INSTRUMENTATION FOR P&IDs

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

Ground rules for additional equipment

Send 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 equipment

Storage Tanks Provide an off spec tank for the Product sized for 12 hours of hold-up at normal rates In addition, provide at least 2 tanks for the Product Provide 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 loading Show Recovr_water storage tank sending water to waste treatment plant - recycle issues?

Ground rules for additional equipment

Pumps Put 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 equipment

? hrs

? hrs
12 hrs

8 hrs

Now Back to our regularly scheduled show...

Instrumentation Cookbook Instrumentation

Why Are We Doing This ESTIMATOR - To Size The Pumps We Need To Include Inline Instrumentation Provide A Basic Understanding Of Controls Nomenclature and Their Application

FE

PI

Instrumentation Cookbook Instrumentation

Objective: 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 pumps To have some examples of controls that could be applied to our process
To understand why these control schemes were selected so that you can form your own judgement

Instrumentation Cookbook Control Loop

A Simple Feedback Control Loop
Set Point Often not shown

Measured Variable (temp, pressure, flow...)

FE FIT

Controller

Manipulated Variable

FIC FV

Controllers

Initiating or First Measured Variable Letter Analysis A Burner, Combustion B Users Choice C Users Choice D Voltage E Flow Rate F Flow Quantity FQ Flow Ratio FF Users Choice G Hand H Current (Electrical) I Power J Time K Level L Users Choice M

Instrumentation Naming
ERC FRC FQRC FFRC EIC FIC FQIC FFIC HIC IIC JIC KIC LIC EC FC FCV FICV FFC HC ER FR FQR FFR HR IR JR KR LR EI FI FQI FFI HI II JI KI LI ESH FSH FQSH FFSH ESL FSL FQSL FFSL ESHL FSHL IRC JRC KRC LRC KC LC KCV LCV ISH JSH KSH LSH ISL JSL KSL LSL HS ISHL JSHL KSHL LSHL

Recording Indicating blind ARC AIC AC BRC BIC BC

Readout Devices Switches and Alarm Devices Self Actuated Control Valves Recording Indicating High Low Comb AR AI ASH ASL ASHL BR BI BSH BSL BSHL

Transmitters

Recording Indicating Blind ART AIT AT BRT BIT BT

ERT FRT

EIT FIT FQIT

ET FT FQT

Instrument Society Of America (ISA)

HRT IRT JRT KRT LRT

HIT IIT JIT KIT LIT

HT IT JT KT LT

Initiating or Measured Variable Analysis Burner, Combustion Users Choice Users Choice Voltage Flow Rate Flow Quantity Flow Ratio Users Choice Hand Current (Electrical) Power Time

First Letter A B C D E F FQ FF G H I J K

Solenoids, Relays, Computing Primary Devices Element AY AE BY BE

Well Of Test Point Probe AP AW BW

Viewing Device, Glass BG

Safety Device

Final Element AV BV

EY FY FQY

EE FE FQE FE

FP

FG

EZ FV FQV FFV HV IZ JV KV

HY IY JY KY

IE JE KE

ISA Typical Letter Combinations.xls

Instrumentation Cookbook P&IDs - Symbology

Equipment Symbology Instrumentation Symbology See the document P&ID Symbols and Photos.DOC

Instrumentation Cookbook P&IDs - Symbology

LIC

Located in DCS (process control computer) Software Signal

Physically located in field Physical wire hardwired

LT

Instrumentation Cookbook The Control Valve

Actuator driven by Compressed Air

Elec Signal To valve (4-20 mA DC signal)

Valve

Instrumentation Cookbook Typical Controls

Level Flow Pressure Temperature Composition

Instrumentation Cookbook Level Control

Purpose Prevent the tank from overfilling / running dry

LT
LIC

LV

Instrumentation Cookbook Level Control

Purpose Hold a liquid Seal

LT
LIC

No Gas!
LV

Instrumentation Cookbook Level Control

Purpose Prevent pump from running dry and thus being destroyed
LT
LIC

LV
Note: - valve always on disch to prevent flashing on pump suction - pump may also require a minimum flow bypass

Control Systems Aside - Speed

Measured 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 Systems Aside - Speed

Slow Things Say > few seconds Reducing Pressure by Opening a valve on a large gas filled tank Measure Composition (analysers) Change Level In Large Tank Fast Things Less than a second Measure Pressure Measure Flow (Diff Press) Measure Temp (?)

But. Its all RELATIVE !!

Instrumentation Cookbook Flow Control

Purpose: Ensure steady material flow rate
Smooth feed to columns Set Production rate

Fast to Measure Flow 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 Cookbook Flow Control

FT
FIC

FE
FT FV
M I

FIC

FE

SIC Variable Speed Drive

Mount FE upstream in vapour systems to minimize pressure/density effects

Instrumentation Cookbook - Ratio Flow Control

FIC
SP

FT FV
FIC
SP

FRIC

SP

FE FT

Set one flow rate Other flow is proportionally controlled to first flow
Ensure correct mixture / recipes

FE

FV

Instrumentation Cookbook Pressure Control

Similar to Level (control of material inventory) Very fast for incompressible fluids Hard to say for compressible fluids, depends on system volume but probably slow

Instrumentation Cookbook Pressure Control

Control Upstream | Control Downstream
PIC PT PV PV PIC PT

Need to control vessel pressure

Need to downstream (header or process) pressure

Instrumentation Cookbook Pressure Control

Condensable Gas

PIC PV PT
Need to control vessel pressure Fast or slow?

