EH2208N

DESIGN PROJECT II (MARCH 2016)

PRODUCTION OF 50, 000 METRIC TONNES OF

TETRAHYDROFURAN PER YEAR

CHAPTER 4: PROCESS CONTROL AND

INSTRUMENTATION

GROUP MEMBERS

MUHAMMAD FAWWAZ AFIQ BIN MOHD 2013600508

ZAINUDDIN
MOHAMAD ALIF BIN MOHD RADZUAN 2013411196
MUHAMMAD KHAIRI BIN TAJURUS 2013233736
MUHAMMAD IDHAM BIN REZALI 2013811872
MOHAMAD HAZRUL BIN TAIB 2013674906
SITI SARAH BINTI AZMI 2013464376

SUPERVISOR:
PUAN NURHASLINA CHE RADZI

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
SHAH ALAM

1
 Table of Content

CHAPTER 4 4.1 Introduction to Process Control 1

4.1.1 Control Elements 2
4.1.2 Control System Procedure 3
4.1.3 Control Strategies 4-6
4.1.4 Types of Variables 7
4.2 Introduction to THF Plant 8
4.3 THF PLANT PROCESS DESCRIPTION
8
AND FLOW DIAGRAM
4.3.1 Chemistry 9
4.3.2 THF Plant Process Flow
10
Diagram
4.3.3 THF Plant Process Description 11-12
4.4 Control for Major Equipment 13
4.4.1 Reactor 13
4.4.1.1 Continuous Stirred
Tank Reactor, CSTR 13-15
(R-100)
4.4.1.2 Plug Flow Reactor, PFR
16-18
(R-101)
4.4.2 Heat Exchanger 19
4.4.2.1 Cooler (E-102) 19-21
4.4.3 Reactor Column (T-100) 22-25
4.4.4 Distillation Column (T-102) 26-28
4.4.5 Separator (V-100) 29-31
4.5 Control System for Other Equipment 32
4.5.1 Control System for Pumps 32
4.5.1.1 Pump (P-100) 33-35
4.5.2 Control System for Compressor 36-38
4.6 Piping and Instrumentation Diagram (P&ID) 39
4.7 References 40

2
 CHAPTER 4

PROCESS CONTROL AND INSTRUMENTATION

4.1 INTRODUCTION TO PROCESS CONTROL

Process control in industries refers to the regulation of all aspects of the

process and become one of the most important things in industrial plants. The
variables such as flow, temperature, pressure and level are critical to be controlled in
many process applications. The term ‘process’ defined to the method of changing
raw materials to create desired end product. Meanwhile, the term ‘process control’
means that the method used to control related variables in order to produce the end
product. The main objectives of process control usually divided into three as follows:

1. To reduce variability
2. To increase efficiency
3. To ensure safety

By implementing all three objectives of process control above, cost reduction is

possible in which usually more concern in real industries. The applications of process
control can vary from oil refining, paper manufacturing, chemical plants, power plants
and many more. The control loops function as to correct the deviation of a process
called an error to desired setpoint by using many control instruments such as sensor,
valves, transmitter and controller. The control system also reacts in three
consecutives ways that are measurement, decision and action. The sensor functions

1
 as to measure the process variable which is the controlled variable of the process.
The measurement part is usually made by transmitter and will transmit the signal to
controller. The decision part is made by controller in which will compare the signal
receive with the setpoint and then send the signal to the action mechanism in usual
case is valve.

4.1.1 Control Elements

In industrial practice, in order to achieve all three main tasks of control system which
are measurement, decision and action, instruments and strategies are needed to
achieve the setpoint. The basic components usually used in control system are
summarized in the Table 4.1 below.

Table 4.1: Basic components in control system.

