Workshop for Flipped Class

Based on students having completed the Chapter 2 e-Lesson before class

Chapter 2
Control Objectives and Benefits

Copyright © Thomas Marlin 2016

 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS
Workshop 1. Fired Heater Control Objectives
Identify at least one example for each of
1. Safety the seven categories of control objectives.
2. Environmental PIC
1

Protection
AT PI
1 4

3. Equipment
FT
1 TI
PI
1
5
protection TI
5
TI
2

4. Smooth operation TI

production rate PT
1
6

TI
3

5. Product quality TI
TI
7 TI
9
TI
10
4

6. High profit
FT TI
FI
2 8 TI
3
11

7. Monitoring &
PI PI PI
diagnosis 2 3 6
 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS
Workshop 2. Distillation Control Objectives
Identify at least one example for each of the seven categories of control objectives.

1. Safety
PC-1

L4

2. Environmental
P3
T5

Protection
LC-1
3. Equipment 17

protection 16
F7

LC-2 dP-1
15

4. Smooth operation
T6

AC-1

production rate T10

3
TC-7
F3
2
5. Product quality dP-2 F4

6. High profit

7. Monitoring & LC-3

diagnosis
F9
F8
 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS

Workshop 4. Residuum viscosity control

Crude oil residuum viscosity control: The product viscosity is

controlled by adjusting the flow of expensive light gas oil that reduces
the product viscosity. The initial distribution is given. Determine
what the distribution with improved control should be.
Any viscosity values within the red
bars are acceptable
LC Before: mean = 376, stnd dev = 13

AC 40
Residuum

Frequency (%)
30
20
10
0

5
32

34

36

38

40
Viscosity (cst)
Light Gas Oil
(expensive)
Ciatation3
 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS

Workshop 5. Energy benefits for distillation control

The bottoms product impurity is not

currently controlled. The maximum PC
impurity (light key) is 2 percent. Based on
the data in the following slide,

a. Determine the reboiler duty that is due

AC
to lack of controlling the bottoms at
exactly 2% (the design value). Express
Reboiler duty
your answer as a fraction of reboiler
duty that is in excess of the minimum.
AC
b. What additional data would you need to
calculate the economic effect of this
excess reboiler duty. Give the equation
that you would use to relate fraction
Bottoms purity not controlled
reboiler duty to $/h.
 2
CHAPTER 2. CONTROL

Reboiler duty (Fraction of design value)

1.8 Note that the duty is highly non-linear
OBJECTIVES AND
BENEFITS
1.6

1.4

Workshop 5 1.2

Distillation data for the 0.8

0 0.0025 0.005 0.0075 0.01 0.0125 0.015 0.0175 0.02
variation in the bottoms Bottoms impurity (mole fraction LK)

product impurity (light key) 0.35

Acceptable product quality
with the top impurity (heavy 0.3
key) maintained constant at
Fraction of data in indicated range
0.25
2%.
0.2

Any value of bottoms 0.15

impurity under 2% is
0.1
acceptable, while values
over 2% result in materials 0.05

that cannot be sold. 0

0 0.0025 0.005 0.0075 0.01 0.0125 0.015 0.0175 0.02
Bottoms purity (mole fraction LK)
 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS

Workshop 6. Identify and evaluate key assumption

A few assumptions were tacitly made when the frequency distribution

and the performance correlation were used in calculating the average
performance. Identify the assumptions and determine when they are
valid.

Calculations for the average performance

(Pave) for the data set
 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS
Workshop 8. Calculate profitability for a control improvement

Measure and control O2 to

operate

• Safety improved; less chance

of fuel-rich environment

• Higher efficiency by reducing

excess oxygen

Is the investment justified by

the fuel savings? Continued on
next slide.
 CHAPTER 2. CONTROL OBJECTIVES AND BENEFITS
Workshop 8. Calculate profitability for a control improvement

You have been asked to evaluate the profitability for installing an oxygen analyzer
on a boiler. You have collected the following information. Any other values that
you need you must estimate; please state all assumptions clearly.

Analyzer capital cost including installation = $20,000

Analyzer maintenance cost = $4000/year
Benefit due to reduced fuel cost = $9500/year

You can depreciate the analyzer over a 5-year life using the straight-line method.
The analyzer has an expected serviceable life of 10 years without replacement.
After 5 years, the analyzer has a salvage value of $0.

It is January, and the analyzer can be installed immediately. The boiler will be
operated for eight years from now, after which it will be shutdown permanently.

The company expects to be profitable for all future years. The tax rate is 35%, and
the MARR (minimum acceptable rate of return) is 15% after tax.