4.

1 Introduction
The P&ID of butadiene plant is mainly focus on the piping system and control system,
such as level control, temperature control, pressure control and composition control. This
diagram is purposely used to detail out the control system of equipment required. Most of the
main control valves will have their own by-pass valve calibration or alternative.

4.1.1 Piping and Instrumentation Diagram (P&ID)

Piping and Instrumentation Diagram is a diagram in the process industry which shows
the piping of the process flow together with the installed equipment and instrumentation. The
process flow sheet exhibits the arrangement of the major equipment and their
interconnection. All in all, it is a description of the process’s nature. On the other hand, the
Piping and Instrumentation Diagram shows the engineering details of the equipment,
instrument, piping, valves and fittings as well as their arrangements. Sometimes it is referred
as Engineering Flow Sheet or Engineering Line Diagram.

The advantages of P&ID control is oscillations can be dampened with respect to PI

control. The disadvantages of P&ID control are harder in tuning because three parameters
must be specified which are KC, I and D and the derivative action may amplify
measurement noise that lead potential wear on the final control element.

4.1.2 General Objective

The general objective for instrumentation and control schemes are:

1. Safe plant operation:

(a) To keep the process variables within known safe operating limits.
(b) To detect dangerous situations as they develop and to provide alarms and automatic
shut-down systems.
(c) To provide interlocks and alarms to prevent dangerous operating procedures.
2. Production rate:
To achieve the design product output.
3. Product quality:
To maintain the product composition for specified quality standards.
4. Cost:
To operate at the lowest production cost, commensurate with the other objectives.
1
4.1.3 Types of Instrument
This is indicated on the circle representing the instrument-controller by a letter code.
Table 4.1 shows some of the examples of letter code for instrument symbols

Table 4.1: Letter Code for Instrument Symbols (Based on BS 1646: 1979)
(SINNORT, 1993)
Indicating Recording
First Indicating Recording Controlling
Property measured and and
letter only only only
controlling controlling
Flow-rate F FI FR FC FIC FRC
Level L LI LR LC LIC LRC
Pressure P PI PR PC PIC PRC
Quality, Analysis Q QI QR QC QIC QRC
Radiation R RI RR RC RIC RRC
Temperature T TI TR TC TIC TRC
Weight W WI WR WC WIC WRC
Any other property X XI XR XC XIC XRC
(specified in a
note)

Notes:
(1) The letter A may be added to indicate an alarm; with H or L placed next to the
instrument circle to indicate high or low.
(2) D is used to show difference or differential; for example, PD for pressure
differential.

2
4.1.4 Proportional Control
The key concepts behind proportional control are the following:
1. The controller gain, KC can be adjusted (“tuned”) to make the controller output
(manipulated variable) changes as sensitive as desired to deviations between set point
and controlled variable.
2. The sign of KC can be chosen to make the controller output (manipulated variable,
p(t)) increase(or decrease) as the error signal increases.

The advantages of the proportional control are theoretically simple and easy to tune
which a single parameter is needed, KC while the disadvantage is cannot remove off-set
because the off-set is enforced by the controlled variables.

4.1.5 Proportional Integrated (PI) Control

The advantages of PI control steady state off-set can be eliminated and the process
response can be considerably speeded up with respect to open-loop. The tuning for PI control
is harder because two parameters must be specified which are KC and I. The process
response becomes oscillatory because bad tuning may lead to instability and the integral
action may “saturate” because reset wind up or integral wind up.

4.1.6 Derivative Control

The basis behind derivative action is to anticipate the future behaviour of the error
signal by considering its rate of change. The anticipatory strategy used by the experienced
operator can be incorporated in automatic controllers by making the controller output
proportional to the rate of change of the error signal or the controlled variable. Table 4.2
shows the differences between P, PI and PID control.

Table 4.2 : Differences between P, PI, and PID control (E-Seborg et al., 2004)
P Control PI Control PID Control
 Simplest controller to  More complicated to tune  Most complicated to tune
tune (KC) (KC, I). (KC, I, D).
 Off set with sustained  Better performance than P  Better performance than PI
disturbance or set-point  No offset  No offset
change  Most popular FB controller  Derivative action may be
affected by noise

3
4.1.7 Feedback Control
One of the simplest process control schemes. A feedback loop measures a process
variable and sends the measurement to a controller for comparison to set point. If the process
variable is not at set point, control action is taken to return the process variable to set point.
The advantage of this control scheme is that it is simple using single transmitter and also
directly controls the desired process variable. This control scheme does not take into
consideration any of the other variables in the process. It is important to make a distinction
between negative feedback and positive feedback. Negative feedback is desirable situation
where the corrective action taken by controller forces the controlled variable toward the set
point. Positive feedback which controller makes things worse by forcing the controlled
variables farther away from the set point (E-Seborg et al., 2004). Figure 4.1 shows the
schematic diagram of feedback control.

Figure 4.1: Schematic diagram of feedback control.

4.1.8 Feedforward Control

Feedforward Control is a control system that anticipates load disturbances and
controls them before they can impact the process variable. For feedforward control to work,
the user must have a mathematical understanding of how the manipulated variables will
impact the process variable. An advantage of feedforward control is that error is prevented,
rather than corrected. However, it is difficult to account for all possible load disturbances in a
system through feedforward control. The limitations of feedforward control are the effects of
disturbance or command input must be predictable, it may not generalize to other conditions
and it will not be accurate if the system changes. Table 4.3 shows some advantages and

4
disadvantages for the feeback and feedforward control system. Figure 4.2 shows the
schematic diagram of ratio control.

Figure 4.2: Schematic diagram of feedforward control

Table 4.3: Advantages and disadvantages for the feeback and feedforward control system
Feedforward Feedback
Advantages  Compensates for a disturbance  Provides zero steady-state offset.
before the process output is  Effective for all disturbances.
affected.
 Does not affect the stability of the
control system.
Disadvantages  Cannot eliminate steady-state offset  Does not take control action until
 Requires a sensor and model for the process output variable has
each disturbance deviated from its set point.
 Affects the stability of the closed-
loop control system.

5
4.1.9 Ratio Control
Ratio control is used to ensure that two or more flows are kept at the same ratio even
if the flows are changing. Application for the ratio control are blending two or more flows to
produce a mixture with specified composition, blending two or more flows to produce a
mixture with specified physical properties and maintaining correct air and fuel mixture to
combustion (E-Seborg et al., 2004). Figure 4.3 shows the schematic diagram of ratio control.