Instrument Task
 Used to detect process variables
 Example:
 Flow: Orifice, venture, rotameter, turbine.
Sensor  Temperature: Thermocouple, resistant temperature
detector (RTD), thermometer.
 Pressure: Bourdon tube, bellows, diaphragm sensor.
 Level: Air bubble sensor
 Is a device that converts measurement from sensor into electrical
Transmitter
signal to be interpreted by controller
 Functions to compare process signal received from transmitter
with a desired set point value.
 It also produces an appropriate controller output signal to control
the process. Two types of controller which are:
Controller
 Regulatory control: for process that the control variable
deviates from set point because of disturbances;
 Servo: for process that most important disturbance is the
set point itself.
 Used to throttling purposes and general flow control. There are
Control Valve two types of control valve which are reciprocating stem and
rotating stem.

2
4.1.2 Control System Procedure

In determining the suitable control system for equipment, specific procedure must be
followed as reference to get the best control over the process. The procedure to
determine the suitable and designing the control system is summarized in the Figure
4.1 below

Define the control objective: the central element in any control configuration is the process
that needed to be controlled.

Variables Selection- Variables such as manipulated and measured variables are crucial to
set up a control system.

Select the control configuration-the most common configuration that has been used are
feedback control configuration in chemical plant.

Design and decide which type of controller should be used.

Figure 4.1: Procedure in designing control system

3
4.1.3 Control Strategies

There are a few control strategies that commonly used in industrial practice. These
control strategies are purposed to control the system in order to reduce variability in
process setpoint. Commonly used control strategies are including feedback,
feedforward, and cascade and ratio control. These control strategies description will
be explained further in Table 4.2 below.

4
 Table 4.2: Type of control strategies
Control Strategies Description Advantages Disadvantages
-Measure process variable and send -Does not require identification and -Action is taken after the disturbances affect
the measurement to a controller to measurement of any disturbances. the system.
compare with set point. -Insensitive to modelling error. -Unsatisfactory for slow process or process
Feedback Control
-If process variable deviates from set -Insensitive to parameter changes. with large dead time.
point, control action is taken to correct -May create instability for closed loop
the measurement. response.
-Anticipates load disturbances and -Good for slow system. -Requires identification of all possible
controls them before they affect the -Disturbances are corrected before it disturbances and their direct measurement.
process variables. affects the system. -Cannot cope with unmeasured
Feed Forward
-Does not introduce instability for disturbances.
Control
closed loop response. -Sensitive to process parameter variations.
-Requires good knowledge of process
knowledge.
-Secondary control loop is set up to -Easy to operate in industry level. -Require additional measurement to work
control a variable that is a major -Improvement in performance is large such as flowrate.
source of load disturbance for primary when the secondary is much faster -There are additional controllers that have to
control loop. than primary. be tuned.
Cascade Control
-Simple technology with PID -Control strategy is more complex.
algorithms.
-Use of feedback at all levels. Primary
has zero offset for “step-like”

5
 disturbances.

-A type of feedforward control. -Allow users to connect two streams -Requires a ratio relationship between
-The main objective is to maintain the to produce a certain ratio set for the variables that need to be maintained.
ratio of two variables at a specified process variables. -Quite complex for variables other than
value. -Does not require complex model. flowrate.
Ratio Control
-User-friendly system. -Often one of flowrates not measured
directly, thus the controller assumes that the
flows have the correct ratio as set.

-A type of protective strategy to

Selective and maintain the process variables within
Override Control limits.

6
4.1.4 Types of Variables

There are a few types of variables that needed to be carefully selected and control to
ensure precise control system. There are tabulated in Table 4.3 below:

Table 4.3: Types of variables

Measured/Controlled Variables
Manipulated The variable that need to be regulated in order
to maintain the controlled variable at the set
point
Disturbances Variable that tend to drive the controlled
variable away from the setpoint
Uncontrolled Variable in process that are not controlled

7
4.2 INTRODUCTION TO THF PLANT

The demand of Tetrahydrofuran (THF) is increasing over the years and consume by
various industries over the world. Therefore, in order to design a THF chemical plant,
analysis of market and economic sector must be properly done. The study is also
consists of estimation of the lost and profit of running the industry. It considers the
application and end-product, production conditions, producer and statistical capacity,
supply status and forecast market trends, supply and demand analysis, cost analysis,
and import & export of chemical conditions to be. The purpose of performing market
analysis is to determine the attractiveness of market of a product and to understand its
evolving opportunities and threats as they relate to the strengths and weaknesses of a
firm as well.

