Process Operability Class Materials

Operating Window
LAH

Basic flowsheet Design with Operability

LAL
L
2

LC
LC
1 1

FC
1 FC
1

TC
2 TC
1

F
4
fuel
T
10 T
11
T
12

T
13

Copyright © Thomas Marlin 2013

The copyright holder provides a royalty-free license for use of this material at non-profit
educational institutions
Key Operability
issues
PROCESS OPERABILITY :
1. Operating
window
THE OPERATING WINDOW
2. Flexibility/ In this Lesson, we will learn
controllability
• What is an Operating Window?
3. Reliability
- Flash Drum, CSTR
4. Safety &
equipment
• What defines the “Frame”?
protection - Distillation
5. Efficiency &
profitability
• How can we set equipment capacity (the operating
window) to achieve desired operation?
6. Operation - Equipment capacity: Heat exchanger, pump
during
transitions - Alternative Equipment: Pump, flash

7. Dynamic • How do we determine if operation is possible

Performance
within the window?
8. Monitoring & - Pump, distillation
diagnosis
 Define Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
The range of achievable steady-state operations. This
2. Flexibility/ is affected by manipulated and disturbance variables.
controllability
The limitations can be due to equipment (e.g.,
3. Reliability maximum flow), safety, product quality, etc.
4. Safety & Flash Drum Example
equipment
protection
80

Minimum heating
5. Efficiency &
profitability T6 P1
Vapor 60

feed temperature (C)

product
Maximum
liquid
40
6. Operation T5
feasible product
T1 T2 valve
during opening
transitions Feed
20
F1 T4
T3 L1
Design
7. Dynamic 0
Maximum heating
Performance F2 F3
valve opening
AC
Liquid
Process Steam
L. Key
product-20
fluid
8. Monitoring & 50 70 90 110 130 150 170 190
diagnosis feed flow
 Define Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window

2. Flexibility/
The variables in the plot can be
controllability
• Set points of controlled variables
3. Reliability
• Disturbance variables
4. Safety &
equipment
protection
The frames (boundaries) of the window can be
• “hard” constraints that cannot be violated
5. Efficiency &
profitability
• “soft” constraints than can be violated at a
6. Operation
during
(usually large) economic penalty
transitions

7. Dynamic
Class Workshop: Determine the category for
Performance each of the constraints for the flash drum.
8. Monitoring &
diagnosis
 Define Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Minimum heating valve opening is “hard”
2. Flexibility/
controllability
80

3. Reliability Minimum heating

60
Maximum feed
feed temperature (C)

4. Safety &
equipment
Maximum
liquid
valve
40
protection
feasible product
opening is
valve
opening
“hard”
20
5. Efficiency &
profitability Design

0
Maximum heating
6. Operation valve opening
during
transitions -20
50 70 90 110 130 150 170 190

7. Dynamic
feed flow
Performance
Minimum feed valve opening is “soft”
8. Monitoring & (The valve can be fully closed)
diagnosis
 Define Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Class Workshop: Discuss the operating window for
2. Flexibility/
this non-isothermal CSTR. Note:
controllability
This shows a
range of set
3. Reliability
points that can
be achieved
4. Safety & (without
equipment Solvent
protection infeasible disturbances).

5. Efficiency &
profitability T
feasible
A
6. Operation infeasible
during Reactant
transitions

Coolant
7. Dynamic
Performance AB
What do you note about the shape
-rA = k0 e -E/RT
CA
8. Monitoring & of the operating window?
diagnosis
 Define Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Class Workshop: Discuss the operating window for
2. Flexibility/
this non-isothermal CSTR.
controllability

3. Reliability
• We can determine the operating window using
modelling (flowsheeting)
4. Safety &
equipment
protection
• If the plant exists, we could determine the
operating window empirically (but maybe make
5. Efficiency &
profitability
off-specification products)

6. Operation
• The operating window is not always a polygon
during
transitions • The operating window is not always 2-
7. Dynamic
dimensional (can be much higher dimension)
Performance
• Operation can occur outside the window during
8. Monitoring &
diagnosis
transients (or when assumptions are violated)
Define Oper.
Window
OPERATING WINDOW