Figure 4.3: Schematic diagram of ratio control

4.1.10 Cascade Control

It uses the output of the primary controller to manipulate the set point of the secondary
controller as if it were the final control element. Cascade control allow faster secondary
controller to handle disturbances in the secondary loop, allow secondary controller to handle
non-linear valve and other final control element problems and allow operator to directly
control secondary loop during certain modes of operation (such as startup). The requirements
for cascade control are secondary loop process dynamics must be at least four times as fast as
primary loop process dynamics. Second, secondary loop must have influence over the
primary loop and lastly, secondary loop must be measured and controllable (E-Seborg et al.,
2004). Figure 4.4 shows the schematic diagram of cascade control.

6
 Figure 4.4: Schematic diagram of cascade control

4.2 SENSORS
A sensor is a device that measures a physical quantity and converts it into a signal
which can be read by an observer or by an instrument.

4.2.1 Sensors (Sensing Element)

The main categories of measurements used process control are temperature, pressure,
flow rate, and liquid level. Table 4.4 show the lists sensor options for each of these four
categories.

Table 4.4: Sensor options for each of these four categories

Temperature Flow Pressure Level
 Thermocouple  Orifice  Liquid column  Float-activated
 Resistance  Venturi  Elastic element - Magnetically
Temperature  Rotameter - bourdon tube coupled
Detector (RTD)  Turbine - bellows  Head devices
 Filled-system  Vortex- - diaphragm - bubble tube
thermometer shedding  Strain gauges  Electrical
 Bimetal  Ultrasonic  Piezoresistive (conductivity)
thermometer  Magnetic transducers  Radiation
 Pyrometer  Thermal mass  Optical fiber  Radar
- total radiation  Target

7
4.2.2 Temperature Control
Temperature control is important to ensure the product achieves the desired
composition or specification. Besides that, temperature control also can minimize the energy
required by reboiler as well as consumed by heat exchanger through controlling the flow of
steam and input stream exchanger. The life span of the equipment can be preserved as long as
the temperature deviation is small.

Resistance Thermometer Detectors, RTD and thermocouple is one of the basic

temperature sensors than have been widely use in various application. RTD is a temperature
sensors that use the electrical resistance of metals changes to measure the local temperature
changes while thermocouples is a temperature sensors that use two different metals in the
sensor to produce a voltage that can be read to measure the local temperature. Generally,
thermocouples are better than RTDs when comparing the cost as it cost 2.5 to 3 times less
than RTD, ruggedness, measurement speed, more durable, react faster towards the changes
in temperature and the range of temperatures that can be measured using them. RTDs are
only can measure up to 1000 degrees Fahrenheit while thermocouples can measure up to
2700 degrees Fahrenheit (Brei, 2013). Table 4.5 shows the descriptions of thermocouple
sensor.

Therefore, thermocouple sensor is chosen in this plant regarding on the wide range of
operating temperature and lower price. It used in temperature control and located at boiler H-
101 and H-102, reactor R-101, heat exchanger E-101 and E-103, condenser E-102, reboiler
E-105 and quench tower V-103.

Table 4.5 : Descriptions of thermocouple sensor

Types of Sensors Specification and Constraint
Thermocouple Specification
 An electrical device consisting of  Accuracy:
two dissimilar electrical conductors - Standard: +/- 2.2 or +/- .75%
forming electrical junctions at - Special Limits of Error: +/- 1.1 or 0.4%
differing temperatures  Size:
- less than 1.6 mm (0.063 in) in diameter
Constraint
 Temperature range
- Thermocouple grade wire: –270 to 1260
- Extension wire: 0 to 200

8
4.2.3 Pressure Control
Pressure is crucial for system consist of gas or vapor. It must be maintain at the
specific value especially in reactor and distillation so that the equipment can function and
reaction can happen. Besides the pressure also cannot be too high as it might cause failure to
the equipment or worse cause explosion. This control method depends to the nature of
process, for instance, pressure is control via manipulating the flow from or to equipment.
Table 4.6 shows type of the sensors for pressure control that used in the process plant for
pressure control.

High Spatial Resolution Distributed Fiber-Optic and strain gauge are two types of
pressure sensors that have been develop in industrial plant. Fiber-optic is normally applied to
measure pressure in high temperature environment up to 800 . This sensor has good
resistant to harsh environments, high temperature up to 800 and high pressure up to 2500
psi (Chen, 2016). Thus, this sensor is suitable to be used in reactor since the temperature of
the reactor is up to 650 Table 4.6 shows the sensors for Pressure control of the strain
gauge.

On the other hand, a strain gauge is normally used in electronic measurement to

convert the diaphragm deflection in differential pressure instrument in the same way as in
pressure instrument. Basically, the liquid or gas stream cannot be brought into direct contact
with sensing element such as diaphragm due to high temperature and corrosion condition (E-
Seborg et al., 2004). Therefore, strain gauge is also chosen for the plant and applied in most
of the equipment such as condenser E-102, hydrocarbon absorption column V-102, stripping
tower V-103 and condenser E-104. This is because the operating temperature in the
equipment is less than 250 . Table 4.7 shows the sensors for Pressure control of the strain
gauge.

9
 Table 4.6 : Sensors for Pressure control
(High Spatial Resolution Distributed Fiber-Optic) (Chen, 2016)

Types of Sensors Specification and Constraint

High Spatial Resolution Distributed Fiber- Specification
Optic  Resistant to harsh environments
 High neutron radiation (to be evaluated)
 Radiation-harden microstructural fiber for
• Fully embeddable into concrete, metal,
simultaneous temperature and pressure and existing infrastructures
measurements • high spatial resolution (1-10cm)
Constraint
 Pressure Range: up to 2500 psi
 Operating Temperature:
- up to 800

Table 4.7 : Sensors for Pressure control (strain gauge)

Types of Sensors Specification and Constraint

Strain Gauge Pressure Specification
Strain-gauge is normally used for narrow-span  Accuracy:
- 0.5000
pressure and for differential pressure
 Media Liquid:
measurements. Essentially, the strain gauge is - Gas
used to measure the displacement of an elastic  Signal Output:
diaphragm due to a pressure difference across - Analog Voltage
 Features:
the diaphragm. It can detect gauge pressure if
- Temperature compensated
the low pressure port is left open to the Constraint
atmosphere or differential pressure if connected  Working Pressure Range:
- 0.0 to 3000 psi (0.0 to 2111 m
to two process pressures.
H2O)
 Operating Temperature:
- (-269 to 250 )

10
4.2.4 Level Control
Level control is important in equipment with interface existence. It is to maintain the
interface level so that the system may not overflow or dry out during the process. Typically
level control is incorporated in the design with the flow out from equipment. Table 4.8 shows
type of the sensors for level control that used in the process plant for level control.