THF is cyclic ether with two primary industrial uses. The major use is as a
monomer in the production of polytetramethylene ether glycol (PTMEG), a component of
cast and thermoplastic urethane elastomers, polyurethane stretch fibers (spandex) and
high-performance copolyester-polyether elastomers (COPE). A smaller amount of THF
is used as a solvent in polyvinyl chloride (PVC), cements, pharmaceuticals and coatings,
in precision magnetic tape manufacture and as a reaction solvent.

In this chapter, THF supply and demand is discussed by emphasizing the market
trend in one of the country in Asia. Other than that, the market for raw material used in
our process is also discussed.

8
4.3 THF PLANT PROCESS DESCRIPTIONS AND FLOW DIAGRAM

4.3.1 Chemistry

Tetrahydrofuran is produced by the hydrogenation of Maleic Acid (MA) in the presence

of an acid catalyst. In this THF plant, MA is synthesized first by reacting Maleic
Anhydride (MAH) and water. 100% of the Maleic Anhydride reacts steadily with water to
produce MA. The reaction is as follow:

𝐶4 𝐻2 𝑂3 (𝑙) + 𝐻2 𝑂𝑙 → 𝐶4 𝐻4 𝑂4 (𝑙)

𝑀𝑎𝑙𝑒𝑖𝑐 𝐴𝑛ℎ𝑦𝑑𝑟𝑖𝑑𝑒 + 𝑊𝑎𝑡𝑒𝑟 → 𝑀𝑎𝑙𝑒𝑖𝑐 𝐴𝑐𝑖𝑑

The basic THF reactor raw materials are Maleic Acid and Hydrogen. Pd/Re is used as
the catalyst. MA conversion is 100%, where approximately 92.7% of the MA fed to the
reactor are converted to THF and the rest to gamma butyrolactone (GBL). There are 3
reactions occur in series in the THF reactor. The reactions are,

𝐶4 𝐻4 𝑂4 (𝑔) + 𝐻2 (𝑔) → 𝐶4 𝐻6 𝑂4 (𝑔)

𝑀𝑎𝑙𝑒𝑖𝑐 𝐴𝑐𝑖𝑑 + 𝐻𝑦𝑑𝑟𝑜𝑔𝑒𝑛 → 𝑆𝑢𝑐𝑐𝑖𝑛𝑖𝑐 𝐴𝑐𝑖𝑑

𝐶4 𝐻6 𝑂4 (𝑔) + 2𝐻2 (𝑔) → 𝐶4 𝐻6 𝑂2 (𝑔) + 2𝐻2 𝑂(𝑔)

𝑆𝑢𝑐𝑐𝑖𝑛𝑖𝑐 𝐴𝑐𝑖𝑑 + 2𝐻𝑦𝑑𝑟𝑜𝑔𝑒𝑛 → 𝐺𝐵𝐿 + 2𝑊𝑎𝑡𝑒𝑟

𝐶4 𝐻6 𝑂2 (𝑔) + 2𝐻2 (𝑔) → 𝐶4 𝐻8 𝑂(𝑔) + 𝐻2 𝑂(𝑔)

𝐺𝐵𝐿 + 2𝐻𝑦𝑑𝑟𝑜𝑔𝑒𝑛 → 𝑇𝑒𝑡𝑟𝑎ℎ𝑦𝑑𝑟𝑜𝑓𝑢𝑟𝑎𝑛 + 𝑊𝑎𝑡𝑒

9
4.3.2 THF Plant Process Flow Diagram

Figure 4.2: THF Plant Process Flow Diagram

10
4.3.3 THF Plant Process Description

Process flow diagram for the THF process is shown in Figure 4.1. Raw material for
this process is Maleic Anhydride (MAH) and hydrogen. Firstly, fresh MAH feed enters
stream 1 and is fed to R-100, where the MAH reacts with water from stream 2 to give
Maleic Acid (MA). MAH is fed to the THF plant from MAH storage tank located in the
process tank yard. R-100 is basically a vessel where MAH and water is mixed and
steadily reacts to form MA. MA stream is vaporized by E-100, prior to being sent to
packed bed reactor, R-101, THF reactor.

