INSTRUMENTATION FORP&IDs

But first....Design pressures...Its best to group equipment and give it all the same maximum op. pressureWhat groups would you create?What would the max op. pressure be?

Ground rules for additional equipmentSend non-useful gases (Gas_purge 200 kg/hr, Lights 51 kg/hr) for combustion in the syngas htr (its a fired heater)

Send Fusil_oil (19 kg/hr) to waste treatment plant or to the syngas htr (need tank & pump) - implications?

Ground rules for additional equipmentStorage TanksProvide an off spec tank for the Product sized for 12 hours of hold-up at normal ratesIn addition, provide at least 2 tanks for the ProductProvide an 8 hour storage tank for the Recovr_water Storage Tanks can have L/D = 1 (or less)

Show product storage tanks sending material to existing truck and railcar loadingShow Recovr_water storage tank sending water to waste treatment plant - recycle issues?

Ground rules for additional equipmentPumpsPut a pump on the acetone column bottoms product so we can run it at as low a pressure as possible (at simulation stated pressures) to ensure we remove all lights etc. dont put a pump on degasser bottoms (lets increase the pressure accordingly)what are the trade-offs?Provide a pump on the off spec storage tank to recirc material back to the Acetone column feed.This will help us during start-up or upsets

Ground rules for additional equipment8 hrs12hrs?hrs?hrs

Now Back to our regularly scheduled show...

Instrumentation Cookbook InstrumentationWhy Are We Doing ThisESTIMATOR - To Size The Pumps We Need To Include Inline InstrumentationProvide A Basic Understanding Of Controls Nomenclature and Their ApplicationPIFE

Instrumentation Cookbook InstrumentationObjective:To Produce A Viable Control Scheme in a way that uses and improves our understanding of the simulation and gives us essential information to size the pumpsTo have some examples of controls that could be applied to our processTo understand why these control schemes were selected so that you can form your own judgement

Instrumentation Cookbook Control LoopA Simple Feedback Control LoopSet PointMeasuredVariable (temp, pressure, flow...)

ControllerManipulatedVariableOften not shownFICFITFVFE

Instrumentation NamingInstrument Society Of America (ISA)

ISA Typical Letter Combinations.xls

Sheet1

RCICCCVRISHSLSHLRTITTYEPWGV

ControllersReadout DevicesSwitches and Alarm DevicesTransmitters

Initiating or Measured VariableFirst LetterRecordingIndicatingblindSelf Actuated Control ValvesRecordingIndicatingHighLowCombRecordingIndicatingBlindSolenoids, Relays, Computing DevicesPrimary ElementTest PointWell Of ProbeViewing Device, GlassSafety DeviceFinal Element