Instrumentation Cookbook Pressure Control

Liquid Pressure Control

PIC PT PV
Control pump discharge pressure - not very useful

Instrumentation Cookbook Pressure Control

Liquid Pressure Control

PIC PT FT PV
Control pump discharge pressure - ensure constant feed pressure to FV

FIC

FE

FV

Instrumentation Cookbook Temperature Control

Normally control the flow of one fluid to change the temperature of another In Reality its an LMTD change that affects the exchanger duty

Q = U A Tln

Instrumentation Cookbook Temperature Control

Liquid / Liquid - control on cooling media

C/w

Instrumentation Cookbook Temperature Control

Liquid / Liquid - control on process

C/w

Instrumentation Cookbook Temperature Control

Steam Pressure Control

Increase Stm Pressure

Instrumentation Cookbook Temperature Control

Condensate Level Control

Reduce flooded Area

Instrumentation Cookbook Cascade Control

Example - Driving to Montreal Youre driving / steering the car Someone else is telling you which roads to drive on and when to turn

Instrumentation Cookbook Cascade Control

One Control Loop Determines Setpoint of a Second Loop
FT
-Using the flow through the pump to control the rotational speed of the pump

FE
High Speed

FIC

SP

P
Low Speed

I
SIC
SP

Flow

Variable Speed Drive

Instrumentation Cookbook Cascade Control

PIC FIC

FT

FE PT

FV

Common Around Distillation Columns Where There Are Slow Loops

Instrumentation Cookbook Controller Interaction

Many Controllers Interact but some configurations Interfere with each other I.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 Interaction

Duelling Control ?

LT
LIC

FIC

FT FE

LV

Instrumentation Cookbook Controller Interaction

Duelling Control ?

LIC

LT

FIC

FT FE
LV

Instrumentation Cookbook Controller Interaction

Duelling Control ?
SP= 75 psig
SP= 35 psig PIC

PIC PT
100 psig Compressed Air

PT PV

PV
User 1

User 2 User 3

User 1

User 2 User 3

P&ID Cookbook -By Equipment

P&ID Cookbook - Pumps

PRV

PI

PI

HS HS

Pump - Min Flow Bypass

RO

PI

LT

PI

LIC

LV
HS HS

Reflux Tanks
Set@ From Condenser
PI

Vent to Safe Locn

From Pump

TI

LSLL

HLL = 4-6 NLL = 3-6 LLL = 2-0 LLLL = 2-0

LIT

LAHL LIC

TO LV

LALL

Pump S/D

To Pump

Compressors - Centrifugal
For our purposes treat controls as a black box But... Provide an input control signal (cascade) Remember cooling water reqd (lube system...) CWS Control From ?

CWR

SIC

By Vendor By Owner

Columns
Composition control Pressure control
Put a control scheme to ensure Feed rate is constant or is slowly changing Level control

Level control

Treat the top and bottom independently of each other

Composition control

Columns Bottoms

Put level control on bottoms outflow when outflow rate > 10 x boil up rate Put level control on Steam control boilup rate > 10 x outflow rate otherwise either scheme okay

FIC
HHLL

FT
5 bar Stm

LIT

HLL NLL LLL LLLL

Low P Cond

TE
LAHL

LIC

TIC

TE

TIC

Columns - Overhead
PIC
CWS

PT

FV

CWR

FIC
FT
TI

Set@

PI

PV

RO
HLL = 4-6 NLL = 3-6 LLL = 2-0 LLLL = 2-0 LAHL LIC

LIT

PI PI

LSLL

LALL

Pump S/D

LV
HS HS

Instrumentation Cookbook Column Control

If a flow rate dominates use it to control the level Column Overhead Control - Scheme 1 when the draw rate is 10 x > reflux rate
Manipulate Distillate draw rate to control Reflux level Manipulate reflux rate to control Column Composition

Instrumentation Cookbook Column Control

Column Overhead Control - Scheme 2 when the reflux rate is 10 x > draw rate
Manipulate Distillate draw rate to Manipulate Column Composition Manipulate reflux rate to control control Reflux Drum level

Instrumentation Cookbook Tanks - Storage

PRV
LAHH

LSHH

LY

TI

LSHH

Temperature Control May Be Required -does material freeze / boil?

LI
LAHL

LSLL

LIT
LV

Workshop

Hand this in at the end of class...

Draw the level control that should go on a storage tank Provide a different control scheme for the reactor / condenser / flasher P&ID
draw it explain how your scheme works and responds to upsets explain the pros/cons of your scheme

using a BFD, including the syngas process, show how pressure control can be done

END

Instrumentation Cookbook Tanks - Process Surge

PSV

Consider Pressure Control

LT

LIC

LV

Heat Exchangers - Condenser

Vent to Safe Locn

TV

TIC

TV on condenser outlet to prevent c/w flashing inside condenser during turndown

CWS TAHL

TE