Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Brief Introduction to Distillation Control:All distillation columns have to be carefully operated in order to achieve the
required production rates and product quality. The 3 main objectives of column
control can be stated as:

To set stable conditions for column operation.

To regulate conditions in the column so that the product(s) always meet
the required specifications.
To achieve the above objective most efficiently, e.g. by maximising
product yield, minimising energy consumption, etc.

Process variables like temperatures, pressures, flow rates, levels and

compositions must be monitored and controlled in all distillation processes.
These process variables within a distillation system affect one another, whereby
a change in one process variable will result in changes in other process variables.
Thus, in column control one should be looking at the whole column and not
focusing on any particular sections only.

Each column has a control system that consists of several control loops. The
loops adjust process variables as needed to compensate for changes due to
disturbances during plant operation.

Each of the process variables has its own control loop, which typically consists of
a sensor and transmitter, controller and control valve. See the Figure below. Each
control loop keeps track of the associated process variable. An adjustment is
made to a process variable by varying the opening of its control valve. The
stream flow rate is therefore adjusted and a desirable variable is being
controlled.
Block diagram for control loop:-

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

The sensor
measures
the process
variable
from the
plant (i.e.
plant data)
and the
transmitter
sends the
information to the DCS (Distributed Control System) controller located in the
control room.The controller checks if the process variable agrees with the set
point. If not, it will send corrective signal to the control valve that will make
adjustment in the plant so as to match the process variable to the set point. This
goes on continuously, essentially in a loop - hence the term "control loop".

Distillation Control Philosophy:Some of the general guidelines are noted below:

Column pressure normally controlled at a constant value.
Feed flow rate often set by the level controller on a preceding column.
Feed flow rate is independently controlled if fed from storage tank or surge tank.
Feed temperature controlled by a feed preheater. Prior to preheater, feed may be
heated by bottom product via feed/bottom exchanger.
Top temperature usually controlled by varying the reflux.
Bottom temperature controlled by varying the steam to reboiler.
Differential pressure control used in packed columns to monitor packing
condition, also used in tray columns to indicate foaming.
The compositions controlled by regulating the reflux flow and boiled-up (reboiler
vapour).
Pressure is often considered the prime distillation control variable, as it affects
temperature, condensation, vaporisation, compositions, volatilities and almost
any process that takes place inside the column. Column pressure control is
frequently integrated with the condenser control system.
Reboiler and condensers are integral part of a distillation system. They regulate
the energy inflow and outflow in a distillation column.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Distillation Control - Material & Energy

Balance
A distillation column is controlled by regulating its material balance and the
energy balance.
In essence, a material balance means that the sum of the products leaving the
column must be equal (approximately) to the feed entering the column; and an
energy balance means that the heat input to the column must equal
(approximately) to heat removed from the system.
When a column is in material and energy balance, there is no accumulation or
generation of material or heat within the column, i.e. the column is "stable".
The control system is dynamic, i.e. if a process variable changes, the control
system reacts by adjusting the affected process variables until the system
returns to normal condition. Sample plant picture
The term "steady state operation" describes the condition in a column when the
process variables are changing in small amounts within prescribed limits.
When a column is in steady-state operation, the changes to the column's
material balance and energy balance variables are minimal and are handled by
the control system. As mentioned in the start of this chapter, one of the
objectives of control is to maintain the products within the required
specifications, or simply "specs". A "spec" is a value, or a range of values, for a
physical property or a set of physical properties that is required for a product or
products. A sample of typical properties of interest in petroleum refining is shown
in Appendix A.

Product specifications are set by the demands of downstream processes and by

the marketplace. Products must meet certain quality standards. For a product to

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

be saleable, it must comply with certain pre-determined quality.Products are

routinely tested to ensure that the specifications are met. Testing can be done by
direct composition measurement or by indirect measurement, according to
prescribed standards, such as ASTM.
Direct composition measurements are analysis that allows personnel to directly
observe the percentages of components in a product. An example is the process
chromatograph. It provides a direct read-out of the component percentages. The
readings of the chromatograph can be compared against the specifications to
see if any adjustments are needed to ensure that the product meets
specifications.
Indirect composition measurements are analysis in which one measured property
is used as an indicator of another property. One common indirect measurement
is the boiling temperature. For example, since the boiling points of the
components in a feed mixture are known, the components in a product can be
indirectly identified by their boiling points. When the product is tested, its
composition can be indirectly measured by recording the temperatures at which
the different components in the product boil.
If the composition of a product is outside of the normal limits for that product,
the product is referred to as "off-specification".Exceeding product specifications
or producing better quality product than is required is known as product
giveaway.