Since continuous level measurement is necessary in this plant, there are several types
of the sensors that can be used such as ultrasonic and radar sensor. The working principle of
ultrasonic transmitters is by sending sound waves from a piezoelectric transducer to the
process material surface that being measured. The function transmitter is measure time taken
for the reflected sound wave to return towards transducer. A successful measurement depends
on the wave, reflected from the process material and moving in a straight line back to the
transducer. However, the returning signal of this sensor can be affected by dust, heavy
vapors, tank obstructions, surface turbulence, foam, and even surface angles. Besides,
maximum operating temperature of 60°C and varying process temperatures may generate
inaccurate level readings. Thus, this sensor cannot be chosen for this process as most of the
process required high temperature.

Next, Guided-wave radar (GWR) is one of the radar based sensor. GWR is a
contacting level measurement which uses a probe to guide high-frequency electromagnetic
waves from a transmitter to the media based on the principle of time domain reflectometry
(TDR). A low-energy electromagnetic pulse is guided along a probe. When the pulse reaches
the surface of the medium being measured, the pulse energy is reflected up the probe to
circuitry and then measure the fluid level based on the time difference between the sent pulse
and the received reflected pulse. This sensor has more benefit over ultrasonic sensor such as
not affected by environmental and application conditions and high temperatures and
pressures do not affect device performance (Grumney, 2011).

Hence, radar sensor is chosen for this plant and used in n-butene storage tank TK-101,
quench tower V-101, condenser E-102 and E-104, hydrocarbon absorption column V-102
and butadiene storage tank for level control.

11
 Table 4.8: Sensors for Level control
Types of Sensors Specification and Constraint
Radar Level Transmitter Specification
Radar level measurement has been used  Power:
widely in all industries such as be it in - AC: 115 VAC, 60 Hz (± 20%) or 230
simple storage tanks, in corrosive or VAC, 50 Hz (± 20%), 1.7 VA
aggressive media or high accuracy tank - DC: 12 to 30 VDC, 0.07 Amps max. @
gauging applications. This is due to non- 24 VDC
contact radar with simple commissioning,  Output:
trouble-free operation saves time and - Signal: 4-20 mA, 6.1 uA resolution;
money. For usage in a wide range of 750 ohms
applications ("WL900 RADAR LEVEL  Accuracy: ±0.25%
TRANSMITTERS," 2015).  Frequency: 6.3 GHz
 Dimension: 4 inch diameter x 18 inch long
(10cm dia. x 45.7cm long)
 Features:
- Accurate, non-contact measurement
- Works in conditions where ultrasonic is
not acceptable
- Simple push-button calibration
- Standard 4-20mA signal output
Constraint
 Measurement Range: 10 inch to 50 ft (0.254
to 15.2 m)
 Operation Temperature: -40°C to 60°C
 Operating Pressure: 150 psi max

12
4.2.5 Flow Control
Flow control is usually associated with inventory control in a storage tank or other
equipment. There must be a reservoir to take up the changes in flow-rate. Table 4.9 shows the
sensors for the flow control that used in the process plant.

There are three types of common technology flow sensor that have been used. First,
pitot tubes which compare the pressure in a small diameter tube to the static pressure around
the tube. However, the disadvantages of this sensor are can clog from mineralization and
harsh in a landfill gas application, binding fluids yielding false readings and poor accuracy
when flows under 20 scfm. Hence, pitot tubes sensors cannot be chosen for this plant due to
non-user friendly characteristics ("The Advantages and Disadvantages of Traditional Flow
Measurement Devices," 2017).

Second, venturi meter in which the flow measurements are taken before and at the
mid-point of a constriction, then the flow rate is calculated from the difference of the two
measurements. This type of sensor also cannot be chosen for this plant because it can have a
significant pressure drop at high flows, expensive and bulky, it occupies considerable space,
relatively complex in construction and not suitable for flow measurement of highly viscous
slurries.

Last, Orifice meter are a famous flow measurement technology that has been widely
used. Orifice meter is a sensor used for measuring the rate of flow of a fluid through a pipe.
The working principle of the orifice meter is same as venturi meter. However, this sensor has
more benefits compared to venture meter such as orifice is cheaper and easy to install
compare to venturi meter, has greater flexibility and orifice meter can show higher
manometer reading at a given velocity compared to venturi meter.

In this butadiene production plant, orifice meter sensor is chosen for the flow control
loop due to its advantages such as high efficiency, easy to measure flow rate as it produces
considerable pressure drop across the orifice, cheap and simple construction. The sensor is
built in most of the equipment process such as mixer M-101, reactor R-101, heat exchanger
E-101 and E-103, quench tower V-101, condenser E-102 and E-104, hydrocarbon absorption
column V-102

13
 Table 4.9 : Sensors for Flow control
Types of Sensors Specification and Constraint
Orifice Meter Specification
 an orifice sensor is a circular plate  Accuracy: varies with flow rate, from 1 to
inserted between flanges of a pipe with 3%
a round or other shape hole bored in  Very cost-effective for measuring flows in
the plate center, matching system flow larger ones (over 6" diameter)
range and characteristics (E-Seborg et  very cheap and easy method to measure flow
al., 2004) rate
Constraint
 Dynamic range: limited to about 4:1
 Range down : Up to 200:1 (14:1 flow
turndown)
 Measurement Range :
Up to 1000 inH2O (2,48 bar) differential,
Up to 3626 psia (250,00 bar) absolute,
Up to 3626 psig (250,00 bar) gage

4.2.6 Transmitters
Transmitter is a device that converts the sensor output to a signal level appropriate for
input to controller. It generally designed to be direct acting which output signal increases as
the measured variables increase. It also designed to drive the transmission lines connecting
the two which are sensor and controller.

14
 4.2.7 Transducer
Transducer is a device that used to convert the magnitude of a process variable into a
signal that can be sent directly to the controller.

4.2.8 Final Control Element

Final Control Element is a device that directly controls the value of manipulated
variable of control loop. Final control element may be control valves, pumps, heaters, etc.

4.2.9 Chemical Process

It indicates the material equipment together with the physical or chemical operations
that occur there. Figure 4.5 shows the process representation.

Input Output

Manipulated Controlled

Disturbance Process Constraint

Other Other

Figure 4.5 : Process representation

15
4.2.10 Manipulated Variables (MVs)
Manipulated variables are the process input that adjusted dynamically to maintain the
controlled variables at set points.

4.2.11 Controlled Variables (CVs)

Process output which quantify the performance or quality of the final product, which
are also called output variables (Set point).

4.2.12 Disturbance Variables (DVs)

Process input that also called "load" variables and represent input variables that can
cause the controlled variables to deviate from their respective set points which cannot be
manipulated.

4.2.13 Constraint
Constraint can be defined as the value that a constraint parameter must not exceed for
proper operation of the process.

