Shell Global Solutions
Process Control Schemes
By Somboon Pattanawijit GSEO
Process Control & Optimization Group
28 September 2005 (rev. 1.0)
Table of contents
• Single control loops
• Multiple control loops
• Introduction to Multivariable control systems
Shell Global Solutions 2
Single control loops
• Flow control loop
-For short distance, the response will be like a first-order lag at
most a few second.
Solid
- For long distance (kilometers), the response has the long lag
time.
-Generally the flow tx range match the control valve range. It
can be concluded that the gain of flow controller should be
adjusted to a low value. Integral action is important in order to
reduce offset.
FC
Shell Global Solutions 3
Single control loops
• Liquid pressure control loop
-Liquid is supplied to a number of users and the task is to
maintain a constant supply pressure irrespective of load
Solid
changes.
- The dynamic behavior is similar to a flow process.
-The pressure tx range need not match the range of the control
valve. Therefore the process gain may vary from case to case
PC
Shell Global Solutions 4
Single control loops
• Liquid pressure control loop
-The vessel volume is used as a buffer capacity and its pressure
is controlled by throttling the control valve in the inlet line
Solid
-This process has a first-order lag. Lag time is greater than
dead time.
- The controller gain can be high depending on the tx range.
PC
Shell Global Solutions 5
Single control loops
• Vapour pressure control loop
- Controlling vapor pressure involves heat transfer.
Solid
- The temperature is indirectly controlled by the vapor pressure.
- This is a very small dead time process, relatively high
controller gain can be used and only a small amount of
integral action will be required.
Evaporation
Evaporation takes
takes heat
heat from
from the
the
PC liquid
liquid reducing
reducing the
the temperature
temperature
(indirect
(indirect temperature control)
temperature control)
T>>d
T>>d so:
so:
Vapour phase
-high
-high Gc
Gc setting
setting and
and
LNG -little
-little or
or no
no I-action
I-action
-160 oC
Shell Global Solutions 6
Single control loops
• Level control loop
- Level is an integrating process (unstable)
-There are 2 types where level is a critical
process variable and others where a
smooth flow from the vessel is the more
important consideration
LC - Critical level control, high controller gain,
integral time depends on the hold-up time.
- Buffer capacity, offset is allowed, little
integral time required (In fact a
proportional only controller may be used)
Shell Global Solutions 7
Single control loops
• SSVC (Shell Surge Volume Control)
- Using SSVC algorithm minimizes flow moves allowing the
level free to move within predefined boundaries.
Solid
-Good for slug flow, foaming or unpredictable flow into the
vessel.
Shell Global Solutions 8
Single control loops
• Temperature control
- Temperature processes are the heat transfer processes.
Solid
-Most heat transfer processes have variable parameters and
show non-linearity. Generally it is a slow response process.
-The controller gain can be an intermediate value, but integral
action will be required. Adding of derivative action can be
useful to speed up the response.
ProcessSolid flow
particle
Air flow
Fuel flow
TT
TC
Shell Global Solutions 9
Single control loops
• Quality control
-The control condition is a physical or chemical property or
composition of a product, such as Octane number, Viscosity,
Solid
pH, etc.
-In general, it has a large lag time. Dead time can be up to 20
min.
-Might consider using PIT (Propertional plus Integral plus Time-
delay) control algorithm
- Alternatively, a dynamic quality estimator (QE).
Shell Global Solutions 10
Overview of Responses
• Flow
Flow control
control (FC):
(FC): relatively
relatively fast
fast response
response
•• Pressure control
control (PC):
PressureSolid (PC):
•• Liquid
Liquid relatively
relatively fast
fast response
response
•• Gas
Gas intermediate
intermediate response
response (depends
(depends on
on volume/flow
volume/flow relation)
relation)
•• Vapour
Vapour intermediate
intermediate response
response
•• Level
Level control
control (LC):
(LC): intermediate
intermediate response
response (depends
(depends on
on volumne/flow
volumne/flow relation)
relation)
•• Temp
Temp control
control (TC):
(TC): intermediate
intermediate response
response
•• Quality
Quality control
control (QC):
(QC): relatively
relatively slow
slow response
response
Shell Global Solutions 11
Multiple control loops
• The multiple control loops are frequently used
and can be seen as building blocks for more
complicated control systems.
