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AS Library offers a design and simulation tool in the construction of hydraulic, pneumatic and electrical circuits. AS Library will offer a tool in designing and managing industrial processes. Two packages of process control components following the international standards of ISA and ISO will be considered.
Industrial Processes
Row Material
. . . .
Final Product(s)
Intermediate Processes
Main Process
Industrial processes are extremely varied. Process modeling and control are specific to each industry.
Mechanization or industrialization of this sort has really only left man with one all-important mission in life: to conquer nature.
Alex Campbell
The preservation of wilderness areas is but one aspect of a series of conflicts, compromises, and accommodations involving use and preservation.
Lawrence Rakestraw, "Conservation Historiography: An Assessment," Pacific Historical Review
Cooking
Occurs in canning and preserving of food, making biscuit, breweries, sugar refining and tomato-paste production.
Dehydratation
Carried out in heated chambers (fixed dryers, drying tunnels), is practiced in the coffee, tea industry
Distillation
Used in the making of spirits (cognac, scotches).
Arnold Holstein Distillation - Small distillery (product: alcohol for consumption) http://www.a-holstein.de/en/index_en.htm
Fermentation
Plant/animal extraction
Separation - Distillation
Transformation
Converting the heavy fuel oil into diesel motor fuel (gas-oil), and petrol (gasoline) by catalytic cracking and hydrocracking
Blending
Blending the distillate products to obtain the required product
Oil & Gas filter separator (remove solid and liquid from gas streams) http://www.spxprocessequipment.com/literature/spxpe/spxpe-001_ov_spxpe.pdf
Process Control
Generally, modeling an industrial process involves:
Designing a multivariable system (interaction between two or more process variables). Modeling control loops and the relationship between them (open & closed loops). Controlling the process itself hydraulically, pneumatically, electrically or digitally to respond to a set of parameters as constant gain, time response, and delay. Customizing the inputs/outputs to match the controlled model accordingly to the preset technical conditions such as: pressure, flow, level, temperature etc.
Closed loop control - A continuous feedback is involved ensuring that the conditions imposed are met.
Ex: Multivariable process schemes containing more than 2 loops: distillation towers, chemical reactors, heat exchangers etc.
Automation Studio Needs Analysis for Process and Control Workshop Summary
Number of Components in Library:
ISO Library: ~ 164 Components Symbols are different from the ISO symbols of hydraulic and pneumatic
ISA Library: ~ 261 Components libraries
Editor:
Lines type: The lines type are different form those of the standard editor, it depends on the signal that is flowing through the line. However, a general pattern could be employed for any type of signal, but this is not advised when different types of signals are present in the same diagram. Components identifiers: The names (or identifiers) of the components are different from the ISO standards of hydraulic and pneumatic components. They are based on the components function and are chosen from the tables provided by the ISO and the ISA standards. In other words, a configurator for the components identifiers is needed. Configurators: Most of the components are composed of the device and the actuator that controls that device (i.e Valves + Solenoid). This is why a configurator is needed for those components similarly to the configurators of hydraulic valves and electrotechnical components. Connection ports: The connections among the components is done in the same way of the other workshops of Automation Studio.
Automation Studio Needs Analysis for Process and Control Workshop Summary (Continued)
Simulation:
Multi-Fluid: In industrial processes, more than one fluid are often present in the same process (i.e Water used to cool oil). The option of using several fluids should be available. The fluid that enters a component can be different from the fluid that exits from that same component. However, the fluid that enters a component should be the same as the fluid of that exits from the one to which it is connected. The best way to achieve this restriction is to have a parameterizable fluid defined by its density vs. temperature, viscosity vs. temperature and bulk modulus. Or to begin in a simpler way, at least have the basic fluids available (Oil, Air, Steam and Water)
Processes Display: The color of a process depends on its state: Normal, broken down, emergency state, critical state, opened, closed, on , off The ISA standards provide a table that specifies the color of a process depending on its functioning state, and a table that specifies the mnemonic of every process.
