Process Control Engineering - Essay Example

Insert your name here Insert Grade Course Insert Tutor’s Name 3, 4, 2017 Table of Contents Table of Contents 2 i.Abstract 3 1.0.Introduction 4 2.0.Process Control Engineering in Western Australia 4 3.0.Process Modeling for Control for Arrow Energy 5 4.0.Sensors and Instrumentation 7 5.0.Heat Transfer Processes 8 6.0.The Laws of Conservation of Mass and Energy 9 7.0.Conclusion 11 Reference List 12 i. Abstract Process control has found a wide application in the manufacturing industry for the process output maintenance within the required limits. This paper will check the applicability of process control systems in manufacturing industries. A case study of the application of the mechanisms in a typical industry in Western Australia is presented. Pressure control, temperature control, flow control,   level control and speed control are some of the Process control engineering in Western Australia. An in-depth research on process modeling for control, sensors and instrumentation aspects of control systems applicable in Arrow gas company Ltd is presented. Finally, the study assesses heat transfer process as a unit of operation in control processes as well as discussing the law of mass and energy conservation.   1.0. Introduction Process control is a system in engineering dealing constructions, techniques and algorithmic programs that are utilized in the maintenance of the output a given process within a scope that is desirable. Controlling the temperature of chemical reactors is an example of process control aimed at maintaining the consistency of the production of products. There is an extensive utility for such systems in industries enabling flexibility to a great product manufacturing from processes with continuous operations like power stations, chemicals, manufacture of paper, food and beverage industries and pharmaceutical among others. The control system allows a small number of operating experts working from the central control room to take monitoring of the complex systems through enabled automation. The system can monitor the production surrounding and control the generation flow or process electronically grounded on some user set standards. Involved in the process is the collection of data and having a high bandwidth control of the system on a large scale. The achievement of such a control is possible through doing a measurement of some particular components of the set of procedures used in the production, using specialized processors, which widget machines that have an influence on the industrial process. It is significant to change bandwidth, frequency, the rate of flow with the voltage output, temperature, scrutinize the changes in step on the necessary actions to the flow rate and the major value disturbance. 2.0. Process Control Engineering in Western Australia There are several examples of the typical industrial application of the process control engineering in Western Australia in speed control, level control, flow control, temperature monitoring and pressure control. Arrow Energy, Bass Strait Oil Company Ltd and Carnarvon Petroleum Ltd all have process control for temperature for their plants. ConocoPhillips Australia Pty Ltd applies the Control of flow and pressure whereas control of flow is applicable in Bass Strait Oil Company Ltd. Some of the companies utilize many control systems for their operations. 3.0. Process Modeling for Control for Arrow Energy Process modeling for process control trainer uses an element of heating under the supervision of a thyristor circuit, feeding heat into the airstream circulated by an axial fan along with a polypropylene tube. The sensing of the temperature at a point is achieved by a thermistor detector placed at one of the three locations along the length of the tube. The heater receives a signal that is converted to electrical power. The modeling in such this scenario changes and measures the effects of the parameters under investigation on changes in temperature. The measurements are compared to the some set standards that will trigger the generation of electrical signals enabling regulation of electrical power supply to heaters. The control systems in industries are justified from the fact that most processes in industries utilize energy whose acquisition is becoming expensive and therefore an optimal utilization is of significant value to the companies. A formulation of mechanisms for ensuring that the processes optimize the use of resources is thus of great necessity for ensuring that the plant is run without serious obstacle (Friedland 2012; Peacock & Richardson 2012; Isermann 2013).The system is usually connected to a personal computer with ideal data retrieval software before the start if data recovery and the connecting the cables for power supply to the main supply. Safe operating envelopes have been developed for Arrow's Central Gas Processing Facilities comprising of reciprocating compressors and tri-ethylene glycol (TEG) dehydration packages assisting Operations to understand the operating and design limits of the equipment and facilities and make decisions relevant to maximizing the production capacity and revenue for the company. Below is a diagram showing process control flow: 4.0. Sensors and Instrumentation The use of scrutiny that does not depend on the operator