Learner Guide 2013

Faculty of Engineering, and the Built Environment

DEPARTMENT: Chemical Engineering

Qualification: ND: Chemical Engineering / ND: Pulp & Paper Tech NDCME2 / NDPPT2 SUBJECT: Process Control 3 (Subject Code: PCCR301)

Vision of the Department of Chemical Engineering

The Department strives for excellence in Chemical Engineering education with a comprehensive undergraduate teaching program and a vibrant post-graduate research program focusing on developing technologies for addressing South Africas needs.

Mission Statement

In pursuit of educational excellence, the department commits itself to: Developing and maintaining a relevant programme, with a good balance between theory and practice to fulfil the needs of the Chemical and Allied Industry and society at large, Providing students with a holistic learning experience which will maximize their chances of success Establishing and maintaining partnerships with industry, Maintaining a robust and relevant research and community outreach programme.

Department Goals for 2013

Through quality and effective teaching, and allocation of appropriate human and physical resources, the department aims to: Continually focus on achieving high student throughput Produce graduates with marketable skills Increase research activities and outputs Promote staff development Promote knowledge transfer through external engagement

Date Revised: July 2013 Revised by: Dept. of Chemical Engineering

LECTURER: DEPARTMENT: OFFICE: TELEPHONE: FAX: E-MAIL: HEAD OF DEPT: DEPARTMENT: OFFICE: TELEPHONE: FAX: E-MAIL: LECTURES:

Mr A F Bassa Chemical Engineering S4 L1 031 373 2502 0866741148 ahmedb@dut.ac.za Dr M Chetty Chemical Engineering S4 L1 031 373 2384/2218 031 373 2285 chettym@dut.ac.za Tuesday 11h00 to 11h50 LC017 12h00 to 12h50 LC017 Friday 10h00 to 10h50 LC027 11h00 to 11h50 LC017

CONSULTATION:

Tuesdays (10h00 to 11h00 and 13h00 to 14h00) (preferably make an appointment)

1.

Welcome And Introduction Welcome to Process Control 3. This learner guide provides the learner with all of the requirements for the successful completion of this subject.

2.

Purpose of this Subject This course is intended to introduce the student to the fundamental concepts of process control including the instrumentation that is involved, which the student is likely to encounter in industry. The main objective is to create an understanding of the basic principles involved in the control of independent processes in a chemical plant. At the end of the course the student should be able to: Identify the symbols and layout of a P&I diagram. Identify the various types of pumps and valves and understand the basic operation and selection procedure. Identify and understand the theory behind different measuring instruments, including instrumentation for pressure and vacuum, temperature, flow, and liquid level measurement. Understand the theory of control; including control objectives, types of controller mechanisms, design aspects and hardware elements for a process control system and the development of mathematical models. Know the theory and use of alarms, safety trips, and interlocks Understand the basic principles of HAZOP studies.

3.

Pre-Requisites There are no pre-requisites, however the normal promotional rules from S2 to S3 and S4 apply.

4.

Recognition of Prior Learning (RPL) Learners that have passed a similar subject at another tertiary institution are welcomed to apply for a credit for this subject.

5.

Specific Outcomes and Course Outline

SPECIFIC OUTCOMES
The learner will be competent to:
1. Identify and draw the various symbols of a P&I diagram.

ASSESSMENT CRITERIA
The learner has:
a. drawn the various symbols individually and as a combination. b. the understanding of what should be in a P&I diagram and how it should be laid out. c. used the appropriate letter codes for instrument symbols. d. drawn and explained typical control schemes for level, pressure, flow, temperature (heat exchangers), distillation and simple reactor control.