Appendix A: Examples of Typical Petroleum Cut or Fraction

Properties
NOTE: "Cut" is the refinery term of a fraction obtained direct from a fractionating
unit. Several cuts can be blended for the manufacture of a certain product. A
"fraction" is a portion of petroleum separated from other portions in the
fractionation of petroleum products. It is often characterised by a particular
boiling range.
Initial Boiling Point (IBP)
The temperature at which the first drop of distillate appears after
commencement of distillation in the standard ASTM laboratory apparatus
Final Boiling Point (FBP)
The maximum temperature observed on the distillation thermometer when a
standard ASTM distillation is carried out.
Boiling Range

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Petroleum products (which are mixtures of many compounds, each having a

different boiling point) do not have a simple boiling point but have a boiling
range instead, i.e. the temperature range from bubble point to dew point.
API Gravity
In the U.S. an arbitrary scale known as the API degree is used for reporting the
gravity of a petroleum product. The degree API is related to the specific gravity
scale (15oC / 15oC) by the formula:
Viscosity
The dynamic viscosity of a liquid is a measure of its resistance to flow. The
kinematic viscosity is equal to the dynamic viscosity divided by the density of
the liquid.

Cloud Point
The temperature at which a fuel, when cooled, begins to congeal and present a
cloudy appearance owing to the formation of minute crystals of wax.
Flash Point
The lowest temperature under closely specified conditions at which a
combustible material will give off sufficient vapour to form an inflammable
mixture with air in a standardised vessel. Flash point tests are used to assess the
volatilities of petroleum products.
Freezing Point
The temperature at which crystals first appear when a liquid is cooled under
specified conditions. It is an important characteristic of aviation fuels.
Pour Point
The temperature below which an oil tends to solidify and will no longer flow
freely.
Reid Vapour Pressure (RVP)
The pressure caused by the vaporised part of a liquid and the enclosed air and
water vapour, as measured under standardised conditions in standardised
apparatus: the result is given in psi at 100 oF, although normally reported simply
as "RVP in lb". RVP is not the same as the true vapour pressure of the liquid, but
gives some indication of the volatility of a liquid, e.g. gasoline.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Octane Number
The octane number of a fuel is a number equal to the percentage by volume of
iso-octane in a mixture of iso-octane and normal heptane having the same
resistance to detonation as the fuel under consideration in a special test engine.
It is a measure of the "anti-knock" value of a gasoline and the higher the octane
number the higher the anti-knock quality of the gasoline.
("Anti-knock" is an adjective signifying the resistance to detonation (pinking) in
spark-ignited internal combustion engines).
Smoke Point
The maximum height of flame measured in millimetres (mm) at which a kerosene
will burn without smoking when tested in a standard lamp for this purpose.

The following controls are briefly discussed in this

Section:

Reboiler and Steam Control

Condenser and Pressure Control
Analyser Control
Temperature Control
Feed Preheat Control

Reboiler Control

This is required to provide good response to column disturbances, and to protect

the column from disturbances occurring in the heating medium. The reboiler boil-

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

up is regulated either: (1) to achieve desired product purity, or (2) to maintain a

constant boil-up rate.

In a typical reboiler control (see Figure below), the control valve is located in the
reboiler steam inlet line.

Typical reboiler control - steam flow

For inlet steam controlled reboiler, the heat transfer rate is regulated by varying
the steam control valve opening, thereby changing the steam condensing
pressure and temperature.
When an additional boil-up is required, the valve opens and raises the reboiler
pressure, which increases the temperature, and in turn increases the boil-up
rate. This scheme has the disadvantage of non-linear relationship between
pressure and boil-up, and is affected by fouling in the reboiler.
An alternative is to control the condensate flow, i.e. by putting the control valve
on the condensate line (see Figure below). The main disadvantage is that this
scheme has poorer dynamic response than the previous scheme. Manipulating
the inlet valve immediately changes the vapour flow, giving faster dynamic

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

response. On the other hand, the condensate outlet valve has no direct effect on
vapour flow. The response time varies with the condensate level in the
exchanger.

Alternative reboiler control - condensate side

The other main disadvantage is the sizing of the condensate valve. If condensate
cannot be drained in time, vapour flow may be restricted as much of the reboiler
remains flooded. On the other hand, too fast of condensate draining (faster than
vapor condensation in the reboiler) as result in loss of liquid seal in the reboiler
and steam will pass into the plant's condensate recovery system.
Some reboiler control features the use of condensate pot. This is particularly
important in fouling or corrosive services (where leakage is a serious problem).
An example is shown in the Figure below.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Reboiler control with condensate pot

In the system shown, by varying the level control set point, the tube surface area
in the reboiler that is exposed for vapour condensation can be adjusted, thus
changing the available heat transfer area. The heat transfer rate can therefore
be adjusted.
This arrangement also automatically minimise the condensation (and therefore,
tube wall) temperature. A pressure-balancing line is provided to maintain a
steady pressure and level in the condensate pot.