4.3 VALVES
Mechanical devices specifically designed to direct, start, stop, mix or regulate the
flow, pressure or temperature of a process fluid which manufactured from various materials,
mostly made from steel, iron, plastic, brass, bronze and special alloys.

4.3.1 Categories of Control Valve

Control valve can be classified into two types, air-to-open valve and air-to-close
valve. Table 4.10 shows the classes of control valve

Table 4.10 : Classes of control valve

Air-to-open valve Air-to-close valve
As pneumatic controller output signal As the pneumatic controller output signal
increases, the pressure on the diaphragm increases, the pressure on the diaphragm
increase which compresses the spring, thus the increase which compresses the spring, thus the
stem is pulling out and opening the valve stem is pulling out and closing the valve
further. further.

16
4.3.2 Types of valves
There are two broad classes depends on the primary functions that can be used in the
plant. Table 4.11 shows types of valves that used in the process plant.

1. Control valves as final element in manual or automatic control system

2. Shut-off valves can be used for stopping fluid flow in pipeline

Table 4.11: Types of valves used in process plant

Symbol in P&ID Code Functions

Control Valve  Used to stabilize the process with the

Fail-Open Fail-Close target to offset the set point change and
reject any disturbance occurred
V-16, V-18, V-1, V-3,
 The control valve received signals from
V-20, V-22, V-5, V-7,
controller and change the valve position
V-25, V-27, V-9, V-11,
according to order from controller which
V-29, V-31, V-13, V-42,
makes changes to the fluid flow in the
V-34, V-36, V-54,
pipelines
V-38, V-40,
V-44, V-46,
V-48, V-50,
V-52,
Hand Manual V-2, V-4, V-6, V-8, V-10,  Used for bypass through a control valve
Valve V-12, V-14, V-17, V-19,  Allows fully open and fully close in a
(Fully closed) V-21, V-23, V-26, V-28, pipeline
V-30, V-32, V-35, V-37,
V-39, V-41, V-43, V-45,
V-47, V-49, V-51, V-53,
V-55
Angle Valve V-15, V-24, V-33, V-58  Used for regulating the flow of a fluid in a
(Fully Closed) pipe
 Used as pressure relief valve

17
Drain Valve V-56, V-57  used to drain off material that has
(Fully Closed) separated from a fluid or gas stream, or
one used to empty a process line, vessel,
or storage tank
 A valve at the bottom of a combustion
chamber. When the engine shuts down,
these valves open and prevent an
accumulation of fuel in the combustion
chamber.
Check Valve V-59  safety valves that allows gases and liquids
(Fully Closed) to flow in only one direction
 prevent process flow from reversing in the
system which could damage equipment or
upset the process
 applied in process systems that have
varying pressures, which must be kept
separate
 Used for protecting pumps in liquid
applications or compressors in gas
systems where backflow could cause the
pump or compressor to shut down.

18
4.4 Control Design
The starting point for control system design and analysis is preliminary process
design, perhaps with some initial control loops, along with specifications of the desired
process performance.

4.4.1 Storage Tank (TK-102)

Function: To store the product in liquid phase (Butadiene)

Control System: Level Control

Tagging Label LIC10506
Objective of Control To control and maintain the level of the storage tank
Measurements Level of liquid in the tank
Manipulated Outlet flowrate
Variables
10% of the storage tank space need to be free to ensure the safety
Constraints
of the stored liquid
Disturbances Inlet flowrate
Controller Proportional Integrated (PI) Control
Control Structure Feedback Controller
Additional  Control valve is fail to opened
Considerations  Hand manual valve is fully closed

In the storage tank, butadiene will be stored in the liquid phase at the desired
temperature and pressure. However, the storage tank need to be monitor to ensure there is no
spilling or leakage due to the exceeding of storing the product (butadiene). Hence, the level
of the product in the storage tank is measured using radar sensors to detect the butadiene level
and control the out flow of the butadiene by manipulating the flow rate through V-54. Thus,
the optimum safety level storage of the product in this storage tank is achieved. Therefore, in
this system, feedback control system is implied with a PID controller to provide an
immediate action on controlling the final control element, V-54. Radar will detect the level of
the liquid in the storage tank and the transmitter (LT) will detect any changes of the level and
transmit the signal to level indicator controller (LIC) where it alter the control valve to either
open or close before the liquid exceeding the allowable level that can be stored in the tank.

19
 LT
10506

LIC
TK-102 10506

I/P

31 Butadiene

V-54

V-56
V-55

20
4.4.2 Boiler (H-101, H-102, E-105)
Function: To boil the feed (butene)

Control System: Temperature Control

Tagging Label TIC10001
Objective of To control the temperature of the feed in the boiler and ensure that the
Control requirement temperature of the feed for the process is achieved
Measurements Temperature of the feed components
Manipulated Flowrate of feed into the boiler
Variables
Thermocouple at inlet and outlet stream:
Constraints
 25 and 650
Disturbances Variation of feed stream composition
Controller Proportional Integrated (PI) Control
Control structure Feedback Controller
Additional  Control valve is fail to opened
Considerations  Hand manual valve is fully closed

Heating of the feed in the boiler requires energy. The various parts of the total process
thus are interconnected in a manner that makes the dynamics very complex, usually leading
to positive feedback and sometimes to problems with stability. Therefore, automatic control
is absolutely necessary. In this boiler, the fuel is used to heat up the feed gases to the desired
temperature. Hence, the temperature of the output feed gases is measured to control the
temperature inside the boiler in order to achieve the maximum desired temperature of the
feed gas. As the feed gas temperature is under standard condition, when the fuel inflow is
insufficient, the heating effect reduces and it would affect the final product of this process.
Therefore, in this system, feedback control system is implied with a PI controller to provide
an immediate action on controlling the final control element, V-05. The fuel will be
automatically added into the system to ensure the feed gas temperature can be achieved at
their required condition. Thermocouple will detect the temperature of the fluid in the boiler
and the transmitter (TT) will detect any changes of the temperature and transmit the signal to
temperature indicator controller (TIC) where it alter the control valve to either open or close
to allow the coil to heat up the feed to the desired temperature.