Hydrogen, in stream 6, from Hydrogen storage tank is fed to THF plant in

excess at 200 bar. The hydrogen stream is fed to a valve, to decrease the pressure
to 1020 kPa. The stream is then fed to E-101 to be heated to 235°C before entering
THF reactor, R-101.

The MA and hydrogen stream are fed to THF reactor, R-101. Inside the
reactor, the MA-Hydrogen mixture is reacted in the presence of Pd/Re catalyst.
Typical inlet reaction temperatures are in the range of 235°C - 275°C. As the reaction
temperature does not exceeded 400°C, the material of construction of the reactor is
carbon steel. The reactor operated at 1 MPa. About 92.7% of the MA fed is
converted to THF in the reactor (Ruichao Zhang et al., 2007). The by-product form in
this reaction is GBL and water.

Reactor effluent, containing THF, GBL, MA, Hydrogen and water are sent to
E-102 for cooling from 235°C to 40°C. The cooled stream is then fed to V-100 to
separate unreacted hydrogen from the product mixture. The overhead V-100
contains all the unreacted Hydrogen with a little THF and water carries over. The
bottom V-100 contains the product stream free from Hydrogen.

The bottom stream is then sent to Reactor Column, T-100 where the
function is to separate the THF product from unreacted MA and GBL. The overhead
of the Reactor Column contains about 35.55% THF, 63.47% Water and 0.99% MA.
The residue of the Reactor Column, containing unreacted MA and GBL, are fed back
to R-101.

The overhead of Reactor Column containing 33.55% THF, will be purify to

polymerization grade monomer by pressure swing distillation using T-101 and T-102.
Pressure swing distillation is used to break THF/Water azeotrope.

11
 Firstly, the overhead of Reactor Column will enter T-101, Distillation
Column. The column is operated nearly at atmospheric pressure. The overhead of
the Distillation Column contains THF/Water azeotrope at 93.3% THF and 6.7%
Water. The residue of the column, containing water and traces of MA are fed to
wastewater treatment plant.

The overhead of T-101, will be pumped to the finishing column, T-102, at

833 kPa. The column is operated at higher pressure to introduce pressure swing
which will break the THF/water azeotrope. The overhead of the column containing
THF and water will be recycled back to T-101. Polymerization grade THF is produced
as the bottom product. The product specification for THF is less than 200 ppm of
water. Then, the THF product is sent to the product tank.

In the THF process, there are two recovery processes, unreacted MA and
GBL recovery and unreacted Hydrogen recovery. Unreacted MA and GBL are
recovered from T-100 residue. The mixture will then be pumped back to the reactor
for further reaction.

For the hydrogen, as the mixture of hydrogen, water and THF emerges from
the overhead of V-100, it will be cool by refrigerant to -18°C and then be fed to the
next flash drum, V-101. In this flash drum, most of THF and water are collected at the
bottom and is fed to T-101 for purification while the overhead contains all the
unreacted hydrogen and traces of THF. The overhead stream is combined with the
fresh hydrogen feed which will then be fed to the THF reactor, R-101.

12
4.4 Control System for Major Equipment

4.4.1 Reactor

4.4.1.1 Continuous Stirred Tank Reactor, R-100

CSTR R-100 is a reactor that functions to produce maleic acid from maleic anhydride
and water. The reaction will take place at temperature range of 65°C to 133.5°C at
pressure of 300 kPa. To achieve the production rate of 50,000 tonnes of THF per
year, this reactor is expected to produce MA at a flowrate of 10398 kg/h. The purity of
produced MA from this reactor is 100% since it only involving the mixing of water and
maleic anhydride.

