Greg McMillan is a retired automation expert who has written many books on process modeling and control. He discusses improving control loop performance for both batch and continuous processes. Some key techniques include properly tuning loops, selecting high-quality valves and flow meters, and applying model-based control strategies like model predictive control.
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pipeline Sizing. This is an introduction to understand more about their:-
-The basic idea.
-Simplified method for calculations.
-Equations.
-Data Tables.
-Worked Examples.
-Excel Sheets for Calculation.
-Links to other topics which may be interesting.
You can find also more at:
http://hassanelbanhawi.com/staticequipment/linesizing/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Setpoint Integrated Solutions is an industry leader in applying Control Valve solutions across industry segments.
Brannon Gant - Regional Sales Manager
Line Sizing presentation on Types and governing Equations.Hassan ElBanhawi
Based on my 8 years of experience in Oil & Gas industry I can claim that you can find here All what you need to know about Pipeline Sizing. This is an introduction to understand more about their:-
-The basic idea.
-Simplified method for calculations.
-Equations.
-Data Tables.
-Worked Examples.
-Excel Sheets for Calculation.
-Links to other topics which may be interesting.
You can find also more at:
http://hassanelbanhawi.com/staticequipment/linesizing/
All the data and the illustrative figures presented here can be found through two reference books:-
ENGINEERING DATA BOOK by Gas Processors Suppliers Association
Process Technology - Equipment and Systems by Charles E. Thomas
Thank you.
Setpoint Integrated Solutions is an industry leader in applying Control Valve solutions across industry segments.
Brannon Gant - Regional Sales Manager
Control Loop Foundation - Batch And Continous ProcessesEmerson Exchange
This presentation, by Emerson's Terry Blevins and Mark Nixon, is a guide for engineers, managers, technicians, and others that are new to process control or experienced control engineers who are unfamiliar with multi-loop control techniques.
Their book is available in the ISA Bookstore at: http://emrsn.co/1E
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Control Valves types, control valves characterstics, affects on control valves due to various process fluctuations or cavitations or flashing and remidies.The model datasheets also included.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
PID Control of Runaway Processes - Greg McMillan DeminarJim Cahill
On-line demo / seminar presented by ModelingAndControl.com's Greg McMillan on August 25, 2010.
Recorded version of presentation will be available post live session at: http://www.screencast.com/users/JimCahill/folders/Deminars
Piping and Instrumentation / Process Flow DiagramPatel Ghanshyam
Overview of Piping and Instrumentation / Process Flow Diagram
3 Levels of Diagram
The Block Flow Diagram (BFD)
Definitions of BFD
PFD Drawing Symbols
The Process Flow Diagram
P&ID – Construction Bible
Revamp objectives
Revamp Philosophy
Revamp options
Semi-Regenerative Reforming Unit
Typical Flow Scheme
Continuous Reforming Unit
Typical Flow Scheme
Revamp to Hybrid Operation
What may be achieved?
Typical C5+ Yield at Decreasing Pressure
Changes Required for Full Conversion
Typical Benefits of Full Conversion
Revamping of Existing Continuous Reforming Units
Fired Heaters Revamp
Burners
Reactor Options
Regeneration Section
Summary
The HYSYS program was used to make simulations of gas and steam stations, the method of entering data into the program, with the possibility of calculating the generated energy, the efficiency of the thermal cycle, and the method of extracting the results and calculations
Split Range Control - Greg McMillan DeminarJim Cahill
Presented March 9, 2011 by Greg McMillan as on-line demo/seminar. Video recording available at: http://www.screencast.com/users/JimCahill/folders/Public
PID Control of Valve Sticktion and Backlash - Greg McMillan Deminar SeriesJim Cahill
Greg McMillan shows the limit of PID control options to help with sticky valves and valves with excessive deadband in this live deminar (demo/seminar).
Recorded video at: http://www.screencast.com/t/OTJjYjE1Nz
Control Loop Foundation - Batch And Continous ProcessesEmerson Exchange
This presentation, by Emerson's Terry Blevins and Mark Nixon, is a guide for engineers, managers, technicians, and others that are new to process control or experienced control engineers who are unfamiliar with multi-loop control techniques.
Their book is available in the ISA Bookstore at: http://emrsn.co/1E
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Control Valves types, control valves characterstics, affects on control valves due to various process fluctuations or cavitations or flashing and remidies.The model datasheets also included.
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
PID Control of Runaway Processes - Greg McMillan DeminarJim Cahill
On-line demo / seminar presented by ModelingAndControl.com's Greg McMillan on August 25, 2010.