Class Workshop: Discuss the operating window for this non-

isothermal CSTR.
Design Procedure The design must define the range of
operations (set points and
• Set goals and design specifications
disturbances) to be achieved.
• Select process technology
We can accept less than full
• Define process structure (sequence) production rate or top efficiency for
extreme situations.
• Simulate the flowsheet
The flowsheet typically involves basic We must document specifications
M&E balances, equilibrium and rate and range or operations and review
processes. It does not consider practical
with all stakeholders!
issues for achieving the operation.
• Design equipment These “specifications” are in the
Equipment design achieves the base case Design Basis Memorandum.
flowsheet (plus other concerns). This
sets the “capacity” of the plant.
 Define the
Key Operability frame
issues OPERATING WINDOW
1. Operating
window
The frame defines the “size” of the operating window.
2. Flexibility/
controllability
These are typically physical bounds, equipment
operation and stream specifications.
3. Reliability
Determine the constraints (limitations) that
4. Safety & define the frame (boundary) of the window
equipment
protection

5. Efficiency &
profitability
Process variable 2

6. Operation
during
transitions
feasible

7. Dynamic
Performance

8. Monitoring &
diagnosis Process variable 1
 Define the
Key Operability frame
issues OPERATING WINDOW
1. Operating
window

Class Workshop: Determine typical constraints that

2. Flexibility/
controllability affect the operating window for a distillation tower.
3. Reliability

4. Safety &
equipment
protection xD

5. Efficiency &
profitability FR

6. Operation
during
transitions
FV

7. Dynamic
Performance

8. Monitoring &
diagnosis xB
 Define the
Key Operability frame
issues OPERATING WINDOW
1. Operating
window
Class Workshop: Distillation Constraints
2. Flexibility/
controllability

Maximum cooling capacity

3. Reliability

Maximum and
4. Safety &
minimum liquid
equipment
and vapor flow
xD Product composition
protection
rates

5. Efficiency &
FR
profitability
Pumping, pipe, valve capacity
Maximum and
6. Operation
minimum liquid FV
during
and vapor flow Maximum heating
transitions
rates

7. Dynamic Flow pipe, valve capacity

Performance Minimum
natural
circulation to xB Product composition
8. Monitoring &
diagnosis
reboiler
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
The design specification will define a boundary of
2. Flexibility/ the operating window.
controllability

3. Reliability
Heat exchanger Q = U AY (T)lm

4. Safety & Hot process fluid

equipment into shell
protection
Cooling water into
tubes The exchanger
5. Efficiency & exists to cool
profitability
this stream

6. Operation
during
transitions

7. Dynamic
Performance
What are the “worst case” operating conditions
we would use to design the heat exchanger?
8. Monitoring &
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
The design specification will define a boundary of
2. Flexibility/ the operating window – The Worst Case gives the
controllability
largest area for heat exchange.
3. Reliability
Highest flow rate,
Lowest flow rate, Highest temperature
4. Safety & Highest temperature
equipment Hot process fluid
protection into shell

Cooling water into

5. Efficiency & tubes
profitability

6. Operation
during
transitions Lowest temperature

7. Dynamic
Performance Greatest fouling, How do we
Lowest U determine
8. Monitoring & values?
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
The design specification will define a boundary of
2. Flexibility/ the operating window.
controllability

3. Reliability

4. Safety &
equipment
protection

5. Efficiency &
profitability

6. Operation
during
transitions

7. Dynamic
Consider the flow system. What variables must
Performance we determine? What is the “worst case” we
8. Monitoring &
would use to design the system, specifically the
diagnosis required pump outlet pressure?
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
The design will define a boundary of the operating
2. Flexibility/ window - Worst case gives the largest pump. Highest vessel
controllability
pressure
Highest flow,
Lowest level largest friction
3. Reliability
(lowest head) factor

4. Safety &
equipment
protection
P Highest
5. Efficiency & pressure drop
profitability

Highest
6. Operation
during pressure drop
transitions

What variables must we determine?

7. Dynamic
Performance
- Pipe diameter - by guideline (Liq: 1 m/s, Gas: 30 m/s)
- Pump horsepower - from highest flow rate and PP and
8. Monitoring &
diagnosis the lowest suction pressure
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
In general, we want a large operating window. Why
2. Flexibility/ not always design and construct equipment with very
controllability
large capacities?
3. Reliability

4. Safety &
Class Workshop: Complete the following table.
equipment
protection Small Large
Just satisfies base case
equipment* equipment
5. Efficiency &
profitability

Advantages
6. Operation
during
transitions

7. Dynamic Disadvantages
Performance

8. Monitoring &
diagnosis * = small equipment just satisfies base case design point
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Class Workshop: Complete the following table.
2. Flexibility/
controllability
Small
equipment
3. Reliability

