CHAPTER 2 : CONTROL OBJECTIVES AND BENEFITS

When I complete this chapter, I want to be able to do the following.

Recognize examples of the seven (7) control objectives in chemical processes Calculate indicators of variability in a process variable Be able to calculate the economic impact of variability

CHAPTER 2 : CONTROL OBJECTIVES AND BENEFITS

Outline of the lesson.

Seven (7) Control Objectives

1. Safety 2. Environmental protection 3. Equipment protection 4. Smooth operation 5. Product quality 6. Profit 7. Monitoring and diagnosis

Variability measures Economic impact of variability Workshop

EXAMPLE PROCESS: FLASH SEPARATION

Lets discuss this process
T6 P1

Vapor product
P 1000 kPa T 298 K

Feed
Methane Ethane (LK) Propane Butane Pentane

T1

T2

T5

F1

T4

T3

L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1

High pressure in drum is dangerous

T6

PC

Vapor product

T2

T5

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

To flare 1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1

Never release hydrocarbons to atmosphere

T5

T6

P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1

No flow could damage the pump

T5

T6

P1

Vapor product

T2

Feed
F1 T4 T3 LC

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection
T1

Always keep the production rate smooth

T6

P1

Vapor product

T2

T5

Feed
4. Smooth operation production rate 5. Product quality 6. High profit 7. Monitoring & diagnosis
FC T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1

Achieve L.Key by adjusting the heating

T6 P1

Vapor product

T2

T5

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

AC
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Use the least costly heating

T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

AC
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1 T5

Give example
T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality
F2 F3 T1

Calculate & plot key parameters, T6 e.g., UA.

T5

P1

Vapor product

T2

Feed
F1 T4 T3 L1

6. High profit 7. Monitoring & diagnosis

Process fluid

Steam

A1
L. Key

Liquid product

UA
time

SEVEN CONTROL OBJECTIVES

1. Safety 2. Environmental Protection 3. Equipment protection 4. Smooth operation production rate 5. Product quality 6. High profit 7. Monitoring & diagnosis
F2 F3 T1 T5

All seven must be achieved. Failure to do so will lead to operation that is

unprofitable or worse, unsafe.

T6 P1

Vapor product

T2

Feed
F1 T4 T3 L1

Process fluid

Steam

A1
L. Key

Liquid product

BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of key variables to achieve the seven objectives. Without feedback control
Composition (% H. Key)
6 outlet concentration 5 4 3 2

50

100

150

200

250 time (min)

300

350

400

450

500

valve position (% open)

51 50.5 50 49.5 49 0

Reflux valve

50

100

150

200

250 time (min)

300

350

400

450

500

BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of key variables to achieve the seven objectives. With feedback control
3.5 outlet concentration

Composition (% H. Key)

2.5 0

50

100

150

200

250 time (min)

300

350

400

450

500

valve position (% open)

100 80 60 40 20 0

Reflux valve

50

100

150

200

250 time (min)

300

350

400

450

500

Variability is moved from controlled to manipulated variable!

BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of key variables to achieve the seven objectives.
What statistics can we calculate from this data?

How do we relate variability to process performance?

BENEFITS FROM PROCESS CONTROL

Process performance = efficiency, yield, production rate, etc. It measures performance for a control objective. Calculate the process performance using the distribution, not the average value of the key variable!

Example of Benefits of reduced variability for chemical reactor Goal: Maximize conversion of feed ethane but do not exceed 864C Which operation, A or B, is better and explain why.

Example of Benefits of reduced variability for chemical reactor Goal: Maximize efficiency and prevent fuel-rich flue gas Which operation, A or B, is better and explain why.

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 1

Determine one example for each of the seven control objective categories.
PIC 1

Flue gas
PI 4 PI 5 TI 5

AT 1 FT 1 TI 1

feed
PT 1 TI 3 TI 4

The feed flows through a pipe and is heated by the combustion of fuel
TI 6

TI 2

product
TI 9 TI 10

TI 7

air

FT 2

TI 8

FI 3

TI 11

PI 2

PI 3

PI 6

fuel

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 2 Two process examples show the benefit of reduced variability, the fired heater reactor and the boiler. Discuss the difference between the two examples. Can you think of another example that shows the principle of each?
Squeeze down the variability

0.4

0.3

0.2

0.1

frequency of occurrence
0 -3 -2 -1 0 1 2 3

deviation from mean

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 3 In both the flash drum and the fired heater examples, temperature measurement is very important. Describe several methods for measuring temperature and recommend the most appropriate for the flash drum example. How hot is it?
T1 T2 T5 T6 P1

Vapor product

Feed
F1 T4 T3 L1

F2

F3

Process fluid

Steam

A1
L. Key

Liquid product

CHAPTER 2 : CONTROL OBJECTIVES & BENEFITS

When I complete this chapter, I want to be able to do the following.

Recognize examples of the seven (7) control objectives in chemical processes Calculate indicators of variability in a process variable Be able to calculate the economic impact of variability
Lots of improvement, but we need some more study! Read the textbook Review the notes, especially learning goals and workshop Try out the self-study suggestions Naturally, well have an assignment!

CHAPTER 2: LEARNING RESOURCES

SITE PC-EDUCATION WEB - Instrumentation Notes - Interactive Learning Module (Chapter 2) - Tutorials (Chapter 1/2)

CHAPTER 2: SUGGESTIONS FOR SELF-STUDY

1. Discuss the importance of consistent quality in your decisions to purchase food, clothing, etc. 2. A P&I drawing of a distillation process is given in Woods*. Determine at least one example of each of the seven control objectives for this process. Evaluate the control designs given; do they achieve your objectives? 3. Find process examples in your previous textbooks and determine the advantage for reduced variability in each. Can you provide quantitative values for the economic benefit?
* Woods, D. Process Design and Engineering Practice, Prentice-Hall, 1995 (page 2-65).