CHAPTER 7

INSTRUMENTATION AND CONTROL

7.0 INTRODUCTION

The plant wide control strategy is designated to maximize the specified throughput of the
plant with the highest purity value that can be achieved. The plant control strategy is divided
into different sections that involve control of different unit operations. The control of a
process is often accomplished by measuring the variables (controlled variables), comparing
this measurement with the value at which it is desired to maintain the controlled variables (set
point), and adjusting some further variables (manipulated variables) which has a direct or
indirect effect on the controlled variables.

For the proposed ethylene oxide production plant, the objectives for designing control system
are:

i. To enable safe plant operation and avoid explosion. Hence, the control of operating
parameters in unit operations at set point is vital.

ii. To control the production rate of ethylbenzene at 500,000 metric ton per year.

iii. To maintain the product purity of ethylene oxide above 98 mol%.

iv. To optimize the usage of cooling and heating utilities.

In order to achieve the above objectives, the following considerations are made:

i. Safe Plant Operation

• To keep the process variables within known safe operation limits.

• To ensure the temperature and pressure at the desired level for reactor and columns.
• To detect signs of danger by providing alarms and automatic shutdown systems.

• To provide interlocks and alarms to prevent dangerous operating conditions.

ii. Production Rate and Quality

• To achieve the product output composition specification for outlet stream of

reactor according to the literature specification.

• To maintain the desired purity and specified quality standard for

ethylbenzene

iii. Cost

• To operate at the lowest production cost and to commensurate with the other
objectives.

• To optimize the usage of heating and cooling utilities, thus reduce the cost of utilities.

Several types of indicator controllers are used in the control system of the proposed plant:

1. Temperature indicator and controller (TIC)

2. Pressure indicator and controller (PIC)

3. Flow indicator and controller (FIC)

4. Level indicator and controller (LIC)

5. Ratio controller (RC)

7.1 BASIC CONCEPT OF PROCESS CONTROL

7.1.1 Feedback Controller

The feedback control system is widely used in the process industry. The system seeks to
bring the measured quantity to its required value or set point. The feedback control system
uses direct measurements of the controlled variables to adjust the values of the manipulated
variables. The corrective action occurs as soon as the controlled variable deviates from the set
point, regardless of the source and type of disturbance.

Manipulated Controlled variable

variable
Process System

Feedback
Controller

Figure 7.1: Feedback Control Loop

7.1.2 Feedforward Control

The basic concept of feedforward control is to measure important disturbance variables and
take corrective action before they upset the process. In contrast, the feedback controller does
not take corrective action until after the disturbance has upset the process. Feedforward is
effective in reducing the influence of disturbances.

Disturbance, D
Feedforward
Controller

Control Plant
PFB
Valve

Figure 7.2: Feedforward Control Loop

7.1.3 Cascade Control

Cascade control is widely used in process industries, which consists of a master controller
that serves as the set point for a slave controller. Two feedback control loops are nested, with
secondary control loop (slave controller) located inside the primary control loop (master
controller). It is one way to improve the dynamic behaviour response to load changes by
locating secondary controller to recognize any upset conditions before primary controlled
variable is affected. Cascade controls are usually implemented as part of the temperature,
pressure and flow control strategy.

Controller Controller Plant

S.P

Secondary Feedback
Primary Feedback

Figure 7.3: Cascade Control Loop

7.1.4 Ratio Control

Ratio control is a special type of feedforward control that has had widespread application in
the process industries. Its objective is to maintain the ratio of two process variables at a
specified value. The process variable which is usually controlled by a ratio controller is the
flow rate.

Disturbance stream

FT

RC
Ratio Set Point
FT FC

Manipulated stream

Figure 7.4: Ratio Control

7.2 DEGREES OF FREEDOM

The degrees of freedom of a processing system are independent variables that must be
specified in order to define the process completely. Consequently, the desired control of a
process will be achieved when and only when all the degrees of freedom have been specified.
However, for such a system of equations to have a unique solution, the number of unknown
variables must equal the number of independent model equations. An equivalent way of
stating this condition is to require that the degrees of freedom be zero, that is,

NF = NV – NE = 0

Where, NF = degree of freedom, NV = total number of variables (unspecified inputs plus

outputs) and NE = number of independent equations.

7.3 REACTOR CONTROL SYSTEM

Reactor is the most important equipment in our plant. Control system is part of the Layer of
Protection (LOPA) to avoid from loss of containment and accident. Outlet temperature and
composition are two important outputs from reactor. Since reaction in the reactor is highly
exothermic reaction (releases heat) and runaway operation may cause explosion, temperature
control is very crucial.

