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Materials
Process Flexibility
Design with
Basic flowsheet
Operability
LC
1
FC
1
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Key Operability
issues
1. Operating
window
Why
flexibility
?
FLEXIBILITY
bl
a
t
ep
c
c
una
e
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
Why
flexibility
?
FLEXIBILITY
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
Why
flexibility
?
FLEXIBILITY
5. Efficiency &
profitability
8. Monitoring &
diagnosis
6. Operation
during
transitions
7. Dynamic
Performance
FV
What is adjusted
??
??
??
Key Operability
issues
1. Operating
window
Why
flexibility
?
FLEXIBILITY
2. Flexibility/
controllability
We add a
valve to every
adjustable flow.
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
FV
We could
have alternative
feed trays, with
manual valves used
to change the tray.
Naturally, the
equipment must
have capacity
Key Operability
issues
What to
achieve?
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
FLEXIBILITY
How do we decide what to control?
1. Safety
2. Environmental
Protection
3. Equipment
protection
4. Smooth operation
production rate
8. Monitoring &
diagnosis
T6
T1
T2
F1
T4
P1
7. Monitoring &
diagnosis
Vapor
product
T5
Feed
T3
L1
5. Product quality
6. High profit
7. Dynamic
Performance
Give example
F2
Process
fluid
F3
Steam
A1
L. Key
Liquid
product
Key Operability
issues
What to
achieve?
FLEXIBILITY
1. Operating
window
2. Flexibility/
controllability
3. Reliability
Variables to
satisfy desired
trajectory
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
time
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Flexibility:
where & how
many?
FLEXIBILITY
Key Operability
issues
Flexibility:
where & how
many?
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
v8
F2
F1
T1
T3
v3
T4
F5
T5
F3
v5
v6
v7
T2
Hot Oil
8. Monitoring &
diagnosis
P1
F4
L1
v1
v2
7. Dynamic
Performance
T6
T8
T9
Hot Oil
F6
T7
L2
Key Operability
issues
Flexibility:
where & how
many?
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
DEGREES OF FREEDOM
A requirement for a successful design is:
The number of valves (adjustable variables)
number of variables to be achieved (controlled)
v8
5. Efficiency &
profitability
F2
F1
6. Operation
during
transitions
7. Dynamic
Performance
T1
T3
v3
T4
F5
T5
F3
T6
L1
v1
v5
v2
v6
v7
T2
Hot Oil
T8
T9
Hot Oil
v4
8. Monitoring &
diagnosis
P1
F4
F6
T7
L2
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
Flexibility:
where & how
many?
FLEXIBILITY Where?
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Independent
Connected by
Interaction
spring
Connected by
Linearly
beam
dependent
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Flexibility:
where & how
many?
FLEXIBILITY Where?
CV1 0 K11
CV2 0 K 21
K12
K 22
MV1 K d 1
K D
MV2 d 2
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
Flexibility:
where & how
many?
FLEXIBILITY
3. Reliability
Blending Process
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
FA, xA
FM, xAM
FS, xAS = 0
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
Flexibility:
where & how
many?
FLEXIBILITY
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
FA, xA
Connected
by spring
FM, xAM
FS, xAS = 0
F'M F' A F'S
FS
x' AM
(Fs FA )
FA'
ss
FA
FS'
(Fs FA )
ss
FS
FA
Det ( K )
0
2
2
( FA FS )
( FA FS )
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
Flexibility:
where & how
many?
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
FLEXIBILITY
v1
CB
A B + 2C
-rA = k0 e -E/RT CA
CC
v2
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
Flexibility:
where & how
many?
FLEXIBILITY
A B + 2C
CC
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
v2
Connected
by beam
-rA = k0 e -E/RT CA
C B 0 K11
C 0 2 K
11
C
K12
2 K12
MV1
MV
2
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
Flexibility:
where & how
many?
FLEXIBILITY
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
T
Stream A
(cold)
Stream B
(hot)
Stream A
Stream B
1. Constant
Adjustable
2. Adjustable
Constant
3. Constant
Constant
Key Operability
issues
Flexibility:
where & how
many?
FLEXIBILITY
1. Operating
window
2. Flexibility/
controllability
3. Reliability
1
TC
Stream A
(cold)
4. Safety &
equipment
protection
5. Efficiency &
profitability
Stream B
1. Constant
Adjustable
2. Adjustable
Constant
3. Constant
Constant
Stream B
(hot)
3
TC
6. Operation
during
transitions
TC
Stream A
(cold)
Stream A
(cold)
7. Dynamic
Performance
8. Monitoring &
diagnosis
Stream B
(hot)
Stream B
(hot)
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
Flexibility:
where & how
many?
FLEXIBILITY
5. Efficiency &
profitability
6. Operation
during
transitions
Stream A
(cold)
7. Dynamic
Performance
8. Monitoring &
diagnosis
Stream B
(hot)
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Flexibility:
where & how
many?
Goals:
FLEXIBILITY
Stream A
(cold)
Stream B
(hot)
Q UAY (T ) lm
From an energy balance on entire system:
QHot = Qcold
Connected
by beam
Key Operability
issues
Flexibility:
where & how
many?
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
FLEXIBILITY
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
Flexibility:
where & how
many?
FLEXIBILITY
Disturbances:
Set points:
Fluid inlet
temperatures
Outlet temperature
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
Flexibility:
where & how
many?
FLEXIBILITY
3. Reliability
4. Safety &
equipment
protection
TC
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
Flexibility:
where & how
many?
FLEXIBILITY
4. Safety &
equipment
protection
PIC
1
5. Efficiency &
profitability
AT
1
FT
1
PI
4
TI
1
PI
5
TI
5
TI
2
6. Operation
during
transitions
TI
3
TI
7
TI
4
TI
8
FT
2
7. Dynamic
Performance
air
PI
2
TI
9
PI
3
P-27
TI
10
FI
3
TI
11
PI
6
P-28
8. Monitoring &
diagnosis
TC
TI
6
PT
1
fuel
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
Flexibility:
where & how
many?
FLEXIBILITY
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
To be achieved
disturbance
To be achieved
Key Operability
issues
What to
achieve?
FLEXIBILITY
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
acid
substrate
base
5. Efficiency &
profitability
6. Operation
during
transitions
steam
Cooling
water
7. Dynamic
Performance
8. Monitoring &
diagnosis
air
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
FLEXIBILITY
INDUSTRIAL PRACTICE
1. Flexibility enables achieving points in the operating
window.
2. The choice of adjustable equipment is based on
principles and experience.
3. Controllability is often determined by qualitative
analysis; however, flowsheeting can be used to see if
the dependent variable values can be achieved by
changing the selected adjustable variables.
4. Whether the adjustable variable is manipulated by
process control or by a person depends on the
response time required.
Key Operability
issues
FLEXIBILITY
1. Operating
window
INDUSTRIAL PRACTICE
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis
Key Operability
issues
1. Operating
window
2. Flexibility/
controllability
3. Reliability
4. Safety &
equipment
protection
5. Efficiency &
profitability
6. Operation
during
transitions
7. Dynamic
Performance
8. Monitoring &
diagnosis