AnalysisAARCAICACARAIASHASLASHLARTAITATAYAEAPAWAV

Burner, CombustionBBRCBICBCBRBIBSHBSLBSHLBRTBITBTBYBEBWBGBV

Users ChoiceC

Users ChoiceD

VoltageEERCEICECEREIESHESLESHLERTEITETEYEEEZ

Flow RateFFRCFICFCFCV FICVFRFIFSHFSLFSHLFRTFITFTFYFEFPFGFV

Flow QuantityFQFQRCFQICFQRFQIFQSHFQSLFQITFQTFQYFQEFQV

Flow RatioFFFFRCFFICFFCFFRFFIFFSHFFSLFEFFV

Users ChoiceG

HandHHICHCHRHIHSHRTHITHTHYHV

Current (Electrical)IIRCIICIRIIISHISLISHLIRTIITITIYIEIZ

PowerJJRCJICJRJIJSHJSLJSHLJRTJITJTJYJEJV

TimeKKRCKICKCKCVKRKIKSHKSLKSHLKRTKITKTKYKEKV

LevelLLRCLICLCLCVLRLILSHLSLLSHLLRTLITLTLYLELWLGLV

Users ChoiceM

Users ChoiceN

Users ChoiceO

Pressure, VacuumPPRCPICPCPCVPRPIPSHPSLPSHLPRTPITPTPYPEPPPSV, PSEPV

Pressure DifferentialPDPDSHPDSLPDRTPDITPDTPDYPEPPPDV

QuantityQQRCQICQRQIQSHQSLQSHLQRTQITQTQYQEQZ

RadiationRRRCRICRCRRRIRSHRSLRSHLRRTRITRTRYRERWRV

Speed, FreqSSRCSICSCSCVSRSISSHSSLSSHLSRTSITSTSYSESV

TemperatureTTRCTICTCTCVTRTITSHTSLTSHLTRTTITTTTYTETPTWTGTSETV

Temperature DifferentialTDTDRCTDICTDCTDCVTDSHTDSLTDRTTDITTDTTDYTETPTWTDGTDV

MultivariableUURUIUYUV

Vibration, Mechanical AnalysisVVRVIVSHVSLVSHLVRTVITVTVYVEVWVGVZ

Weight, ForceWWRCWICWCWCVWRWIWSHWSLWSHLWRTWITWTWYWEWWWGWZ

Weight, Force DifferentialWDWDRCWDICWDCWDCVWDRWDIWDSHWDSLWDRTWDITWDTWDYWEWDWWDGWDZ

UnclassifiedX

Event, State or PresenceYYICYCYRYIYSHYSLYTYYYEYWYGYZ

Position, DimensionZZRCZICZCZCVZRZIZSHZSLZSHLZRTZITZTZYZEZWZGZV

Gauging DeviationZDZDRCZDICZDCZDCVZDRZDIZDSHZDSLZDRTZDITZDTZDYZDEZDWZDGZDV

Other Possible Combinations

FO(Restriction Orifice)PFR(Ratio)

FRK, HIK(Control Stations)KQI(Running Time Indicator)

FX(Accessorsies)QQI(Indicating Counter)

TJR(Scanning Recorder)WKIC(Rate-Of-Weight-Loss Controller)

LLH(Pilot Light)HMS(Hand Momementary Switch)

Sheet2

Sheet3

Sheet1

RCICCCVRISHSLSHLRTITTYEPWGV

ControllersReadout DevicesSwitches and Alarm DevicesTransmitters

Initiating or Measured VariableFirst LetterRecordingIndicatingblindSelf Actuated Control ValvesRecordingIndicatingHighLowCombRecordingIndicatingBlindSolenoids, Relays, Computing DevicesPrimary ElementTest PointWell Of ProbeViewing Device, GlassSafety DeviceFinal Element

AnalysisAARCAICACARAIASHASLASHLARTAITATAYAEAPAWAV

Burner, CombustionBBRCBICBCBRBIBSHBSLBSHLBRTBITBTBYBEBWBGBV

Users ChoiceC

Users ChoiceD

VoltageEERCEICECEREIESHESLESHLERTEITETEYEEEZ

Flow RateFFRCFICFCFCV FICVFRFIFSHFSLFSHLFRTFITFTFYFEFPFGFV

Flow QuantityFQFQRCFQICFQRFQIFQSHFQSLFQITFQTFQYFQEFQV

Flow RatioFFFFRCFFICFFCFFRFFIFFSHFFSLFEFFV

Users ChoiceG

HandHHICHCHRHIHSHRTHITHTHYHV

Current (Electrical)IIRCIICIRIIISHISLISHLIRTIITITIYIEIZ

PowerJJRCJICJRJIJSHJSLJSHLJRTJITJTJYJEJV

TimeKKRCKICKCKCVKRKIKSHKSLKSHLKRTKITKTKYKEKV

LevelLLRCLICLCLCVLRLILSHLSLLSHLLRTLITLTLYLELWLGLV

Users ChoiceM

Users ChoiceN

Users ChoiceO

Pressure, VacuumPPRCPICPCPCVPRPIPSHPSLPSHLPRTPITPTPYPEPPPSV, PSEPV

Pressure DifferentialPDPDSHPDSLPDRTPDITPDTPDYPEPPPDV

QuantityQQRCQICQRQIQSHQSLQSHLQRTQITQTQYQEQZ

RadiationRRRCRICRCRRRIRSHRSLRSHLRRTRITRTRYRERWRV

Speed, FreqSSRCSICSCSCVSRSISSHSSLSSHLSRTSITSTSYSESV

TemperatureTTRCTICTCTCVTRTITSHTSLTSHLTRTTITTTTYTETPTWTGTSETV

Temperature DifferentialTDTDRCTDICTDCTDCVTDSHTDSLTDRTTDITTDTTDYTETPTWTDGTDV

MultivariableUURUIUYUV

Vibration, Mechanical AnalysisVVRVIVSHVSLVSHLVRTVITVTVYVEVWVGVZ

Weight, ForceWWRCWICWCWCVWRWIWSHWSLWSHLWRTWITWTWYWEWWWGWZ

Weight, Force DifferentialWDWDRCWDICWDCWDCVWDRWDIWDSHWDSLWDRTWDITWDTWDYWEWDWWDGWDZ