21
 10001

TAH

V-04 TT
10001

1 H-101 2
V-03

V-06
V-05
Fuel 3

I/P

22
4.4.3. Mixer (M-101) and Oxidative Dehydrogenation Fixed Bed Reactor (R-101)

Mixer
Function: Mix all the output from H-101(boiler), C-101(blower) and H-102 (boiler) before
entering R-101

Control System: Flow control

Tagging Label FIC10001
Objective of To control the output flow rate of the mixer by adjusting the three inlet
Control flow rate from boiler H-101, blower C-101 and boiler H-102
Measurements Flow rate
Manipulated Inlet flow rates from boiler H-101, blower C-101 and boiler H-102
Variables
Ratio of air : n-butene : water is 2.6 : 1 : 10
 Radar at boiler H-101
- 13.50– 183.86 ton/hr
Constraints  Radar at blower C-101
- 35.36– 183.86 ton/hr
 Radar at boiler H-102
- 135.00– 183.86 ton/hr
Disturbances Inlet temperatures
Controller PID
Control Structure Cascade control system
Additional  Control valve (fail close)
Considerations  Hand manual valve (fully closed)

Before entering the reactor, the raw material which is n-butene, air and water must
undergo mixing process in order to obtain a desired mixture at an equilibrium temperature.
N-butene which is the raw material, air and water are flow into the mixer from boiler H-101,
blower C-101 and boiler H-102 respectively. Hence, flow control is applied in order to
control the output flow rate of the mixer by adjusting the inlet flow rates. Cascade control
system and PI controller are responsible to make an action on air-to-close valve when a
deviation from the set point occurs. The sensor chosen for this loop is orifice meter under
specific ratio constraint.

23
Oxidative Dehydrogenation Fixed Bed Reactor
Function: To produce butadiene from n-butene by using oxidative dehydrogenation process

Control System: Flow control

Tagging Label FIC10101
Objective of To control the outlet flow rate
Control
Measurements Flow rate
Manipulated Inlet flow rate from M-101
Variables
Constraints Maximum flow rate at fully opened valve is 1200 ton/hr
 Inlet temperature of the reactor
Disturbances
 Impurities in the mixture
Controller PID
Control Structure Feedback and cascade loop
Additional  Control valve (fail opened)
Considerations  Hand manual valve (fully closed)

In reactor, the output flow rate is essential to make sure the inlet flow rates of the
mixture are under a right ratio condition. As stated in the mixer, the flow rate ratio is air : n-
butene : water is 2.6 : 1 : 10. Therefore, flow control is applied to control the outlet flow rate
with feedback and cascade loop. The control structure of this loop is PID controller. All of
the feedback and cascade control system and PID controller responsible to make any
corrective action on air-to-close valve. Additionally, orifice meter is the chosen flow sensor
while maximum flow rate at fully opened valve is 1200 ton/hr is the constraint.

24
 Control System: Temperature control
Tagging Label TIC10203
Objective of To reach and maintain the temperature in the reactor at 540 in order
Control to achieve the desired product composition
Measurements Temperature
Manipulated Inlet flow rate of coolant
Variables
Constraints 500-650
Disturbances Inlet temperature of the coolant
Controller PID
Control Structure Cascade control system
Additional  Control valve (fail opened)
Considerations  Hand manual valve (fully closed)

During the reaction process in the reactor, a desired product composition can be
obtained at 540 of temperature operating condition. Hence, temperature loop is necessary
to reach and maintain the temperature in the reactor at 540 . This objective can be achieved
by manipulating the inlet flow of coolant. Cascade control system with PID controller is
applied to reduce any error when the deviations occurred. For example, when the temperature
in the reactor which detected by thermocouple sensor is higher than the set point, the air-to-
close valve, V-18 will open to allow more coolant enter. Hence, temperature in the reactor
can be reduce and reach the set point.

25
 Control System: Pressure control
Tagging Label PIC10001
Objective of To maintain the pressure in the reactor at 1atm by controlling the inlet
Control flow rate
Measurements Pressure
Manipulated Inlet flow rate of coolant
Variables
Constraints 1-1.5 atm
 Unwell mixing
Disturbances
 Temperature drop at stream 9 might occur
Controller PID
Control Structure Feedback control system
 Control valve (fail opened)
Additional  Hand manual valve (fully closed)
Considerations  Pressure alarm high to alert the operator about the overpressure
condition

The purpose of pressure control in the reactor is to maintain the pressure in the reactor
at 1atm by controlling the inlet flow rate. The pressure must be control to avoid overpressure
vessel conditions and safety precautions. In this case, feedback control system and PID
controller is applied. The constraint for this control is 1-1.5 atm. If the pressure output signal
deviates from the set point, the controller will make an immediate corrective action to reduce
the error. For example, when the pressure above the constraint, pressure alarm high will ring
to alert the operator about the overpressure condition, then controller immediately do any
necessary corrective action to reduce the error.

26
27
4.4.4. Heat Exchanger (E-101)
Function: To cool down the outlet stream of the reactor from 500 to 100 before enter the
Quench tower.

Control System: Temperature control

Tagging Label TIC10505
To reduce the temperature of stream, S-10 at desired value (100°C) so
Objective of
that the plant operates safely and can achieve maximum energy
Control
recovery.
Measurements To measure the outlet temperature
Manipulated Manipulate the inlet stream of heat exchanger in the shell side.
Variables
 Thermocouple at inlet and outlet stream
- 100 to 500
Constraints
 Thermocouple at inlet and outlet coolants
- 30 to 140
Disturbances Change in process fluid flow rate
Controller PID
Control Structure Cascade Control Loop
Additional  Control valve is fail to opened
Considerations  Hand manual valve is fully closed

In the heat exchanger, the coolant water is used in order to cool down the temperature
from 500 to 100 , so that the plant operates safely and can achieve maximum energy
recovery. Hence, the temperature is measured in order to control the inlet stream of the heat
exchanger in the shell side to achieve the aim of changes of temperature from 500 to 100 .
In this system, the cascade control loop is implied with the PID controller in order to provide
an immediate action on controlling the final control element, V-27. For temperature sensor,
the thermocouple will detect the amount of the heat flow in the heat exchanger, and the
transmitter (TT) will detect any changes of the temperature and transmit the signal to
temperature indicator controller (TIC) where it alter the control valve to either open or close
to allow the inlet stream of the heat exchanger.

28
 Control System: Flow control
Tagging Label FIC10404
Objective of To maintain the flow of the coolant in the heat exchanger in a stable
Control or required condition.
Measurements To measure the inlet flow of coolant
Manipulated The amount of the coolant inlet stream into the heat exchanger
Variables
Constraints  Flow rate at inlet and outlet stream
- 13.81 kg/s
Disturbances Outlet stream of coolant
Controller PID
Control Structure Cascade Control Loop
Additional  Control valve is fail to opened
Considerations  Hand manual valve is fully closed

The flow of coolant water that enters the heat exchanger is measured in order to
control the amount of the coolant inlet stream at 13.81 kg/s. In this system, the cascade
control loop is implied with the PID controller in order to provide an immediate action on
controlling the final control element, V-27. For flow sensor, the orifice meter will detect the
amount of coolant flow rate in the inlet stream of the coolant at heat exchanger, and
transmitter (FT) will detect any changes of the flow rate and then transmit the signal to flow
indicator controller (FIC) where it alters the control valve to either open or close to allow the
inlet stream of the heat exchanger.