Recorded version of presentation will be available post live session at: http://www.screencast.com/users/JimCahill/folders/Deminars
Piping and Instrumentation / Process Flow DiagramPatel Ghanshyam
Overview of Piping and Instrumentation / Process Flow Diagram
3 Levels of Diagram
The Block Flow Diagram (BFD)
Definitions of BFD
PFD Drawing Symbols
The Process Flow Diagram
P&ID – Construction Bible
Revamp objectives
Revamp Philosophy
Revamp options
Semi-Regenerative Reforming Unit
Typical Flow Scheme
Continuous Reforming Unit
Typical Flow Scheme
Revamp to Hybrid Operation
What may be achieved?
Typical C5+ Yield at Decreasing Pressure
Changes Required for Full Conversion
Typical Benefits of Full Conversion
Revamping of Existing Continuous Reforming Units
Fired Heaters Revamp
Burners
Reactor Options
Regeneration Section
Summary
The HYSYS program was used to make simulations of gas and steam stations, the method of entering data into the program, with the possibility of calculating the generated energy, the efficiency of the thermal cycle, and the method of extracting the results and calculations
Split Range Control - Greg McMillan DeminarJim Cahill
Presented March 9, 2011 by Greg McMillan as on-line demo/seminar. Video recording available at: http://www.screencast.com/users/JimCahill/folders/Public
PID Control of Valve Sticktion and Backlash - Greg McMillan Deminar SeriesJim Cahill
Greg McMillan shows the limit of PID control options to help with sticky valves and valves with excessive deadband in this live deminar (demo/seminar).
Recorded video at: http://www.screencast.com/t/OTJjYjE1Nz
Greg teaches you about Auto Tuning and Adaptive Control of Nonlinear Processes that are self regulating. Recorded video available for viewing at: http://www.screencast.com/t/NDY1NTQx
PID Control of True Integrating Processes - Greg McMillan DeminarJim Cahill
Presented August 11, 2010 by Greg McMillan as on-line demo/seminar. Video recording available at: http://www.screencast.com/users/JimCahill/folders/Public
In this day and age of automated computer control valve sizing, the logic and theories behind it are invisible. In his presentation, Al Holton of Allagash Valve & Controls will look at the basic principles that apply and how they affect the application and installation of a wide range of control valve types. He will also review the reasoning behind valve type selection.
In these days when environmental management has finally found its way into our minds and enterprises, the pure mechanical principle of the Rotameter regains even more momentum. For manufacturers it is important to optimize productivity, consume less energy and reduce energy costs. Using Rotameters with their comparably low pressure loss results in low pumping costs and therefore energy savings. Rotameters work without power and are therefore sustainable. The new RGC4 can be completely disassembled and consists from recyclable materials only. The RGC4 design, made from common standard components and parts being used from other Yokogawa flow products, leads to a synergy effect in production and to resource and energy conservation. This is key to sustainable future Yokogawa takes into account at every stage of the product lifecycle. Think of your carbon foot print – use Rotameters!
New Kids on the I/O Block - Transferring Process Control Knowledge to Millenn...Jim Cahill
Presented at 2014 Emerson Exchange conference by Danaca Jordan and Jim Cahill.
As retirement rates accelerate in Western nations, efficiently transferring knowledge and lessons learned to new instrumentation and automation professionals grows in importance. Given generational differences in learning styles and limited spare time to develop training, what are some effective ways to accomplish this? A Boomer and a Millennial collaborate to share practical methods to take back with you.
A Unified PID Control Methodology to Meet Plant ObjectivesJim Cahill
Presented at the AIChE 2013 Spring Meeting and 9th Global Congress on Process Safety meeting by Greg McMillan, CDI Process & Industrial and Hector Torres, Eastman Chemical
Social Media and Collaboration in Automation and ManufacturingJim Cahill
Presented at the ARC Industry Forum in Orlando, Florida. The presentation highlights the important of surfacing expertise to make it findable and expanding your social network connections.
Social Media for Process Automation - Why?Jim Cahill
Some reasons process automation suppliers may want to consider the use of social media in their business efforts. Presented by Jim Cahill at the 2011 Valve Manufacturers Association Market Outlook Workshop (http://jimc.me/p5uOFC)
Foundation Fieldbus - Control in the FieldJim Cahill
Presented by Emerson's Travis Hesketh at the 2011 General Assembly in Mumbai, India on March 9-10.
Download the file to get the full effect of the slide builds.
Wireless Measurement and Control - AIChE New OrleansJim Cahill
Wireless Measurement and Control - Opportunities for Diagnostics Process Metrics Inferential Measurements and Eliminating Oscillations
Presented by Greg McMillan on March 15, 2011.
