MALAYSIAN INSTITUTE OF CHEMICAL AND BIO-

ENGINEERING TECHNOLOGY

MINI PROJECT
CPD20302
PROCESS CONTROL

LECTURER’S NAME: SIR SYAHIDI FADZLI ALFAN

GROUP: L01

STUDENT’S NAME ID
MUHAMMAD ALIFFUDDIN BIN AKHIRI 55102118016
MUHAMMAD AFIQ BIN AZRI 55102118019
BADRUL AIMAN BIN MOHD 55102118005
NURLIA AZRINA BINTI MUHAMMAD AZHAR 55102118011
OVERVIEW

The objective of control system is to keep key process-operating parameters within

narrow bounds of the reference value or setpoint. This project describes the theory behind
control circuits to maintain automatic control over different type of process. The basis of
automatic control is the control loop. A control loop for a given process must have at least
one sensor, a controller, and a control element to which the results are applied. The controller
reads the error and makes a decision. The action taken can be very simple to very
complicated, depending on the system and the size of the acceptable error. Automatic process
control were used in continuous production processes is a combination of control engineering
and chemical engineering disciplines that uses industrial control systems to achieve a
production level of consistency, economy and safety which could not be achieved purely by
human manual control.
Introduction

A control system manages, commands, directs, or regulates the behavior of other devices or

systems using control loops. It can range from a single home heating controller using
a thermostat controlling a domestic boiler to large Industrial control systems which are used
for controlling processes or machines. For continuously modulated control, a feedback
controller is used to automatically control a process or operation. The control system
compares the value or status of the process variable (PV) being controlled with the desired
value or setpoint (SP), and applies the difference as a control signal to bring the process
variable output of the plant to the same value as the setpoint. Main control system, sometimes
called industrial control systems (ICS), function as pieces of equipment along the production
line during manufacturing that test the process in a variety of ways, and return data for
monitoring and troubleshooting. Many types of process control systems exist, including
supervisory control and data acquisition (SCADA), programmable logic controllers (PLC), or
distributed control systems (DCS), and they work to gather and transmit data obtained during
the manufacturing process. The main control system can be a relatively simple item with a
sensor, often called a primary transducer, that receives an input, along with a controller that
processes the input, and a receiver that processes an output. More complicated PCS devices
are robotic and perform many tasks. The PCS devices can communicate their data to a
company’s enterprise resource planning (ERP) computer application through middleware
software called a manufacturing execution system (MES). A great number of measurements
can be taken on production lines. An equipment's sensor can pick up many measurements
including pressure, flow rate, density, acidity, velocity, speed, stress, temperature, and
weight. Also, sensors can detect if an operation has occurred, such as the fill of a bottle,
whether the correct pressure has been achieved, or if a certain temperature has been reached.
Many sensors exist on production lines, falling under some different areas, such as pressure
sensors, flow meters, force sensors, and temperature sensors.
Process & Instrumentation Diagram of Ethylbenzene Production

Figure 1.0 Process Flow Diagram of Ethylbenzene Production

Main Components of Control System

Based on the process flow diagram shown in Figure 1.0, it can be identified that two
types of sensor are used which are the flow indicating controller (FIC) and the level
indicating controller (LIC). Sensors can detect as well as measure any physical changes
occurring in the system. The FIC is found to be 4 units in the plant located after the control
valves of benzene feed drum V-301, benzene recycle pumps P-305 A/B, benzene reflux
pumps P-302 A/B and also EB reflux pumps P-303 A/B. It is installed to measure the flow
rate of liquid flowing into the tower and feed heater. Meanwhile, LIC installation is designed
to indicate the level of solution in a confined tank. Therefore, 5 units are found to be
positioned in front of the benzene feed drum V-301, the benzene reflux drum V-303, the
benzene tower T-301, the EB reflux drum V-304 and even before the T-302.

In a system, a controller functions to minimize the difference between a system's

actual value and the system's desired value. However, there is no controller that can be
identified along the process. The value of the controlled variable is therefore not measured
and maintained at the plant.

Lastly for the final control element, it is installed mainly as a mechanical device that
changes a process physically that responds to a change in a control system set point. There is
one type of final control element installed in this plant which is control valve. There is 10
units of it which installed before entering drums, heaters, separator and also tower. This is
because it is needed to control the fluid flows to its size of opening which enables a direct
flow control rate and the consequential control of process pressure, temperature and the liquid
level.