29
30
4.4.5. Quench Tower (V-101) and Condenser (E-102)
Quench Tower
Function: To lower the temperature of product gases and to remove the water content.

Control System: Flow control

Tagging Label FIC10103
Objective of To control the inlet flow rates of water
Control
Measurements Inlet flow rate of product gases
Manipulated Inlet flow rate of water
Variables
Constraints Maximum flow rate at fully opened V-22 is 1200 ton/ hr
-Pump efficiency
Disturbances -Flow rate of water into pump P-101
-Impurities in water inlet
Controller PID
Control structure Feedback control
Additional Recycle stream back to pump P-101
Considerations

In the quench tower, water is used to cool down the product gases down to condense
steam into water. Hence, the flow rate of the input product gases is measured to control the
input flow rate of the water in order to achieve the aim of changes of steam from gaseous
phase to liquid water. As the boiling temperature of water is about 100 under standard
condition, when the water inflow is insufficient, the cooling effect reduces and less steam
would able to condense into water. Therefore, in this system, feedback control system is
implied with a PID controller to provide an immediate action on controlling the final control
element, V-22. However, there are still some constraints as stated in the table above. For
example, the decreases in efficiency of pump P-101 due to failure. When the pumped output
flow rate of water is larger than the desired flow rate, the excessive water can be returned
back to P-101 via the recycling stream to avoid overpressure towards valve V-22.

31
 Control System: Level control
Tagging Label LIC10102
Objective of To control the water level in vessel V-101
Control
Measurements Water Level
Manipulated Outlet flow rate of waste water
Variables
Constraints Maximum flow rate at fully opened valve is 1200 ton/ hr
Disturbances Channeling of water on vessel wall
Controller PI
Control structure Feedback control
Additional Recycle stream back to pump P-101
Considerations

As the steam content in the product gases would be condensed into water, the water
temporary stored at the bottom of the vessel V-101 and eventually removed via V-13.
However, the water level in the vessel required control system to avoid overflow in the
vessel. Thus, the water level in the vessel is measured using radar sensors to detect the water
level and control the removal of water by manipulating the flow rate through V-13. In this
case, a feedback control system with PI controller is installed to monitor the deviation of
water level beyond it set point and take action on controlling V-13 by increasing the opening
of valve. Since the high water level gives insignificant effect to the main aims of the
quenching process other than overflowing, additional considerations are eliminated to cut
cost.

32
Condenser
Function: To condense portion of top product from quench tower V-101

Control System: Temperature Control

Tagging Label TIC10505
Objective of To reduce the temperature at outlet stream from 80 -38
Control
Measurements Temperature
Manipulated Inlet flow rate of cold water
Variables
Constraints 20-100
Disturbances Inlet temperature of the cold water
Controller PI
Control Structure Cascade loop

Additional  Control valve (fail opened)

Considerations  Hand manual valve (fully closed)

Condenser E-102 is used to condense portion of top product from quench tower V-
101. First and foremost, the temperature of the top product must be reduced before undergo
condensation process. Hence, temperature control becomes very effective in order to reduce
the temperature at outlet stream from 80 -38 . This objective can be achieved by
manipulating the inlet flow of cold water. Cascade control system with PID controller is
applied to reduce any error when the deviations occurred. For example, when the outlet
temperature which detected by thermocouple sensor is higher than the set point, the air-to-
close valve, V-27 will open to allow more coolant enter. Hence, outlet temperature can be
reduce and reach the set point.

33
 Control System: Level Control
Tagging Label LIC10203
Objective of To make sure the level of waste water always at the safe level
Control
Measurements Level
Manipulated The final control element which is air-to-close (fail open) valve
Variables
Constraints Maximum level at fully opened valve is 1200 ton/hr
Disturbances Flow rate inlet and outlet of waste water
Controller PI
Control Structure Feedback loop
 Control valve (fail opened)
Additional  Hand manual valve (fully closed)
Considerations
 Level alarm high to alert operator about the excessive level

After the outlet temperature has been reduced, the top product is then undergoes
condensation process in order to remove waste water from the top product. Hence, to make
sure the level of waste water always at the safe level, level control is applied. The variable
that must be adjusted to achieve the objective is the final control element which is air-to-close
(fail open) valve. For this case, feedback control system and PI controller is applied. Both
feedback control system and PI controller are responsible to take any action in order to
reduce the error. In this loop, the constraint in this loop is maximum level at fully opened
valve is 1200 ton/hr while the sensor is orifice meter. For example, when level above the
constraint, level alarm high will ring to alert the operator about the excessive level conditions.
After that, the control valve V-29 is open to allow more waste water flow out.

34
 Control System: Pressure Control
Tagging Label PT10102
Objective of To maintain the pressure in the reactor at 1atm by controlling the output
Control flow rate
Measurements Pressure
Manipulated Inlet flow rate
Variables
Constraints 1-1.5 atm
Disturbances Input flow rate
Controller PI
Control Structure Feedback loop

Additional  Control valve (fail opened)

Considerations  Hand manual valve (fully closed)

The purpose of pressure control in the condenser is to maintain the pressure in the
reactor at 1atm by controlling the inlet flow rate. The pressure must be controlled for the
safety purpose. In this case, feedback control system and PID controller is applied. Basically,
the constraint for this control is 1-1.5 atm. If the pressure output signal deviates from the set
point, the controller will make an immediate corrective action to reduce the error. For
example, when the pressure deviates from the set point, controller immediately do any
necessary corrective action to reduce the error.

35
 Cold Water
33
FT FIC
10404 10404

V-28 V-27 I/P

TT TIC
10505 10505

16 PT
10102 10102

E-102 18
12
LT
10203

I/P V-24 Hot V-31 I/P

Water LIC
V-32
10203

LAH
17
15 I/P
V-22 V-29 V-30
Water 14
Driver V-23
11
Motor P-101 V-101
Waste
Water

FIC
10303

FT
10303 LTLT
10102

LIC
10102

V-25
V-26 I/P

13

Waste Water

36
4.4.6. Hydrocarbon Absorption Tower (V-102) and Stripping Tower (V-103)
Hydrocarbon Absorption Tower
Function: To remove the flue gases from the product gases mixture by absorbing butadiene
using oil.