4. Safety &
equipment Low capital cost
protection
Advantages Most efficient at base case

5. Efficiency & Achieve “precise” operation (smaller equipment to

profitability adjust)

6. Operation
during Cannot achieve higher capacity
transitions
Cannot compensate for large range of disturbances
Disadvantages
7. Dynamic Cannot achieve fast transition (no overshoot in
Performance
manipulated variable)

8. Monitoring &
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Class Workshop: Complete the following table.
2. Flexibility/
controllability
Large
equipment
3. Reliability

4. Safety &
Can achieve higher capacity
equipment
protection
Can compensate for likely range of disturbances
Advantages
Can achieve faster transition (allows overshoot in
5. Efficiency & manipulated variable)
profitability

6. Operation
during
transitions High capital cost
Disadvantages Likely lower efficiency at base case and lower
7. Dynamic production rates
Performance
Might not achieve “precise” operation at base case
8. Monitoring &
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
In general, we want a large operating window. Why
2. Flexibility/ not design and construct equipment with very large
controllability
capacities?
3. Reliability

4. Safety &
equipment So, we design plants that have “just the right”
protection
capacity in “the right places”. We have to consider
5. Efficiency & the Boundaries and the Internal Points of the
profitability
operating window.
6. Operation
during
transitions
The following class workshops demonstrate
7. Dynamic
examples of equipment designs that achieve
Performance
operability with acceptable cost through modest
8. Monitoring &
modifications to the process structure.
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Some designs increase the operating window
2. Flexibility/
controllability
Centrifugal pumps - Configurations to
3. Reliability increase the operating window
Typical pump head curve
4. Safety &
equipment Series
protection

Head
5. Efficiency &
profitability

6. Operation Parallel
during Flow rate
transitions

7. Dynamic
Performance
Pumps provide “pressure (head)” and “flow”. How
8. Monitoring &
diagnosis
do we select the correct option, if needed?
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Some designs that increase the operating window
2. Flexibility/
controllability
Centrifugal pumps - Configurations to
3. Reliability increase the operating window

4. Safety & Series: This configuration

equipment
protection Series provides higher pressure at
(approximately) the same
5. Efficiency & flow rate.
profitability

6. Operation
during Parallel: This configuration
transitions provides higher flow rate at
(approximately) the same
7. Dynamic Parallel pump exit pressure.
Performance

8. Monitoring &
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window
Some designs that increase the operating window
2. Flexibility/
controllability

T6 P1
Vapor
3. Reliability product

4. Safety & T5
T1 T2
equipment
protection Feed
F1 T4 T3 L1
5. Efficiency &
profitability

F2 F3
6. Operation A1
Liquid
during Process Steam product
L. Key
transitions fluid

7. Dynamic The vapor flow rate is usually small. However, in

Performance
some cases (e.g., start up) , it is 20 times more that
8. Monitoring & its typical value. What do we do?
diagnosis
 Size of Oper.
Key Operability Window
issues OPERATING WINDOW
1. Operating
window We provide a larger pipe
and valve in parallel. The
2. Flexibility/
controllability
pressure control will
adjust the small valve first,
3. Reliability then the large valve. T6 P1
Vapor
product
4. Safety &
equipment
protection T1 T5
T2

5. Efficiency &
Feed
profitability F1 T4 T3 L1

6. Operation
during
transitions F2 F3

A1
Liquid
7. Dynamic Process Steam
L. Key
product
Performance fluid

8. Monitoring &
The vapor flow rate is usually small. However, in some cases,
diagnosis it is 20 times more that its typical value. What do we do?
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
After the frame has been established, we check the
2. Flexibility/
controllability
internal points. Are there any “donut holes”?

3. Reliability

4. Safety &
equipment
Determine whether the
protection process and equipment
function correctly
5. Efficiency &
profitability
everywhere within the
window.
feasible
Process variable 2

6. Operation
during
transitions

7. Dynamic
Performance

8. Monitoring &
diagnosis Process variable 1
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability
Orifice meter
3. Reliability heating
FC
4. Safety &
equipment Cold
protection (20C)
liquid

5. Efficiency &
profitability

6. Operation
Any concerns about
during this design?
transitions

7. Dynamic
Performance
Velocity increases;
Bernoulli says that
8. Monitoring & pressure decreases
diagnosis
Sensors: Principles of the orifice meter
P orifice
Measure pressure drop

                                                                                       
pressure

P orifice =P1 – P3

Distance 
 Sensors: Principles of the orifice meter

Nice visual display of concept.