In maintaining the exact flowrate and desired purity of maleic acid, two
variables must be control so that it can meet the production rate. The variables
involved are level and pressure variable. By controlling the flowrate, the level can be
controlled. The pressure and temperature must be maintained so that the reaction
can take place and produce the desired purity of maleic acid. The most suitable
control strategy is feedback control for pressure variable and ratio control for level
variable. Pressure transmitter will send signal to the controller to verify the value. The
controller will take action after the disturbance has disturbed the system, in this case
the pressure in the reactor. The controller will open and closed the valve to make
sure that pressure is always consistent with the input setpoint.

Ratio control is suitable to be used to control the proportion of flowrate so that

one stream is proportionate to another stream according to fixed ratio. In this reactor,
Stream 1 acts as wild flow stream that need not to be controlled. The flowrate of
Stream 2 will be adjusted according to ratio of Stream 1 by using multiplier or divider
controller.

13
 Piping & Instrumentation Diagram

Symbols:
Equipment: Continuous Stirred Tank Reactor (CSTR), R-
FT-Flow Transmitter
100
FC-Flow Controller
PT-Pressure Transmitter
Date: 10/6/2016
PC-Pressure Controller
Figure 4.3: P&ID for CSTR (R-100)

14
Table 4.4: Summary for control system of R-100
No Control Objective Measured Manipulated Disturbances Action Type of Controller Set Point
Variables Variable
1 Control the Pressure inside Flow of product Inlet flow of By adjusting the inlet Feedback control 300 kPa
pressure in reactor, the reactor stream of R-100 reactants flowrate
R-100
2 Control the level in Level inside the Flow of water and Inlet flow of By adjusting the inlet Ratio control Ratio of
the reactor, R-100 reactor maleic anhydride reactants flowrate maleic
anhydride
to water is
0.24:1

15
4.4.1.2 PFR, R-101

PFR-10 is the main reactor is this production plant. In this reactor, reactants which
are hydrogen and maleic acid are reacted with presence of Pd/Re catalyst to produce
THF along with other side products. This reactor is operated in gas phase at
temperature of maleic acid and hydrogen gases at 235°C to 250°C. The reaction is
exothermic and cooling water is needed to maintain isothermal condition. In making
sure that the reaction goes well, this temperature has to be maintained along with
pressure at 1000 kPa.

Precise control is needed to make sure the pressure and temperature

variables can be maintained. Selective control strategy is chose to control the
temperature inside the reactor so that it does not exceed 250°C. Selective control is
suitable to control the temperature so that the temperature does not exceed the high
or low setpoint with multiple transmitters. When one of transmitters’ values achieved
the limit or setpoint, the cooling water flowrate will be adjusted so that the
temperature can be controlled below 250°C. Meanwhile, for pressure and flow
control, feedback controller is chose to control the deviations.

16
 Piping & Instrumentation Diagram

Symbols:
Equipment: Plug Flow Reactor, R-101
PT-Pressure Transmitter
PC-Pressure Controller
TT-Temperature Transmitter
TC-Temperature Controller Date: 10/6/2016
FT-Flow Transmitter
FC-Flow Controller
Figure 4.4: P&ID for PFR (R-101)

17
 Table 4.5: Summary of control system for R-101
Measured Manipulated Type of
No Control Objective Disturbances Action Set Point
Variables Variable Controller
To control the Temperature in the The flowrate of Heat from The selector will Selective 250°C
temperature in the reactor at three cooling water reaction detect the highest
reactor different places temperature whether
exceed 250°C or not.
The controller will
1
adjust the cooling
water valve opening
to control the
temperature below
setpoint.
To control the
The pressure of Flow of outlet gas Temperature By releasing the gas
2 pressure in the Feedback 1 MPa
outlet stream to scrubber inside the reactor to scrubber
reactor
The flow of feed
To control the flow of The flowrate of Inlet flowrate of By controlling flow
3 inlet into the Feedback 12967 kg/h
inlet feed reactants reactants of feed of reactant
reactor

18
4.4.2 Heat Exchanger

4.4.2.1 Cooler, E-102

The objective of this control system is to maintain the outlet temperature of Cooler E-
102 at 40°C from 127.82°C before its enter separator,V-100. Cooling water at inlet
temperature of 30°C is used as coolant to cool down the hot process fluid. The
controller must be set that when the outlet temperature deviates from the setpoint,
the cooling water valve is control to compensate the error.