Process Control
Process Control
Li and Vi - liquid and vapor flow from stage i [kmol/min], xi and yi - liquid and vapor composition of light component on stage i [mole fraction], Mi - liquid holdup on stage i [kmol], D and B - distillate top and bottoms product flowrate [kmol/min], L = LT and V = VB - reflux flow and boilup flow [kmol/min], F, zF - Feed rate [kmol/min] and feed composition [mole fraction], qF - fraction of liquid in feed i - stage no. (1 = bottom. NF = feed stage, NT = total condenser) alpha - relative volatility between light and heavy component taul - time constant [min] for liquid flow dynamics on each stage lambda - constant for effect of vapor flow on liquid flow ("K2-effect")
1. Total material balance om stage i: dMi/dt = L{i+1} - Li + V{i-1} - Vi 2. Material balance for light component on each stage i: d(Mi xi)/dt = L{i+1} x{i+1} + V{i-1} y{i-1} - Li xi - Vi yi which gives the following expression for the derivative of the liquid mole fraction: dxi/dt = ( d(Mi xi)/dt - xi dMi/dt ) / Mi
Process Control
following expression for the vapor flows (except at the feed stage if the feed is partly vaporized, where VNF = V{NF-1} + (1-qF)F):
Vi = V{i-1} The liquid flows depend on the liquid holdup on the stage above and the vapor flow as follows: Li = L0i + (Mi - M0i)/taul + (V-V0){i-1} x lambda Where L0i [kmol/min] and M0i [kmol] are the nominal values for the liquid flow and holdup on stage i 4. The previous equations apply at all stages except in the top (condenser), feed stage and bottom (reboiler). Feed stage, i = NF (we assume the feed is mixed directly into the liquid at the feed stage): dMi/dt = L{i+1} - Li + V{i-1} - Vi + F d(Mi xi)/dt = L{i+1} x{i+1} + V{i-1} y{i-1} - Li xi - Vi yi + FzF
Process Control
ISO Standards:
A line (usually pipe) that belongs to the process is represented with a bold continuous line (arrows could be used to indicate the flow direction).
A line that goes to a measuring instrument in general, is represented with a continuous thin line having a stroke repeated along its length. The strokes are inclined at 60o to the main line and are distant of 7mm.
PDI-100
P-100A FEED PUMP 0 Psi
DISTILLATION COLUMN
DISTILLATION COLUMN
Capillary
Radiation
STEAM
HS-127
FI-101 1 1
TR
OR
Lines Intersection (junction): The diameter of the connection point should be 5 times the thickness of the line.
OR
ISA Standards:
A line (usually pipe) that belongs to the process is represented with a regular plain line (arrows could be used to indicate the flow direction).
STEAM
HS-127 FI-101
Those abbreviations can be used to denote the type of power flowing in the process line
ES: Electric Supply GS: Gas Supply HS: Hydraulic Supply NS: Nitrogen Supply SS: Steam Supply WS: Water Supply
A line that goes to a measuring instrument in general, is represented with a continuous thin line having a stroke repeated along its length. The strokes are inclined at 60o to a horizontal line and -45o to a vertical line and are distant of 12mm.
PDI-100
P-100A FEED PUMP 0 Psi
Or
L L L
Electric Hydraulic
Complete Functionalities
Level instruments: A configurator allows to select the type and the identifier* of the Level instrument that is needed among the following options
Actuators: A configurator allows to select the type of the actuator (that could be used for any regulating component) and its technical data among the following options
* The Instrument Identifier Depends on its function and is chosen according to the table provided by ISO for this purpose
Advanced Representation:
TIZA
0 200 C
0 200 C
0 200 C
Heat Exchanger
P
FI 24
FRC
412
FR
Flow Recording on Shared Display
LICA
106
LZA 107
Cascaded Control
TA
100
TA 110
FRC
101
HS 103
Hand and Level Instrumentation: A configurator allows to select the type and the identifier* of the Hand and Level Instrument that is needed among the following options
Trap instrumentation: A configurator allows to select the type of Trap that is needed among the following options
Burner/Combustion: A configurator allows to select the type the identifier* and the technical data of the Burner that is needed among the following options
Voltage: A configurator allows to select the type, the name* and the technical data of the voltage instrument that is needed among the following options
Time or Time Schedule: A configurator allows to select the type and the identifier* of the Time instrument that is needed among the following options
Pressure: A configurator allows to configure the type, the identifier*, the composing instruments (if details are needed) and the technical data of the Pressure Element that is needed among the following options
Quantity, Radiation and Speed: A configurator allows to configure the type, the identifier* and the technical data of the Quantity, Radiation or Speed Element that is needed among the following options
Weight Force, Position and Dimension: A configurator allows to configure the type, the identifier* and the technical data of the Weight Force, Position or Dimension Element that is needed among the following options
Energy Supply: A configurator allows to configure the type, the identifier* and the technical data of the Energy Supply Instrument that is needed among the following options
Filters:
HVAC:
Rotating Equipment:
* The Instrument identifier Depends on its function and is chosen according to the table provided by ISA for this purpose
PC 502
ZC 800 E ZY
H L L ZT
PT
Pressure controller (PC) acting through servo-valve (ZY) acting as voltage-to-hydraulic converter to modulate double-acting-cylinder-actuated control valve having positioning system (ZT)
Flow Diagram
Logic Diagram
Simple diagram
Supervisory set point Control Analog Controller with conventional Faceplate. Computer Supervisory Set Point via Communication link
Respond to any process designer preferences and tastes by displaying a large spectrum of symbols, from valves/actuators, display instrumentation, logic and computer systems to energy supply and diagramming binary logic;
Offer a wide variety of instrumentation for all types of PV-s: pressure, flow, level, temperature, analytical (measure the chemical/physical properties of a process), differential-pressure, speed, weight, vibration, acceleration;
LG 6
T A N K
LT
LC 10
T A N K
LT 11