Allowable outlet reactor temperature is in range of 250 ºC to 290 ºC. Higher temperature
results in deactivation of catalyst used in reactor. In short, higher temperature will lead to
lower yield. An effective, well-designed control system is essential to assure stable operating
condition.

The control system objectives are defined as:

• To maintain the reactor operation at optimum temperature and pressure.

• To sustain the product quality in order to ensure the maximum production rate can be
maintained at the annual production rate of 500,000 metric ton per year.

• Provide the safeguards against the process runaway and maintain the safe operation.

• To maintain optimum feed condition and composition to ensure high production rate.

• To maximize catalyst and prolong the life cycle.

 Reactor temperature can be controlled by regulating flow of the cooling medium. Cooling
medium will flow through the shell side of shell-tube reactor, while process fluid flows
through the tube side.

Cooling medium flows in the shell, removing heat liberated by reaction and condensation of
the vapor in the external boiler helps to make maximum use of heat recovered by production
of steam.

Table 7.1: Reactor Control System Details

Control Measured Manipulated Type of

Disturbances Set Point
Variable Variable Variable Controller
Operating Reactor Cooling water Flow rate in the Cascade Tset = …..
temperature temperature, inlet flow rate reactor controller

- TIC
(master loop)

- FIC
(slave loop)

Cascade Controller (TIC and FIC Reactor)

1) Type of Control Implemented: Cascade Control

2) Control Objective: To maintain the temperature in the reactor by manipulating the flow
rate of cooling water.

3) Control Philosophy: Cascade control can improve the response to a set-point change by
using an intermediate measurement point .A cascade control system can function properly
if the secondary control loop (slave) response faster than the primary (master) loop.
Cascade control can improve the dynamic response of the heat removal system in reactor.
In this control system, slave loop (flow rate of cooling water) response faster compared to
master loop (temperature of reactor). Any changes in temperature of reactor will affect
flow rate of cooling water. Adjustment by controller is made by comparison of set point
and process variable provided by the temperature controller. Output of primary controller
changes set point of secondary controller. Cascade control decreases time delay of control
caused by process disturbance from outside.
 7.4 DISTILLATION CONTROL SYSTEMS
The control system in the distillation column is important in order to have a sharp separation
between the components in the feed. The control system must be able to cause the average
sum of the product streams to be exactly equal to the average feed stream. It must also be
able to maintain the desired concentration of the products at the bottom and the top streams.
However, certain safety operation must be considered in designing the control system of the
distillation column. The same control system is applied for all the distillation but with
different set point. There are 3 distillations being used in this plant.

Table 7.2: Distillation Column Control System Details

Control Measured Manipulated Type of
Disturbances Set Point
Variable Variable Variable Controller
Column Pressure of the Flow rate of Flow rate in Cascade Pset =
pressure column the inlet feed the column control

PIC (master
loop)FIC
(slave loop)
Distillate Distillate Flow rate of Flow rate of Cascade Tset =
temperature temperature the cooling the distillate control
water inlet TIC (master
loop)FIC
(slave loop)

Liquid level in Liquid level in Flow rate of Temperature Cascade Liquid level =
reflux drum reflux drum bottom stream of the reflux control
of the reflux drum LIC (master
drum loop) FIC
(slave loop)
Liquid level of Liquid level of Flow rate of Change in Cascade Liquid level =
the column distillate flow control
 Control Measured Manipulated Type of
Disturbances Set Point
Variable Variable Variable Controller
the column the column bottom stream rate and reflux LIC (master
ratio loop) FIC
(slave loop)
Temperature of Temperature of Flow rate of Flow rate of Cascade Tset =
the boilup the boilup the steam inlet the boilup control

TIC (master
loop) FIC
(slave loop)

Cascade Controller (TIC, FIC) – Temperature of the distillate/boilup

1) Type of Advance Control Implemented: Cascade Control

2) Control Objective: To maintain the temperature of the distillate/boilup by

manipulating the flow rate of the cooling water/steam.

3) Control Philosophy: Due to the slow dynamic response of a column system, a cascade
control with primary loop of temperature controller and secondary loop of flow
controller is implemented. The cascade control is placed to improve the dynamic
response of the system and also to eliminate possible disturbances that may be caused
by flow rate of the distillate/boilup. Since the dynamic response of the secondary loop
is faster than the primary loop, the flow controller should be able to adjust the flow of
cooling water/steam based on the set point given by the temperature controller.

