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Chapter 9: Process Control

and Instrumentation

Gas Conditioning and Processing

Volume 1

Learning Objectives

In this course you will learn to:

– Speak the language of process control
– Explain the different controller modes (PID)
– Understand different control loop types
• Simple, reverse acting, cascade, feed forward
– Explain control valves and their trim
– Understand a few ways to measure flow

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Simple Level Control System

Figure 9.1
(Pg. 316)

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Process Control Block Diagram for Level Control System

Figure 9.2
(Pg. 317)

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If you can’t measure it, you can’t control it

What are the Five Senses?

1. Pressure Fast
2. Flow
3. Level
4. Temperature
5. Composition Slow

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Learning Objectives

In this course you will learn to:

– Speak the language of process control
– Explain the different controller modes (PID)
– Understand different control loop types
• Simple, reverse acting, cascade, feed forward
– Explain control valves and their trim
– Understand a few ways to measure flow

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Modes of Control

On-Off (pages 320 - 321)

– Snap acting
Proportional (page 321) Magnitude
– Adjusts valve proportional to measured error
Magnitude
Integral or reset (page 324)
and Duration
– Resets proportional action based on how long you’ve
been away from the set point.
Derivative (pages 325 - 326) Rate of Change
– Looks at the rate of change of the error signal

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Level in Separator at Normal Flow – No Offset

Figure 9.5
(Pg. 323)

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Level in Separator when Liquid Flow

Increases 50% – Offset Present
Figure 9.6
(Pg. 323)

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Control Mode vs. Application

See Table 9.2, page 326

P for level
– If offset is tolerable
P+I for Level, Pressure and Flow
– To correct offset
P+I+D for Temperature and Composition
– Correct offset and respond to rate of change

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Control Mode vs. Application

See Table 9.2, page 326

P for level
– If offset is tolerable
P+I for Level, Pressure and Flow
– To correct offset
P+I+D for Temperature and Composition
– Correct offset and respond to rate of change

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Learning Objectives

In this course you will learn to:

– Speak the language of process control
– Explain the different controller modes (PID)
– Understand different control loop types
• Simple, reverse acting, cascade, feed forward
– Explain control valves and their trim
– Understand a few ways to measure flow

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Examples of Controller – Control

Valve Combinations
Figure 9.10
(Pg. 327)

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Split Range Control: J-T Bypass Control on an Expander

Figure 9.11
(Pg. 327)

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Cascade Control

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Simple Refrigeration System

What are you trying to control?

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Simple Temperature Control

Figure 9.12
(Pg. 328)

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Cascade Control System

Figure 9.13
(Pg. 328)

Slave (Floating Master (Fixed

Set Point) Set Point)

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Feed-Forward Control System

Figure 9.14
(Pg. 329)

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Distillation columns need complex feed-forward control

systems
Figure 16.28
(Pg. 326)

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Problem 9.1a

Draw the control schemes for two flow sheets.

Show what type of controller (Pressure Control,
Temperature Control etc.) and what valve or
device the controller is manipulating.
a) Amine Unit
b) Condensate Stabilization Unit

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Amine Unit

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Amine Unit

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•© 2014 PetroSkills, LLC. All rights reserved.

Learning Objectives

In this course you will learn to:

– Speak the language of process control
– Explain the different controller modes (PID)
– Understand different control loop types
• Simple, reverse acting, cascade, feed forward
– Explain control valves and their trim
– Understand a few ways to measure flow

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Control Valves (Pages 330 – 337)

Sliding Stem Valves

– Globe valves
– Gate valves
Rotary valves
– Butterfly
– Ball, characterized ball

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Schematics of Different Types of Control Valves

Figure 9.16
(Pg. 331)

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Globe Valve
Figure 9.17
(Pg. 332)

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A Butterfly Valve
Figure 9.18
(Pg. 332)

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Performance of Valve Trim

Figure 9.21(c)
(Pg. 334)

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Performance of Valve Trim

Figure 9.21
(Pg. 334)

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Learning Objectives

In this course you will learn to:

– Speak the language of process control
– Explain the different controller modes (PID)
– Understand different control loop types
• Simple, reverse acting, cascade, feed forward
– Explain control valves and their trim
– Understand a few ways to measure flow

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Schematic of an Orifice Plate

Figure 9.26
(Pg. 343)

C d A 2 g P
q
1  4
Cd - discharge coeffient
A - cross sectional area of pipe
g - acceleration due to gravity
P - pressure drop
 - ratio of diamters (orfice to line)

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Schematic of a Venturi Meter

Figure 9.27
(Pg. 344)

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Sonic Flow Meter

Figure 9.24
(Pg. 342)
𝛾𝑃
𝑐
𝜌
𝑃𝑀𝑊𝑡
𝜌
𝑧𝑅𝑇
𝛾𝑧𝑅𝑇
𝑐
𝑀𝑊𝑡

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Multiphase Flow Meter Operational Ranges

Figure 9.29
(Pg. 346)

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Learning Objectives

In this course you will learn to:

– Speak the language of process control
– Explain the different controller modes (PID)
– Understand different control loop types
• Simple, reverse acting, cascade, feed forward
– Explain control valves and their trim
– Understand a few ways to measure flow

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