a. the understanding of the different construction and the operation of the various types of valves. b. drawn and described the operation of the air-to-close and air-to-open pneumatic valves. c. drawn and described the various types of plugs that may be used. d. illustrated and described the valve flow characteristics for the various plugs. e. done preliminary valve sizing. f. described the difference between positive displacement and rotadynamic pumps. g. identified the advantages and disadvantages of the two types of pumps. 3. Understand the a. the understanding of the importance and objectives of specifying principles of instrumentation and control schemes. various flow, b. the understanding of the basic principles and uses of manometers. temperature, c. derived the equations needed to calculate the pressure difference across pressure and liquid various types of manometers. level d. drawn and explained the principles of operation of the Bourdon pressure measurements. sensor and strain gauge for pressure measurement. e. an understanding of the various methods of measuring temperature (electrical and non-electrical) f. explained the principles of operation of the thermocouple and resistance thermometers (including the Wheatstone Bridge). g. an understanding of the various types of flow measuring devices. h. derived and applied equations for the calculation of flow using the orifice meter, pitot tube and venturi meter. i. explained the basic operation of the rotameter and ultrasonic flow meters. j. an understanding of the basic liquid level measuring devices including pressure differential and ultrasonic devices. 4. Understand the a. understand the concept of stability. theory of control; b. draw in control mechanisms for specific control objectives. including control c. classified variables into input, output, manipulated, disturbances, measured, objectives, control unmeasured, etc. mechanisms, design d. an understanding of the different control mechanisms including feedback, aspects and feedforward, inferential, cascade, etc. hardware elements e. an understanding of the operations of the different types of controllers and mathematical including P, PI and PID controllers. models. f. identify, draw and describe the various hardware elements of a control system. g. an understanding of the use of digital computers in process control. h. written/derived ODEs to describe the transient behaviour of various systems.

2. Identify the various types of pumps and valves and understand the basic operation and selection procedure.

5. Understand and conduct basic HAZOP studies.

a. understood the basic procedure and sequence to follow in conducting an operability study. b. an understanding of the meanings and use of the various guide words. c. conducted HAZOP studies on simple systems.

INSTRUCTIONAL SEQUENCE 1. INSTRUMENTATION 1.1 1.2 1.3 Pressure and vacuum gauges Temperature measurement Flow meters 1.3.1 1.3.2 1.3.3 1.3.4 1.4 Magnetic flow meters Vortex shedding flow meters Ultrasonic flow meters D.P. Devices

BOOK REF.

CR1, Chp 5 CR3, Chp 3 CR1, Chp 5 Own Notes

Liquid level measurement 1.4.1 1.4.2

CR3, Chp 3 Own Notes

Ultrasonic devices Hydrostatic head type devices

2.

THE P&I DIAGRAM 2.1 2.2 Introduction CR6, pg 148 P & I Diagram CR6, pg 148 2.2.1 Symbols and layout (working knowledge of P,T,F,etc.,) CR6, pg 149

3.

VALVES, PUMPS AND PIPING 3.1 3.2 3.3 3.4 Selection of valves (understanding of valve characteristics) CR6, pgs 150 - 154 Pumps (2 principles) CR6, pgs 155 - 157 Mechanical design CR6, pgs 157 158 Selection of pipe sizes (qualitative view only) CR6, pgs `58 - 167

4.

CONTROL 4.1 4.2 4.3 4.4 Control objectives Types of controller mechanisms Characteristics for control mechanisms Incentives for chemical process control 4.4.1 Introduction 4.4.2 Suppress the influence of external disturbances 4.4.3 Ensure the stability of a process 4.4.4 Optimize the performance of a chemical process CR6, pg 167 CR6, pg 168 CR6, pg 168 S, pgs 2 - 11 S, pg 2 S, pg 4 S, pg 7 S, pg 10

4.5

Design aspects of a process control system S, pgs 12 - 27 4.5.1 Classification of the variables S, pg 12 4.5.2 Design elements of a control system S, pg 14

4.5.3

Control aspects of a complete Chemical plant

S, pg 25

4.6

Hardware for a process control system S, pgs 28 - 33 4.6.1 Hardware elements of a control S, pg 28 system 4.6.2 Use of digital computers in process S, pg 30 control Development of a mathematical model 4.7.1 Why do we need a model 4.7.2 State variables and state equations 4.7.3 Additional elements 4.7.4 Dead time 4.7.5 Additional examples 4.7.6 Modeling difficulties Modeling considerations for control purposes 4.8.1 Input-output mode 4.8.2 Degrees of freedom 4.8.3 Degree of freedom and process controllers 4.8.4 Formulating the scope of modeling for process control S, pg 45 - 79 S, pg 46 S, pg 48 S, pg 55 S, pg 58 S, pg 59 S, pg 74 S, pgs 80 - 97 S, pg 80 S, pg 86 S, pg 89

4.7

4.8

S, pg 93

5.

