Instrumentation Documents

PKE-4510
Unit -III
 Introduction
Here we will discuss three different types of
instrumentation diagrams:
– Process Flow Diagrams (PFDs)
– Process and Instrument diagrams (P&IDs)
– Loop diagrams (“loop sheets”)
– SAMA diagrams
 Process Flow Diagram
• At highest level, the instrument technician is
interested in the interconnections of;
– Process vessels,
– Pipes, and flow paths of process fluids.
• The proper form of diagram to represent the
“big picture” of a process is called a “Process
Flow Diagram”.
• Individual instruments are sparsely
represented in a PFD.
 Process Flow Diagram
Level transmitter (LT)

Signal (LV) that controls

the level.

Temperature
transmitter (TT)
 Process & Instrument Diagram
• Process and instrument diagrams (P&IDs) lie somewhere in
the middle between Process Flow Diagrams and Loop
Diagrams.

• A P&ID shows the layout of all relevant Process Vessels,

Pipes, and Machinery (e.g. pumps, compressor etc), but
with Instruments superimposed on the diagram showing
– What gets measured and what gets controlled.

• Here, one can view;

– the flow of the process as well as
– the flow of information
• between instruments measuring and controlling the
process.
 P&ID
Electrical & Pneumatic signals

Piping & Valves

Instruments

The rectangular
box enclosing
both
Machines temperature
recorders shows
they are part of
the same and
only one physical
instrument.
Process Vessels
 P&ID Symbols
“Bubbles”
• The type of “bubble” used for each instrument tells us
something about its location.
• This is quite important when working in a facility with
many thousands of instruments scattered over acres of
facility area, structures, and buildings.
Lines
Process/Instrument line connections
Instrument bubbles
Process Valves
Valves Actuators
Valve Failure Mode
Flow Sensors
Flow Sensors
Process Equipments
 Loop Diagram
• The details we do not see on this P&ID
include;
• Cable types
• Wire numbers
• Terminal blocks
• Junction boxes
• Instrument calibration ranges,
• Failure modes,
• Power sources, and the like. To examine this
• For these information we must go to the
Loop Diagram.
• At the lowest level, the instrument technician is
interested in the interconnections of individual
instruments, including all the wire numbers,
terminal numbers, cable types, instrument
calibration ranges, etc.
• The proper form of diagram for this level of fine
detail is called a loop diagram.
• Here, the process vessels and piping are sparsely
represented, because the focus of the diagram is
the instruments themselves.
Loop Diagram
 SAMA Diagram
• SAMA is an acronym standing for Scientific Apparatus
Makers Association.
• These diagrams focus on the flow of information within a
control system rather than on the process piping or
instrument interconnections (wires, tubes, etc.).
• The general flow of a SAMA diagram is top-to-bottom, with
the process sensing instrument (transmitter) located at the
top and the final control element located at the bottom.
• No attempt is made to arrange symbols in a SAMA diagram
to correlate with actual equipment layout:
• These diagrams are all about the algorithms used to make
control decisions, and nothing more.
• Example of SAMA diagram, showing a flow transmitter
(FT) sending a process variable signal to a PID
controller, which then sends a manipulated variable
signal to a flow control valve (FCV).
A cascaded control system, where the output of one controller
acts as the setpoint for another controller to follow,
appears in SAMA diagram form like this;

In this case, the primary controller senses the level in a vessel,

commanding the secondary (flow) controller to maintain the necessary
amount of flow either in or out of the vessel as needed to maintain
level at some setpoint.
• Rectangular blocks such as the , P, I, and D shown in this diagram represent
automatic functions.
• Diamond-shaped blocks such as the A and T blocks are manual functions which
must be set by a human operator.
• Showing even more detail, the following SAMA diagram indicates the presence of
setpoint tracking in the controller algorithm, a feature that forces the setpoint
value to equal the process variable value any time the controller is in manual
mode:
SAMA Diagram Symbols
Conventional Control Loops in Process Industry

Flow Control

Pressure Control

Level Control

Temperature Control

Product Quality Control

 Flow Control
Loop
FC FT

Fluid
Flowing
in Pipe

• Flow is usually controlled using a PI controller.

•The signal from the flow sensor is noisy due to turbulent flow so that a large
proportional band (about 150) is used.

• A small reset time (10-20s) is used for good set-point tracking.

 Pressure Control Loop
PT PC

• The dynamics of pressure in a pressure control loop can be very fast (flow like) or
slow (level like) depending on the process system.

• PI controllers are usually used for pressure loops with a small proportional band
(10-20%) and integral time (0.2-2 mins) for tight pressure control.

• Tight pressure control is usually desired in most processing situations.

 Level Control Loop
❑ In order to filter out flow
disturbances, the level should be
controlled loosely.

❑ P controller is used for level

LT
control.

LC
❑ A proportional band of 50% is
commonly used so that the valve
fully closes / opens for a 25%
change in the level assuming the
valve is initially 50% open.

Exceptions to loose level control

❑ The level in a CSTR
 Temperature Control Loop

❑ Moderately slow due to sensor lags and heat transfer

lags.

TT TC ❑ PI and PID controllers often used.