Insertion or Addition Main Components Control System

For sensors, multiple temperature indicator must be located at all columns primarily
those where reaction occurs. In that case, location indicated by diamond pattern with number
of 6, 8 and 11 and an addition at feed heater H-301 as the feed is heated to operable
temperature for benzene to react with ethylene. That being said, pressure indicators must also
be present at pipes as spatial variations may occur during transportation from one pipe to
another. Thus, location at 20 and the top vent for T-301 are suitable locations for pressure
indicators.
 Controllers can influence the efficiency of plants significantly if the suitable
controllers are placed at necessary location. That being said, multiple types of controller can
be implemented seeing that the plant above does not contain any sort of controllers. Firstly,
inferential controller are highly suitable as two control variables are present in this process
which is pressure and temperature which are constantly present extensively near columns,
they are also considered as proportional integral controller that seeks to deplete any
disturbance that might occur with current operating conditions. Inferential controllers will be
able to measure these control variables and provide information regarding the operating
conditions of selected column, rather than measuring the composition of benzene and
ethylene which are considered to be impossible as they require on-line measurements.

Another controller that should be add in conjunction with inferential controller are
feedback and feedforwards controller. Both are considered as proportional controller as they
operate with respect to the amount of disturbance or error occur at various area of the system.
Feedback controller operates after receiving disturbances from system, while feedforward
controller operates by measuring the possible error that may occur with current operating
conditions to avoid error from happening. In other words, feedback controller seeks to
eliminate error while feedforwards controller reduces the error. Conclusively, feedfoward and
feedback controller at suitable to be placed near heating or cooling element such as boiler or
condenser and heat exchanger and at pipes exiting columns.

Lastly for controllers, ratio controller is the key controller for this plant as it revolves
around distillation in order to produce the product. That being said, distillation occurs where
two or more reactant are mixed with each other to produce a single solution. Hence, ratio
controller also known as a proportional controller are able to measure the error frequently
primarily the ratio of benzene and ethylene in this case to ensure the right portion of benzene
and ethylene are present to produce quality ethylbenzene. This means that ratio controller
works best near distillation columns or any mixing columns.

Finally is the final control element. The choice of final control element can be
determined by the types of fluid and operating condition of the system. Generally, various
type of valve can act as a final control elements as they require manual operation and affect
the physical conditions of a system primarily the flow or solution or pressure of solution. One
good example for a final control element is globe valve or butterfly valve as they are able to
manage pressure drop at various range depending on the system temperature or flow rate both
which affects the pressure of a fluid.
Process & Instrumentation Diagram of Maleic Anhydride Production

Figure 2.0 Process Flow Diagram of Maleic Anhydride Production

Main Components Control System

Based on the process flow diagram shown in figure 2.0, two types of sensors are
identified in the process which are flow indicating controller (FIC), level indicating controller
(LIC) and pressure indicating controller (PIC). There are 4 FIC and LIC units each, and 1 PIC
units each. The FIC are located after the control valves of benzene feed pumps P-601 A/B,
benzene feed vaporizer E-601, reactor R-601 and MA reflux drum V-602. Meanwhile, the
LIC located before the drums in the process and the PIC is located at MA reflux drum. These
three types of sensor have the same uses which to measure changes in the process quantities
such as flow rate, level and even fluid flow pressure within the system.

For controllers, there is no controller to be identified in the plant. The desired values
and actual values are not measured, and the controlled variable value is not maintained at the
set point.

Finally there is only one type of control element used for the final control element
which is the control valve. In total the control valves used in the plant are 9 units. It is
installed before entering any equipment in the plant. The control valve regulates fluid flows
by changing the flow size which increases, decreases or keeps the flow steady. This responds
to the controller's orders, and controls the flow by either opening or closing the internal flow
accordingly.

Insertion or Addition Main Components Control System

For sensors, multiple temperature indicator must be located at all columns primarily
those where the properties of volatility is accounted for. In that case, location at feed heater
H-601, vaporizer E-601 and reactor R-601 as the feed is heated to operable temperature for
Dibutyl Phthalate Make-up, Air and benzene to react with producing Maleic Anhydride.

For controllers, ratio controller is the key controller for this plant as it involved 3
reactant in order to produce the product. That being said, reaction occurs when all 3 reactant
namely Dibutyl Phthalate Make-up, benzene and air reactant are mixed with each other to
produce a single solution which in this case is Maleic Anhydride. Hence, ratio controller also
known as a proportional controller are able to measure the error frequently primarily the ratio
of Dibutyl Phatalate Make-up, air and benzene in this case to ensure the right portion of each
reactant are present to produce quality Maleic Anhydride. This means that ratio controller
works best near vaporizers, reactors or any scrubbers.

Another controller that should be add in conjunction with ratio controller are feedback
and feedforwards controller. Both are considered as proportional controller as they operate
with respect to the amount of disturbance or error occur at various area of the system mainly
vaporizers as they change the physical properties of reactant such that major compensations
are required. Feedback controller operates after receiving disturbances from system that may
indicate different is pressure as vapour tend to fill more space compared to its liquid form,
while feedforward controller operates by measuring the possible error that may occur with
current operating conditions to avoid error from happening which is a favour as vaporizer
require in depth observation to ensure the vapour produced are always at constant
dimensions. In other words, feedback controller seeks to eliminate error while feedforwards
controller reduces the error. Conclusively, feedforward and feedback controller at suitable to
be placed near vaporizers and scrubber.

