Industrial Process Control (PCI 1192)

Exercise 1 (P&ID)

Process 1: Modulating level control

Description

A modulating level control system consists of a capacitance probe and appropriate controller, which
provides a modulating output signal, typically 4-20 mA. Refer to Figure 8.3.5. This output signal may be
used to affect a variety of devices including:

• Modulating a control valve.

• Operating a variable speed pump drive.

Advantages:

1. Because the probe and controller only provide a signal to which other devices respond, rather
than providing the power to operate a device, there is no limit on the size of the application.
2. Steady control of level within the tank.

Disadvantages:

1. More expensive than a conductivity probe system.

2. More complex than a conductivity probe system.
3. Supply system must be permanently charged.
4. Less suitable for 'stand-by' operation.
5. Possibly greater electricity consumption.

Point to note:

To protect the supply pump from overheating when pumping against a closed modulating valve, a
re-circulation or spill back line is provided to ensure a minimum flowrate through the pump (neither
shown in Figure 8.3.5).

Process 2: Flow control system

Typical applications:

1. Feed-forward systems on boiler plant, where the rate of steam flow from the boiler will influence
other control points, for example: feedwater make-up rate, and burner firing rate.
2. Rehydration processes, where a measured quantity of steam (water) is injected into a product,
which has been dried for transportation or storage. Examples of this can be found in the tobacco,
coffee and animal feedstuff industries.
3. Batch processes, where it is known from experience that a measured quantity of steam will
produce the desired result on the product.

The selection and application of components used to control flowrate require careful thought.

The flowmeter (pipeline transducer)

The flowmeter is a pipeline transducer, which converts flow into a measurable signal. The most
commonly used pipeline transducer is likely to relate flow to differential pressure. This pressure signal is
received by another transducer (typically a standard DP (differential pressure) transmitter) converting
differential pressure into an electrical signal. Some pipeline transducers are capable of converting
flowrate directly to an electrical signal without the need for a DP transmitter.

Figure 8.3.7 shows a variable area flowmeter and standard DP transmitter relating differential pressure
measured across the flowmeter into a 4 - 20 mA electrical signal. The standard DP transmitter is
calibrated to operate at a certain upstream pressure; if this pressure changes, the output signal will not
represent the flow accurately. One way to overcome this problem is to provide a pressure (or
temperature) signal if the medium is saturated steam, or a pressure and temperature signal if the fluid is
superheated steam, as explained in the next Section. Another way is to use a mass flow DP transmitter,
which automatically compensates for pressure changes.
Flow control system

The possible need for a computer

If steam is the fluid in the pipeline, then other temperature and/or pressure sensors may be necessary to
provide signals to compensate for variations in the supply pressure, as shown in Figure 8.3.7.

Multiple inputs will mean that an additional flow computer (or PLC) containing a set of electronic steam
tables must process the signals from each of these flow, pressure and temperature sensors to allow
accurate measurement of saturated or superheated steam.

If a flow computer is not readily available to compensate for changes in upstream pressure, it may be
possible to provide a constant pressure; perhaps by using an upstream control valve, to give stable and
accurate pressure control (not shown in Figure 8.3.7).

The purpose of this pressure control valve is to provide a stable (rather than reduced) pressure, but it will
inherently introduce a pressure drop to the supply pipe.

A separator placed before any steam flowmetering station to protect the flowmeter from wet steam will
also protect the pressure control valve from wiredrawing.
Process 3: Electropneumatic temperature control

Description

These control systems may include:

• P + I + D functions to improve accuracy under varying load conditions.

• Set point(s) may be remotely adjusted, with the possibility of ramps between set points.

Advantages:

1. Very accurate and flexible.

2. Remote adjustment and read-out.
3. No limit on valve size within the limits of the valve range.
4. Excellent turndown ratio.
5. Fast operation means they respond well to rapid changes in demand.
6. Very powerful, and can cope with high differential pressures.

Disadvantages:

1. More expensive than self-acting or pneumatic controls.

2. More complex than self-acting or pneumatic controls.
3. Electrical supply required.

Applications:

1. Which need accurate and consistent temperature control.

2. With variable and high flowrates, and/or variable upstream pressure.

Points to note:

1. A clean, dry air supply is required.

2. A skilled workforce is required to install the equipment, electrical personnel are required for
power supplies, and instrument personnel to calibrate and commission.
3. Can be part of a sophisticated control system involving PLCs, chart recorders and SCADA
systems.
4. The failure mode must always be considered. For example, 'spring-to-close' on air failure is
normal on steam heating systems, 'spring-to-open' is normal on cooling systems.
5. Probably the most common control system - it has the sophistication of electronics with the pace
/ power of pneumatics.


Process 4: Pressure reduction - electropneumatic

Description

These control systems may include:

• P + I + D functions to improve accuracy under varying load conditions.

• Set point(s) which may be remotely adjusted, with the possibility of ramps between set points.

Advantages:

1. Very accurate and flexible.

2. Remote adjustment and read-out.
3. No limit on valve size within the limits of the valve range.
4. Acceptable 50:1 flow rangeability (typically for a globe control valve).
5. Fast operation - rapid response to changes in demand.
6. Very powerful actuation being able to cope with high differential pressures across the valve.

Disadvantages:

1. More expensive than self-acting or pneumatic controls.

2. More complex than self-acting or pneumatic controls.
3. Electrical control signal required. Costly for hazardous areas.
Applications:

A system which requires accurate and consistent pressure control, and installations which have variable
and high flowrates and/or variable or high upstream pressure, including autoclaves, highly rated plant
such as large heat exchangers and calorifiers, and main plant pressure reducing stations.

Points to note:

1. A clean, dry air supply is required.

2. A skilled workforce is required to install the equipment, and instrument personnel are required for
calibration and commissioning.
3. Can be part of a sophisticated control system involving PLCs, chart recorders and SCADA
systems.
4. Always consider the failure mode, for example, spring-to-close on air failure is normal on steam
systems.

Exercise 1

Refer to Figure 8.3.5, 8.3.7, 8.2.4 and 8.1.5 please answer the followings:

a) Identify the controlled variable

b) Identify the manipulated variable
c) Specify the possible disturbances
d) Please draw the P&ID according to ANSI/ISA–5.1–1984 (R1992).