ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey

Updated for Experion PKS by DB Mowrey
1/11 9/4/2013





Exothermic Reactor Unit (ERU)


Operating Manual
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
2/11 9/4/2013

1. Background
Complex industrial processes must be controlled well to ensure an economic return on
investment, the safety of operating personnel and the local community, and to preserve the
environment. Though steady state operations may often be the ideal condition for such
processes, the behavior of industrial processes is often not static but very dynamic,
requiring control systems to ensure safe and profitable operations. Even what appear to be
simple processes can present difficult control challenges. The exothermic reactor process
is one such seemingly simple process.
2. Description of Equipment
A schematic of the test facility is shown in Figure 1.

Figure 1 Exothermic Reactor Apparatus (as shown with Honeywell Station software)
In this simulated constant-volume reactor, both the reactor and the cooling jacket are
perfectly mixed, the product and feed have the same constant density and heat capacity,
the cooling water density and heat capacity are constant, and the following irreversible first-
order exothermic reaction occurs:
A B
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
3/11 9/4/2013

Automatic control valves are used to regulate the flow rates of the feed and cooling water
streams. The feed valve is air-to-open, and the cooling water valve is air-to-close. Flow
rates are measured by differential pressure (orifice) flow rate transmitters, temperatures are
measured by thermocouples, and the concentration of component A is measured by an
analyzer on the product stream.
The experiment is interfaced to Honeywells Experion PKS (Process Knowledge System)
distributed control system (see below). The system receives process measurements and
makes adjustments to the control valve positions to control the feed and cooling water flow
rates, which then control the reactor and cooling jacket temperatures and product
concentration. The experiment utilizes cascade control structures commonly used in the
process industries. Low level regulatory loops (secondary or slave controllers) are used to
control the feed and cooling water flow rates. A higher level (primary or master) controller
maintains the product composition by manipulating the setpoint of the feed flow rate
controller. The other cascade structure has three levels: the highest (primary) level
maintains the reactor temperature by manipulating the setpoint of the cooling jacket
temperature controller (the upper secondary), which maintains the cooling jacket
temperature by manipulating the setpoint of the cooling water flow rate controller (the lower
secondary).
3. Using the Honeywell Experion PKS Control System
Honeywells Experion is a distributed control system (DCS) widely used in industry and on
many lab experiments here at LSU. In Experion, each process variable is represented by
an entity called a Control Module (CM). Each CM is a collection of Function Blocks (FB).
And each FB consists of many values called parameters. Within a CM (and sometimes
between CMs), the FBs are wired together in various ways to monitor and control the
process. Desired values of many parameters may be entered via the computer keyboard.
The purpose of the next few sections is to explain how to use Experion to run this
equipment.
4. Logging in to Honeywell
Access to the Honeywell Experion DCS application is through a virtual machine using
VMware software. After logging into one of the computers in the UO Control Room, among
the icons on the desktop to be found there is the VMware Horizon View Client icon.
Double-clicking this icon should bring up the following popup:

ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
4/11 9/4/2013



In the Connection Server field, enter che-view.lsu.edu if this identification is not
already in that field. Check the Log in as current user checkbox to allow the
VMware application to login to this virtual machine using the same credentials used to login
to the physical computer in the control room. Click the Connect button.
If login credentials are valid, the following popup should appear:



Virtual machines are available for the microscope in the UO Analytical Lab (shown as
Microscope) and for access to the Honeywell DCS (shown as UOLAB). If UOLAB is not
highlighted, click on it make it so, then click the Connect button. A splash screen for the
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
5/11 9/4/2013

virtual machine should appear with an OK button. Click OK. The VMware software should
startup a virtual machine and show you the desktop of that machine.
Open the Honeywell Station software by navigating to
Start>All Programs>Honeywell Experion PKS>Client Software>Station
If login credentials are proper, the Station program will appear and exercise patience here
the following default splash screen within it:

The Honeywell login process is now complete.
5. Overview of Operations
The simulated process runs continuously and is controlled from a computer schematic.
From the Unit item on the Station menu, select ERUn (where n is 1 for Mon-Wed teams
and 2 for Tue-Thu teams). The ERUn P&ID schematic will appear. This schematic is much
like a Process and Instrumentation Diagram (P&ID) with four controller faceplates.
6. Controlling From The P&ID Schematic
Every controller is represented by a small colored circle containing the tagname of the CM,
with the values of the setpoint (backlit in green) and the process value (backlit in cyan) near
the circle. The first letter indicates the type of measurement - T for temperature, F for flow,
or A for analyzer (concentration of component A in this case). To change any analog value
from a schematic, you must click on it (if it can be changed, its background will change),
and then enter the new value. The changeable objects in this display are the SP and tuning
constant values near each controller, and there are additional objects on the faceplates, all
of which are explained below.
The main value associated with a controller is the measured input, or process value (PV). In
addition to the PV, controllers have many more values, the most important of which is the
setpoint, or SP. A common example of a SP is the speed setting on a cruise control - the
controller will manipulate its output (the throttle position in this case) to move the PV to the
SP and hold it there. The SP (in green) and the PV (in cyan) are shown immediately to the
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
6/11 9/4/2013