has been enabled through the utility of sensors and instruments with a high degree of accuracy in indications and measurements instead of the player’s control. Sensors and instrumentations from very significant components of process control and only a good measurement system produce a quality of the inspection process. A crafty distinction between a sensor and an instrument is that a sensor is a device capable of measuring the amplitude of a physical variable though cannot provide an indicator of the action directly, while an instrument is a device measuring and displaying the magnitude of a physical variable. Such mechanism is capable of providing combinations of different characteristics under study that are better and can be connected to produce the desired outcome in the industrial processes that are under control. Heating application is the generation and conveying of heat and regulating it within the conditions required to prevent losing the previous energy. Process protection devices, process recorders, process controllers and Pneumatic valve positioners complete the list of instrumentation package for measuring flow level, temperature, and pressure. The sensors can sense even slight alterations in the variables measured and send the signal to the control computers that should automatically in managing the cause resulting in the stabilization of the manufacturing process. The process control uses an automated control loop system of the sensor for measuring the process variable at a set reference value. The signal is sent to a controller incorporating an error detecting device and comparing the variable with the set point. The driver reacts depending on the detected error in the incoming signal and manipulates the variable restoring the production condition back to normal. 5.0. Heat Transfer Processes One of the kinds of heat transfer is a parameter active heat control hinged on single fluid flow in which there has been conducted and examinations on the testing and evaluation of a program by executing data in real-time on its optimization (Zeidler 2013; Åström & Wittenmark 2013). The fluid flows through the system at a particular uniform velocity and varying temperature, and the output is controlled by a heat controllable time wise flux. There is a regular transfer of heat into the flowing fluid from the tube walls. The system promotes an efficient transfer of heat from the heat-supplying element to the liquid (Smith et al. 2010). To achieve recovery of heat, recuperation heat exchanger system of heat is applicable in case of prior heating of the gas undergoing removal of contaminants up to a set temperature through mixing with the burner’s combustive products. The mechanism has founded a broad application in the oil and gas industries for purification (Raynal et al. 2016). The process that follows is passing of the gas via embedded coils containing some stimulants for increasing the rate of reaction of the impurities and oxygen capable of combustion from the gas. The counter flow of current of cold water from the heat does the function of cooling the hot and contamination free gas. The same stimulant is applicable as a heat transfer medium in the cases of regenerative heat control system (Hershkowitz et al. 2011). For the production of Ammonia gas in large scale, the use of not less than two pumping systems is used. The absorbent and refrigerant containing solution are heated and the condenser fitted with cold water flowing counter-current cooling the hot vapor of the refrigerant. A similar mechanism has also been in broad utility in underground mining activities especially in the conveyances heating load and backfill induced in dark sites. Research on the use of a tube inside another tube for transporting backfill has been conducted with the building of a laboratory experimental design for stimulation of heat control systems (Watson et al. 2012; Wills & Napier-Munn 2015). The purified water providing cooling for the activities located deep underground in such a scenario is made to flow in a counter direction to the movement of backfill. 6.0. The Laws of Conservation of Mass and Energy The laws of conservation of mass and energy state that when a system is closed, it is not possible to either create or destroy matter through both the physical transformations and chemical reactions. According to this law, matter can change forms or states but is conserved and that the mass of reactants in a chemical reaction must equal the mass of products (Kays et al. 2012; De Groot & Mazur 2013). The law of conservation of mass and energy is significant in its applicability in some calculations and in solving for unknown masses like the volume of produced gas during a chemical reaction. Conservation of energy is the first law of thermodynamics which is the branch of physics dealing with the associations between heat and the other forms of energy like chemical energy, electrical and mechanical energy and can be extended to relations between all forms of energy. The study of the law indicates that passing energy into a system or out of a system with matter, as heat or as work changes the internal energy of the scheme. It is for the same reason that motion and heat production in the steam engine is linked with the theory of “transfer of heat from a body with higher temperature to the