In practice, pressure difference
is measured by a reliable and
electronic sensor = P orifice

From: Superior Products, Inc. http://www.orificeplates.com/

 v = velocity
Relate the
pressure drop F = volumetric flow rate
to the flow rate
f = frictional losses
= density
A = cross sectional area

Bernoulli’s eqn.

General meter eqn.

Installed orifice meter 0 = aver. density

(requires density C0 = constant for

specific meter
measurement)

Installed orifice meter F  K P1  P3 Most common flow

calculation, does not
require density
(assuming constant density) measurement
 Sensors: Principles of the orifice meter
When an orifice meter is used, the
calculations in yellow are performed.
Typically, they are not shown on a process
“Measured value” to flow controller drawing.

Multiply signal by
meter constant K K FC

Take square root of

measurement 

Measure pressure
difference
P

liquid

cooling
 Sensors: Are there limitations to orifices?

v = velocity
Relate the
pressure drop F = volumetric flow rate
to the flow rate
f = frictional losses
= density
A = cross sectional area

General meter eqn.

We assume that the meter coefficient is

Cmeter constant. The flow accuracy is acceptable
only for higher values of flow, typically
25-100% of the maximum for an orifice

Reynolds number
 Sensors: Is there a downside to orifices?

What is a key
disadvantage of the
orifice meter?

Ploss = P1 – P2

Pressure loss!
When cost of pressure
pressure

P orifice =P1 – P3
Non-
increase (P1) by
recoverable pumping or compression
pressure
drop is high, we want to avoid
the “non-recoverable”
Distance 
pressure loss.
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability
Orifice meter
3. Reliability heating
FC
4. Safety &
equipment
protection Cold
(20C)
liquid
5. Efficiency &
profitability

The fluid can partially vaporize.

6. Operation
during
The pressure difference will
transitions not reliability indicate
the flow rate!
7. Dynamic Velocity increases;
Performance
Bernoulli says that
8. Monitoring &
pressure decreases
diagnosis
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability

3. Reliability heating
FC
4. Safety &
equipment
protection Cold
(20C)
liquid
5. Efficiency &
profitability Simple solution,
• Locate flow
6. Operation
measurement where the
during pressure is highest
transitions and temperature lowest.

7. Dynamic • Ensure that flashing does not

Performance occur - design calc’s

8. Monitoring &
diagnosis
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability
Any concerns about this design?
3. Reliability
Hint: Describe the condition
4. Safety & of the liquid in the bottom of
equipment
protection
the tower Bubble point

5. Efficiency & What happens

Bottom tray
profitability when the
pressure is
6. Operation reduced?
during
transitions

Bottoms
7. Dynamic product
Performance
Centrifugal pump
reboiler
8. Monitoring &
diagnosis
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability

3. Reliability

Centrifugal pump
4. Safety &
equipment
protection
Bottoms
product
5. Efficiency &
profitability reboiler

6. Operation
during
transitions
What happens
Pressure drop due to Pressure drop in the
7. Dynamic the velocity increase in due to flow pump?
Performance
the eye of the pump frictional losses
8. Monitoring &
diagnosis
 Basic concept of a centrifugal pump

http://www.britannica.com/EBchecked/topic-art/632655/7 http://www.sprayingequipmentsupply.com/pumps/cent
035/Volute-centrifugal-pump rifugal-pumps.html
 Basic concept of a centrifugal pump
Constant
Impeller speed
diameter

Towler, G. and R. Sinnott (2008) Chemical Engineering Design, Elsevier-Butterworth-Heinemann, page 254
Basic concept of a centrifugal pump

http://hiramada.wordpress.com/2009/07/07/introduction-to-centrifugal-pump-technical-selection/
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within theLet’s prevent
bubbles from
2. Flexibility/ operating window forming.
controllability

3. Reliability

Centrifugal pump
4. Safety &
equipment
protection
Bottoms
product
5. Efficiency &
profitability reboiler

6. Operation
during
transitions Cavitation: The liquid partially vaporizes. As the
pressure increases in the pump, the vapor is
7. Dynamic
Performance subsequently condensed. This collapsing of bubbles
(cavitation ) causes noise, vibration and erosion - all of
8. Monitoring &
diagnosis which are bad.
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability

NPSHR: The
3. Reliability
manufacturer must
4. Safety &
define the minimum
equipment net positive suction
protection
head required.
5. Efficiency & The process engineer
profitability reboiler
must design to provide
6. Operation
it. NPSHA>NPSHR
during
transitions Centrifugal pump This liquid head increases
the pressure at the inlet to
7. Dynamic
Performance the pump and prevents
Bottoms
product cavitation.
8. Monitoring &
diagnosis NPSHA
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability NPSHR: The manufacturer
must define the minimum net
3. Reliability positive suction head required.

