Myke King’s Process Control – Advance Process Control Techniques – Part 2

Instructor: Myke King (view profile)

Upcoming Session: Bogor, 16-20 May 2016

Download Course Brochure open-file-icon mini


Course Overview
Following on from the introductory course Process Control – A Practical Approach, this course takes the techniques that the delegate has learnt and, using the same practical hands-on approach, shows how they are applied to common processes.
While course delegates will find it helpful to have a basic understanding of the processes, in each case an introduction covers their general principles and key operating variables. Each module addresses the implementation of basic controls on the process and then moves on to the application of more advanced techniques. In the case of the distillation these include both multivariable control and optimisation. The methodology covered, when later applied by the delegate to real processes, will ensure that the maximum benefit is captured by each layer of the control hierarchy.

Delegates would include control engineers, process engineers, mechanical engineers and plant supervisors. It is strongly recommended that those attending this course have previously attended the introductory course. The learning is intensive and, while some refresher material is included, delegates without the appropriate basic skills will have difficulty keeping up with others.

Course Content:

  • Compressor Control
  • Steam Boiler and Fire Heater Control
  • Distillation Column Control

Pre-requisite Knowledge:







I. Steam Boiler and Fired Heater Control

  • process description
  • fuel gas flow compensation
  • fuel gas heating value compensation
  • total duty control with dual firing of oil and gas
  • steam drum swell and inverse response
  • 3-element steams drum level control
  • flue gas oxygen and CO control
  • cross-limiting control
  • feed forward on feed rate and feed enthalpy
  • heater pass-balancing
  • steam header pressure control

II. Compressor Control

  • compressor types
  • polytropic head
  • equal percentage and quick opening valves
  • discharge throttling
  • inlet guide-vanes
  • speed control
  • anti-surge and surge recovery control
  • multi-compressor balancing

III. Distillation Control

III.1. Process Technology

  • mechanism of distillation
  • vapour pressure
  • relative volatility
  • azeotropes
  • key components
  • feed quality “q”
  • cut and separation
  • impact of column design
  • modeling correlations
  • adjusting product composition

III.2. Basic Controls

  • control problems
  • maintaining the energy balance
  • column pressure control
  • condenser duty control
  • internal reflux control
  • flooded condenser
  • hot gas bypass
  • inverse response problems
  • manipulation of vapour rate
  • use of split range control
  • maintaining mass balance
  • energy versus material balance schemes
  • Rijskamp scheme
  • overcoming reflux drum lag
  • tuning the drum level controller

III.3. Composition Controls

  • temperature profile
  • locating tray temperatures
  • choice of manipulated variable
  • pressure compensation
  • cut and separation models
  • inferential properties
  • feedforward on feed rate
  • feedforward on feed enthalpy
  • feedforward on feed composition
  • sigma-T/delta-T control
  • steady state decouplers
  • relative gain analysis
  • dynamic decoupling
  • on-stream analyzers
  • towers with side streams
  • multivariable control packages
  • technology suppliers

III.4. Optimization

  • available variables
  • common constraints
  • benefits
  • available technologies
  • flooding protection
  • pressure minimization
  • energy-yield optimization

 Watch Myke King’s Process Control Video