side of the circle representing the controller. Just below these values are the tuning
constants (in tan): Kc (proportional gain), i (integral time constant, or reset), and d
(derivative time constant, or rate). The four small windows to the left and right of the P&ID
are the faceplates for four of the five controllers. Honeywell schematics can display only
four faceplates at once. To see the fifth faceplate (either the reactor temperature or the
cooling water flow rate), click on the Display Xnnn Faceplate button just above and
to the left of the cooling water temperature controller.
From a controller faceplate, you can see the tagname, description, engineering units,
instrument range, and several of the most important parameters on the controller. You can
also change many of these parameters. Near the bottom of the faceplate is a drop-down
menu box labeled MD, which can be used to select the mode of the controller. Immediately
above the mode are the OP (changeable), the PV (not changeable) and the SP
(changeable). To change the OP or SP, single click the value, type in the new value and
press ENTER. The SPs and tuning constants on the schematic can be changed the same
way.
7. Controller Modes
As mentioned above, a controller has an SP and an OP. The OP is always given in percent
(0-100%) and the SP has the same engineering units as the PV (in this experiment, the flow
rates are in m
3
/min, the temperatures are in degrees K, and the concentration is in
kmol/m
3
).
When the controller mode is MANual, the OP is held until the operator changes it. When you
want to change it, simply click the OP in the faceplate, type in the new value, and press
ENTER. The new OP will be held until you change it again. Note that you may enter an OP
only while a controller is in MAN. When the mode is not MAN, the controller uses the PV,
SP and tuning constants to calculate the OP. When the mode is AUTOmatic, you may enter
a new SP to be used for control. Note that changing an SP affects the OP only while a
controller is in AUTO.
For practice, change the output of the feed flow rate controller to 50% (wait a few seconds
for the PV to reach a steady flow rate), then to 100% (wait a few more seconds), and then
back to 6.9% (-6.9% is known as tight shutoff in the Experion system). Notice the small
bar under the control valve on the schematic its length is proportional to the output.
Sometimes controllers are stand-alone (i.e. there are no connections to any other
controller), and sometimes they are in a cascade structure (like the concentration-to-feed
flow rate controllers and the reactor temperature-to-cooling jacket temperature-to-cooling
water flow rate controllers in this equipment - cascade connections are indicated by solid
lines with small circles on the schematic). The upper controller in a cascade (the one which
can receive its SP only from a human) is called the primary and the lower controller (the
one which can receive its SP from another controller) is called the secondary. Secondary
controllers require an additional mode so the computer system will know when to close the
cascade (i.e. put the cascade structure fully on control). In the Experion system, this
additional mode is called CAScade. When the mode of the primary is AUTO and the mode of
the secondary is CAS, the cascade is said to be closed and the primary is sending its OP
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
7/11 9/4/2013

to the SP of the secondary. When the mode of the secondary is AUTO, the operator is
responsible for changing the SP of the secondary to control the process.
The circle representing a controller is filled with a color which indicates the current mode of
the controller. For all controllers, yellow means the mode is MAN. For primary controllers,
cyan means the mode of the primary is AUTO, but the mode of the secondary is not CAS
(i.e. the primary is ready to start sending new SPs as soon as the secondary goes to CAS).
For secondary controllers, cyan means the mode is AUTO (i.e. any new SP must come from
you, not from the primary). And finally, for all controllers, white means the mode is in its
normal state - fully on control, which is AUTO for primary controllers and CAS for secondary
controllers. For practice, set both the concentration and feed flow rate controllers to AUTO.
Notice that the background of both controllers changed from yellow to cyan. Now set the
feed flow rate controller to CAS (i.e. close the cascade). Notice the change in background
colors of both the primary and secondary controllers. Now put both controllers back in MAN
and set the flow rate OP back to -6.9% to stop the flow.
8. Sampled Data Control
Unlike dedicated analog instrumentation for process control, the Honeywell Experion uses
microprocessor-based digital computers to perform regulatory control tasks, and
workstation and server PCs to configure the system, build control strategies and
schematics, gather and display data, etc. The calculations in such systems are typically
performed at regular intervals of time. The time between two consecutive data readings is
referred to as the sampling time and such systems are referred to as sampled data
systems. The sampling time used in this Experion system is one (1) second. All data are
collected, control algorithms processed, and outputs sent each second.
9. Display Navigation
When you logged into Flex Station, you used an item from the menu bar to call up the main
ERU schematic. There are several additional ways to go from one display to another. For
example, you can enter the tagname of a controller in the Command field at the top of the
screen and press F12 to call up the detail display. Try it with your feed flow rate controller
(F700 for section 1, or F710 for section 2). For a controller, the detail display has 7 tabs.
The one labeled LOOP TUNE will probably be useful for tuning your flow rate controllers.
Most of the toolbar buttons are used for navigation some require a name or number to be
entered, and some go directly to the display. Most of the same functions are on the function
keys. For example, to return to the previous display, click , or press F8. To return to the
display before that, do it again.
From most displays (both system displays and custom schematics such as ERUn), double
clicking any value associated with a CM will take you to its detail display. From a detail
display, click or press F2 to return to the main ERU schematic. On most custom
schematics there may also be buttons to quickly get you from one display to another.

ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
8/11 9/4/2013

10. Using Trends
There are two buttons on the main ERU schematic to call up trends. The button labeled
Temps & CW displays the PVs, SPs and final OP of the temperature and cooling water
flow rate controllers. The button labeled Conc & Feed displays the PVs, SPs and final
OP of both the concentration and feed flow rate controllers. Either trend can be used to
show the interactions between the two primary controllers. With all controllers on computer
control, a well-tuned system will bring the system back to steady state (i.e. both primary
controllers within 0.5% of SP) within 15 minutes of any reasonable disturbance or setpoint
change to the reactor temperature and/or the product concentration controller(s). Click the
Conc & Feed button.
At the bottom of the trend is the legend with all the tag.block.parameters associated
with the traces. The checkboxes in the Pen column indicate which traces are currently on
the trend. Click on the chart area of the trend and a white hairline cursor appears on the
chart and the values at the hairline cursor appear in the Reference Value column of the
legend. Along the bottom of the chart area is a horizontal scroll bar which allows you to
scroll the chart area back and forth. Along the left axis youll find the low and high range of
the selected trace. These allow you to change the range of the trace for the selected
parameter. Practice by changing the range of the product concentration controller to 1-5
kmol/m
3
.
Immediately above the left side of the chart area is a drop-down list which allows you to
select one of the traces (you may also click anywhere on the line for this trace in the legend
area). When you select an active trace, it is highlighted (i.e., becomes thicker) in the chart
area. Above the right side of the chart area is the Period drop-down list. This drop-down
list allows you to select the period of time for which you want data to be displayed in the
chart area. To the right of that is the Interval drop-down list. This drop-down list allows
you to select the interval between points in the chart area. Practice changing to a different
period and interval. Leave the period set to 1 day and the interval at 1 minute for now.
For practice, scroll back until some variation in some of the traces appears. Notice that the
timestamps below the chart area change as you scroll. Find some local max or min in one
of the traces and click on it. Now change the period back to one hour and notice that the
cursor is centered on (or at least near) the local max or min. If necessary, move the hairline
so it is exactly on the peak or valley and notice that the values, as well as the date and
time, are shown in the Reference Value column in the legend. Now return the trend to
the current time by clicking .
All changes you make to the trend can be saved by clicking the familiar Windows Save icon
just above the right end of the chart area next to the word (Modifed).
11. Saving Data into Excel
Tuning the level and pH controllers will require analysis of a great deal of data in the time
domain. To collect this data, an Excel workbook containing a Visual Basic Add-In is
provided. In Windows Explorer, navigate to
X:\CHE4162\CHE4162-HW Excel Data Recorders
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
9/11 9/4/2013

and double click on ERURecordern.xls (where n is your section number).
The workbook will open with a Start button, the experiment name, a collection frequency
drop-down menu box, and a Stop button on the top line. Click Start, and the workbook will
start collecting the relevant data at the specified collection frequency. These data will be
extremely useful in analyzing your results. While the workbook is collecting data, it may be
scrolled, but you should not attempt to do anything else in this instance of Excel until after
you click Stop. If you do, the collector may stop and you may lose valuable data.
When you finish a run, click Stop and cut or copy whatever data you need to your daily
workbook in a separate instance of Excel. Let the workbook collect data while you complete
the following step for practice.
12. Manual Control (Single Stable Steady State)
If the study to be conducted WILL NOT include examination of multiple steady states then
manual control should be achievable over a wide range of reactor temperatures. Practice
controlling the experiment manually from the Experion Flex Station as follows:
Start Excel data collection.
Place all five (5) controllers in MAN if these are not already so.
Adjust the OP of the feed flow controller to deliver 3.2 m
3
/min of feed, which is 50%
of the full range of that flow controller (OP 75.79%).
Adjust the OP of the cooling water flow controller to deliver 1.65 m
3
/min of cooling
water, which is about 75% of the full range of that flow controller (OP 25%).
The process should come to steady state at a particular set of values for the reactor
temperature, cooling water temperature, and reactor concentration.
While leaving the feed rate at its current value, adjust the OP of the cooling water
flow controller to deliver 0.55 m
3
/min of cooling water, which is about 25% of the full
range of that flow controller (OP 75%).
The process should again come to steady state at a particular set of values for the
reactor temperature, cooling water temperature, and reactor concentration.
Click on the Stop button in the Excel workbook.
Compare the values of both temperatures and concentration from these two trials.
The relative values should make sense, given the nature of the reaction.
Practice saving the data to another workbook in a separate instance of Excel (do not copy
or cut the buttons or the drop-down list box), then save that workbook to the C:\Temp
directory on this workstation, and finally save the copy in C:\Temp to your groups directory
using COPY/PASTE (not SAVE AS).
13. Manual Control (Multiple Steady States)
If the study to be conducted WILL include examination of multiple steady states then use
the method described below to practice controlling the experiment manually from the
ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
10/11 9/4/2013