Cascade control is chose as control strategy for this heat exchanger in order
to maintain the desired process fluid outlet temperature at 40°C as it able to provide
much faster compensation when cooling water flowrate is disturbed. By using
cascade controller, cooling water flowrate can be more flexible in supplying the
cooling water in case of disturbances in outlet temperature of hot fluid stream,
Stream 11.

The flowrate of process fluid inlet into heat exchanger also controlled to
maintain the correct flowrate throughout the process. Feedback control is used to
control the inlet feed flowrate by measuring the flowrate of inlet before its entering the
heat exchanger.

19
 Piping & Instrumentation Diagram

Symbols:
Equipment: Shell and Tube Heat Exchanger, E-102
FT-Flow Transmitter
FC-Flow Controller
TT-Temperature Transmitter Date: 10/6/2016
TC-Temperature Controller
Figure 4.5: P& ID for Shell and Tube Heat Exchanger (E-102)

20
 Table 4.6: Summary of control system for E-102
Manipulated Type of
No Control Objective Measured Variables Disturbances Action Set Point
Variable Controller
Adjusting the cooling
To control the outlet Cooling water
Outlet temperature Inlet flowrate of water flowrate to get the
1 temperature of E- inlet Cascade 40°C
of E-102 cooling water desired outlet
102 temperature
temperature of E-102
Inlet flowrate of Adjusting the process
To control inlet feed Inlet feed flowrate of Process fluid
2 process fluid at tube fluid flowrate to achieve Feedback 12967 kg/h
flowrate into E-102 process fluid inlet
side the flowrate setpoint

21
4.4.3 Reactor Column, T-100

The general function of distillation column is to separate the mixture of fluids based
on the relative volatility of every pure component. The light key component, which
indicated by higher volatility will vaporised at lower temperature than heavy key
component. At light key component boiling point, the light key component will
separate and leave heavy key at bottom of column.

The main objective of this reactor column is to fully separate THF from
unreacted MA and GBL. This column is operated at temperature of reboiler at
151.1°C and pressure of 230 kPa. To make sure the separation process running
smoothly, the flowrate of feed inlet must be controlled so that there is no flooding
occurs. That means the level of fluid in the column must be carefully controlled along
with pressure and temperature. The pressure in column also must be controlled to
avoid safety failure.

22
 Piping & Instrumentation Diagram

Symbols:
Equipment: Reactor Column, T-100
FT-Flow Transmitter
FC-Flow Controller
LT-Level Transmitter
LC-Level Controller
PT-Pressure Transmitter Date: 10/6/2016
PC-Pressure Controller
TT-Temperature Transmitter
TC-Temperature Controller
Figure 4.6: P&ID for Reactor Column (T-100)

23
Table 4.7: Summary of control system for T-100
Measured Manipulated Type of
No Control Objective Disturbances Action Set Point
Variables Variable Controller
To control the
By adjusting the
flowrate of feed Fluctuation of feed 11914.1
1 Inlet feed flowrate Inlet feed flowrate feed flowrate valve Feedback
into the column flowrate kg/h
at stream 14
(stream 14)
By adjusting the
flowrate of distillate
Flowrate of stream and
To control the The pressure in Fluctuation of top
2 distillate stream of increase N2 inlet Feedback 200 kPa
pressure in column column stream flowrate
column stream if pressure
drops lower than
setpoint
To control the level By adjusting the
in the reactor The level in reactor Flowrate of bottom flowrate of bottom 11914.1
3 Feed inlet flowrate Feedback
column to avoid column stream stream to reactor kg/h
flooding column
By adjusting the
To control the Flowrate of cooling
Temperature at Cooling water inlet cooling water
4 temperature at water inlet into Feedback 84.84°C
distillate stream flowrate fluctuation flowrate into the
distillate stream condenser
condenser
To control the Flow of reflux Flowrate of reflux Flowrate of Control the
5 Cascade 1.24
reflux rate stream stream disturbance stream flowrate of reflux

24
 stream into the
column
By adjusting the
To maintain
Temperature at inlet flowrate of
6 reboiler Flowrate of steam Flowrate of steam Feedback 151.1°C
bottom stream steam into the
temperature
reboiler

25
4.4.4 Distillation Column, T-102

Distillation column, T-102 is part of pressure swing column that operate to purify the
THF product from column T-100. The pressure swing column is used to break the
azeotrope between water and THF and hence to obtain pure THF product before it is
stored into product tank.

