Ensure that the simulator is in “Freeze” at time
“00:00:00F”.
4. Load in the “Acid and Base Flow in Manual” Exercise from the “Unique ICs”
Volume. Ensure the controllers listed below are in the following state:
i. Process feed flow controller, FIC-101: Automatic Mode
ii. Acid flow controller, FIC-102: Manual Mode
iii. Alkali flow controller, FIC-103: Manual Mode
iv. Bottoms pH controller, AIC-106: Manual Mode
v. Tank Level / Bottoms Flow, LIC-104 / FIC-105: Automatic / Cascade
5. In this state the process feed flow is controlled by adjusting the Setpoint of FIC-
101. Acid and alkali flows are controlled manually with the control valves in the
field, and the bottoms level / bottoms product cascade loop is engaged (the
trainee does not have to maintain level manually).
6. In this first simulator run you will adjust the process feed via the FIC-101
controller from the DCS. The acid and alkali flows will be adjusted with the flow
control valves in the Outside Operator.

pHControlLsn6_ComparingControlTechniques ©PetroSkills – Simulation Solutions

 7. Click “run” on your simulator and allow the system to run for 2 minutes before
making any adjustments.
8. Check the readings on the following Outside Operator gauges: FG-102, FG-103,
FG-105 and AG-106. If you have trouble reading the Outside Operator gauges
you can cross check with an associated DCS instrument.
9. Before adjustments are made take note of the steady-state readings of the
instruments in Table 6A and complete the “Initial Steady State Reading” column.
10. Access process feed flow controller FIC-101 faceplate. Adjust the Setpoint from
22.71 m3/h to 23.71 m3/h.
11. After increasing the process feed flow, complete the remainder of Table 6A with
the current readings of the associated gauges. Allow the system to reach a new
steady-state.
Table 6A

Instrument Tagname Initial Steady State Reading after FIC-101 is

Reading increased to 23.71 m3/h
Process feed flow Setpoint, FIC-101
Acid feed flow, FG-102
Alkali feed flow, FG-103
Bottoms feed flow, FG-105
Bottoms pH, AG-106

12. After taking the readings and seeing the pH Control unit dynamically respond
exit out of the simulator. There is no need to save this introduction simulator
run.
13. NOTE: The tank level / bottoms flow (LIC-104/FIC-105) control loop is very slow
responding. As you go through your next three runs it is okay to end the run if
the level controller and bottoms flow are still cycling. You can consider this an
acceptable process fluctuation. If you have the time, feel free to extend your
runs so that all process variables stabilize including these two controllers, but be
aware you may have to go through each run for 30-45 minutes.

(Section B on next page)

B. Acid and Alkali Flows Controlled in Outside Operator

pHControlLsn6_ComparingControlTechniques ©PetroSkills – Simulation Solutions

 1. Reset the simulator to the “Design IC”. Ensure that the simulator is in “Freeze” at
time “00:00:00F”.
2. After resetting to “Design IC”, load in the same “Acid and Base Flow in Manual”
Exercise from the “Unique ICs” Volume.
3. Create a plan to steadily increase FIC-101 Setpoint over the course of 15 minutes
of simulator time from 22.71 m3/h to 25.71 m3/h. Account for running the
simulator for one minute without making any adjustments so that you have
steady-state data to compare against.
4. In addition to increasing FIC-101 from the DCS it will be up to the trainee to
manually adjust acid and/or alkali flow control valves FCV-102 and/or FCV-103 to
maintain the bottoms pH close to 7.0 pH. Based on your data in Section A decide
which of these flow valves you want to adjust in the Outside Operator as you
increase process feed.
5. Fill out Table 6B below tracking the flows and bottoms pH as you adjust FIC-101
Setpoint as well as FCV-102 and/or FCV-103 in the Outside Operator. It is
important to take a reading once every two minutes because you will trend this
data later.
6. Remember: Use the DCS for adjusting process feed flow and use the Outside
Operator to adjust alkali and/or acid flows.
7. Click “run” on the simulator, allow the process to run for at least 1 minute, and
then begin adjusting the process feed flow (DCS) and alkali and/or acid flows
(Outside Operator). Remember your goal:
i. Process feed flow Setpoint (FIC-101): 25.71 m3/h (by the end of the run)
ii. Bottoms pH (AG-106): 7.0 pH (to be maintained the entire run)
8. Ensure that you have reached a process feed flow Setpoint (FIC-101) within 15
minutes. Allow your simulator to run for at least an additional 5 minutes to make
final adjustments to FCV-102 or FCV-103. Read Section A: Step 13 “note”
regarding the level controller fluctuating.
9. After the 20 minute simulator run pause your simulator. Ensure you have Table
6B filled out.
10. Feel free to save your event log file after the 20 minute simulator run for further
analysis if you have permissions to save files on your simulator program. If you
are unsure how to do this refer to the tutorial on exporting data in the eLearning
environment.

