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Condenser Hot Vapor Bypass Control: Petrocontrol

This document discusses different methods for controlling condenser hot vapor bypass to regulate column pressure in distillation columns. Figure 1 shows a simple and effective method using separate controllers for column pressure and accumulator pressure. Figure 2 shows a "improved" method using a single pressure difference controller, but this creates interactions that make the loops impossible to tune. Figure 3 proposes using the column pressure setpoint instead of actual pressure in the difference controller, restoring the favorable dynamics of the original method while keeping the convenience of a single controller.

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229 views6 pages

Condenser Hot Vapor Bypass Control: Petrocontrol

This document discusses different methods for controlling condenser hot vapor bypass to regulate column pressure in distillation columns. Figure 1 shows a simple and effective method using separate controllers for column pressure and accumulator pressure. Figure 2 shows a "improved" method using a single pressure difference controller, but this creates interactions that make the loops impossible to tune. Figure 3 proposes using the column pressure setpoint instead of actual pressure in the difference controller, restoring the favorable dynamics of the original method while keeping the convenience of a single controller.

Uploaded by

onizuka-t2263
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Petrocontrol

Leader in inferential control technology

Condenser hot vapor bypass control

By
Y. Zak Friedman, PhD
Principal Consultant

June 2008

34 East 30th Street, New York, NY 10016 • Tel: 212-481-6195 • Fax: 212-447-8756 •
[email protected]
Condenser hot vapor bypass control
What is the worst mistake? It is one that is repeated in practically every refinery, and yet
we haven’t managed to learn from it. I have chosen today to discuss the very simple
distillation column pressure control by partial flooding of the condenser. This method is
used often when the column overhead vapor is totally condensed into the accumulator.

As illustrated in figure 1 a valve is placed on the condenser outlet to create a flow


restriction and build up liquid level inside the condenser. As level rises, condensing area
shrinks and then the column pressure starts trending up. And vice versa, upon draining
the condenser, condensing area increases and pressure starts trending down. This
control method must allow some hot vapor to bypass the condenser in order to control
accumulator pressure. Hot vapor coming into the accumulator condenses on the
subcooled liquid surface, and hence the hot vapor flow is always unidirectional.
Accumulator pressure should be set somewhat lower than column pressure to permit
proper operation of the condenser outlet valve.

This system of figure 1 works well and is easy to tune. Accumulator pressure is tuned
fairly tight, whereas the column pressure is tuned slowly, much like a level controller.
That makes sense because in response to a change in outlet valve position
uncondensed vapor keeps accumulating and the pressure acts like a pure integrator.
While these two control loops interact, they interact in such a way as to help each other.
When column pressure goes up the accumulator pressure controller would shut the
bypass and the column pressure controller would open the condenser outlet, and both
these actions go in the same direction of reducing the column pressure.

Next visit the “enhanced” system of figure 2, where the accumulator pressure controller
is replaced by a pressure difference controller. A minor DCS change with a very good
intention. In the configuration of figure 1, when the column pressure is to be changed the
operator must change the setpoints of both controllers. While these columns operate
day in and day out at constant pressure, there may be some seasonal changes, and the
configuration of figure 2 might save the operator one minute or so upon changing column
operating pressure. In any case, this is a tiny DCS change, so why not do it?

Because this tiny DCS modification creates a not-so-tiny change of loop interaction
pattern. In the previous configuration, upon an increase of column pressure the bypass
valve closes, but with this new figure 2 configuration, when column pressure goes up –
the bypass valve would open. IE, as the column pressure controller is trying to drain the
condenser the bypass control acts to increase accumulator pressure, preventing
condenser drainage. That interaction makes the control loops next to impossible to tune.
I must have seen at least a hundred figure 2 configurations and none of them worked.
Invariably the hot vapor bypass was operating manually, and the good intention of
avoiding the nuisance of changing two setpoints instead of one has caused a much
bigger nuisance of having to change the hot vapor bypass position manually, and
experiencing frequent pressure disturbances.

Figure 3 offers a way to “have the cake and eat it”. Use pressure difference for
controlling the hot vapor bypass, but instead of the actual column pressure use the
column pressure setpoint. Another tiny change of DCS structure will now restore the

Controlling hot vapor bypass, July 2007, Page 1


favorable dynamics of figure 1 while maintaining the intended convenience of figure 2.
Do please try that and see the magic of an impossible to tune loop becoming a cinch.

Controlling hot vapor bypass, July 2007, Page 2


Figure 1. Condenser hot vapor bypass control

P
C
P
C

L
C

F F F
C C C

F
C
L
C

F
C

Controlling hot vapor bypass, July 2007, Page 0


Figure 2. “Improved” hot vapor bypass control

P
C D
P
C
L
C

F F F
C C C

F
C
L
C
F
C

Controlling hot vapor bypass, July 2007, Page 1


Figure 3. “Have the cake and eat it”

Pressure
setpoint
P
C D
P
C
L
C

F F F
C C C

F
C
L
C
F
C

Controlling hot vapor bypass, July 2007, Page 2

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