Chemical Engineering 3P03, Process Control

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Chemical Engineering 3P03, Process Control Why,
Why, Why ????
You want to gain the prize, the B. Eng. Diploma
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FEEDBACK CONTROL
Now for 25 more interesting points, blah, blah,
blah, ..
I dont want to be a P.C. specialist.
Why am I taking this course?
Is this part of chemical engineering?
How can I survive 3P03?
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SOME BASIC INFORMATION OF THE PROCESS CONTROL
COURSE, 3P03

• What is in the course?
• Why is Process Control important/required?
• How will this affect my career?
• Where does it fit into Chemical Engineering
  program?
• Survival, no excellence!

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Process control emphasizes the dynamic behavior
of the plant
Flow rate of sewage to plant
Dundas clarifier from Hydromantis WWW site.
24-hour period
screen
reactor
clarifier
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Process control emphasizes the dynamic behavior
of the plant
Flow rate of sewage to plant
Dundas clarifier from Hydromantis WWW site.
Much smaller plant equipment!
24-hour period
V?
Holding vessel
screen
reactor
clarifier
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Process control emphasizes the control behavior
of the plant
Dundas clarifier from Hydromantis WWW site.
The rightmount of air Acceptable water, low
energy!
reactor
Holding vessel
A
Too much air is wasteful, Too little leads to
unsafe effluent
clarifier
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WHY IS PROCESS CONTROL IMPORTANT?
You designed this flash separator in 2E04, 3O04,
3D03, And got all A s !!!
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WHY IS PROCESS CONTROL IMPORTANT?
You built it as designed and .
You lost 100,000 per week no one would buy your
product. .
Vapor product
Then, the pump was damaged .
Feed Methane Ethane (LK) Propane Butane Pentane
Also, it polluted all of Burlington
Liquid product
Process fluid
Steam
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WHY IS PROCESS CONTROL IMPORTANT?
We need to be able to drive the process
Vapor product
T6
P1
T5
T1
T2
Feed Methane Ethane (LK) Propane Butane Pentane
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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WHY IS PROCESS CONTROL IMPORTANT?
We need to be able to drive the process
Vapor product
T6
P1
We need an active element that uses measurements
to influence the process
T5
T1
T2
Feed Methane Ethane (LK) Propane Butane Pentane
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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WHY IS PROCESS CONTROL IMPORTANT?
We need to be able to drive the process
We need an active element that uses measurements
to influence the process. This can be automated
Vapor product
T6
P1
T5
T1
T2
Feed Methane Ethane (LK) Propane Butane Pentane
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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WHY IS PROCESS CONTROL IMPORTANT?
We need to be able to drive the process
Vapor product
T6
P1

• WHY??
• The process never functions as designed
• Errors in design models
• Disturbances
• Changes to requirements

T5
Feed Methane Ethane (LK) Propane Butane Pentane
T1
T2
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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WHY IS PROCESS CONTROL IMPORTANT?
PROCESS CONTROL FACTOIDS

• Products and services for automation in the
  process industries topped 44 billion (US) in
  2001.
• The market is expected to be 57 billion (US) in
  2006.
• This does not include the substantial cost of
  employees in the operating companies!