Table 6B

pHControlLsn6_ComparingControlTechniques ©PetroSkills – Simulation Solutions

 Time FIC-101 S.P. FG-102 FG-103 FG-105 AG-106
(m3/h) (lpm) (lpm) (m3/h) (pH)
00:00 22.71 0.00 0.38 22.74 7.0
02:00
04:00
06:00
08:00
10:00
12:00
14:00
16:00
18:00
20:00

C. Acid and Alkali Flow Controllers in Local Auto

1. Re-launch the pH Control simulator. Ensure that the simulator is in “Freeze” at

time “00:00:00F”.
2. After resetting to “Design IC”, load in “Acid and Base Flow in Local Auto”
Exercise from the “Unique ICs” Volume. You will now see that FIC-102 and FIC-
103 are set to Automatic and you can adjust these flow rates from the DCS.
3. Create a plan to steadily increase FIC-101 Setpoint over the course of 15 minutes
of simulator time from 22.71 m3/h to 25.71 m3/h. Account for running the
simulator for one minute without making any adjustments so that you have
steady-state data to compare against.
4. In addition to increasing FIC-101 from the DCS it will be up to the trainee to
adjust the acid and/or alkali flow controller Setpoints to maintain the bottoms
pH close to 7.0 pH. Based on your data in Sections A and B, decide which of these
flow controllers you want to adjust from the DCS as you increase process feed.
5. Fill out Table 6C below tracking the flows and bottoms pH as you adjust FIC-101
Setpoint as well as FIC-102 and/or FIC-103 Setpoints from the DCS. It is
important to take a reading once every two minutes because you will trend this
data later.
6. Remember: Use the DCS for adjusting your three flow controllers in this
experiment. The Outside Operator can just be used to take gauge readings.
7. Click “run” on the simulator, allow the process to run for at least 1 minute, and
then begin adjusting the flow controller(s) Setpoint(s). Remember your goal:
i. Process feed flow Setpoint (FIC-101): 25.71 m3/h (by the end of the run)
ii. Bottoms pH (AG-106): 7.0 pH (to be maintained the entire run)
8. Ensure that you have reached a process feed flow Setpoint (FIC-101) within 15
minutes. Allow your simulator to run for at least an additional 5 minutes to make

pHControlLsn6_ComparingControlTechniques ©PetroSkills – Simulation Solutions

 final adjustments to FIC-102 or FIC-103. Read Section A: Step 13 “note” regarding
the level controller fluctuating.
9. After the 20 minute simulator run pause your simulator. Ensure you have Table
6C filled out.
10. Feel free to save your event log file after the 20 minute simulator run for further
analysis if you have permissions to save files on your simulator program. If you
are unsure how to do this refer to the tutorial on exporting data in the eLearning
environment.
Table 6C

Time FIC-101 S.P. FG-102 FG-103 FG-105 AG-106

(m3/h) (lpm) (lpm) (m3/h) (pH)
00:00 22.71 0.00 0.38 22.74 7.0
02:00
04:00
06:00
08:00
10:00
12:00
14:00
16:00
18:00
20:00

