study guide instrumentation process control

7/28/2019 Study Guide Instrumentation Process Control

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Learner Guide

2013

Faculty of Engineering, and

the Built Environment

DEPARTMENT: Chemical Engineering

Qualification:

ND: Chemical Engineering / ND: Pulp & Paper Tech

NDCME2 / NDPPT2

SUBJECT: Process Control 3

(Subject Code: PCCR301)
http://staffportal.dut.ac.za/


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Date Revised: July 2013

Revised by: Dept. of Chemical Engineering

Vision of the Department of Chemical Engineering

Mission Statement

Department Goals for 2013

Through quality and effective teaching, and allocation of appropriate human and

physical resources, the department aims to:

Continually focus on achieving high student throughput

Produce graduates with marketable skills

Increase research activities and outputs

Promote staff development

Promote knowledge transfer through external engagement

In pursuit of educational excellence, the department commits itself to:

Developing and maintaining a relevant programme, with a good

balance between theory and practice to fulfil the needs of the Chemical

and Allied Industry and society at large,

Providing students with a holistic learning experience which will

maximize their chances of success

Establishing and maintaining partnerships with industry,

Maintaining a robust and relevant research and community outreach

programme.

The Department strives for excellence in Chemical Engineering education with a comprehensive

undergraduate teaching program and a vibrant post-graduate research program focusing on

developing technologies for addressing South Africas needs.


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LECTURER: Mr A F Bassa


OFFICE: S4 L1

TELEPHONE: 031 373 2502

FAX: 0866741148

E-MAIL: [email protected]

HEAD OF DEPT: Dr M Chetty


OFFICE: S4 L1

TELEPHONE: 031 373 2384/2218

FAX: 031 373 2285

E-MAIL: [email protected]

LECTURES: Tuesday 11h00 to 11h50 LC017

12h00 to 12h50 LC017

Friday 10h00 to 10h50 LC027

11h00 to 11h50 LC017

CONSULTATION: Tuesdays (10h00 to 11h00 and 13h00 to 14h00)

(preferably make an appointment)


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1. Welcome And IntroductionWelcome to Process Control 3. This learner guide provides the learner with all

of the requirements for the successful completion of this subject.

2. Purpose of this SubjectThis course is intended to introduce the student to the fundamental concepts of

process control including the instrumentation that is involved, which the

student is likely to encounter in industry. The main objective is to create an

understanding of the basic principles involved in the control of independent

processes in a chemical plant.

At the end of the course the student should be able to:

Identify the symbols and layout of a P&I diagram.

Identify the various types of pumps and valves and understand the basic

operation and selection procedure. Identify and understand the theory behind different measuring instruments,

including instrumentation for pressure and vacuum, temperature, flow,

and liquid level measurement.

Understand the theory of control; including control objectives, types ofcontroller mechanisms, design aspects and hardware elements for a

process control system and the development of mathematical models.

Know the theory and use of alarms, safety trips, and interlocks

Understand the basic principles of HAZOP studies.

3. Pre-RequisitesThere are no pre-requisites, however the normal promotional rules from S2 to

S3 and S4 apply.

4. Recognition of Prior Learning (RPL)Learners that have passed a similar subject at another tertiary institution are

welcomed to apply for a credit for this subject.

5.

Specific Outcomes and Course Outline

SPECIFIC

OUTCOMES

ASSESSMENT CRITERIA

The learner will

be competent to:

The learner has:

1. Identify and drawthe varioussymbols of a P&Idiagram.

a.drawn the various symbols individually and as a combination.b.the understanding of what should be in a P&I diagram and how it should be

laid out.c.used the appropriate letter codes for instrument symbols.

d.drawn and explained typical control schemes for level, pressure, flow,temperature (heat exchangers), distillation and simple reactor control.


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2. Identify thevarious types ofpumps and valvesand understand the

basic operation andselection procedure.

a.the understanding of the different construction and the operation of thevarious types of valves.

b.drawn and described the operation of the air-to-close and air-to-openpneumatic valves.

c.drawn and described the various types of plugs that may be used.d.illustrated and described the valve flow characteristics for the various

plugs.e.done preliminary valve sizing.f.described the difference between positive displacement and rotadynamic

pumps.g.identified the advantages and disadvantages of the two types of pumps.