Control System: Flow control

Tagging Label FIC10505
Objective of To control the inlet flows at desired ratio
Control
Measurements Input flow rate of product gas
Manipulated Input flow rate of oil
Variables
Constraints Maximum flow rate at fully opened valve is 1200 ton/ hr
 Efficiency of the pump
Disturbances
 Inlet flow of water into pump P-101
Controller PID
Control Structure Ratio Control loop with feedback controller
Additional Recycle stream back to pump P-102
Considerations

To control the effectiveness of the absorption of butadiene by oil from the product
gases, the ratio between the oil and the gas plays an important role and hence, the input flow
rate of the product gas is measured to manipulate the input flow rate of oil at the fixed ratio.
Hence, ratio control loop with feedback PID controller is applied in the control to provide to
maintain the input of both oil and butadiene at desired ratio and flow rate. Similarly, the
disturbance such as unstable pump efficiency can be adjusted by the additional or safety
consideration which a recycling stream is installed to avoid overpressure at valve V-50.

37
 Control System: Pressure control
Tagging Label PIC10304
Objective of To prevent overpressure in the vessel
Control
Measurements Pressure
Manipulated Outlet flow rate of butadiene gas
Variables
Constraints 1atm - 2atm
Disturbances Temperature in the vessel
Controller PID
Control Structure Feedback Control
Additional Relief valve
Considerations

This separation process can be carried out under relatively low pressure at the
atmospheric pressure. However, the process might build up pressure in the process due to it is
a closed vessel even it is insignificant at slightly higher than 1 atm, a safety measure is still
essential. The pressure inside the vessel will be detected by the strain gauge pressure sensor
installed, transmitting the information to electrical signal to the controller and thus transducer
carry out the job of adjusting the pneumatic valve as discussed in section 4.2.3. The outlet
flow rate of the flue gas from the top of V-102 is manipulated to control the pressure in the
vessel as pressure built up. For example, when the pressure in the vessel built up due to the
increase in oil level or temperature, the opening of the valve V-34 would open wider,
allowing waste gas to flow to the downstream and prevent overpressure. For safety
consideration, relief angle valve is located at the top of the vessel to release pressure when
necessary.

38
 Control System: Level control
Tagging Label LIC10304
Objective of To prevent overflow
Control
Measurements Oil level in the vessel
Manipulated Output flow of the oil to V-102
Variables
Constraints Maximum flow rate at fully opened valve is 1200 ton/ hr
Disturbances Channeling on the wall of the vessel
Controller PI
Control Structure Feedback Control
Additional Bypass valve
Considerations

In V-102, oil is flow from the top of the vessel, in contact with the product gases,
absorbing the hydrocarbon butadiene and flow out from the vessel. Hence, there is definitely
oil assembled at the bottom of the vessel before flowing out via stream 21 to downstream V-
102. It is important to monitor and control the flow rate of the oil to the downstream as
overflow in the vessel leads to inefficient absorbing effect which causes loss and less
production. A radar level sensor used here to continuously detect the level of the oil in the
vessel to manipulate the opening of valve V-36 to the downstream stripping tower. A PI
controller is used in a feedback control loop to monitor the level and when exceeding the
safety level, control action will be taken on controlling the outlet of oil via valve V-36 to the
downstream equipment, the stripping tower (V-103). To be safe, a hand actuated bypass
valve, V-37 is installed to enable manual handling of the process to control the level.

39
Stripping Tower (V-103)
Function: To separate butadiene from oil

Control system: Temperature Control

Tagging Label TIC 10708
Objective of To control the temperature in vessel V-103 at 130 ºC
Control
Measurements temperature
Manipulated Input flow rate of fuel to reboiler E-105
Variables
Constraints Detection of sensor at range -269 to 250 ºC
Disturbances Channeling on the wall of the vessel
Controller PID
Control Structure Feedback control
Additional Bypass valve
Considerations

To optimize the separating process of butadiene from the oil, temperature is the main
concern to be controlled. In this temperature control loop, the temperature in the vessel V-103
is detected and controlled by manipulating the flow rate or amount of fuel used in E-105 for
refluxing the oil. The high temperature is maintained aiming to separate as much as possible
of the butadiene gas from the liquid oil. Therefore, the fuel input representing the amount of
heat energy input at E-101 to further rise the temperature up to desired set point. In this case,
PID controller is installed in the feedback control loop to take immediate action as the
temperature varies from set point.

40
 20 Waste gas Cold Water

35
V-35 V-34 I/P FT FIC
10707 10707

TIC
PIC V-41 V-40 I/P 10708
PT
10203 10304
V-58 TT
10707

I/P
PIC
22 10405

PT
30
Hot Water 10405
V-52

V-102 V-39 V-38 I/P

E-104 V-53

LT
10405
PT PIC
10304 10304
V36 LIC
10405

V-43
19
LT V-42
29
FT
FT
10304
10505

LIC
10304
FIC I/P
10505

V-103
TT TIC
10808 10708
I/P
RC
10102

V-36
28 21
V-37 25

I/P
TT TIC
10909 10809
Cold E-105
Water

V-50
FT
10606
23
34
V-51 FIC
10606 V-45
24
P-102 V-44

I/P V-48 V-49 26

27 V-47

Fuel I/P
TIC TT
10506 10606
V-46

E-103
I/P

Hot
wat
er

41
4.4.7. Heat Exchanger (E-103)
Function: To cool down the outlet stream of the stripping tower from 130 to 38 before
enter pump.

Control System: Temperature control

Tagging Label TIC10506
Objective of To reduce the temperature of stream, S-26 at desired value (38°C) so that
Control the plant operates safely and can achieve maximum energy recovery.
Measurements To measure the outlet temperature
Manipulated Manipulate the inlet stream of heat exchanger in the shell side.
Variables
Constraints  Thermocouple at inlet and outlet stream
- 38 to 130
 Thermocouple at inlet and outlet coolants
- 25 to 40
Disturbances Change in pressure that cause change to the steam flow rate
Controller PID
Control Structure Cascade Control Loop
Additional  Control valve is fail to opened
Considerations  Hand manual valve is fully closed

In the heat exchanger, the coolant water is used in order to cool down the temperature
from 130 to 38 , so that the plant operates safely and can achieve maximum energy
recovery. Hence, the temperature is measured in order to control the inlet stream of the heat
exchanger in the shell side to achieve the aim of changes of temperature 130 to 38 . In
this system, the cascade control loop is implied with the PID controller in order to provide an
immediate action on controlling the final control element, V-48. For temperature sensor, the
thermocouple will detect the amount of the heat flow in the heat exchanger, and the
transmitter (TT) will detect any changes of the temperature and transmit the signal to
temperature indicator controller (TIC) where it alter the control valve to either open or close
to allow the inlet stream of the heat exchanger.