UnclassifiedX

Event, State or PresenceYYICYCYRYIYSHYSLYTYYYEYWYGYZ

Position, DimensionZZRCZICZCZCVZRZIZSHZSLZSHLZRTZITZTZYZEZWZGZV

Gauging DeviationZDZDRCZDICZDCZDCVZDRZDIZDSHZDSLZDRTZDITZDTZDYZDEZDWZDGZDV

Other Possible Combinations

FO(Restriction Orifice)PFR(Ratio)

FRK, HIK(Control Stations)KQI(Running Time Indicator)

FX(Accessorsies)QQI(Indicating Counter)

TJR(Scanning Recorder)WKIC(Rate-Of-Weight-Loss Controller)

LLH(Pilot Light)HMS(Hand Momementary Switch)

Sheet2

Sheet3

Instrumentation Cookbook P&IDs - SymbologyEquipment SymbologyInstrumentation Symbology

See the document P&ID Symbols and Photos.DOC

Instrumentation Cookbook P&IDs - SymbologyLICLocated in DCS(process control computer)LTPhysically locatedin fieldPhysical wire hardwiredSoftware Signal

Instrumentation Cookbook The Control ValveElec SignalTo valve(4-20 mADC signal)Actuator - driven by Compressed AirValve

Instrumentation Cookbook Typical ControlsLevelFlow PressureTemperatureComposition

Instrumentation Cookbook Level ControlPurposePrevent the tank from overfilling / running dryLTLVLIC

Instrumentation Cookbook Level ControlPurposeHold a liquid SealLTLVLICNo Gas!

Instrumentation Cookbook Level ControlPurposePrevent pump from running dry and thus being destroyedLTLVLICNote: - valve always on disch to prevent flashing on pump suction - pump may also require a minimum flow bypass

Control SystemsAside - SpeedMeasured Variable can be slow to measure (I.e. the composition using an analyser) or fast (pressure)The Manipulated Variable can be slow too (I.e. adjusting the hot water tap in your shower)The level in a tank can take hours to change (slow)

Control SystemsAside - SpeedSlow ThingsSay > few secondsReducing Pressure by Opening a valve on a large gas filled tankMeasure Composition (analysers)Change Level In Large TankFast ThingsLess than a secondMeasure PressureMeasure Flow (Diff Press)Measure Temp (?)

But. Its all RELATIVE !!

Instrumentation CookbookFlow ControlPurpose: Ensure steady material flow rate Smooth feed to columnsSet Production rateFast to MeasureFlow Changes usually require a control valve to change its position which can take seconds.Vapour systems have a capacitance that need to be overcome before the flow changes are experienced everywhere in the system

Instrumentation CookbookFlow ControlFVFTFICMIFTSICFICVariable Speed DriveFEFEMount FE upstream in vapour systems to minimize pressure/density effects

Instrumentation Cookbook- Ratio Flow ControlSet one flow rateOther flow is proportionally controlled to first flowEnsure correct mixture / recipesFVFTFICFEFVFTFEFICFRICSPSPSP

Instrumentation CookbookPressure ControlSimilar to Level (control of material inventory)Very fast for incompressible fluidsHard to say for compressible fluids, depends on system volume but probably slow

Instrumentation CookbookPressure ControlControl Upstream | Control DownstreamPICPTPVPICPTPVNeed to control vessel pressureNeed to downstream (header or process) pressure

Instrumentation CookbookPressure ControlCondensable GasPICPTPVNeed to control vessel pressureFast or slow?

