Educational Institute for Equipment and Process Design
Advanced Control
Educational Institute for Equipment and Process Design
Description
If you are a process or instrument engineer, then you have definitely have passed some courses
on process control during university time. To be honest, with all due respect, none of them was
practical and unfortunately none of them is implemented when it comes to petrochemical, gas
processing, refinery plants or generally process plant. Nonetheless, the course was needed to
get you familiar with simple basics. In this course you learn how to apply and display different
elements of control loops on P&IDs.
Who should take this course?
1.Process engineers
2.Chemical engineers
3.Control room operators
3.Instrument engineers
4.Control system engineers
Educational Institute for Equipment and Process Design
Part 1: Simple Control Loop
Session 1: Introductory session
In this session the presenter provides the instruction on basics of process control which are
need for next sessions. The following subjects are discussed with pragmatic approach:
• The definition of process value, set pint, measured value and how a controller functions.
• How a controller is shown in FCS-Faceplate- and how different parameters such as
manual mode, auto mode, logic and tuning, could be manipulated by control room
operators.
• The definition of BK, BKIN, BKINERR, PVERR, BKOUT, BKOUTERR, direct, indirect and
ramp for controllers
• An overview of tuning parameters like PB, TD, and TI and their common values which is
recommended to be used during start-ups and normal operation are provided.
• An overview of different types of process controllers namely, simple control loop, split-
range control, cascade control, override, and complex loops is provided.
Session 2: Flow controlling loops [FIC]
Different practical examples from previous projects are provided in a way that not only familiarize
learners with process itself but also make them absorb the concept of FIC loops easily. Only in
this way learners can truly understand how to use and where to use FIC from the bottom of their
heart.
The instructor provides two comprehensive and practical examples, the first of which being
controlling water flow over a packed column. Alongside the example the presenter provides the
learners with some design notes over flowmeter selection and their locations in control loops;
more importantly, he introduces a systematic approach for selection of control system. In second
example, he goes over protection steam flow control which is used alongside oxygen for ATRs in
hydrogen-related plants and shows how the process and assumption can impact control type
selection.
Session 3: Pressure controlling loops [PIC]
In this session, you will learn the followings:
• Inlet Knock-out drum pressure control.
• When pressure control and when flow control should be used for heat exchangers. The
presenter provides his experience-thermodynamics and start-ups- over the matter, which
one to select, why and how to present the control loop in P&ID. To help the learners better
understand the concept he alludes to distillation column reboilers and oxygen preheaters.
• In forth example, he explains what steam headers are and why import steam control just
needs a simple pressure control loop.
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• In last example, he elucidates the process of pressure control in fired heaters. The
instructor at first gives information about different components of a fired heater in brief,
then explains why drought pressure should be kept within specific limit. Additionally, he
explains how inlet guide vane works and how it can impact pressure control.
Session 4: Level controlling loops [LIC]
In this session the instructor provides two comprehensive examples, through which you will learn:
• Which type of control system is used for a vertical separator which is located at the suction
of a centrifugal compressor.
• Which type of control system is used for a horizontal separator whose function is to provide
enough surface area so that the dissolved gas could simply escape. In addition, the
instructor alludes to the pressure control of the drum which have been given as homework
to design.
• Due to importance of the separators, he introduces two-out-of-three voting system; he
goes through IEC-61511 to show why such voting system should be implemented and
how it could be shown on P&IDs and ESDs. Finally, he uses such configuration for the
separators and illustrates how it is displayed on the P&ID for the examples.
• He also brings up the examples of reboiler and oxygen pre-heater. He shows why a simple
level control is enough for drums whose function is to hold-up steam condensate coming
out of the reboiler and oxygen preheater.
Session 5: Temperature controlling loops [TIC]
In this session, the following examples will be discussed:
• Temperature control at the inlet of a reactor
• Temperature control of lube oil used in turbine console
• Temperature control of steam headers using BFW as quench water.
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Part 2: Split-range Control
Session1: Introduction
He starts the session with a practical and actual example and shows why a simple level control
is not suitable for such applications and is meaningless if applied. Then he introduces split-range
control and how it can help the separator to keep its level within the range. Additionally, he
elucidates the functions of low and high selectors. Afterwords, he compares the opening of split-
range control valves against Master LIC output in a plot. Finally, he instructs how split-range
control could be shown on P&ID.
Session 2: Split-range for combined FICs and LICs
In this session he provides two thorough examples in which you will learn the followings:
• Split range for flow control of washing water for a trayed separator and split range control
for level control of a separator. Since both separators interacts with each other, their
control system collides with each other; the presenter adroitly shows how a low selector
can solve our problem; but why not high selector? He goes through two scenarios and
shows why high selector is not suitable.
• In second example he shows how start-up and off-conditions can impact control system.
He then emphasizes that the process control specialist should be really experienced to
take into account all conditions and translate them with a advanced control language. The
process stated in the example is about steam drum, evaporator, and deaerator.
Session 3: Split-range for deaerator pressure control
In this session the presenter explains the process of deaeration and the purpose of the deaerator;
then he tries to design a control system for deaerator pressure. To do so he explains how the
DMW temperature and LPS pressure both can impact the deaerator pressure; as a result, he
concludes that implementing a simple control is meaningless and only split-range control should
be used. Additionally, he explains how plot showing control valve opening against PIC output
could be drawn. Afterwards to complete his control system, he introduces the concept of override
and how implementation of such system could be beneficial.
For the second example, then he moves to reflux drum pressure control system and split range
could be the solution.
Finally, he ends the session with steam header which prevalent in approximately all process
plants. In this wonderful example, instead of designing control system for pressure control of each
header, he elaborates on two practical approaches towards two different steam headers pressure
control. He goes through each approach and reveals why such approach has been taken; in every
moment he grabs the opportunity to connect process to advanced control and address the Why
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and Why not questions. Through this example and deaerator, the learners gain deep
understanding of the controller being direct or reverse.
Part 3: Cascade Control
Session 1: Introductory session
In this introductory session, the presenter provides BFW headers pressure control as an example,
during which he shows why simple pressure control cannot be suitable for such applications. Then
he introduces cascade control and explains what a cascade controller is, why and how it should
be used, and which configuration should be applied. Finally, he applies the cascade for the
example.
Session 2: LIC-FIC cascade control
In second session to help the learners obtain deep understanding of cascade controllers, he
provides cascade control of reflux drum level and reflux flow assembly as an example. He starts
with simple level control but provides the reasons why such controller is not suitable. He alludes
to process consequences if simple control loop is applied and show how cascade control can
resolve all issues. Finally, he proposes the right cascade configuration for the application.
Session 3: Combined cascade and split-range
To show how sometimes complex it might become, the instructor provides the learners with a
comprehensive example, in which you will learn the followings:
1.TIC-FIC cascade control
2.FIC split range control
3.LIC split range control
4.Combination of above item and their interactions.
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Part 4: FY, LY, PY Calculators-Expert Mode
You will see a lot of them on P&ID and complex loop documents!
Session 1: Distillation column inlet control
In this session the presenter shows what these calculation blocks are and why you should not
fear them! In order that you can gain complete insight towards the matter, he gives distillation
column inlet feed control as an example. You will learn:
• Switching system when we have two controllers which can control one parameter.
• How three-element calculation block works and determines setpoint for FIC controlling
inlet feed.
Session 2: Steam Drum level control
Session 3: Turbine extraction loop
Part 5: SAMA and Complex loop – Expert Mode
Session 1: Fired heater process description
Session 2: Firing system control loop
Session 3: Combustion air flow control loop