Cascade Controller (PIC, FIC)-Pressure of the column

1) Type of Control Implemented: Cascade Control

2) Control Objective: To maintain the pressure in the column by manipulating the flow rate
of the inlet feed
3) Control Philosophy: The pressure of column can be controlled by manipulating the flow
rate of inlet feed. The set point pressure is the maximum allowable working pressure in
the column. If the pressure of column exceeds the set point pressure, less flow rate of the
inlet feed will be supply thus reduce the pressure in the column.

Cascade Controller (LIC, FIC) - Liquid level in condenser / column

1) Type of Control Implemented: Cascade Control

2) Control Objective: To avoid overflow of the condenser/column

3) Control Philosophy: The maximum liquid level of the condenser/column is maintained by

manipulating the flow rate of the bottom stream.

7.5 HEAT EXCHANGER CONTROL SYSTEM

The purpose of performing a control system for heat exchanger is to maintain the desired
temperature of its outlet stream either by providing heating or cooling utility. The outlet
stream of the heat exchanger will be compared with the set point. If the temperature is not at
the desired level, the controller will take action by manipulating the flow rate of utility. In the
plant, there are … heat exchangers and … cooler, the detail description is shown in Table
7.6 below. All the heat exchanger and cooler used same control system. The objective is to
control the outlet temperature at the desired set point. The type of controller being use is
cascade controller.

Table 7.3: Heat Exchanger in Plant

Equipment Description

E-
 E-

E-

Table 7.4: Reactor Heat exchanger Control System Details

Control Measured Manipulated Type of

Disturbance Set Point
Variable Variable Variable Controller

Temperature Temperature Flow rate of Changes in Cascade Tset

at outlet at outlet steam/cooling steam/cooling controller =
stream stream water into heat water flow
exchanger rate - TIC
(master loop)

- FIC
(slave loop)

Cascade Controller (TIC, FIC E-201)

1) Type of Advance Control Implemented: Cascade Control

2) Control Objective: To maintain the temperature in the heat exchanger output

process stream by manipulating the flow rate of the coolant or heating medium.

3) Control Philosophy: Due to the slow dynamic response of a heat exchanger system, a
cascade control with primary loop of temperature controller and secondary loop of
flow controller is implemented. The cascade control is placed to improve the dynamic
response of the system and also to eliminate possible disturbances that may be caused
by fluctuation of flow rate of utility. Since the dynamic response of the secondary
loop is faster than the primary loop, the flow controller should be able to adjust the
flow of utility to the heat exchanger based on the set point given by the temperature
controller.

7.6 MIXER 1(INLET BENZENE)

The purpose of performing a control system for the inlet benzene is to minimize the inlet flow
rate of the benzene from the battery limit by comparing it with the benzene recycle stream.
 Control Measured Manipulated Type of
Disturbances Set Point
Variable Variable Variable Controller
Amount of Ratio of Amount of Composition of Open loop ratio Rset
benzene benzene from benzene from inert controller =
from the the battery the battery limit (RC)
battery
limit and
limit and
recycle recycle
stream stream

Table 7.5: Mixer1 (Inlet benzene) Control System Details

Ratio Controller

1) Type of Advanced Control Implemented: Ratio Control

2) Control Objective: To control the flow ratio of benzene from the battery limit and recycle
stream

3) Control Philosophy: Ratio control is implemented to minimize the inlet flow rate of the
benzene from the battery limit by comparing it with the benzene recycle stream.

7.7 PUMP

Function of pump is to increase the pressure of the liquid. The purpose of performing a
control system for the pump is to maintain the desired pressure of the outlet stream. Outlet
pressure can be controlled by manipulating the flow rate of the pump inlet.

Control Measured Manipulated Type of

Disturbances Set Point
Variable Variable Variable Controller
Outlet Outlet Inlet flow rate Temperature Cascade Pset =
pressure pressure increase that is controller
cause by the - PIC
heat generated (master loop)
by the pump
- FIC
(slave loop)
Table 7.6: Pump Control System Details

Cascade Controller (PIC and FIC Pump)

4) Type of Control Implemented: Cascade Control

5) Control Objective: To maintain the outlet pressure of the pump by manipulating the flow
rate of pump inlet.

6) Control Philosophy: Cascade control can improve the response to a set-point change by
using an intermediate measurement point .A cascade control system can function properly
if the secondary control loop (slave) response faster than the primary (master) loop. In
this control system, slave loop (flow rate of pump inlet) response faster compared to
master loop (outlet pressure of pump). Any changes in outlet pressure of pump will affect
flow rate of pump inlet. Adjustment by controller is made by comparison of set point and
process variable provided by the pressure controller. Output of primary controller changes
set point of secondary controller. Cascade control decreases time delay of control caused
by process disturbance from heat produce from pump operation. If the pressure is not at
the desired level, the controller will take action by manipulating the flow rate of pump
inlet. In the plant, there are 2 pumps.

