Control System

Objective

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 1 Control System Objective
Control System Objectives
The objectives of a control system may be
grouped into the following areas:
Æ Economic Incentive
Æ Safety
Æ Equipment Protection

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 2 Control System Objective
Economic Incentive
A process parameter’s effect on product depends
greatly on the plant’s limitations and operating
condition. Production variations fall into two
categories
1. Global production maximum for a given operating
condition
2. Production maximum occurs at an upper or lower
bound on a parameter for a given operating condition.

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 3 Control System Objective
Global Production Maximum
Maximum $ LostÆ For this case,
production is
$/HR greatest when
Profit the band of
variation is
reduced to
zero and the
process
Maximum $ Lost parameter is
maintained at
the value
$/HR corresponding
Profit to maximum
production
“Better” Control

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 4 Control System Objective
Global Production Maximum (Cont)
Æ To benefit from
improvement in
Maximum control, the loop must
operate at the target
that provides
$/HR $ Lost
Profit maximum production.
Æ The plant design
conditions may be
“Better” Control used as a guide in
“Wrong” Setpoint establishing setpoints
for best operation

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 5 Control System Objective
Production Maximum at Limit
Æ For this case,
Maximum
maximum production
$/HR $ Lost is obtained by
Profit maintaining the
process parameter at
a limit determined by
some plant limitation.
Æ How close to the limit
Maximum you can operate is
determined by the
$ Lost quality of the control
$/HR
Profit

“Better” Control
©2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 5 - 6 Control System Objective
Production Maximum at Limit
Production improvement is obtained by operating closer to product
specification or operating limit.

$$ Savings
Limit or
Spec Target
Setpoint

Poor Control Better Control

Time
©2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 5 - 7 Control System Objective
Ammonia Process Example

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 8 Control System Objective
Synthesis Converter
3500

3400

3300

Production, Mol/Hr
3200

3100

3000

2900

2800
350 400 450 500
Bed #1 Inlet Temperature, degC

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 9 Control System Objective
Cost of Synthesis Temperature Variation

@410 degC
% production change
Change in bed #1 inlet temp

3441 – 3413
3441
430-410 *100 = 0.4

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 10 Control System Objective
Ammonia Plant - Synthesis Loop
Pressure
3400

3300

3200

Production, Mol/Hr
3100

3000
Maximum
Pressure
2900
Limit
2800

2700

130 135 140 145 150

Loop pressure (atmospheres)

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 11 Control System Objective
Cost of Synthesis Pressure Variation

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 12 Control System Objective
Primary Reformer Methane Leakage

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 13 Control System Objective
Primary Reformer Temperature
Control
Æ Maximum operating
temperature limit is
determined by the
Primary Reformer
material of
construction
TT
TT

TT
TT
TT
Æ Exceeding maximum
TT
temperature can
result in tube rupture
and shutdown of the
process

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 14 Control System Objective
Cost of Variation from Minimum Leakage

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 15 Control System Objective
Safety – Boiler Draft Control
PC
PT
Æ Boiler draft
control is used
to remain
negative
pressure within
the boiler.
ID Fan Æ If the pressure
were to go
FD Fan positive, then
hot gases from
the boiler could
Max Design Positive blow back
Pressure Pressure through access
ports on
-10 -9 -4 -3 -2 -1 0
operating people
Draft Pressure, in H2O
Normal
©2006 Fisher-Rosemount Systems, Inc.
Slide 5 - 16 Value Process Control
Control System Objective
Equipment Protection – Standpipe Level Control
Æ Standpipe
level must be
maintained to
avoid loss of
LT LC
10 10 liquid flow to
pump.
SC
10 Æ Loss of flow
for an
extended
Pump Standpipe period of time
Runs Dry Overflow may damage
the pump
0% Standpipe Level 100%

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 17 Control System Objective
Control System Benefits Balance
Æ Various techniques may be used to
improve the control of a process

Control Æ As the complexity of the control

System Benefits system increases, so does cost for
Complexity Provided operator training and maintenance
Æ The complexity (cost) of the control
system should be balanced with the
benefits provided
Æ The benefits of control improvement
may be influenced by market
conditions i.e. value of product, cost
of feedstock, energy cost

©2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 5 - 18 Control System Objective