CHAPTER 2 : CONTROL OBJECTIVES AND BENEFITS
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1 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
2 CHAPTER 2 : CONTROL OBJECTIVES AND BENEFITS Outline of the lesson. Seven (7) Control Objectives 2. Environmental protection 3. Equipment protection 6. Profit 7. Monitoring and diagnosis Variability measures Economic impact of variability Workshop
3 EXAMPLE PROCESS: FLASH SEPARATION Let s discuss this process P 1000 kpa Methane Ethane (LK) Propane Butane Pentane T 298 K A1
4 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
5 SEVEN CONTROL OBJECTIVES 2. Environmental Protection High pressure in drum is dangerous PC 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
6 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
7 SEVEN CONTROL OBJECTIVES 2. Environmental Protection Never release hydrocarbons to atmosphere To flare 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
8 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
9 SEVEN CONTROL OBJECTIVES 2. Environmental Protection No flow could damage the pump 3. Equipment protection ion rate LC 6. High profit 7. Monitoring & diagnosis A1
10 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
11 SEVEN CONTROL OBJECTIVES 2. Environmental Protection Always keep the ion rate smooth 3. Equipment protection ion rate FC 6. High profit 7. Monitoring & diagnosis A1
12 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
13 SEVEN CONTROL OBJECTIVES 2. Environmental Protection Achieve L.Key by adjusting the heating 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis AC
14 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
15 SEVEN CONTROL OBJECTIVES 2. Environmental Protection Use the least costly heating 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis AC
16 SEVEN CONTROL OBJECTIVES Give example 2. Environmental Protection 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
17 SEVEN CONTROL OBJECTIVES 2. Environmental Protection Calculate & plot key parameters, e.g., UA. 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis UA A1 time
18 SEVEN CONTROL OBJECTIVES 2. Environmental Protection All seven must be achieved. Failure to do so will lead to operation that is unprofitable or worse, unsafe. 3. Equipment protection ion rate 6. High profit 7. Monitoring & diagnosis A1
19 BENEFITS FROM PROCESS CONTROL When we control a process, we reduce the variability of key variables to achieve the seven objectives. Without feedback control 6 Composition (% H. Key) outlet concentration valve position (% open) time (min) Reflux valve time (min)
20 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 Composition (% H. Key) outlet concentration 3 valve position (% open) time (min) Reflux valve time (min) Variability is moved from controlled to manipulated variable!
21 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?
22 BENEFITS FROM PROCESS CONTROL performance = efficiency, yield, ion rate, etc. It measures performance for a control objective. Calculate the process performance using the distribution, not the average value of the key variable!
23 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. A B
24 Example of Benefits of reduced variability for chemical reactor A Goal: Maximize efficiency and prevent fuel-rich flue gas Which operation, A or B, is better and explain why. B
25 CHAPTER 2: GOALS AND BENEFITS WORKSHOP 1 Determine one example for each of the seven control objective categories. feed FT 1 TI 2 TI 1 PIC 1 AT 1 Flue gas PI 4 PI 5 TI 5 The feed flows through a pipe and is heated by the combustion of fuel TI 3 TI 4 PT 1 TI 6 TI 7 TI 9 TI 10 air FT 2 TI 8 FI 3 TI 11 PI 2 PI 3 PI 6 fuel
26 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 frequency of occurrence deviation from mean
27 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? A1
28 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 Lot s 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, we ll have an assignment!
29 CHAPTER 2: LEARNING RESOURCES SITE PC-EDUCATION WEB - Instrumentation Notes - Interactive Learning Module (Chapter 2) - Tutorials (Chapter 1/2)
30 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. Design and Engineering Practice, Prentice-Hall, 1995 (page 2-65).
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