In this column, the mixture of THF and water is introduced to high pressure at
833.4 kPa in order to break the azeotrope of mixture. The overhead stream will
contains water and a little of THF and is recycled into distillation column T-101 to re-
introduce to pressure swing condition. The bottom stream will contain pure THF and
will be pumped into product tank.

Since the pressure in the column is the most crucial variable in this equipment
process, the pressure will be carefully controlled. The temperature in this column also
must be constant at 64.39°C and must be maintained to avoid undesirable THF
purity.

26
 Piping & Instrumentation Diagram

Symbols:
Equipment: Distillation Column, T-102
FT-Flow Transmitter
FC-Flow Controller
LT-Level Transmitter
LC-Level Controller
PT-Pressure Transmitter Date: 10/6/2016
PC-Pressure Controller
TT-Temperature Transmitter
TC-Temperature Controller
Figure 4.7: P&ID for distillation column (T-102)

27
Table 4.8: Summary of control system for T-102
Manipulated Type of
No Control Objective Measured Variables Disturbances Action Set Point
Variable Controller
To control the By adjusting the
Pressure in the Flowrate of distillate Fluctuation of
1 pressure in the flowrate of distillate Feedback 792.9 kPa
column stream pressure
column stream
By adjusting the
To control the level To avoid
Flowrate of bottom The feed inlet into bottom stream
2 in the column to Level in T-102 Feedback flooding in
product the column flowrate to avoid
avoid flooding column
flooding
By adjusting the
To control the inlet
Feed flowrate into Changes in feed valve at feed inlet to
3 flowrate into the Flowrate of feed Feedback 9047 kg/h
the column flowrate increase to
column
decrease flow
To control By adjusting the
Temperature at Flowrate of cooling Changes in cooling
4 temperature at cooling water Feedback 135°C
distillate stream water water flowrate
distillate stream flowrate valve
To maintain the By adjusting the
Temperature at Flowrate of steam Fluctuation in
5 reboiler flowrate of steam Feedback 151.1°C
bottom stream into reboiler steam temperature
temperature into reboiler
Control the flowrate
To control the reflux Flow of reflux Flowrate of reflux Flowrate of
6 of reflux stream into Cascade 2.9
rate stream stream disturbance stream
the column

28
4.4.5 Separator, V-100

Vapour-liquid separator is a device used in several industrial applications to separate

a vapour-liquid mixture. For the common variety, gravity is utilized in a vertical vessel
to cause the liquid to settle to the bottom of the vessel, where it is withdrawn. Since
its function to separate the mixture according to their density differences, it is
important to design suitable control strategy for this type of vessel.

The main objective of this separator is to separate unreacted hydrogen from

stream 11 produced by the main reactor, R-101. The separation of this mixture takes
place at temperature of 40°C and pressure of 970 kPa. In order to make sure that the
separation process takes place, these two variables must be carefully controlled.

The most suitable control strategy for this equipment is feedback controller
which will measure the pressure and level of liquid in the vessel. The transmitter will
transmit signal to controller to determine whether the setpoint deviate from original
and corrected the error.

