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Simple Control FIC

The document discusses two examples of control loop design. The first example describes a packed column used to return flashed product in a storage tank back to liquid state. It is determined that a simple control loop using a FIC to control the flow of cooled water is sufficient. The second example discusses maintaining the temperature of a burner tip using a FIC to control the constant flow of HPS to oxygen.

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jigar navadiya
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21 views6 pages

Simple Control FIC

The document discusses two examples of control loop design. The first example describes a packed column used to return flashed product in a storage tank back to liquid state. It is determined that a simple control loop using a FIC to control the flow of cooled water is sufficient. The second example discusses maintaining the temperature of a burner tip using a FIC to control the constant flow of HPS to oxygen.

Uploaded by

jigar navadiya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Educational Institute for Equipment and Process Design

Advanced Control
Simple Flow Control Loops
Educational Institute for Equipment and Process Design

Example 1:
It is common practice in oil and gas industry that when we have unpurified product, then the
product is sent to distillation column to be purified and the grade of the product is improved. In
order to avoid any disturbance at the inlet of the distillation unit, there is an unpurified product
storage tank. Since the tank operating pressure is atmospheric due to economical analysis, then
a part of the product is flashed. In order to get the flashed product back to the liquid state and
mitigate the loss, a packed column is used on the storage tank so that the flashed product comes
to contact with cooled water over the packings and as a result, the flashed product is washed and
comes back to the liquid state. Here is the PFD-like sketch:

Now we know the process and we should specify:


1. The type of control system (simple, cascade, split-range, override and complex)
2. The parameter which should be controlled
3. The configuration
To answer the first question, we should delve into the design of packed column. Don’t worry, we
are not going to talk about that much details.
The existing packed column is countercurrent and its performance is determined mainly by the
surface area and the flow of cooled water. In fact the higher the surface area and the higher the
flow of cooled water, then the higher the amount of the flashed product would return to liquid state.
Educational Institute for Equipment and Process Design

The surface area during design is fixed and as a result, the only parameter which should be
controlled is flow. Therefore,
1. We don’t need to implement split range since only one parameter impacts the
performance.
2. We don’t need to implement cascade control since flow controllers are the fastest.
3. We don’t need to have override control since we don’t have two controllers here to
compare their output and select the safest one.
4. The control loop does not incorporate above control types and the system itself is not that
much complex, so the complex loop is not needed here.
So finally, we select simple control loop.
Regarding the second question, now it is crystal clear that flow should be controlled. Thus, we
need a FIC.
Lastly, we need to determine the configuration. To complete the configuration, we need to:
1. Show FIC on the P&ID
2. Show flowmeter on the P&ID and locate it before the valve
3. Show the control valve and its assembly
4. Connect them together like below
Educational Institute for Equipment and Process Design

Note for flowmeter selection:


Educational Institute for Equipment and Process Design

Example 2:
In ammonia and methanol plant, Syngas which is a mixture of H2 + CO + CO2 is produced is
produced by ATR technology or simply auto thermal reactors which principally based on mixing
and reaction of NG and oxygen to produce heat required for catalytic zone. The burner in which
oxygen and NG mix and produce flame has special material. As a result, the tip of the burner
should be maintained as specific temperature so that the damage to burner is prevented.
To maintain the temperature, simply HPS could be added to the oxygen, not only to reduce the
oxygen concentration and avoid any explosion, but more importantly to cool the burner tip.
Based on CFD analysis the maximum flow of 4000 kg/hr. of HPS should be added to oxygen. On
the surface, a TIC controller with TV valve would do the job and keep the temperature within the
range. When the capacity of NG and oxygen change, the TIC can lower the opening of the TV
and reduce the flow since less flow is needed. But how about this: We maintain the flow at 4000
kg/hr. at all phases with one main reason, which is the safety of the burner since the TIC control
can possibly cause some fluctuations and lead to the damage to the burner. Keeping this in mind,
we need a FIC.
Now let’s take the same procedure and develop the control loop.
1. The type of control system (simple, cascade, split-range, override and complex)
2. The parameter which should be controlled
3. The configuration
For the first one:
1. We don’t need to implement split range since only one parameter impacts the
performance.
2. We don’t need to implement cascade control since the FIC is the fastest.
3. We don’t need to have override control since we don’t have two controllers here to
compare their output and select the safest one.
4. The control loop does not incorporate above control types and the system itself is not that
much complex, so the complex loop is not needed here.
So finally, we select simple control loop.
Regarding the second question, now it is crystal clear that flow should be controlled. Thus, we
need a FIC.
Lastly, we need to determine the configuration. To complete the configuration, we need to:
1. Show FIC on the P&ID
2. Show flowmeter on the P&ID and locate it before the valve
3. Show the control valve and its assembly
Connect them together like below
Educational Institute for Equipment and Process Design

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