body with a lower temperature.” The heat transfer and not caloric combustion leads to restoration and maintenance of equilibrium. Radiation does not play a significant role in heat controllers handling the transfer of heat from one liquid to another or within the fluid. The rate of heat transfer follows the cooling law by Newton stating a direct proportionality between the differences in temperature speed of energy transfer. In addition to this concept is the principle of resistance as for phenomenon of transfer of electric energy making the heat flow rate directly proportional to the driving force (temperature difference) and indirectly proportional to the resistance to heat flow. The nature of the material and the surface area available for transfer of heat energy is a factor that affects the heat flow and determines the resistance to heat flow. The combination of the net work done on the system W and the net heat transfer into the system Q gives the change in internal energy of a system ΔU and is represented in the form of an equation as: ΔU=Q+W Where W is the network done in the system, Q is the sum of all heat transfer into and out of the system, and ΔU is the change in internal energy U of the system. The law of energy conservation finds a broad range of application in all forms of heat engines, heat pumps, air conditioners, and refrigerators. In the heat engines, mechanical energy is converted into thermal energy and vice versa. The foundational mechanism of the system is based on pressure, volume, and temperature of the working liquid. The fluid is usually in the gaseous state though it can change form to liquid and back to gas. Heating a gas leads to its expansion and confining the gas raises its pressure. The pressure exerted by the gas can be harvested to the desired work depending on the amount of weight. For the steam engines, there is the conversion of water into steam and using the force in driving the piston for the conversion of heat energy to mechanical energy. The heat pumps and refrigerators use heat engines with the ability to transform mechanical energy to heat. Compression of gas especially in the closed systems increases its pressure and temperature enabling the gas to transfer heat energy to the systems around it. Allowing the compressed gas to undergo expansion leads to a reduction in its temperature even to a lower degree than it was before compression since some heat energy of the gas is lost during the heat. The gas is, therefore, cold enough to absorb heat energy from the surrounding. Noting that there is a change in temperature of a fluid leads to a changing density, and specific heat is significant since there will be a need for adjusting the specific heat and the mass flow rate to the real temperatures. 7.0. Conclusion A wide range of control systems is covered by process control and is applicable in manufacturing industries to maximize on the efficiency of production, supervision, as well as data acquisition amongst other aspects of controlled systems. The controlled systems meet control of the systems by ensuring both the feedback and the feed forward loops are deployed automatically within a specified time interval. Western Australia has industries that apply process control such as pressure control, temperature control, flow control, level control and speed control. Sensors and instrumentation are significant components of process control and only a good measurement system produce quality the inspection process. The integration of the best practice, instrumentation analysis, and regulatory control in a single system gives support to troubleshooting, diagnostic and monitoring process. Reference List Åström, K. J., & Wittenmark, B. (2013). Computer-controlled systems: theory and design. Courier Corporation. De Groot, S. R., & Mazur, P. (2013). Non-equilibrium thermodynamics. Courier Corporation. Friedland, B. (2012). Control system design: an introduction to state-space methods. Courier Corporation. Hershkowitz, F., Deckman, H. W., Northrop, P. S., & Kelley, B. T. (2011). U.S. Patent No. 7,938,886. Washington, DC: U.S. Patent and Trademark Office. Isermann, R. (2013). Digital control systems. Springer Science & Business Media. Kays, W. M., Crawford, M. E., & Weigand, B. (2012). Convective heat and mass transfer. Tata McGraw-Hill Education. Peacock, D. G., & Richardson, J. F. (Eds.). (2012). Chemical Engineering, Volume 3: Chemical and Biochemical Reactors and Process Control (Vol. 3). Elsevier. Raynal, L., Augier, F., Bazer-Bachi, F., Haroun, Y., & da Fonte, C. P. (2016). CFD Applied to Process Development in the Oil and Gas Industry–A Review. Oil & Gas Science and Technology–Revue d’IFP Energies nouvelles, 71(3), 42. Smith, R. J., Loganathan, M., & Shantha, M. S. (2010). A review of the water gas shift reaction kinetics. International Journal of Chemical Reactor Engineering, 8(1). Watson, J. D., Kobler, M. H., & Brock, D. (2012). U.S. Patent No. 8,127,865. Washington, DC: U.S. Patent and Trademark Office. Wills, B. A., & Napier-Munn, T. (2015). Wills' mineral processing technology: an introduction to the practical aspects of ore treatment and mineral recovery. Butterworth-Heinemann. Zeidler, E. (2013). Nonlinear Functional Analysis and Its Applications: III: Variational Methods and Optimization. Springer Science & Business Media. Read More