3. Understand theprinciples ofvarious flow,temperature,pressure and liquid

level

measurements.

a.the understanding of the importance and objectives of specifyinginstrumentation and control schemes.

b.the understanding of the basic principles and uses of manometers.c.derived the equations needed to calculate the pressure difference across

various types of manometers.

d.drawn and explained the principles of operation of the Bourdon pressure

sensor and strain gauge for pressure measurement.e.an understanding of the various methods of measuring temperature

(electrical and non-electrical)f. explained the principles of operation of the thermocouple and resistance

thermometers (including the Wheatstone Bridge).g.an understanding of the various types of flow measuring devices.h.derived and applied equations for the calculation of flow using the orifice

meter, pitot tube and venturi meter.i. explained the basic operation of the rotameter and ultrasonic flow meters.j. an understanding of the basic liquid level measuring devices including

pressure differential and ultrasonic devices.

. Understand the

theory of control;including controlobjectives, controlmechanisms, designaspects andhardware elementsand mathematicalmodels.

a.understand the concept of stability.

b.draw in control mechanisms for specific control objectives.c.classified variables into input, output, manipulated, disturbances, measured,

unmeasured, etc.d.an understanding of the different control mechanisms including feedback,

feedforward, inferential, cascade, etc.e.an understanding of the operations of the different types of controllers

including P, PI and PID controllers.f. identify, draw and describe the various hardware elements of a control

system.g.an understanding of the use of digital computers in process control.h.written/derived ODEs to describe the transientbehaviour of various

systems.

5. Understand and

conduct basicHAZOP studies.

a.understood the basic procedure and sequence to follow in conducting anoperability study.

b.an understanding of the meanings and use of the various guide words.c.conducted HAZOP studies on simple systems.


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INSTRUCTIONAL SEQUENCE BOOK REF.

1. INSTRUMENTATION

1.1 Pressure and vacuum gauges CR1, Chp 5

1.2 Temperature measurement CR3, Chp 31.3 Flow meters CR1, Chp 5

Own Notes

1.3.1 Magnetic flow meters

1.3.2 Vortex shedding flow meters

1.3.3 Ultrasonic flow meters

1.3.4 D.P. Devices

1.4 Liquid level measurement CR3, Chp 3

Own Notes

1.4.1 Ultrasonic devices

1.4.2 Hydrostatic head type devices

2. THE P&I DIAGRAM

2.1 Introduction CR6, pg 148

2.2 P & I Diagram CR6, pg 148

2.2.1 Symbols and layout

(working knowledge of P,T,F,etc.,) CR6, pg 149

3. VALVES, PUMPS AND PIPING

3.1 Selection of valves

(understanding of valve characteristics) CR6, pgs 150 - 154

3.2 Pumps (2 principles) CR6, pgs 155 - 157

3.3 Mechanical design CR6, pgs 157158

3.4 Selection of pipe sizes

(qualitative view only) CR6, pgs `58 - 167

4. CONTROL

4.1 Control objectives CR6, pg 167

4.2 Types of controller mechanisms CR6, pg 1684.3 Characteristics for control mechanisms CR6, pg 168

4.4 Incentives for chemical process control S, pgs 2 - 11

4.4.1 Introduction S, pg 2

4.4.2 Suppress the influence of external

disturbances S, pg 4

4.4.3 Ensure the stability of a process S, pg 7

4.4.4 Optimize the performance of a

chemical process S, pg 10

4.5 Design aspects of a process control system S, pgs 12 - 27

4.5.1 Classification of the variables S, pg 124.5.2 Design elements of a control system S, pg 14


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4.5.3 Control aspects of a complete