Solid
• There are four systems will be discussed
• Master-slave (cascade) control
• Ratio control
• Split range control
• Selective (override) control
Shell Global Solutions 12
Multiple control loops
• Master Slave control
Solid
C-1
C-1 LC C-2
C-2
FC
Shell Global Solutions 13
Multiple control loops
• Master Slave control
Solid
ProcessSolid flow
particle
Air flow
TC
PC
Fuel oil to
Other heaters
From central
Fuel oil supply system
Shell Global Solutions 14
Multiple control loops
• Ratio control
Primary
Primary flow
flow FF11 (uncontrolled)
(uncontrolled) Mixed
Mixed flow
flow
PV
PV Ratio
FT X Ratio relay
relay
SV=K.PV
SV=K.PV
PV
PV FC
FT
Tank
Secondary
Secondary flow
flow FF22 (controlled)
(controlled)
Shell Global Solutions 15
Multiple control loops
• Viscosity control (may be required during turn
down)
Primary
Primary flow
flow FF11 (uncontrolled)
(uncontrolled) Mixed
Mixed flow
flow
PV
PV Gain=K
Gain=K
FT X QC
SV=K.PV
SV=K.PV Viscosity
Viscosity
PV
PV FC
FT
Tank
Secondary
Secondary flow
flow FF22 (controlled)
(controlled)
Shell Global Solutions 16
Multiple control loops
• Split-range control
0-1
0-1 0-0.5
0-0.5 0.5-1
0.5-1 0-1
0-1
X X
PC Direct
Direct
Gas
Gas in
in Process Gas
Gas out
out
CV1
CV1 CV2
CV2
Shell Global Solutions 17
Multiple control loops
• Split-range control
Open
Valve position
CV1 CV2
Closed
0 0.5 1 Controller Output
No gap / no overlap between valves
Open
Open
CV1 CV2
CV1 CV2
Closed
Closed
0 0.5 1
0 0.5 1
Overlap between valves
Gap between vlaves
Shell Global Solutions 18
Multiple control loops
• Selective control – Pressure override control
Solid
High
High
pressure
pressure LC
column
column
Output
Output
LSS
Output
Output
ARW
ARW
ARW
ARW
PC
Low
Low
pressure
pressure
Plant
Plant
Shell Global Solutions 19
Multiple control loops
• Selective control – Steam control system
Solid
Steam
Steam system
system 90
90 bar
bar
0.5-1
0.5-1 // 0-0.5
0-0.5
0-1
0-1 0-1
0-1
CV-2
CV-2 X1 X2 LSS
ARW
ARW
PC2
PC1
Reverse
Reverse Direct
Direct
HP
HP
Turbine
Turbine
CV-1
CV-1
LSS
LSS == Low
Low Signal
Signal Selector
Selector
18
18 bar
bar
ARW
ARW == Anti
Anti Reset
Reset Windup
Windup
Steam
Steam system
system
Shell Global Solutions 20
Multivariable Control System
• Temperatuer and level control of liquid in a
vessel
Hot
Hot water
water Cold
Cold water
water
LT LC
TC TT
Interaction
Interaction between
between two
two Process
Process
Variable:
Variable: Temperature
Temperature and
and Level
Level
Shell Global Solutions 21
Multivariable Control System
• Temperatuer and level control of liquid in a
vessel
Hot De-coupling
De-coupling
Hot water
water Cold
Cold water
water
interacting
interacting
control
control system
system
(a-b)
(a-b)
(a+b)
(a+b)
aa
LT LC X
bb
X TC TT
Shell Global Solutions 22
Multivariable Control System
• Heat exchanger bypass control
Hot
Hot Oil
Oil
FC TC
bb aa
(1-a).b
(1-a).b
X1
a.b
a.b
X2
De-coupling
De-coupling of
of heat
heat exchanger
exchanger interacting
interacting control
control system
system
Shell Global Solutions 23
Multivariable Control System
• Block diagram representative
Hot
Hot water
water Temperature
Temperature
22 Variable
Variable
Cold
Cold water
water system
system Level
Level
uu11 ++
G
G1,1
1,1
xx11
++
G
G2,1
2,1
G
G1,2
1,2
uu22 ++
G ++ xx22
G2,2
2,2
Block
Block diagram
diagram of
of aa two-input,
two-input, two
two output
output system
system with
with interaction
interaction
Shell Global Solutions 24
Multivariable Control System
• Block diagram representative
PV1
PV1
--
++ ++
TC
TC (C
(C1,1 )
1,1)
G
G1,1 Temp.
Temp.
SV1
SV1 θθ11 1,1
++
G
G2,1
2,1
G
G1,2
1,2
θθ22 ++
SV2
SV2 uu22 ++
TC
TC (C
(C2,2 )
2,2)
G
G2,2 Level
Level
++ 2,2
--
PV2
PV2
Block
Block diagram
diagram of
of aa two
two interacting
interacting control
control loops
loops
Shell Global Solutions 25
Multivariable Control System
• Block diagram representative
The
The Control
Control Process
Process
PV1
PV1
-- Cold
Cold water
water valve
valve
++ ++ ++
TC
TC (C
(C1,1 )
1,1) G
G1,1 Temp.
Temp.
SV1
SV1 θθ11 ++ 1,1
++
(G11))
(G G
G2,1
2,1
(G22))
(G G
G1,2
1,2
++
SV2
SV2 θθ22 ++ ++ ++
TC
TC (C
(C2,2 )
2,2) G
G2,2 Level
Level
++ 2,2
Hot
Hot water
water valve
valve
--
PV2
PV2
Block
Block diagram
diagram of
of aa two
two loop
loop multivariable
multivariable control
control system
system with
with de-coupling
de-coupling
Shell Global Solutions 26
Benefits of APC (SMOC)
104
102 Specification or limit
100
PERCENT OF LIMIT
98
96
94
Operator target
92 Standard deviation
SETPOINT MOVED of controlled variable
BEFORE APC APC ONLINECLOSER TO LIMIT
90
Base Case Stabilise Exploit
Shell Global Solutions 27
Vertical and Horizontal Integration
Market / contracts
Business systems
Performance Shipment / Storage (ADGENT)
eBusiness
Monitoring
Relational
data Production Scheduling (IMPRESS)
Asset
base
Management Process
Plant Optimisation (SPOT) models
Site / Unit wide
(PROMOTE)
reconciliation
GUI
(SPOT)
Real- Unit optimisation (SPOT)
time Lab systems
data / Accounting
base Advanced Control (SMOC, RQE)
Oil Movement
Event capturing
Basic Control
Real-Time systems
Distributed Control System & Tank gauging
Shell Global Solutions 28
Products in Shell
Optimisation
SPOT
Inferred
RQE
Measurements
Data Excel
Collection
Controller
Identification
AIDA performance
Process Data
Monitoring &
SMOC
MVC M D
Process Diagnosis
Models
Online
Plant test DCS
Implementation
COAST
Shell Global Solutions 29
Thank you
Shell Global Solutions 30