PID Tuning for Near Integrating Processes - Greg McMillan DeminarJim Cahill
Greg McMillan shares how to reduce tuning time for near integrating processes.
Recorded video version available for viewing at: http://www.screencast.com/t/NmUxZTBiNTg
On-line Process Control Lab Access and Use DeminarJim Cahill
Recorded demo/seminar of Greg McMillan presenting On-line Process Control Lab with Access and Use Instructions on May 27, 2010.
Screencast of presentation available at: http://www.screencast.com/t/Y2Q4NjM0Y
PID Control of Slow Valves and Secondary Loops Greg McMillan Deminar SeriesJim Cahill
Greg McMillan shares ways to address slow valves and different time constants between primary and secondary loops.
Recorded deminar (demo/seminar) available for viewing at: http://www.screencast.com/t/YWYxZGUw
A presentation given to the ISA Executive Board on February 25, 2010. It describes opportunities for social media for businesses and institutions, the Emerson social media story, other companies successes, and pitfalls.
PID Control Of Sampled Measurements - Greg McMillan Deminar SeriesJim Cahill
This presentation, PID Control of Sampled Measurements, is from the first in Greg McMillan's live seminar / demo (a.k.a. deminar) series.
You can watch a recorded version of this presentation at: http://www.screencast.com/t/ODhlOWY4M
For future events and background, visit: http://www.emersonprocessxperts.com/archives/2010/04/free_series_of.html
Process Profiling: Investigation And Prediction Of Process Upsets With Advanc...Jim Cahill
2009 HART Plant of the Year Award winner Mitsubishi Chemical Corporation Uses HART Technology to Detect Abnormal Situations and Failures before they Affect the Process
http://hartcomm.org/protocol/realworld/realworld_success_mitsubishi09.html
Read| The latest issue of The Challenger is here! We are thrilled to announce that our school paper has qualified for the NATIONAL SCHOOLS PRESS CONFERENCE (NSPC) 2024. Thank you for your unwavering support and trust. Dive into the stories that made us stand out!
This slide is special for master students (MIBS & MIFB) in UUM. Also useful for readers who are interested in the topic of contemporary Islamic banking.
Acetabularia Information For Class 9 .docxvaibhavrinwa19
Acetabularia acetabulum is a single-celled green alga that in its vegetative state is morphologically differentiated into a basal rhizoid and an axially elongated stalk, which bears whorls of branching hairs. The single diploid nucleus resides in the rhizoid.
Model Attribute Check Company Auto PropertyCeline George
In Odoo, the multi-company feature allows you to manage multiple companies within a single Odoo database instance. Each company can have its own configurations while still sharing common resources such as products, customers, and suppliers.
Synthetic Fiber Construction in lab .pptxPavel ( NSTU)
Synthetic fiber production is a fascinating and complex field that blends chemistry, engineering, and environmental science. By understanding these aspects, students can gain a comprehensive view of synthetic fiber production, its impact on society and the environment, and the potential for future innovations. Synthetic fibers play a crucial role in modern society, impacting various aspects of daily life, industry, and the environment. ynthetic fibers are integral to modern life, offering a range of benefits from cost-effectiveness and versatility to innovative applications and performance characteristics. While they pose environmental challenges, ongoing research and development aim to create more sustainable and eco-friendly alternatives. Understanding the importance of synthetic fibers helps in appreciating their role in the economy, industry, and daily life, while also emphasizing the need for sustainable practices and innovation.
Introduction to AI for Nonprofits with Tapp NetworkTechSoup
Dive into the world of AI! Experts Jon Hill and Tareq Monaur will guide you through AI's role in enhancing nonprofit websites and basic marketing strategies, making it easy to understand and apply.
Safalta Digital marketing institute in Noida, provide complete applications that encompass a huge range of virtual advertising and marketing additives, which includes search engine optimization, virtual communication advertising, pay-per-click on marketing, content material advertising, internet analytics, and greater. These university courses are designed for students who possess a comprehensive understanding of virtual marketing strategies and attributes.Safalta Digital Marketing Institute in Noida is a first choice for young individuals or students who are looking to start their careers in the field of digital advertising. The institute gives specialized courses designed and certification.
for beginners, providing thorough training in areas such as SEO, digital communication marketing, and PPC training in Noida. After finishing the program, students receive the certifications recognised by top different universitie, setting a strong foundation for a successful career in digital marketing.
