Malampaya Offshore JG Summit Petrochemical Group

Pilipinas Shell Petroleum Corporation

First Gen Corporation

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 Control Room – Operator Work Stations

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 Control Room – System Cabinet

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 DCS Graphics

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 DCS Graphics DCS Function Block Program

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 INDUSTRIAL PROCESSES

CONTINUOUS

DISCRETE

BATCH

Continuous production is called a continuous

process because the materials, either dry bulk or
fluids that are being processed are continuously in
motion, undergoing chemical reactions or subject
to mechanical or heat treatment.

Continuous usually means operating 24 hours per

day, seven days per week with infrequent
maintenance shutdowns, such as semi-annual or
annual. Some chemical plants can operate for
more than one to two years without a shutdown.
Blast furnaces can run from four to ten years
without stopping.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 INDUSTRIAL PROCESSES

CONTINUOUS

DISCRETE

BATCH

Discrete manufacturing is the production of distinct items. Automobiles, furniture, toys, smartphones,
and aeroplanes are examples of discrete manufacturing products. The resulting products are easily
identifiable and differ greatly from process manufacturing where the products are undifferentiated, for
example oil, natural gas and salt.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 INDUSTRIAL PROCESSES

CONTINUOUS

DISCRETE

BATCH

Batch production is a method

whereby a group of identical
products are produced
simultaneously (rather than one at a
time). It is up to the manufacturer to
decide how big the batch will be,
and how often these batches will be
made.

Each batch goes through the

separate stages of the
manufacturing process together.
Meaning that another batch can’t
begin a stage, if the previous one is
still within that part of the cycle.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 PROCESS VARIABLES

PRESSURE
TEMPERATURE
FLOW
LEVEL
ANALYSIS

Measurement of process variables is essential in control systems to controlling a process. The value of
the process variable is continuously monitored so that control may be exerted. Four commonly
measured variables that affect chemical and physical processes are: pressure, temperature, level and
flow but there are in fact a large number of measurement quantities which for international purposes use
the International System of Units (SI)

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 CONTROL LOOP ELEMENTS

SENSING
TRANSMITTING
CONTROLLING
FINAL CONTROLLING

A sensing element/sensor is a device that performs the initial measurement and energy conversion of a
process variable into analogous electrical or pneumatic information.

A transmitting element/transmitter is a device that converts a reading from a sensing element into a standard
signal and transmit that signal to a controller/controlling element.

A controlling element/controller is a device that receives data from a transmitter, compares that data to a
programmed set point and if necessary signals the final controlling element to take corrective action.

A final controlling element is the part of the control system that exerts a direct influence on the process. It is
the device that provides those required changes in the process variable to bring it to the set point.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 CONTROL LOOP SIGNALS

ANALOG
DIGITAL

The analog signals were used in many systems to produce signals to carry information. These
signals are continuous in both values and time. The use of analog signals has been declined with
the arrival of digital signals. In short, to understand analog signals – all signals that are natural or
come naturally are analog signals.

Unlike analog signals, digital signals are not continuous, but signals are discrete in value and time.
These signals are represented by binary numbers and consist of different voltage values.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 CONTROL LOOP CLASSIFICATION

OPEN LOOP
CLOSED LOOP

A control system in which the control action is totally independent of the output of the system then it is
called an open-loop control system. A manual control system is also an open-loop control system.

Control systems in which the output has an effect on the input quantity in such a manner that the input
quantity will adjust itself based on the output generated is called a closed-loop control system.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 CONTROL LOOP PARAMETERS

PROCESS VALUE (PV)

SET POINT (SP)
MANIPULATED VALUE (MV)

A process value is the current measured value of a particular part of a process which is being
monitored or controlled. An example of this would be the temperature of a furnace.

A setpoint is the desired or target value for an essential variable, or process value of a system.
Departure of such a variable from its setpoint is one basis for error controlled regulation using
negative feedback for automatic control.

The manipulated value is the parameter that is adjusted to bring the process back to the desired
setpoint.