Experion Flex Station. Using the design cooling water flow rate and design feed flow rate
from supplied project specifications, the system will have three steady states,
corresponding to three different reactor temperatures. Well call these P1, P2 and P3, in
increasing order of temperature. States P1 and P3 are open-loop stable, but to hold the
system at P2 requires automatic control. Well start at P1.
Start Excel data collection.
Leave all controllers in MAN, set the cooling water flow rate OP to 75%.
Adjust the OP of the feed flow controller to deliver the project specification flow rate.
When the reactor temperature rises above 350 K, adjust the cooling water flow rate
OP so the PV is at the project specification rate.
The process will settle at the P3 steady state in a few minutes.
Set the cooling water flow rate OP to 25%.
When the reactor temperature falls below 360 K, adjust the cooling water flow rate
OP so the PV is at the project specification rate.
The process will settle at the P1 steady state in a few minutes.
Now see how closely you can hold the process to P2 by manipulating the OP of the
CW flow rate controller. You may stop trying after 10 minutes.
Click on the Stop button in the Excel workbook.
Practice saving the data to another workbook in a separate instance of Excel (do not copy
or cut the buttons or the drop-down list box), then save that workbook to the C:\Temp
directory on this workstation, and finally save the copy in C:\Temp to your groups directory
using COPY/PASTE (not SAVE AS).
14. Shutdown Procedure
Before leaving for the day:
Put all controllers in MAN and set the PID parameters on all controllers to 1, 0, 0.
Set the feed flow rate OP to 75.79% and the cooling water flow rate OP to 50%.
Log off the computers.

ChE 4162 ERU Operating Manual Fall 2013

Edited by HJ Toups from Original by DB Mowrey
Updated for Experion PKS by DB Mowrey
11/11 9/4/2013

15. Tags, Descriptions, Ranges, and Units
Tag
Name
Service
Description
Instrument
Range
Engineering
Units
A700 R1 Product Concentration 0-to-6 kmol/m
3

F100 R1 Feed Flow Rate 0-to-6.4 m
3
/min
T700 R1 Reactor Temperature 250-to-450 K
T701 R1 Cooling Water Temperature 250-to-450 K
F701 R1 Cooling Water Flow Rate 0-to-2.2 m
3
/min
A710 R2 Product Concentration 0-to-6 kmol/m
3

F110 R2 Feed Flow Rate 0-to-6.4 m
3
/min
T710 R2 Reactor Temperature 250-to-450 K
T711 R2 Cooling Water Temperature 250-to-450 K
F711 R2 Cooling Water Flow Rate 0-to-2.2 m
3
/min
16. Safety Considerations
Even though this is a simulated reactor, you must still fill out a JSA before beginning
operations.
Chemical Hazard
Assume that the feed and product are 0.1 molar HCl, and that the product has
approximately the same toxicity as formaldehyde.
Slipping Hazard
Any process equipment (particularly control valves and pumps) may leak from time to
time, so be on the lookout for and mop up any liquid.
Temperature Hazard
Even though the jacket is insulated, some of the piping is not. Identify the piping which
may be a burn hazard.
17. Relevant Literature References
1. Smith, C.A. and A.B. Corripio. Principles and Practice of Automatic Process Control,
2
nd
Ed. New York: John Wiley and Sons, 1997.
2. Seborg, D. E., T. E. Edgar and D. A. Mellichamp. Process Dynamics and Control,
2
nd
Ed. New York: John Wiley and Sons, 2004.
3. Romagnoli, J.A. and A. Palazoglu. Introduction to Process Control, Boca Raton:
CRC Press - Taylor and Francis Group, 2006.