The process engineer must

4. Safety &
design to provide it. How?
equipment
protection
• Elevate the liquid above the
5. Efficiency & pump (two ways)
profitability • Reduce friction losses
• Subcool the liquid (careful of
6. Operation added pressure drop)
during
transitions
This is issue when liquid is at
(near) its bubble point. Give
7. Dynamic
examples when this is the
Performance
situation in chemical processes.

8. Monitoring &
diagnosis
From: Woods, D.R., Process Design and Engineering Practice, Prentice -Hall, 1995
 “Holes” in
Key Operability Oper. Window
issues OPERATING WINDOW
1. Operating
window
Equipment must function correctly within the
2. Flexibility/ operating window
controllability
This is issue when liquid is at (near) its bubble point. Give examples when this is
the situation in chemical processes.
3. Reliability

4. Safety &
equipment We deal with liquids at their
protection
bubble points often, for example,
5. Efficiency &
profitability
• Distillation/stripper bottoms
• Distillation/absorber condensers and
6. Operation
during OH drums
transitions
• Flash drums
• Concentration by boiling
7. Dynamic
Performance • Vapor compression refrigeration
• Reactor cooling by solvent vaporization
8. Monitoring &
diagnosis From: Woods, D.R., Process Design and Engineering Practice, Prentice -Hall, 1995
Key Operability
issues OPERATING WINDOW
1. Operating
window INDUSTRIAL PRACTICE
2. Flexibility/ Regrettably, no systematic method is used in practice
controllability

3. Reliability First, define the range over which the plant must
4. Safety &
operate. Consider most demanding conditions.
equipment
protection Second, solve flowsheet for the limiting cases
5. Efficiency &
profitability
Third, design equipment to function for each of the
limiting cases; may have to change structure.
6. Operation
during
transitions
Fourth, ensure that interior is operable.

7. Dynamic
Fifth, add features to achieve other operability
Performance features (on list at left), as needed
8. Monitoring &
diagnosis Fortunately, engineers have lots of relevant experience!
Key Operability
issues OPERATING WINDOW
1. Operating
window INDUSTRIAL PRACTICE
2. Flexibility/
controllability
SAFETY FACTORS: Couldn’t we just design for the
3. Reliability
base case and multiply every capacity by a safety
4. Safety &
factor, (1+ X/100) ? (X = 25%, 35%, 50%, …).
equipment
protection
This is not engineering! Any single factor would be
5. Efficiency &
too small for some equipment and too large for
profitability
others.
6. Operation
during
After applying the proper procedure, a small safety
transients
factor can be employed for modelling uncertainty,
7. Dynamic
based on experience. Typical values are 10-15%.
Performance
“For well tested process, safety factors can approach 0%” *
8. Monitoring & * Valle-Riestra, J.F. (Dow Chemical Co.), Project Evaluation in the Process Industries, McGraw-Hill, New
diagnosis York, 1983 (pg 209)
Key Operability
issues OPERATING WINDOW
1. Operating
window INDUSTRIAL PRACTICE
2. Flexibility/
controllability
SAFETY FACTORS: Some “safety factor” is built
3. Reliability
into the design procedure. After we have calculated
4. Safety &
the required pipe diameter, valve diameter, vessel
equipment
protection
size, motor power etc., we purchase the closest
available size.
5. Efficiency &
profitability
Since the manufactured sizes are discrete, we select
6. Operation
the next largest size.
during
transients
This provides some safety margin.
7. Dynamic
Performance

8. Monitoring &
diagnosis
Key Operability
issues
OPERABILITY : THE OPERATING
1. Operating
window
WINDOW
2. Flexibility/ In this Lesson, we will learn
controllability
• What is an Operating Window?
3. Reliability
- Flash Drum, CSTR
4. Safety &
equipment
• What defines the “Frame”?
protection - Distillation
5. Efficiency &
profitability
• How can we set equipment capacity (the operating
window) to achieve desired operation?
6. Operation - Equipment capacity: Heat exchanger, pump
during
transitions - Alternative Equipment: Pump, flash

7. Dynamic • How do we determine if operation is possible

Performance
within the window?
8. Monitoring & - Pump, distillation
diagnosis