Below is a diagram showing process control flow: 4.0. Sensors and Instrumentation The use of scrutiny that does not depend on the operator has been enabled through the utility of sensors and instruments with a high degree of accuracy in indications and measurements instead of the player’s control. Sensors and instrumentations from very significant components of process control and only a good measurement system produce a quality of the inspection process. A crafty distinction between a sensor and an instrument is that a sensor is a device capable of measuring the amplitude of a physical variable though cannot provide an indicator of the action directly, while an instrument is a device measuring and displaying the magnitude of a physical variable.

Such mechanism is capable of providing combinations of different characteristics under study that are better and can be connected to produce the desired outcome in the industrial processes that are under control. Heating application is the generation and conveying of heat and regulating it within the conditions required to prevent losing the previous energy. Process protection devices, process recorders, process controllers and Pneumatic valve positioners complete the list of instrumentation package for measuring flow level, temperature, and pressure.

The sensors can sense even slight alterations in the variables measured and send the signal to the control computers that should automatically in managing the cause resulting in the stabilization of the manufacturing process. The process control uses an automated control loop system of the sensor for measuring the process variable at a set reference value. The signal is sent to a controller incorporating an error detecting device and comparing the variable with the set point. The driver reacts depending on the detected error in the incoming signal and manipulates the variable restoring the production condition back to normal. 5.0.

Heat Transfer Processes One of the kinds of heat transfer is a parameter active heat control hinged on single fluid flow in which there has been conducted and examinations on the testing and evaluation of a program by executing data in real-time on its optimization (Zeidler 2013; Åström & Wittenmark 2013). The fluid flows through the system at a particular uniform velocity and varying temperature, and the output is controlled by a heat controllable time wise flux. There is a regular transfer of heat into the flowing fluid from the tube walls.

The system promotes an efficient transfer of heat from the heat-supplying element to the liquid (Smith et al. 2010). To achieve recovery of heat, recuperation heat exchanger system of heat is applicable in case of prior heating of the gas undergoing removal of contaminants up to a set temperature through mixing with the burner’s combustive products. The mechanism has founded a broad application in the oil and gas industries for purification (Raynal et al. 2016). The process that follows is passing of the gas via embedded coils containing some stimulants for increasing the rate of reaction of the impurities and oxygen capable of combustion from the gas.

The counter flow of current of cold water from the heat does the function of cooling the hot and contamination free gas. The same stimulant is applicable as a heat transfer medium in the cases of regenerative heat control system (Hershkowitz et al. 2011). For the production of Ammonia gas in large scale, the use of not less than two pumping systems is used. The absorbent and refrigerant containing solution are heated and the condenser fitted with cold water flowing counter-current cooling the hot vapor of the refrigerant.

A similar mechanism has also been in broad utility in underground mining activities especially in the conveyances heating load and backfill induced in dark sites. Research on the use of a tube inside another tube for transporting backfill has been conducted with the building of a laboratory experimental design for stimulation of heat control systems (Watson et al.

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