7.8 MIXER 2 (BENZENE AND ETHYLENE INLET)

The purpose of performing a control system for the mixer 2 (benzene and ethylene inlet) is to
maintain the ratio of the benzene and ethylene into the reactor.

Control Measured Manipulated Type of

Disturbances Set Point
Variable Variable Variable Controller
Amount of Ratio of Amount of Composition of Open loop ratio Rset
benzene benzene and ethylene inert controller =
and
 ethylene ethylene (RC)

Table 7.7: Mixer 2 (Benzene and ethylene inlet) Control System Details

Ratio Controller

1) Type of Advanced Control Implemented: Ratio Control

2) Control Objective: To control the flow ratio of benzene and ethylene

3) Control Philosophy: Ratio control is implemented to maintain the ratio of raw material
(ethylene and benzene) for the reactor

7.9 COMPRESSOR

The purpose of performing a control system for the compressor is to increase the pressure of
the gas. In our plant, the compressor is used to increase the pressure of the ethylene stream.

Control Measured Manipulated Type of Set

Disturbances
Variable Variable Variable Controller Point
Outlet Outlet Inlet flow rate of Temperature Cascade controller Pset =
pressure of pressure the compressor increase that is - PIC
the cause by the heat (master loop)
compressor generated by the
- FIC
compressor
(slave loop)
Table 7.8: Compressor Control System Details

Cascade Controller (PIC and FIC Compressor)

7) Type of Control Implemented: Cascade Control

8) Control Objective: To maintain the outlet pressure of the compressor by manipulating the
flow rate of compressor inlet.

9) Control Philosophy: Cascade control can improve the response to a set-point change by
using an intermediate measurement point .A cascade control system can function properly
 if the secondary control loop (slave) response faster than the primary (master) loop. In
this control system, slave loop (flow rate of compressor inlet) response faster compared to
master loop (outlet pressure of compressor). Any changes in outlet pressure of
compressor will affect flow rate of compressor inlet. Adjustment by controller is made by
comparison of set point and process variable provided by the pressure controller. Output
of primary controller changes set point of secondary controller. Cascade control decreases
time delay of control caused by process disturbance from heat produce from compressor
operation. If the pressure is not at the desired level, the controller will take action by
manipulating the flow rate of compressor inlet.

7.10 SPLITTER

The purpose of performing a control system for the splitter is to split the flow .For our plant,
the splitter is used to split the recycle stream and the stream into the transalkylation reactor.

Control Measured Manipulated Type of

Disturbances Set Point
Variable Variable Variable Controller
Amount of Ratio of flow Amount of Pressure of the Open loop Rset
flow into the into the flow into flow ratio =
transalkylation transalkylation transalkylatio controller
reactor and n reactor
reactor and (RC)
recycle stream
recycle stream

Table 7.9: Splitter Control System Details

Ratio Controller

1) Type of Advanced Control Implemented: Ratio Control

2) Control Objective: To control the flow ratio of flow to the recycle stream and to the
transalkylation reactor

3) Control Philosophy: Ratio control is implemented to split the flow that consist mainly
benzene into the recycle stream and to the transalkylation reactor
7.9 DISCUSSION

The need to have control strategy design for a plant is to achieve the highest product purity at
an optimum operating condition, by placing right control systems at each of the unit
operations and process streams. In order to achieve the main objective of the control strategy,
basic control strategy and advanced control strategy for the plant wide process control is
integrated.

Conversely, due to the contradiction of controller algorithms that may occur, some of the
control systems designed theoretically may not be possible to be implemented in the actual
industrial practice. The inconsistency is in fact a result of having a too many constraints for
the same process in order to achieve the overall target of the plant control strategy.
Contradiction between the control strategies may also result from failure to observe the
placement of final control elements in the same process stream.

Further developments can actually be made by running a pilot control strategy for the plant as
designed. A set of data has to be obtained in order to relate between the input and output of a
control strategy. The relative gain array (RGA) is then used to test whether a particular
control strategy will work or otherwise. The whole procedure should be conducted to increase
the possibility for the control strategies designed are feasible within the industrial practice.
Apart from installing process controllers, it is also vital to installed process indicators along
major streams for monitoring purpose and equipment performance.