An increased steam flow to the reboiler means an increase in heat input which will result in

increased vapourisation in the reboiler and an increased bottom temperature. There will be an
increased vapour flow and temperature throughout the column. The liquid level in the bottom of
the column decreases as more liquid is being boiled-off, and the bottom product rate decreases.
Hence, a change in the EB leads to a change in the MB.

Temperature (and pressure) control of a distillation tower will govern the purity of the products. The
control of top temperature is as discussed above in 'reflux'. Control of the feed inlet temperature and
that of the reboiler are also very important.

Again, if feed and bottom temperatures are too high, too much heavy vapour will rise up the tower
and put side-stream products off-spec. This condition, combined with high reflux rate will again lead
to flooding and poor separation. Opposite conditions can lead to liquid starvation across the trays
and again, a very upset process will result.

The careful control of top temperature, feed and reboiler temperatures, together with pressure
control, will give the desired temperature profile across the tower.

An increased steam flow to the reboiler means an increase in heat input which will result in
increased vapourisation in the reboiler and an increased bottom temperature. There will be an
increased vapour flow and temperature throughout the column. The liquid level in the bottom of
the column decreases as more liquid is being boiled-off, and the bottom product rate decreases.
Hence, a change in the EB leads to a change in the MB.

Increased vapour flow to the top will cause a higher temperature at the top of the column, and the
temperature (reflux) controller will increase the reflux flow back to the column. Increased reflux
flow will condense the additional vapour in the column.

The larger amount of vapour also requires additional cooling in the overhead system and this is
handled by the temperature control that increases the fan speed of the overhead condenser. This
will increase the heat removal and tends to restore the EB. Increased condensation leads to
increased liquid flow into the overhead accumulator (reflux drum). The accumulator level
controller responds by increasing the outflow of top product. This increased outflow of materials
from the top will offset the decreased in outflow from the bottom, hence the MB is restored.

2. Provide a pressure gauge (PG or PI) to verify the discharge pressure

ONTROL VALVE

When the minimum flow is reached, the valve start to open.

The pressure gauge should be located close to the outlet of the pump. It will help you diagnose
pump system problem.

Compressor specifically use for the gas stream in order to increase the pressure. Compressor K-100
and K-101 (refer to A1 size PFD attached in Appendix A-1) are used to increase pressure of gas
stream (hydrogen) to 2000 kPa and 4000kPa respectively. For the control strategy of the
compressor, team decided to use cascade control strategy. In this system, if the pressure of outlet
stream is lower than the set point, flow rate of inlet gas stream (hydrogen) will be increase
accordingly. Increase of the flow rate of hydrogen will increase the speed of rotation of
compressors motor, thus outlet pressure will be increased. Table 4-9 and Figure 4-6 shows cascade
control strategy applied at the compressor.

Compressor is used to increase the pressure of a gaseous stream. The control of a compressor is a
cascade control where the pressure of the compressor outlet is controlled by manipulating the flow
rate of the incoming hydrogen. If the pressure of the compressor outlet is lower than the set point,
the compressors motor will be rotated to increase the flow rate of hydrogen, and this will increase
the pressure at the outlet, and vice versa.

In order to maintain the discharge pressure of the compressors, the PT-004 will transmit
the signal to PC-004 which control speed of motor at the compressor. If the pressure is
lower than the set point, the compressor motor speed would be increased. Same method
is applied to PT-005 and PC-005; as well as PT-006 and PC-006.
On the other hand, a continuous flow into the compressor must be maintained in order to
avoid damage to the compressor internal part. This can be done by recycling some
amount of compressor outlet process fluid back to the inlet feed stream. A feed forward
control is installed where FT-007 transmit signal to FC-007 to manipulate control valve
in the recycle stream. Same method is applied to FT-008 and FC-008; as well as FT-013
and FC-013.
Ratio Control
Ratio control is also referred as special type of feedforward control. Ratio control
functions to maintain the ratio of two process variables at a specified value. The two
variables are usually flow rates which are the manipulated variable and disturbance
variable. For example, ratio control is used to control the flows of reactants into a
reaction vessels in correct proportions in order to keep the reaction in ideal condition.
A ratio controller is a special type of feedforward controller. It is used when two or more
ingredients are to be mixed or blended in a particular ratio where disturbances are measured
and their ratio is held at a desired set point by controlling one of the streams. The flow
controlled by the ratio controller is called the controlled flow. Ratio control is also used for
tracking, when one set point is required to follow or track another (Wilson, 2013).

This is a special type of feedforward control which is to maintain

the ratio of two process variables at a specified value. The two
variables are normally of the FLOW parameter, connected in a
particular ratio, R = u / d, where u and d are physical variables and
not deviation variables.

Ratio control is used to ensure that two or more process variables such as material flows are kept
at the
same ratio even if they are changing in value.
In industrial control, examples of ratio control that come to mind are
burner air/fuel ratio,
mixing and blending two liquids,
injecting modifiers and pigments etc into resins before molding or extrusion,
adjusting heat input in proportion to material flow.

For many processes, such as blending and boiler combustion, a key objective is to maintain the
flow rates of two process streams in some proportion to one another. In such cases, ratio control
may be applied. When ratio control is applied, one process input, the dependent input, is
proportioned to the other process input, known as the independent input. The independent input
may be a process measurement or its setpoint. The proportion that is to be maintained between
the inputs is known as the ratio. For example, a ratio of 1:1 would specify that the two inputs are
to be maintained in the same proportion. As the value of the independent input changes, through
ratio control the other process input is changed to maintain the proportion of the inputs specified
by the ratio setpoint. In nearly all ratio control applications, the ratio controller sets the setpoints
of the flow controllers rather than the valve positions, as illustrated below. Thus, any non-
linearity installed characteristics associated with valves is addressed by the flow controllers and
has no impact on the ratio controller being able to maintain the ratio setpoint.

Table X: Control System Strategy of Storage Tank

Control Controlled Manipulated Control Description
Objective Variable Variable Strategy
To control Discharge Outlets flow rate Ratio The flow transmitters
the level in flows of two outlet streams
the storage detect deviation, the
tank signal will send to the
flow control valve to
adjust the flowrate
according to the ratio
setpoint

Both the oil and water flow over weirs where level control is accomplished by a simple displacer
float. The oil overflows the oil weir into an oil bucket where its level is controlled by a level
controller that operates the oil dump valve. The water flows under the oil bucket and then over a
water weir. The level downstream of this weir is controlled by a level controller that operates the
water dump valve.
Startup cost = Fixed capital cost x 0.10
= RM 219,428,621.2 x 0.10 PAPER 5 TO EXPLAIN, PAPER 8 DOUGLAS
= RM 21,942,862,12