TYPICAL CONTROL SYSTEMS 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 Level control Pressure control Flow control Heat exchangers Cascade control Ratio control Distillation column control Reactor control CR6, pg 169 CR6, pgs 169 - 170 CR6, pg 171 CR6, pg 171 CR6, pg 172 CR6, pg 173 CR6, pg 173 CR6, pg 176

6. 7.

ALARMS SAFETY TRIPS AND INTERLOCKS CR6, pg 177 HAZARDS AND OPERATIONAL STUDIES 7.1 Basic principles CR6, pg 292 7.2 Explanation of guide words CR6, pg 294 7.3 Procedure CR6, pg 294 7.4 Examples CR6, pg 296

6.

Critical Cross-Field Outcomes (a) Work effectively with others This outcome is largely achieved through the two practicals (thermofluids and rotameter) that the students are required to do for the course. The practicals are done in groups of up to three students and the general practical rules apply. Students are also encouraged to work in groups during tutorial sessions and during the solving of class problems. (b) Manage oneself This outcome is achieved by forcing students to adhere to due dates for practical reports and penalizing late submissions. This teaches students to manage their time better. Learning material is also given to those students who attend lectures thus making sure that students discipline themselves and come to lectures. Only students that have attempted the tutorials are allowed to sit in for the tutorial session. (c) Use science and technology effectively Throughout the course the learners learn to derive scientific equations which are then used to solve problems. The theory learnt in class is also applied in the practicals thus enhancing the students understanding of science and technology. (d) Communicate effectively This is achieved by encouraging students to participate in the class during lectures and tutorial sessions. The nature of the course makes it appropriate to have general discussion in class.

7.

Learning And Teaching Strategies The course is highly theoretical and as such the lectures will take place with the intention of having general discussions in class. Notes will be provided and learners may need to read the notes prior to the lectures so that useful and vibrant discussions can take place. The lecturer will make use of the OHP during formal lectures. The course consists of 2 practicals viz. Thermofluids which deals with measuring techniques and Rotameter calibration.

8.

Assessment The student is assessed on a year mark system that incorporates a course mark and an examination mark. The course mark is based on the average of two tests and a practical mark (general S4 practical mark) which constitutes 40 % of the final result for the course (each having an equal weighting). A threehour written examination at the end of the semester will determine the other 60 % of the final result. A course mark of not less than 40 % is required for a student to sit for the final examination together with a subminimum of 40% for the practical component. An overall result of 50 % or more is necessary to achieve a pass and a sub-minimum of 40 % is required for the examination itself.

9.

Readings CR1 CR3 CR6 S Coulson & Richardson. Chemical Engineering Volume 1 (3rd Ed.). Coulson & Richardson. Chemical Engineering Volume 3 (2nd Ed.). Coulson, Richardson & Sinnot. Chemical Engineering Volume 6 (1st Ed.) Stephanopoulos, George. Chemical Process Control. Prentice Hall.

10.

Tests Dates: Test 1: Test 2: 26 August 2013 7 October 2013

11.

Plagiarism Plagiarism is the unauthorized use or close imitation of the language and thoughts of another author and the representation of them as one's own original work, (Wikipedia). Plagiarism will not be tolerated and students will be severely dealt with in accordance with Rule G13 (1)(o) in the 2012 rule book for students.

12.

Class Rules and Policies Attendance The departmental rule is that learners must attend a minimum of 80% of the lectures and tutorials. Failure to achieve this will result in the learner not being able to sit for the final examination. Practicals are compulsory and both practicals must be completed. Only learners that have attempted the tutorials will be allowed to attend the tutorial sessions. Random attendance registers will be taken during lectures and tutorials. Missing of Tests Any student who misses a test will have to make a formal application to the department, on the prescribed form, within 5 working days, for permission to write the special test. Students missing either test 1 or test 2 will write a special test at the end of the semester that covers all the work.