Chemical plant S, pg 25

4.6 Hardware for a process control system S, pgs 28 - 33

4.6.1 Hardware elements of a control S, pg 28

system4.6.2 Use of digital computers in process S, pg 30

control

4.7 Development of a mathematical model S, pg 45 - 79

4.7.1 Why do we need a model S, pg 46

4.7.2 State variables and state equations S, pg 48

4.7.3 Additional elements S, pg 55

4.7.4 Dead time S, pg 58

4.7.5 Additional examples S, pg 59

4.7.6 Modeling difficulties S, pg 74

4.8 Modeling considerations for control S, pgs 80 - 97

purposes

4.8.1 Input-output mode S, pg 80

4.8.2 Degrees of freedom S, pg 86

4.8.3 Degree of freedom and process S, pg 89

controllers

4.8.4 Formulating the scope of modeling

for process control S, pg 93

5. TYPICAL CONTROL SYSTEMS

5.1 Level control CR6, pg 169

5.2 Pressure control CR6, pgs 169 - 170

5.3 Flow control CR6, pg 171

5.4 Heat exchangers CR6, pg 171

5.5 Cascade control CR6, pg 172

5.6 Ratio control CR6, pg 173

5.7 Distillation column control CR6, pg 173

5.8 Reactor control CR6, pg 176

6. ALARMS SAFETY TRIPS AND INTERLOCKS CR6, pg 177

7. HAZARDS AND OPERATIONAL STUDIES

7.1 Basic principles CR6, pg 292

7.2 Explanation of guide words CR6, pg 294

7.3 Procedure CR6, pg 294

7.4 Examples CR6, pg 296


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6. Critical Cross-Field Outcomes(a) Work effectively with others

This outcome is largely achieved through the two practicals (thermo-

fluids and rotameter) that the students are required to do for the course.The practicals are done in groups of up to three students and the general

practical rules apply. Students are also encouraged to work in groups

during tutorial sessions and during the solving of class problems.

(b) Manage oneself

This outcome is achieved by forcing students to adhere to due dates for

practical reports and penalizing late submissions. This teaches students to

manage their time better. Learning material is also given to those students

who attend lectures thus making sure that students discipline themselves

and come to lectures. Only students that have attempted the tutorials are

allowed to sit in for the tutorial session.

(c) Use science and technology effectively

Throughout the course the learners learn to derive scientific equations

which are then used to solve problems. The theory learnt in class is also

applied in the practicals thus enhancing the students understanding of

science and technology.

(d) Communicate effectively

This is achieved by encouraging students to participate in the class during

lectures and tutorial sessions. The nature of the course makes it

appropriate to have general discussion in class.

7. Learning And Teaching StrategiesThe course is highly theoretical and as such the lectures will take place with

the intention of having general discussions in class. Notes will be provided and

learners may need to read the notes prior to the lectures so that useful and

vibrant discussions can take place. The lecturer will make use of the OHP

during formal lectures. The course consists of 2 practicals viz. Thermofluids

which deals with measuring techniques and Rotameter calibration.

8. AssessmentThe student is assessed on a year mark system that incorporates a course mark

and an examination mark. The course mark is based on the average of two

tests and a practical mark (general S4 practical mark) which constitutes 40 %

of the final result for the course (each having an equal weighting). A three-

hour written examination at the end of the semester will determine the other

60 % of the final result. A course mark of not less than 40 % is required for a

student to sit for the final examination together with a subminimum of 40% for

the practical component. An overall result of 50 % or more is necessary to

achieve a pass and a sub-minimum of 40 % is required for the examinationitself.


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9. ReadingsCR1 Coulson & Richardson. Chemical Engineering Volume 1 (3rd Ed.).

CR3 Coulson & Richardson. Chemical Engineering Volume 3 (2nd Ed.).

CR6 Coulson, Richardson & Sinnot. Chemical Engineering Volume 6 (1st Ed.)

S Stephanopoulos, George. Chemical Process Control. Prentice Hall.

10. Tests Dates:Test 1: 26 August 2013

Test 2: 7 October 2013

11. PlagiarismPlagiarism is the unauthorized use or close imitation of the language and

thoughts of another author and the representation of them as one's own

original work, (Wikipedia). Plagiarism will not be tolerated and students will

be severely dealt with in accordance with Rule G13 (1)(o) in the 2012 rule

book for students.

12. Class Rules and PoliciesAttendance

The departmental rule is that learners must attend a minimum of 80% of the

lectures and tutorials. Failure to achieve this will result in the learner not being

able to sit for the final examination. Practicals are compulsory and both

practicals must be completed. Only learners that have attempted the tutorials

will be allowed to attend the tutorial sessions. Random attendance registers

will be taken during lectures and tutorials.

Missing of Tests

Any student who misses a test will have to make a formal application to the

department, on the prescribed form, within 5 working days, for permission to

write the special test. Students missing either test 1 or test 2 will write a

special test at the end of the semester that covers all the work.

study guide instrumentation process control

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