D. Cascade Loop Engaged

1. Re-launch the pH Control simulator. Ensure that the simulator is in “Freeze” at

time “00:00:00F”.
2. In this exercise no special exercise needs to be loaded. We will run from the
“design” condition which has the bottoms pH controller control loop engaged.
3. Create a plan to steadily increase FIC-101 Setpoint over the course of 15 minutes
of simulator time from 22.71 m3/h to 25.71 m3/h. Account for running the
simulator for one minute without making any adjustments so that you have
steady-state data to compare against.
4. In this final simulator run, you will simply be increasing the FIC-101 Setpoint and
taking gauge readings to fill out Table 6D. You can utilize the Outside Operator to
find these readings.
5. Fill out Table 6D below tracking the flows and bottoms pH as you adjust FIC-101
Setpoint. It is important to take a reading once every two minutes because you
will trend this data later.

pHControlLsn6_ComparingControlTechniques ©PetroSkills – Simulation Solutions

 6. Remember: You are only adjusting FIC-101 Setpoint in this experiment. The
controls are doing the rest! The Outside Operator can just be used to take gauge
readings.
7. Click “run” on the simulator, allow the process to run for at least 1 minute, and
then begin adjusting the flow controller(s) Setpoint(s). Remember your goal:
i. Process feed flow Setpoint (FIC-101): 25.71 m3/h (by the end of the run)
ii. Bottoms pH (AG-106): 7.0 pH (to be maintained the entire run)
8. Ensure that you have reached a process feed flow Setpoint (FIC-101) within 15
minutes. Allow your simulator to run for at least an additional 5 minutes to allow
your control loop (not you!) to make final adjustments to FIC-102 or FIC-103.
Read Section A: Step 13 “note” regarding the level controller fluctuating.
9. After the 20 minute simulator run pause your simulator. Ensure you have Table
6D filled out.
10. Feel free to save your event log file after the 20 minute simulator run for further
analysis if you have permissions to save files on your simulator program. If you
are unsure how to do this refer to the tutorial on exporting data in the eLearning
environment.
Table 6D

Time FIC-101 S.P. FG-102 FG-103 FG-105 AG-106

(m3/h) (lpm) (lpm) (m3/h) (pH)
00:00 22.71 0.00 0.38 22.74 7.0
02:00
04:00
06:00
08:00
10:00
12:00
14:00
16:00
18:00
20:00

Suggested Deliverables:

 Table 6A including a brief explanation on the response for each variable.

pHControlLsn6_ComparingControlTechniques ©PetroSkills – Simulation Solutions

  Completed Tables 6B, 6C, and 6D.

 Graph of the AG-106 for each of the three experiments. Plot the data of AG-106 for each
experiment on the same trend.
o Analyze the pros and cons of each control technique.
o Which was most effective of maintaining bottoms outlet pH?

 The trainee now has data for the pH in three different dynamic states. Volumetric flow
rate is known for all three of the inlet streams as well as the singular outlet stream.

 The pH for these 4 streams at the design steady-state case can be found below. The pH
for the acid and alkali flow can be found in the pHIntroductionP&ID doc downloaded in
Lesson 2 in the eLearning site:
o Process feed flow pH: 5.0 (on DCS)
o Acid flow pH: 2.0 (not on DCS)
o Alkali flow pH: 12.0 (not on DCS)
o Bottoms flow pH: 7.0 (on DCS)

 Create a process flow diagram including inlet and outlet streams from tank T-101.
Include the flow rate and pH data for each stream.

 Choose any time value (except 00:00) from Table 6D. Validate your mass balance for
that point in time. Consider any potential sources of error.

 pH Development Questions:

1. If the target bottoms stream was 10.74 m3/h with a pH of 5.0, what would your
process feed, alkali and acid flows be once a new steady-state was achieved to
reach this target?

2. If the target bottoms stream was 18.00 m3/h with a pH of 4.2, what would your
process feed, alkali and acid flows be once a new steady-state was achieved to
reach this target?

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