Instrumentation CookbookPressure ControlLiquid Pressure ControlPICPTPVControl pump discharge pressure - not very useful

Instrumentation CookbookPressure ControlLiquid Pressure ControlPICPTPVControl pump discharge pressure - ensure constant feed pressure to FVFVFTFICFE

Instrumentation CookbookTemperature ControlNormally control the flow of one fluid to change the temperature of anotherIn Reality its an LMTD change that affects the exchanger dutyQ = U A Tln

Instrumentation CookbookTemperature ControlLiquid / Liquid - control on cooling media

C/w

Instrumentation CookbookTemperature ControlLiquid / Liquid - control on processC/w

Instrumentation CookbookTemperature ControlSteam Pressure ControlTIncrease StmPressure

Instrumentation CookbookTemperature ControlCondensate Level ControlReduce floodedArea

Instrumentation Cookbook Cascade ControlExample - Driving to MontrealYoure driving / steering the carSomeone else is telling you which roads to drive on and when to turn

Instrumentation Cookbook Cascade ControlOne Control Loop Determines Setpoint of a Second LoopMIFTSICVariable Speed DriveFEFICSPSP-Using the flow through the pump to control the rotational speed of the pump

Instrumentation Cookbook Cascade ControlCommon Around Distillation Columns Where There Are Slow LoopsPTFVFTFEFICPIC

Instrumentation Cookbook Controller InteractionMany Controllers Interact but some configurations Interfere with each otherI.e. the control of reflux flow interacts with the column bottom level control but two flow controllers on the same pipe will interfere with each other (they duel for control of the flow)

Instrumentation Cookbook Controller InteractionDuelling Control ?LTLVLICFTFICFE

Instrumentation Cookbook Controller InteractionDuelling Control ?LTLVLICFTFICFE

Instrumentation Cookbook Controller InteractionDuelling Control ?PICPTPVPICPTPV100 psigCompressedAirSP= 75 psigSP= 35 psig

P&ID Cookbook-By Equipment

P&ID Cookbook- PumpsPRV

Pump - Min Flow BypassMIHS

HS

PI

PI

LVLICLT

Reflux TanksNLL = 3-6LLL = 2-0HLL = 4-6LLLL = 2-0LITLSLLIPumpS/DLICTI

PI

To PumpFrom PumpTO LVVent to Safe LocnLAHL LALLFrom CondenserSet@

Compressors - CentrifugalFor our purposes treat controls as a black boxBut... Provide an input control signal (cascade)Remember cooling water reqd (lube system...)MBy VendorBy OwnerCWRCWSSICControlFrom ?

ColumnsPut a control scheme to ensureFeed rate is constant or is slowly changing

Columns -BottomsLICLAHLLITTETICT5 barStmLowP CondLLLLLLLNLLHLLHHLLPut level control on bottoms outflow whenoutflow rate > 10 x boil up ratePut level control on Steam controlboilup rate > 10 x outflow rateotherwise either scheme okay

FTFIC

Columns - Overhead

Instrumentation CookbookColumn ControlIf a flow rate dominates use it to control the level

Column Overhead Control - Scheme 1when the draw rate is 10 x > reflux rateManipulate Distillate draw rate to control Reflux levelManipulate reflux rate to control Column Composition

Instrumentation CookbookColumn ControlColumn Overhead Control - Scheme 2when the reflux rate is 10 x > draw rateManipulate Distillate draw rate to Manipulate Column CompositionManipulate reflux rate to control control Reflux Drum level

Instrumentation CookbookTanks - StorageLITLSHHPRVM LI LSLLILAHLILY TI LSHH LAHHLVTemperature Control May Be Required-does material freeze / boil?

WorkshopDraw the level control that should go on a storage tankProvide a different control scheme for the reactor / condenser / flasher P&IDdraw itexplain how your scheme works and responds to upsetsexplain the pros/cons of your schemeusing a BFD, including the syngas process, show how pressure control can be doneHand this in at the end of class...

END

Instrumentation CookbookTanks - Process SurgePSVLVLTLICConsider Pressure Control

Heat Exchangers - CondenserVent to Safe LocnTVTV on condenser outlet to prevent c/w flashing inside condenser during turndownTICTAHLTECWS

Pressure control on pump provides a steady pressure to the flow control valve

Essentially the pump flow is fixed through this scheme.

By making the pressure at the inlet of the FV constant the flow control will bebetter (more linear).

Show pump curve dropping as flow increases.Increase in hot flow rate in second boxBottom box shows decrease in hot stream flow rate and corresponding- decrease in LMTD to reduce overall duty of exchanger- increase in c/w outlet to reduce LMTD-decrease in cooling water flowCascade temperature to steam flow