❑ The integral time ≈ process time constant

❑ Derivative time ≈ 0.25 X (process time constant)

 Ratio Control
Maintains ratio between two streams.

Feed forward compensation for through-put changes.

Wild stream

FT

Multiplier × (Ratio)Constant

Flow set point

FC
Flow controller

FT

Manipulated stream

Implementation of ratio control

 Cascade Control
❑ Master (primary) loop sets the set-point for the slave (secondary) loop

Temperature control of an exothermic CSTR

LC
LC

Feedback Control Cascade Control

 Cascade
Control
❑ Slave loop dynamics should be much faster than master loop dynamics

Advantages

❑ Slave controller removes the local disturbances

❑ Slave controller compensates for local non-linearity
❑ Additional loop expense

Tuning
❑ The slave loop is first tuned with the master loop in manual.
❑ Next tune master loop with slave loop on automatic
Control of Reactors and Heat
Exchangers
 Basic Reactor Types

Coolant
in
Reactants Products
in out

Coolant
out
PBR

Products
Reactants out
in

PFR
 Plug Flow Reactor

• Temperature profile for an

adiabatic PFR

Reactor length
 Reactor Heat Management
Adiabatic PFR

Recycle A
Reactor

A Products

B
TC
Limiting
Reactant
Furnace Heat
duty

The reactants (fresh + recycled) are heated to the reaction temperature using a furnace
The furnace heat duty holds the reactor inlet temperature constant.
 Reactor Heat Management
Adiabatic PFR

Furnace
Recycle A
Reactor
Products

Pure A
TC

Pure B

FC
Limiting TC
Reactant
Set

The adiabatic temperature rise sets the reactor outlet temperature.Outlet temperature is
controlled to maintain the reactor conversion and selectivity
The limiting reactant fresh feed rate may be used as the manipulation handle
 Continuous Stirred Tank Reactor

❑ Instantaneous perfect back mixing

❑ Reaction occurs at outlet concentration

❑ S.S. conversion depends on inlet and outlet conditions,

❑ Multiple steady states possible

Simple CSTR
 CSTR Heat
Management
Simple CSTR

Drawback
Heat transfer coeff varies with coolant flow rate

Possibility of local hot spot

 CSTR Heat
Management
Recirculation Loop

❑ Recirculation loop introduces additional thermal lag

 CSTR Heat Management
Recirculation Loop with Cascade arrangement

❑ Significantly improves the closed loop response

CSTR Heat
Management
Use Of Internal Coil
 CSTR Heat Management
External Circulation of Reactor Contents

TT TC

Cooling
Water

❑ External heat exchanger introduces significant lag into slave loop

 CSTR Heat
Management
Bypassing Reactor Contents

❑ Bypassing improves dynamics

 Heat Exchangers

Counter current Shell and Tube heat exchanger

Types

Utility Heat Exchangers Process to Process stream

Heat Exchangers
Heat Exchangers
Utility Heat Exchangers
 Heat Exchangers
Indirect Control of Heat Exchanger

Indirect control of Heat exchanger using partial pressure of non-condensables

 Heat Exchangers
Flooded Condenser

❑ Level of the condensate determines the number of tubes that are submerged
Plant wide Control Structures
 Plant Wide Control Design Procedure
❖ Establish Control Objectives

❖ Determine Control Degrees of Freedom

❖ Establish Energy Management System

❖ Set Production Rate
❖ Control Product Quality and Handle Safety, Environmental, and
Operational Constraints

❖ Fix a Flow in Every Recycle Loop and Control

Inventories (pressures and Liquid levels)
❖ Check Component Unit Operations

❖ Optimize Economics and Improve Dynamic Controllability

 Hydrodealkylation
CC
SP

Purge

TC
open PC
Furnace

Sep
Reactor Ht.Ex
LC TC H2 Feed
Rate
TC
Fuel
FC

PC SP

PC CC PC
Methane LC
LC
SP LC SP
FC FC
FC
Product Column

SP

Recycle Column
Stabilizer Column

Benzene

SP
TC
TC TC

Toluene
LC LC feed
LC

Diphenyl
 Isomerization

Recycle
Furnace

FEHE Reactor

TC
PC
Cooling Fuel FC
water
LC

PC

LC
PC
FC

LC
Product
CC FC

Fresh
Feed

LC

LC

FC
Purge
DIB Column Purge Column
 Recycle benzene
P4
P3
L6
L4

RC Cumene
RC
T7
Recycle T6
Column Recycle
Product
benzene P4 P3
P2 di-isopropyl benzene
Column
P1
L1 FC
Benzene L6 L4
L5 L7
Fuel Gas
F1 RC RC Cumene
Recycle
Benzene
Cumene Process
RecycleF2
Reactor
T7
T6
L2 benzene
Cooler T4
Column
F1 P1 Furnace P2
Product
Propylene
L1 T5
F2 Fuel Gas
Column di-isopropyl benzene
… FC
Recovery
Preheater
Furnace Column
Propylene L5 Fuel Gas
T3L7 L3
HS
Reactor Cooler T4
Preheater T2 L2
T1

T2 … T5
Fuel Gas
T1
Recovery
T3 HS Column
L3