With this much activity, there must be jobs and
careers.
Market survey by ARC, Dedham, Mass, USA
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How will Process Control affect my career?
Designers must provide all required equipment.
Vapor product
T6
P1
T5
Feed Methane Ethane (LK) Propane Butane Pentane
T1
T2
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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How will Process Control affect my career?
Operations must devise strategies for
implementation.
Vapor product
T6
P1
T5
Feed Methane Ethane (LK) Propane Butane Pentane
T1
T2
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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How will Process Control affect my career?
Experimenters must achieve precise, constant
conditions.
Vapor product
T6
P1
T5
Feed Methane Ethane (LK) Propane Butane Pentane
T1
T2
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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How will Process Control affect my career?
P.C. Experts design implement control and
monitoring strategies.
Vapor product
T6
P1
T5
Feed Methane Ethane (LK) Propane Butane Pentane
T1
T2
F1
T4
T3
L1
F2
F3
Liquid product
A1
Process fluid
Steam
L. Key
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How will Process Control affect my career?
Email arriving early summer from a student after
3P03
Hi Dr. Marlin, I started my summer job on
Monday, and I just thought you'd appreciate
hearing that within an hour I had already heard
"float level sensor", "differential pressure
sensor", "now here we have a feedback loop",
"set point this.. set point that..." and the
ever favourite "this was programmed to run using
PID control. Those were about the last terms I
was expecting to hear this summer, but I guess we
can never get away from process control. Have a
good summer, Sxxxx (name withheld to protect
the innocent)
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?
Where does it fit into Chemical Engineering
program?
Series of cap-stone courses reinforce and
integrate knowledge.
Math, science and engineering sciences

• Reinforce
• Learn new aspects
• Integrate knowledge
• Build professional skills

Engineer in training
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Where does it fit into Chemical Engineering
program?
What happens when I open this valve?
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Surviving/Excelling in Process Control
You have lots of learning resources use them!

• Simply coming to class is not sufficient
• Last minute studying is not possible
• In this course, either keep up and do well, or
  fall behind and get lost

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Surviving/Excelling in Process Control
Be active in your learning!

• Follow up questions as they occur
• Test yourself with WEB materials (they have
  solutions!)
• Do your own assignments!

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Surviving/Excelling in Process Control
Assignments Affect the Course Grade (Data from
2004)
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In conclusion, Process Control is not an
obstacle! We will learn the following key
objectives.
Attitudes 1. Plants do not function as
designed 2. Flexibility must be provided for
control 3. Control improves safety, product
quality and profit.
Skills 1. Self-study using WEB
resources. 2. Problem-solving
Knowledge 1. Process dynamics 2. Control
objectives 3. Design, including variable
selection. 4. Implement and troubleshoot
control.
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Finally, some typical reactions to the course.
1. Students are generally satisfied with the
following
Accepting that this as part of chemical
engineering Understanding applications in
chemical engineering.
We continue to develop new learning materials.
Please suggest possible improvements to the
course.
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Finally, some typical reactions to the course.
2. Regarding mathematics in the course
Students in 3P03 Too much mathematics!!
Professors at other universities Too little
mathematics!!
We will use mathematics to gain insights and
solve practical problems. Nothing is included
that should not be used by a B. Eng. Engineer.
All math is reviewed in the course. The
application of engineering is more challenging
than the (routine) mathematics.
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Finally, some typical reactions to the course.
3. Regarding the course difficulty
Students in 3P03 This is too (xxxx) darn
difficult!!

• Some things to consider
• Median grade in 2004 was a B, Average was B-
• Students who failed at other Ontario universities
  have come here to take (and pass) 3P03.
• The course is structured to provide many early
  measures of performance with feedback.

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Finally, some typical reactions to the course.
4. Regarding the course content
Students in 3P03 A few think that it is not
practical

• Some things to consider
• Dr. Marlin has taught and managed control
  training for EXXON Corporation.
• Dr. Marlin has taught over 40 industrial short
  courses (for Dow, Shell, Petro-Canada, Honeywell,
  Procter and Gamble, ABB (UK), Formosa Plastics,
  India PetroChemicals, Honeywell Aerospace, .)

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Finally, some typical reactions to the course.
5. Use of WEB Learning Materials

• Students
• Like the Tutorials
• Think that Interactive Learning Modules are too
  easy
• Use Instrumentation only when forced to in an
  assignment

• Some things to consider
• The Tutorials are most like exams and assignments
• Students cannot answer ILM questions on exams!
• (If you dont understand these simple Q/A, you
  wont be able to solve more complex problems.)
• You will be using Instrumentation resources
  during the remainder of the program (and your
  careers)

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New Viewpoint Process Control is a bridge from
basic courses to engineering practice
Engineering students Engineering studies
Engineers in training Engineering practice
Engineering Practice