Troubleshooting process plant control 2nd Edition by Norman P Lieberman 1119267775 9781119267775

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ISBN-10 :  1119267775 

ISBN-13 :  9781119267775

Author:  Norman P Lieberman 

A practical and engaging guide to running process controls in petrochemical plants and refineries Process control is an area of study dealing with controlling variables that emerge in process plants, such as chemical plants, wastewater purification plants, or refineries. Existing guides to process control are numerous, but they tend to be associated with control engineering, which is more mathematical and theoretical. There is an urgent need for a more straightforward and concrete guide for practical use in petrochemical plants and refineries. Troubleshooting Process Plant Control meets this need with a work dedicated to real-life solutions and problem solving. Rooted in real-world examples and the career experience of the author, it largely avoids complex mathematics in favor of practical, well-established process engineering principles. Now fully updated to reflect the latest best practices and developments in the field, it is indispensable for process controllers in active plants of all kinds. Readers of the third edition will also find: New chapters on alarm disabling, spectrometer use, and reducing CO2 emissions Additional novel examples throughout Guidelines for using spectrometers to directly control reflux rates and steam flow to reboilers Troubleshooting Process Plant Control is ideal for practicing engineers and other technical professionals working in process facilities, as well as advanced students taking professional training courses in these fields.

 

Troubleshooting process plant control 2nd Table of contents:

1 Learning from Experience
Learning From Plant Operators
Learning From Field Observations
Learning From Mistakes
Learning From Theory
Learning From Relationships
Normal Purpose of Control Loops
Manual Versus Auto
Process Control Nomenclature
2 Process Control Parameter Measurement
How are Liquid Levels Measured?
How are Temperatures Measured?
External Fouling of Thermowell
Furnace Temperatures
Measuring Pressures
Measuring Differential Pressures
How are Flows Measured?
3 Dependent and Independent Variables
Changing the Degrees of Freedom
Variables in Distillation
Increasing the Degrees of Freedom
Complex Distillation Towers
Amoco‐Texas City—1974
Variables in Gas Compression
4 Binary Distillation of Pure Components
Proper Control of Water Strippers
5 Distillation Tower Pressure Control
Cooling Water Throttling
Pressure Control with Noncondensable Vapors
Flooded Condenser Pressure Control
Hot Vapor Bypass Pressure CONTROL
Combining Noncondensable and Total Condensation
Split‐Range Control for Noncondensables
Reboiler Controls Tower Pressure
Tower Top Pressure Sensing Point
6 Control of Aqueous Phase (Waste Water) Strippers
Controlling Amine Regenerator and Sour Water Stripper Reboiler Steam Flows
Controlling Reflux Rate
Use of Oil Skimming Site Glass
Controlling Stripping Steam Rate on Towers with No Reflux
Required Stripper Efficiency
Control of Stripper Pressure
Safety Note
7 Pressure Control in Multicomponent Systems
Getting a Sample in a BOTTLE
Heat Does Not Always Make Pressure
Effect on LPG Quality
Test Question
Refrigerant Composition
Adjusting Refrigerant Composition
Explaining Multicomponent Refrigeration to the Panel Board Operators
8 Optimizing Fractionation Efficiency by Temperature Profile
Advanced Computer Control
Superadvanced Computer Control
Full Flood
The Case for Feed PREHEAT
9 Analyzer Process Control
Controlling Diesel Draw‐Off Rate
Direct Analyzer Control
De‐Ethanizer Reboiler Control
Control of Asphalt Viscosity
Example of Direct Analyzer Process Control
Direct Analyzer Control
Spectrometer Control
10 Fired Heater Combustion Air Control
Control of Air with O2 Analyzer
Setting a Target
The Point of Absolute Combustion as a Variable
Automatic Temperature Control
Combustible Analyzer Control
Correct Control of Combustion Air
Fired Heater Safety Note
11 Using Existing Controls to Promote Energy Efficiency
Compression Energy Savings
Elimination of Orifice Plate Pressure Drop
Undersized Control Valves Waste Energy
Opening Control Valve Bypasses
Hand‐Jacks
Oversizing Control Valves
12 Sizing Process Control Valves
Sizing Control Valves
Undersizing Control Valves
Why Ignore Changes in Elevation and Operating Pressure?
Energy Losses In Control Valves
Checking Control Valve Capacity
Increasing Control Valve Size
Effect of Oversizing Control Valves
Unresponsive Control Valves
13 Control Valve Position on Instrument Air Failure
Instrument Air Pressure Control Box
Control Valve on Discharge oF Pump
Control Valve on the Discharge of a Compressor
Pressure Control of Vessels
Fuel Gas to Heaters
Avoid Loss of Air Pressure
Control Valve Chatter & Leakage
14 Override and Split‐Range Process Control
Cascade Control
Override Control
Split‐Range Control
How Does Split‐Range Control Work?
Safety Tips
Enhanced Control Valve Safety
15 Vacuum System Pressure Control
Factors Affecting Loss of Sonic Boost
Specialty Vacuum Ejectors
Throttling on Motive Steam
Positive Feedback Loop
Spillback Pressure Control
Varying Tower Top Pressure
Summary of Control of Vacuum Systems
Spillback
Throttling Motive Steam to First‐Stage Ejector
Throttling on Inlet to First‐Stage Jet
16 Reciprocating Compressors
High Discharge Temperature Trip
Measuring Process Flows
Flow Control
17 Centrifugal Compressor Surge versus Motor Over‐Amping
Understanding Blower Controls
The Second Law of Thermodynamics
Effect of Wet Gas Molecular Weight
Summary
18 Controlling Centrifugal Pumps
Pump Suction Pressure Versus Level Control
Determining Suction Set Point Pressure
Turbine‐Driven Pumps
Safe Minimum Flow Control
Undersized Control Valve Reduces Pump Capacity
19 Steam Turbine Control
Steam Turbine Theory
Use of The Hand Valves
Turbine Over‐Speed Trip
Turbine Exhaust—Surface Condenser Level Control
Level Control Malfunction
Controlling Moisture Content of Turbine Exhaust Steam
20 Steam and Condensate Control
Condensate Level Control
Condensate Drum
Condensate Flow Problems
Boiler Level Control Causes CARRYOVER
Steam Flow to a Reboiler
21 Control of Process Reactions
Control of Hydrotreater Hydrogen Recycle Flow
Backup System for Control oF Air to the Mercaptan Sweetening Plant
Unstable Recycle Gas Flow on a Vacuum Gas Oil Hydrotreater
Control of Fluid Cracking Catalyst Activity
22 Function of the Process Control Engineer
Process Control Engineer’s Safety Responsibility
Later that Evening
Scope of Control Engineer’s Job
Bogging Down a Process Heater
23 Steam Quality and Moisture Content
Flowing Steam
Why Boilers Carry Over
Level Control in a Kettle Waste Heat Boiler
Overflow Baffle in Kettle Waste Heat Boiler
Level Control in Deaerators
Controlling Water Content of Stripping Steam
24 Level, Pressure, Flow, and Temperature Indication Methods
Effects of Temperature on Level
Plugged Taps
High Liquid Level
Effect of Aerated Liquid on Level Indications
Split Liquid Levels
Radiation Level Detection
Vacuum Pressure Measurements
Flow Indication
Non‐Orifice‐Type Flow Measurement Methods
Checking Flows in the Field
Correcting Flowmeter Reading Off‐Zero
Temperature Measurement
References
25 Alarm and Trip Design for Safe Plant Operations
The Concept of Redundancy
Testing the New Pressure Alarm
Use of Conductivity Probe
High‐Temperature Trips
Flows
Optical Sensors
Flushing of Connections
How Not to Test a TRIP
26 Inverted Response of Process Parameters
Effect of the Top Tray Flooding
Common Examples of Inverted Temperature Response
Centrifugal Pump Power Requirement
Variable‐Speed Turbine Drive
Hot Vapor Bypass Pressure Control
27 Nonlinear Process Responses
Effect of Nozzle Exit Loss on Flow Indication
Nonlinear Liquid Level Indications
Centrifugal Pump Discharge Pressure
28 Control Malfunction Stories
High‐Pressure Alarm
Excess Moisture in Turbine Steam
Thermocouple Length
Coked‐Over Thermowell
29 Level Indication Problems in Vessels
Improper Level Tap Location
Elevation of Stripping Steam Nozzle
Moisture in Top Level Tap
Radiation Level Detection
Optimization of Liquid Level Tap Locations
The Purpose of Vessel Level Control
Observing Centrifugal Pump Cavitation
30 Calibration Specific Gravity for Level Control
Selecting Calibration S.G.
Becoming “Tapped‐Out”
Identifying When a Vessel Becomes Tapped‐Out
31 Flow Orifice Plate Cavitation
Field Investigation
Problem Resolved
A Lesson Learned
32 Factors Causing Incorrect Process Parameter Measurements
Temperature
Pressure Indication
Location of a Vessel High‐Pressure Alarm Indicator
Level Indication
Calibration Specific Gravity
Moisture Contamination of Hot Oil Level Indication
Flows
Composition
Lab Analysis Problems
Analyzer Closed‐Loop Control
Reference
33 Optimizing Controls to Reduce Emissions from Sulfur Recovery Plants and Sour Water Strippers
Naphtha in Sour Water
Origins of Naphtha in Sour Water Stripper Feed
Sulfur Plant Air Consumption
Sulfur Plant Air Deficiency
CO2 Emissions
Stripping Steam Usage
Monitoring Naphtha in Sour Water Stripper Bottoms
On‐Stream Analysis of Stripper Bottoms
Reference
34 Positive Pressure in Fired Heaters—Effect of Wind
Why is a Positive Pressure Never Permitted
Development of a Positive Pressure
Effect of Wind
Effect of Wind Gusts 60 Feet above the Bottom of the Heater
Effect of Wind on Combustion Air Flow
Basis for Above Observations
35 A Lesson From Bhopal—Hazards of Ignoring Alarms
Phosgene
The Problem in Bhopal
Pump Mechanical Seal Leakage
Alarms Disabled
Crystal Formation
Phosgene Vented to the Atmosphere
About My Seminars
What’s NEW
Synergism
Who Caused The Problem?
Conservation Ideas In The SEMINAR
Further Readings on Troubleshooting Process Controls
The Norm Lieberman Video Library of Troubleshooting Process Operations
Process Control Nomenclature Used in Petroleum Refineries and Petrochemical Plants

 

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