42
 Control System: Flow control
Tagging Label FIC10606
Objective of To maintain the flow of the coolant in the heat exchanger in a stable
Control or required condition.
Measurements To measure the inlet of coolant flow
Manipulated The amount of the coolant inlet stream into the heat exchanger
Variables
Constraints  Flow rate at inlet and outlet stream
- 2.52 kg/s
Disturbances Outlet stream of coolant
Controller PID
Control Structure Cascade Control Loop
Additional  Control valve is fail to opened
Considerations  Hand manual valve is fully closed

The flow of coolant water that enters the heat exchanger is measured in order to
control the amount of the coolant inlet stream at 2.52 kg/s. In this system, the cascade control
loop is implied with the PID controller in order to provide an immediate action on controlling
the final control element, V-48. For flow sensor, the orifice meter will detect the amount of
coolant flow rate in the inlet stream of the coolant at heat exchanger, and transmitter (FT)
will detect any changes of the flow rate and then transmit the signal to flow indicator
controller (FIC) where it alters the control valve to either open or close to allow the inlet
stream of the heat exchanger.

43
44
4.5 Control Action
Control action is the pathways of each control loop designed for the equipment.

4.5.1 Flow Control System

Since the fluid flow in this plant is mainly in gaseous phase, orifices are the sensors
that mainly used in this production plant due to the reasons as stated in section 4.2.5. The
orifice measure the pressure drops and thus determine the fluid flow rate in a stream. The
flow rate measurement is thus transmitted to a controller by a transmitter. The electric signal
is sent from the transmitter to the flow indication controller which mounted on board where
the measurement readings are shown to ease the monitoring operators. At the same time, the
flow controller takes action to adjust the final control element, mostly is a pneumatic
diaphragm valve. The electric signal converted into pneumatic signal which control the
opening of the valve to manipulate the flow rate.

In this plant, the ratio of the input flow rates of n-butene, air and steam for the process
at mixer M-101 and reactor R-101 is important to produce the product gases at desired
composition. Therefore, feedback controls loop with a ratio controller. By measuring the
input flow rate of n-butene, the input flow rate of air and steam can be manipulated to the
ratio n-butene, air, steam of 1:2.6:10 for the oxidative dehydrogenation process producing n-
butadiene in the fixed bed reactor. In the case of low inflow of n-butene, the PID controller
takes action to control the inflow of both the air and steam into the amount at the fixed ratio
to the n-butene input by manipulating valve V-11 and V-13 simultaneously. Similarly, this
feedback ratio control is also applied in this in V-102.

4.5.2. Level Control System

The field mounted radar sensor is installed for a continuous liquid level control. When
the sensor detected the reflection of radar, the feedback is transmitted into electric signal and
send to a board mounted level indicating controller to display the measurements and take
control action by sending the electric signal to the current-pneumatic (I/P) transducer. The
I/P transducer is then convert the electric into pneumatic signal to control the final control
element of the system, which is mainly the auto-actuated pneumatic diaphragm valve.

45
 For example, n-butene storage tank T-101 in this production plant utilised the level
control system to control the level of the liquid n-butene in the tank. By adjusting the opening
of the valve according to the signals from the sensor to the controller and from the controller
to the transducer, the flow rate of the input n-butene at stream 1 can be controlled. This is to
maintain the level of n-butene in the tank which representing the amount of raw materials for
the production, either to avoid overflow or in this case is to avoid shorts in raw material for
the production. Similar level control action is applied on the process unit V-101, E-102, V-
102, V-103, E-104 for the purpose of level controlling to avoid overflow.

4.5.3. Pressure Control System

To control pressure, the pressure sensor such as strain gauge is one of the most
commonly used in production plant. This sensor detect the pressure, transmitter transmits the
information into electric signal and send to the pressure controller. A pressure indicating
controller thus takes action in manipulating the other variables such as output flow in a
process unit to control the pressure at desired safety level. The electric signal is converted
into pneumatic signal to control the opening of the automated diaphragm valve by air flow.

In hydrocarbon absorption tower, V-102, absorption of butadiene gas into oil can
occurs under relatively low pressure of 1 atm. However, when the vessel is loaded with oil
and gases, the pressure inside the tank may increases and hence a pressure control system is
required to prevent overpressure. In this plant, a PI controller is used in the feedback control
loop to regulate the pressure back to 1 atm by manipulating the output flow rate of the waste
flue gas. The feedback pressure control is located at the process unit R-101, V-101, E-101, V-
102, V-103 and E-104.

46
4.5.4. Temperature Control System

Thermocouple is used as temperature sensor in production plant. By comparing the

voltage differential, the electric signal generated from the sensor is transmitted to temperature
indicating controller. The board mounted temperature indicating controller displays the
measurement of temperature on board, enable the operators to monitor the changes in
temperature precisely when comes to temperature dependent process such as heat exchanger.
The controller is responsible to calculate the deviations from the setting temperature and
corrective action to control the temperature by manipulating other variables such as flow rate
of inputs using pneumatic diaphragm valve.

Taking heat exchanger E-101 as an example, the temperature of the output stream 11
of the heat exchanger is measured using thermocouple. As if the temperature of stream 11 is
above the set point, this means that the heat exchanger did not hit the desired target to lower
the temperature of the product gas to that point. Therefore, the PID controller in the cascade
loop in this case would take immediate action on correcting the error by manipulating the
input flow of cold water into the heat exchanger. When the temperature in stream 11 is
beyond the set point, the controller adjusts the opening of the valve to allow higher flow rate
of water, more heat is able to be transferred by the cold water cooling system in the heat
exchanger and eventually, the temperature drops to the desired one. In this plant, condenser
E-102 and E-104 also utilized the similar principle in temperature controlling.

47
 References

The Advantages and Disadvantages of Traditional Flow Measurement Devices. (2017).

http://www.qedenv.com/News/Latest/The_Advantages_and_Disadvantages_of_Tradit
ional_Flow_Measurement_Devices. Accessed on 27/9 2017.

Brei, T. M. (2013). RTD vs Thermocouple. http://www.surecontrols.com/rtd-vs-

thermocouple/. Accessed on 27/9 2017.

Chen, K. P. ( 2016). High Spatial Resolution Distributed Fiber-Optic Sensor Networks for
Reactors and Fuel Cycle Nuclear Energy.

E-Seborg, D., F.Edgar, T., and A.Mellichamp, D. (2004). Process Dynamic and Control
(second edition ed.): John Wiley & sons, Inc.

Grumney, D. (2011). Ultrasonic Transmitters vs. Guided-Wave Radar for Level

Measurement. http://www.sensorsmag.com/components/ultrasonic-transmitters-vs-
guided-wave-radar-for-level-measurement. Accessed on 26/9 2017.

SINNORT, R. K. (1993) Coulson and Richardson's Chemical Engineering (pp. 878-879).

Amsterdam: Pergamon.

WL900 RADAR LEVEL TRANSMITTERS. (2015).

http://www.globalw.com/products/wl900.html. Accessed on 24/9 2017.

48