Control Loop Foundation for Batch and Continuous Control
1. 06/06/09 Control Loop Foundation for Batch and Continuous Control GREGORY K MCMILLAN use pure black and white option for printing copies
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8. 06/06/09 TS is tactical scheduler, RTO is real time optimizer, LP is linear program, QP is quadratic program Pyramid of Technologies APC is in any technology that integrates process knowledge Foundation must be large and solid enough to support upper levels. Effort and performance of upper technologies is highly dependent on the integrity and scope of the foundation (type and sensitivity of measurements and valves and tuning of loops) The greatest success has been Achieved when the technology closed the loop (automatically corrected the process without operator intervention) Basic Process Control System Loop Performance Monitoring System Process Performance Monitoring System Abnormal Situation Management System Auto Tuning (On-Demand and On-line Adaptive Loop Tuning) Fuzzy Logic Property Estimators Model Predictive Control Ramper or Pusher LP/QP RTO TS
9. Loops Behaving Badly 06/06/09 1 E i = ------------ T i E o K o K c where: E i = integrated error (% seconds) E o = open loop error from a load disturbance (%) K c = controller gain K o = open loop gain (also known as process gain) (%/%) T i = controller reset time (seconds) (open loop means controller is in manual) A poorly tuned loop will behave as badly as a loop with lousy dynamics (e.g. excessive dead time)! Tune the loops before, during, and after any process control improvements You may not want to minimize the integrated error if the controller output upsets other loops. For surge tank and column distillate receiver level loops you want to minimize and maximize the transfer of variability from level to the manipulated flow, respectively.
10. Unification of Controller Tuning Settings 06/06/09 Where: K c = controller gain K o = open loop gain (also known as process gain) (%/%) 1 self-regulating process time constant (sec) max maximum total loop dead time (sec) All of the major tuning methods (e.g. Ziegler-Nichols ultimate oscillation and reaction curve, Simplified Internal Model Control, and Lambda) reduce to the following form for the maximum useable controller gain
11. Definition of Deadband and Stick-Slip 06/06/09 Deadband Deadband Stick-Slip Signal (%) 0 Stroke (%) Digital positioner will force valve shut at 0% signal Pneumatic positioner requires a negative signal to close valve The effect of slip is worse than stick, stick is worse than dead band, and dead band is worse than stroking time (except for surge control) Dead band is 5% - 50% without a positioner ! Stick-slip causes a limit cycle for self-regulating processes. Deadband causes a limit cycle in level loops and cascade loops with integral (reset) action. If the cycle is small enough it can get lost in the disturbances, screened out by exception reporting, or attenuated by volumes
14. Identification of Stick and Slip in a Closed Loop Response 06/06/09 The limit cycle may not be discernable due to frequent disturbances and noise Time ( Seconds ) Stroke % 53 53.5 54 54.5 55 55.5 56 56.5 57 57.5 58 58.5 59 0 100 200 300 400 500 600 700 800 3.25 Percent Backlash + Stiction Controller Output Flow Dead band is peak to peak amplitude for signal reversal slip stick
15. Response Time of Various Positioners (small actuators so slewing rate is not limiting) 06/06/09 Response time increase dramatically for steps less than 1%
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19. Neutralizer Control – “Before” 06/06/09 Static Mixer Neutralizer Feed Discharge AT 1-1 FT 1-1 FT 2-1 AT 2-1 FT 1-2 2 pipe diameters Reagent Stage 1 Reagent Stage 2 AC 1-1 AC 2-1 FC 1-2
20. Nonlinearity and Sensitivity of pH 06/06/09 pH Reagent Flow Influent Flow 6 8 Good valve resolution or fluid mixing does not look that much better than poor resolution or mixing due amplification of X axis (concentration) fluctuations Reagent Charge Process Volume or
21. Neutralizer Control – “After” 06/06/09 Static Mixer Neutralizer Feed Discharge AT 1-1 FT 1-1 FT 2-1 AT 2-1 FT 1-2 Reagent Stage 1 Reagent Stage 2 20 pipe diameters f(x) Feedforward Summer RSP Signal Characterizer *1 *1 *1 - Isolation valve closes when control valve closes AC 1-1 FC 1-2 FC 2-1 AC 2-1
22. Distillation Column Control – “Before” 06/06/09 FC 3-4 FT 3-4 FC 3-3 FT 3-3 LT 3-1 LC 3-1 TE 3-2 TC 3-2 LT 3-2 LC 3-2 Distillate Receiver Column Overheads Bottoms Steam Feed Reflux PC 3-1 PT 3-1 Vent Storage Tank Feed Tank Tray 10 Thermocouple