29
 Piping & Instrumentation Diagram

Symbols:
Equipment: Separator, V-100
LT-Level Transmitter
LC-Level Controller
PT-Pressure Transmitter Date: 10/6/2016
PC-Pressure Controller
Figure 4.8: P&ID for separator (V-100)

30
Table 4.9: Summary of control system for V-100
Manipulated Type of Set
No Control Objective Measured Variables Disturbances Action
Variable Controller Point
The fluctuation of By adjusting the
To control the level Level in separator, The flowrate liquid
1 flowrate at stream outlet flowrate of Feedback
of liquid in separator V-100 outlet at stream 12
12 liquid at stream 12
To control the The fluctuation of By adjusting the
The pressure in the The flowrate of gas 970
2 pressure in the pressure at gas pressure of outlet Feedback
separator, V-100 outlet at stream 13 kPa
separator outlet stream 13 gas stream 13

31
4.5 Control System for Other Equipment

4.5.1 Control System for Pumps

Pumps are used to transport process liquid from one place to another. In other
cases, pumps are also used to increase the pressure of one stream in order to
maximize the process condition. Because of the pumps are quite pricey, this
equipment should have suitable control strategy to avoid any losses and undesired
incident.

There are a few reasons that best control system is needed for a pump.
According to Lieberman, 2009, the needs to control the pump are as follows:

1. To sustain required process flow.

2. To protect pump from cavitation as it can cause damaging vibration to pump’s
mechanical seal, bearings and impeller.
3. To avoid excessively low flowrate that can cause internal damage.
4. Save energy used to operate the pump.
5. To prevent excessive driven pump speed.

32
4.3.1.1 Pump, P-100

Pump, P-100 is functions to increase the pressure of maleic acid (MA), product of
CSTR-100 from 300 kPa to 1050 kPa before it enters the PFR-100. The flowrate of
maleic acid will affect the pressure of the pump. The suitable control strategy to be
used at the pump is feedback controller. The information of variables and action to be
taken is summarized in Table 4.10 below.

33
 Piping & Instrumentation Diagram

Symbols:
LT-Level Transmitter Equipment: Pump, P-100
LC-Level Controller
LS-Low Selector
FT-Flow Transmitter Date: 10/6/2016
FC-Flow Controller
Figure 4.9: P&ID for pump (P-100)

34
Table 4.11: Summary of control system for P-100
Manipulated Type of
No Control Objective Measure Variable Disturbance Action Set Point
Variable Control
To control level in Outlet pressure of Pump valve Flowrate of inlet to When level in R- Selective 1050
CSTR and outlet P-100 and level in opening R-100 100 decrease Override kPa
flow of pump to R-100 below setpoint, flow
avoid pump control at pump
damage outlet will override
1
the system and
restrict pump
opening so that
level can achieve
setpoint

35
4.5.2 Compressor, K-100

Compressor, K-100 is functions to increase the pressure of gas mixture consist of

mainly hydrogen from 910 kPa to 1020 kPa. The gas mixture needed to be recycled
into hydrogen inlet stream at Stream 8. The feed flowrate of gas mixture is 596.8 kg/h
and needed to be manipulated in order to keep the pressure increment stable
throughout the process. The chosen control strategy for this compressor is feedback
control strategy. Any fluctuations in pressure will be adjusted by controller by
adjusting the flowrate of gas mixture into the compressor.

36
 Piping & Instrumentation Diagram

Symbols:
Equipment: Compressor, K-100
PT-Pressure Transmitter
PC-Pressure Controller
Date: 10/6/2016

Figure 4.10: P&ID for compressor (K-100)

37
Table 4.12: Summary of control system for K-100
Manipulated
No Control Objective Measure Variable Disturbance Action Type of Control Set Point
Variable
Control outlet Outlet pressure of Flowrate of inlet to Flowrate of inlet to By adjusting the Feedback 1020
1
pressure of K-100 K-100 K-100 K-100 inlet flow to K-100 Control kPa

38
4.6 THF Piping and Instrumentation Diagram (P&ID)

Figure 4.11: Piping and instrumentation diagram of THF plant

39
4.7 REFERENCES

Doyle J.C, Francis B., Tannenbaum A. (1990). Feedback control theory. Macmillan
Publishing Co., 1990.

Lieberman N.P. (2008). Troubleshooting process plant control. New Jersey, Canada: John
Wiley & Sons, Inc.

PAControl (2006). Fundamentals of control. Retrieved from www.PAControl.com

40