Finally is the final control element. The choice of final control element can be
determined by the types of fluid and operating condition of the system. Generally, various
type of valve can act as a final control elements as they require manual operation and affect
the physical conditions of a system primarily the flow or solution or pressure of solution. One
good example for a final control element is globe valve or butterfly valve as they are able to
manage pressure drop at various range depending on the system temperature or flow rate both
which affects the pressure of a fluid.
Process & Instrumentation Diagram of Styrene Production

Figure 3.0 Process Flow Diagram of Styrene Production

Main Components Control System

Based on the process flow diagram shown in figure 3.0, there are two types of sensors
used in the plant which are flow indicating controller (FIC) and level indicating controller
(LIC). Both these flow and level sensors function as measuring and indicating process
quantities such as fluid flow rate and fluid level, respectively. The FIC are found to be 3 units
of them which located after the control valves of steam heater H-401, reflux pump P-402 A/B
and reflux pump P-403 A/B. Meanwhile, LIC has 4 units in the plant located at the styrene
and benzene toluene column, T-402 and T-401 respectively, and also at the V-402 and V-403
drums. The measures are important to ensure that process quantities such as flow rates and
level are maintained so that the variables are better controlled.

There is one type of controller identified in the plant, which is ratio controller. The
controller are installed before feed heater and before entering the steam plant. The installation
is mainly to compare the calculated ratio with the desired ratio in order to ensure the valve
opens accordingly. The ratio to be considered as an example in the first ratio controller is the
natural gas and air that enters the heater. It is important the amount for both of these
components to maintain a stoichiometric ratio for the reaction in reactor.

Finally, there is one identified final control element in the plant which is control
valve. A total of 9 control valve units are installed mainly to control fluid flow within the
system to its opening size. It is necessary to have a control valve to provide a significant
quantifiable and to increase and decrease process efficiency as well as to reduce maintenance
costs. An installation of control valve system enables direct control of the flow rate and
consequent control of the pressure, temperature and even fluid level.

Insertion or Addition Main Components Control System

For sensors, multiple temperature indicator must be located steam heater H-401,
columns T-401 and T-402 and separator V-401 and primarily those where separation as the
production of styrene involves production of other reactions which needed to be separated to
obtain synthetic styrene to occur. In that case, that being said, pressure indicators must also
be present at pipes as spatial variations may occur during transportation from one pipe to
another in area such as long pipes of 19, 22, 23 and 24.

Controllers can influence the efficiency of plants significantly if the suitable

controllers are placed at necessary location. Firstly, inferential controller are highly suitable
as multiple separation occurs during the process of producing synthetic styrene. Variables are
present in this process which is pressure and temperature which are constantly present
extensively near columns, they are also considered as proportional integral controller that
seeks to deplete any disturbance that might occur with current operating conditions to ensure
the temperature and pressure are sufficient for separation to occur. Inferential controllers will
be able to measure these control variables and provide information regarding the operating
conditions of selected column, rather than measuring the composition of benzene and toluene
in column T-401 and composition of Styrene in column T-402 which are considered to be
impossible as they require on-line measurements.

Additional ratio controller can increase the efficiency and quality of styrene at the end
of the process for this plant as it involved 2 columns and 1 separator in order to produce the
product. That being said, proper separations is crucial to produce a single solution which in
this case is Styrene. Hence, ratio controller also known as a proportional controller are able to
measure the error in portion of side products such as benzene, toluene, hydrogen and Styrene
itself frequently, primarily the ratio to ensure the right portion of each reactant are present to
produce quality Styrene. This means that ratio controller works best near separators, columns
or any scrubbers.

Finally is the final control element. The choice of final control element can be
determined by the types of fluid and operating condition of the system. Generally, various
type of valve can act as a final control elements as they require manual operation and affect
the physical conditions of a system primarily the flow or solution or pressure of solution. One
good example for a final control element is globe valve or butterfly valve as they are able to
manage pressure drop at various range depending on the system temperature or flow rate both
which affects the pressure of a fluid.
CONCLUSION

It conclude that, all of the process had the control system that compares the value or status
of the process variable being controlled with the desired value or setpoint, and applies the
difference as a control signal to bring the process variable output of the plant to the same
value as the setpoint. Many types of process control systems exist, including supervisory
control and data acquisition, programmable logic controllers, or distributed control systems,
and they work to gather and transmit data obtained during the manufacturing process. The
main control system can be a relatively simple item with a sensor, often called a primary
transducer, that receives an input, along with a controller that processes the input, and a
receiver that processes an output.control system leads to automation in various fields of
industry. It also provides more reliability and improvement in product. With control system,
lots of work can be done in single minute of time which reduces more time required for that
work. It enables manufacturers to keep their operations running within specified limits and to
set more precise limits to maximize profitability, ensure quality and safety.