23. Nonlinearity and Sensitivity of Tray Temperature 06/06/09 Tray 10 Tray 6 Distillate Flow Feed Flow % Impurity Temperature Operating Point Measurement Error Measurement Error Impurity Errors
24. Distillation Column Control – “After” 06/06/09 FC 3-2 FT 3-2 FC 3-4 FT 3-4 FC 3-3 FT 3-3 FC 3-1 FT 3-1 LT 3-1 LC 3-1 TT 3-2 TC 3-2 FC 3-5 FT 3-5 LT 3-2 LC 3-2 RSP RSP RSP Distillate Receiver Column Overheads Bottoms Steam Feed Reflux PC 3-1 PT 3-1 Vent Storage Tank Feed Tank Tray 6 f(x) Signal Characterizer RTD FT3-3 FT3-3 Feedforward summer Feedforward summer
25. When Process Knowledge is Missing in Action 06/06/09 2-Sigma 2-Sigma RCAS Set Point LOCAL Set Point 2-Sigma 2-Sigma Upper Limit PV distribution for original control PV distribution for improved control Extra margin when “ war stories” or mythology rules value Benefits are not realized until the set point is moved! (may get benefits by better set point based on process knowledge even if variability has not been reduced) Good engineers can draw straight lines Great engineers can move straight lines
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29. Reset Gives Them What They Want 06/06/09 Proportional and rate action see the trajectory visible in a trend! Both would work to open the water valve to prevent overshoot. Reset action integrates the numeric difference between the PV and SP seen by operator on a loop faceplate Reset works to open the steam valve Reset won’t open the water valve Until the error changes sign, PV goes above the set point. Reset has no sense of direction. Should the steam or water valve be open? SP PV Out 52 44 ? TC-101 Reactor Temperature steam valve opens water valve opens 50% set point (SP) temperature time PV
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36. Batch Control 06/06/09 Reagent Optimum pH Optimum Product Feeds Concentrations pH Product Optimum Reactant Reactant Reactant Variability Transfer from Feeds to pH, and Reactant and Product Concentrations Most published cases of multivariate statistical process control (MSPC) use the process variables and this case of variations in process variables induced by sequenced flows.
37. PID Control 06/06/09 Optimum pH Optimum Product Feeds Concentrations pH Product Reagent Reactant Optimum Reactant Reactant Variability Transfer from pH and Reactant Concentration to Feeds The story is now in the controller outputs (manipulated flows) yet MSPC still focuses on the process variables for analysis
38. Model Predictive Control 06/06/09 Optimum pH Optimum Product Feeds Concentrations pH Product Reagent Optimum Reactant Reactant Reactant Time Time Variability Transfer from Product Concentration to pH, reactant Concentration, and Feeds Model Predictive Control of product concentration batch profile uses slope for CV which makes the integrating response self-regulating and enables negative besides positive corrections in CV
39. Example of Basic PID Control 06/06/09 feed A feed B coolant makeup CAS ratio control reactor vent product condenser CTW PT PC-1 TT TT TC-2 TC-1 FC-1 FT FT FC-2 TC-3 RC-1 TT CAS cascade control Conventional Control
40. Example of Advanced Regulatory Control 06/06/09 feed A feed B coolant makeup CAS ratio CAS reactor vent product maximum production rate condenser CTW PT PC-1 TT TT TC-2 TC-1 FC-1 FT FT FC-2 < TC-3 RC-1 TT ZC-1 ZC-2 CAS CAS CAS ZC-3 ZC-4 < Override Control override control ZC-1, ZC-3, and ZC-4 work to keep their respective control valves at a max throttle position with good sensitivity and room for loop to maneuver. ZC-2 will raise TC-1 SP if FC-1 feed rate is maxed out
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42. Analyzer Block for Online Data Analytics 06/06/09 History Collection of Lab and Spectral Analyzer Data Controller Processing of Sample Data for Use in Analytics Module Lab Results Analyzer Block Historian Operator Station Off-line Modeling Other Data
43. Dynamic Time Warping for Online Batch Data Analytics 06/06/09 Reference trajectory Trajectory to be synchronized Synchronized trajectory
44. Virtual Plant Setup 06/06/09 Advanced Control Modules Process Models (first principal and experimental) Virtual Plant Laptop or Desktop or Control System Station This is where I hang out
45. Virtual Plant Integration 06/06/09 Dynamic Process Model Online Data Analytics Model Predictive Control Loop Monitoring And Tuning DCS batch and loop configuration, displays, and historian Virtual Plant Laptop or Desktop Personal Computer Or DCS Application Station or Controller Embedded Advanced Control Tools Embedded Modeling Tools Process Knowledge