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 To HP Flar
SP = MV: HC
50% 01 PV: 45%
SP: 60 m3/s Header
MV: 40%
FIC FY
ZT ZI 01 01
01 01 MV: 40% <
PV: 50 m3/s
SP: 5 bar PIC PV-01
01B
FT
PIC
SP: 4 bar MV: 30% 01
01A
Gas/LiquidHV-01
From Inlet Separation PV: 3 bar PT FV-01
01 Gas
Process: Separation of To Inlet Co
Gas and Liquid

Process Variables:
Level of Liquid in D01 D01 LT
PV: 45%
LIC SP: 50%
Pressure of Gas in D01 01 01

Flow of Gas exiting D01

MV: 40%

Valve (HV01) opening Liquid

To Condens
Separator
LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 To HP Flar
SP = MV: HC
50% 01 PV: 45%
SP: 60 m3/s Header
MV: 40%
FIC FY
ZT ZI 01 01
01 01 MV: 40%
PV: 50 m3/s <
SP: 5 bar PIC PV-01
01B
FT
PIC
SP: 4 bar 01A MV: 30% 01
HV-01
Gas/Liquid
From Inlet Separation PV: 3 bar PT FV-01
01 Gas
Sensing/Transmitting To Inlet Co
Elements:
LT01
PT01
PV: 45%
FT01 D01 LT LIC SP: 50%
01 01
ZT01
MV: 40%
Controlling Elements:
LIC01 Liquid
PIC01A/B To Condens
FIC01 Separator
FY01 LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 To HP Flar
SP = MV: HC
50% 01 PV: 45%
SP: 60 m3/s Header
MV: 40%
FIC FY
ZT ZI 01 01
01 01 MV: 40%
PV: 50 m3/s <
SP: 5 bar PIC PV-01
01B
FT
PIC
SP: 4 bar 01A MV: 30% 01
HV-01
Gas/Liquid
From Inlet Separation PV: 3 bar PT FV-01
01 Gas
Sensing/Transmitting To Inlet Co
Elements:
LT01
PT01
PV: 45%
FT01 D01 LT LIC SP: 50%
01 01
ZT01
MV: 40%
Controlling Elements:
LIC01 Liquid
PIC01A/B To Condens
FIC01 Separator
FY01 LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 To HP Flar
SP = MV: HC
50% 01 PV: 45%
SP: 60 m3/s Header
MV: 40%
FIC FY
ZT ZI 01 01
01 01 MV: 40% <
PV: 50 m3/s
SP: 5 bar PIC PV-01
01B
FT
PIC
SP: 4 bar MV: 30% 01
01A
HV-01
Gas/Liquid
From Inlet Separation PV: 3 bar PT FV-01
01 Gas
Final Controlling Elements: To Inlet Cooler
HV01
LV01
PV01
PV: 45%
FV01 D01 LT LIC SP: 50%
01 01

Signals:
MV: 40%
Analog - 4-20 mA, 3-15 psi
Liquid
To Condens
Separator
LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 To HP Flar
SP = MV: HC
50% 01 PV: 45%
SP: 60 m3/s Header
MV: 40%
FIC FY
ZT ZI Loop P01B 01 01
01 01 MV: 40%
PV: 50 m3/s <
SP: 5 bar PIC PV-01
01B
Loop Z01 PIC
FT
SP: 4 bar 01A MV: 30% 01
HV-01
Loop H01
Gas/Liquid
From Inlet Separation PV: 3 bar PT Loop P01A/F01 FV-01
01 Gas
Classification: To Inlet Co
Open Loop - H01, Z01

Closed Loop PV: 45%

L01 - Simple PID D01 LT LIC SP: 50%
01 01
P01B - Simple PID
P01A/F01 - Override Loop L01 MV: 40%

Liquid
To Condens
Separator
LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 HC
Re
SP = MV: SP: 60 m3/s
50%
01 PV: 45%
MV: 40% To
FIC FY
ZT
01
ZI
01
01 01 He
MV: 40% <
SP: 4 bar PIC PV-01 PV: 50 m3/s
01B
FT
PIC
SP: 4 bar 01A MV: 30% 01
HV-01
Gas/Liquid
From Inlet Separation PV: 3 bar PT
01
FV-01

Gas
Parameters: To Inlet

PV

SP D01 LT PV: 45% LIC SP: 50%

01 01

MV MV: 40%

Liquid
To Condens
Separator
LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC

 To HP Flar
SP = MV: HC
50% 01 PV: 45%
SP: 60 m3/s Header
MV: 40%
FIC FY
ZT ZI 01 01
01 01 MV: 40% <
PV: 50 m3/s
SP: 5 bar PIC PV-01
01B
FT
PIC
SP: 4 bar MV: 30% 01
01A
HV-01
Gas/Liquid
From Inlet Separation PV: 3 bar PT FV-01
01 Gas
Activity 1 To Inlet Co
Find, explain a process with a
Control System and identify
the following:
PV: 45%
1. Process Variables D01 LT LIC SP: 50%
01 01
2. Loop Elements (Sensing,
Transmitting, Controlling, MV: 40%
Final Controlling)
3. Signals (Analog/Digital) Liquid
4. Parameters (PV, SP, MV) To Condens
5. Loop Classification Separator
(Open, Closed) LV-01

ICE 410 ADVANCED CONTROL SYSTEM DPSC