Practical Process Control Design with Industrial Applications

AvAlan M. Kugelman

Inbunden, Engelska, 2024

1 931 kr

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Beskrivning

Practical guidance on how to apply process control fundamentals to solve real-world control problems Practical Process Control Design with Industrial Applications presents process control essentials and control strategy design fundamentals for modern-day DCS work environments. It uses a unique instructional approach—a process analysis and process understanding framework that enables readers to better understand and more effectively use process control fundamentals. Process analysis, operating objectives, and business drivers guide the identification of control objectives and facilitate control strategy designs of realistic control applications for real-world unit operations. Filling a gap in the literature, coverage includes: Merging process analysis, process understanding, and real-world plant operations with process control essentials and design fundamentalsDetailed discussion of real-world design issues and realistic process-specific control strategies Methods used to ensure acceptable control performance continues when various “what if” issues ariseHow process control design fundamentals are applied in important unit-specific control strategiesHow best to apply specific control attributes (control direction), control options (PID proportional action), standard DCS functionality (algorithms and/or function blocks), and corporate or site standards (input signal validation) to develop control strategies that achieve control objectives with acceptable control performance.Practical Process Control Design with Industrial Applications is an essential reference for control engineers and process engineers who support process control activities in an operating plant, DCS vendor control application specialists, and EPC company project engineers who support process control activities in capital projects.

Produktinformation

Utgivningsdatum:2024-11-03
Mått:183 x 257 x 33 mm
Vikt:1 429 g
Format:Inbunden
Språk:Engelska
Antal sidor:640
Förlag:John Wiley & Sons Inc
ISBN:9781394246496

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Mer om författaren

Alan M. Kugelman, PhD, has more than 40 years’ experience in process control application design and implementation in capital projects, DCS migration projects and DCS modernization projects. Working for ExxonMobil Research and Engineering Company (Florham Park, NJ, later in Fairfax, Va.), he developed his process control applications design and implementation expertise during three onsite assignments at ExxonMobil sites in Europe and Japan. He then supported ExxonMobil control applications activities, in both refineries and chemical plants worldwide, from central engineering offices in Brussels, Florham Park, and Fairfax. He developed, and taught company-administered control application training courses to site control engineers worldwide.

Innehållsförteckning

Preface xiii1 Process Dynamics and Process Control Overview 11.1 Introduction 21.2 The Role of Process Control 31.3 Tag Naming Conventions 41.4 Control Loop Essentials 71.5 Process Dynamics and Dynamic Responses 141.6 Plant Testing 251.7 Classification of Process Control Strategies 281.8 Benefits of Control Applications 412 Feedback Control Essentials 442.1 Introduction 452.2 Single Loop Control, Simple, and Complex Cascades 462.3 Digital Control System (DCS)Work Environment 502.4 PID Control Algorithm Basics 572.5 Noise, Filters, Plant Testing, and Closed-Loop Control 932.6 Ratio Control 972.7 Single Input-Single Output Model-Based Control (MBC) 1042.8 Cascade Wind-up 1123 Feedforward Control Essentials 1203.1 The Role of Feedforward Control 1203.2 Ratio Control and Steady-State Feedforward Control 1243.3 Dynamic Compensation via the Lead-Lag Algorithm 1263.4 Ratio Control and Dynamic Feedforward Control 1303.5 Incremental Steady-State Feedforward Control 1333.6 Incremental Dynamic Feedforward Control 1373.7 Engineering Relationships That Provide Feedforward Corrections 1414 Process Analysis and Understanding 1554.1 Business Drivers, Operating Plans, and Operational Objectives 1564.2 Obtaining Useful Information 1564.3 Use of Process Analysis 1585 Split Range Control 1785.1 Split Range Control Overview 1785.2 Split Range Control Applications 1816 Override Control 1956.1 Override Control Overview 1956.2 Override Control Applications 1986.3 From Override Control to Conventional Constraint Control 2057 Conventional Constraint Control 2087.1 DMC’s Role in Multivariable Constraint Control 2097.2 Introduction to Conventional Constraint Control 2107.3 Natural Draft Heater Combustion Control via Conventional Constraint Control 2107.4 Maximizing Heat Recovery 2187.5 Conventional Constraint Control Cascade Structure 2267.6 Alternate Signal Selector Locations in Constraint Control Designs 2287.7 Active Constraint Variable Switches 2317.8 Constraint Control Design Issues 2338 Design Considerations 2368.1 First Steps: Process Understanding and Operating Objectives 2378.2 Basic Control Attributes, Control Options 2388.3 Standard DCS Functionality 2438.4 Corporate and Site Standards 2448.5 Sample Time, Control Frequency and Controller Scheduling 2468.6 Calculated Control Variables 2468.7 Inferential Variables 2478.8 Input Validation 2528.9 Flow Compensation 2588.10 Cascade Initialization and Wind-up Protection 2598.11 Alarming and Operator Messaging 2608.12 Interactions with Other Control Strategies 2618.13 Testing to Judge Control Strategy Acceptability 2639 Level Control 2659.1 Introduction 2659.2 Single Loop Level Control 2669.3 Light-ends Tower Inventory Control 2689.4 Level Controllers that Manipulate Multiple Flows 2739.5 More Complex Level Control Applications 2779.6 Averaging and Tight Level Controller Tuning 28610 Heat Input/Heat Removal Controls 29110.1 Introduction 29110.2 Feed Preheat Controls 29510.3 Control Strategies in Heat Integrated Units 31110.4 Fired Heater Firing Controls 32311 Energy Conservation Controls 33911.1 Heat Recovery Maximization 34011.2 Lowering Fired Heater Stack Excess O2 Targets 35711.3 Reducing Tower Reboiler Duty and Reflux Flow 37011.4 Reducing Stripping Steam Utilization 38311.6 Reducing Reactor Treat Gas, Recycle Gas Flows 39712 Tower Product Quality Controls 41012.1 Tower Basics 41212.2 Two-product Towers - Process Variable Summary 41212.3 Two-product Towers - Common Product Quality Control CV-MV Pairs 41912.4 Towers with Sidestream - Process Variable Summary 42712.5 Towers with Sidestream - Common Product Quality Control CV-MV Pairs 43212.6 Cutpoint, Fractionation, and Their Impact on Tower Operations 43512.7 Two-product Towers - Overview of Conventional Advanced Control Applications 44312.8 Towers with Sidestream - Overview of Conventional Advanced Control Applications 45312.9 Two-product Towers - Conventional Advanced Control Application Examples 46312.10 Towers with Sidestream - Conventional Advanced Control Application Examples 48513 Fractionator Product Quality Control 49713.1 Fractionator Unit Characteristics 49913.2 Feed True Boiling Point (TBP) Distillation Curve, Cutpoint, and Fractionation 50513.3 Crude Distillation Unit, CDU - The Most Important Primary Fractionator 51513.4 Reactor Effluent Product Separation Section Main Fractionators 54114 Reactor Conversion Control 55414.1 Reactor Control Fundamentals 55514.2 Reactor System Unit Configurations 56414.3 Reactor System Control Objectives, CVs, MVs, and DVs 58114.4 Conventional Reactor Advanced Control Applications 584Control, Inlet Temperature Maximization 608References 613Index 615