Condenser and Pressure Control:The 3 main methods of pressure and condensation control are:

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

(1) Vapour flow variation,

(2) Flooded condenser, and
(3) Cooling medium flow variation.
Vapour Flow Variation
The simplest and direct method for column producing a vapour product. The
pressure controller regulates the vapour inventory and therefore the column
pressure. See the Figure below.

An important consideration here is the proper piping of the vapour line to avoid
liquid pockets.

Flooded Condenser
This method is used with total condensers generating liquid product. Part of the
condenser surface is flooded with liquid at all times. The flow of condensate from
the condenser is controlled by varying the flooded area. Increasing the flooded
area (by reducing flow) increases the column pressure (less surface area for
condensation).

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Flooded condenser pressure control

Cooling Medium Flow Variation

Pressure can also be controlled by adjusting the flow of coolant to the condenser
(see Figure below). Operation using cooling water can cause fouling problems at
low flow condition, when cooling water velocity is low and outlet temperature is
high.

Pressure control - CWS flow

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

For air-fin condensers, the controller varies the fan speed or fan pitch to control
pressure (see Figure below). This arrangement is energy-efficient as it minimises
fan power consumption, but requires the use of variable-pitch fan or variable
speed motor.

Fin-fan pressure control

Other method: pressure control using inerts (see Figure below).

Pressure control with inerts

When column pressure falls, an inert gas is admitted to raise the column
pressure.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Or: split-range pressure control venting excess gas to flare (see Figure below)

Split range pressure control

In most instances, both vapour and liquid phase are present in the column
overhead. The vapour contains components that can condense out but are
undesirable in the liquid, i.e. excessive condensation may lead to offspecification liquid product. In addition, it is also undesirable to lose liquid
product (through insufficient condensation) to the vapour. It is therefore
important to control the rate of condensation to obtain the desired vapour-liquid
split.

This is usually done by controlling the temperature of the liquid product just
downstream of the condenser. One common scheme used is shown the Figure
below.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Temperature Control
Column temperature control is perhaps the most popular way of controlling
product compositions. In this case, the control temperature is used as a
substitute to product composition analysis.
Ideally, both top and bottom compositions should be controlled to maintain each
within its specifications. See the Figure below.

Temperature control and interaction

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

In practice, simultaneous composition control of both products suffer from

serious "coupling" (interaction) between the 2 controllers, resulting in column
instability. In the system shown, suppose that there are concentration changes in
the feed conditions that result in lower column temperature. The top and bottom
temperature controllers will respond by decreasing reflux and increasing boil-up
respectively.

If the actions of the 2 controllers are perfectly matched, and response is

instantaneous, both control temperatures will return to their set points without
interaction.

However, the 2 actions are rarely perfectly matched, and their dynamics are
dissimilar - usually the boil-up response is faster. The reflux and boil-up will
"cycle" as shown in the Figure above.

The interaction can be avoided by controlling only 1 of the 2 product

compositions.

On-line analyser can be used together with temperature control to control

product composition. The principal control action is rapidly performed by the
temperature controller, while the analyser slowly adjusts the temperature set
point to prevent off-specification product purity. A set up is shown in the Figure
below.

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Document Title:

Temperature-analyser control

In the above set-up, delayed analyser response is acceptable, as its time lags
become a secondary consideration. The fast temperature controller action
renders this control method less sensitive to upsets and step changes in an
analyser-only control system.
Another advantage is that, should the analyser become inoperative, the
temperature controller will maintain automatic control of the process.

Feed Preheat Control

Feed preheat is usually practised for heat recovery or to attain the desired
vapour and liquid traffic above and below the feed tray. The objective of the
preheat control system is to supply the column with a feed of consistent specific
enthalpy. With a single-phase feed, this becomes a constant feed temperature
control; with a partially vaporised

feed, a constant fractional vaporisation is

required.
As an example, consider case (a) as shown in the Figure below whereby the feed
is a cold liquid. In this case, all the liquid feed will go to the stripping section. In

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

addition, because the feed is cold, it will also condense some of the rising
vapour.

As a result, the amount of liquid flow in the stripping section is much larger than
the liquid flow in the rectifying section. The vapour flow in the rectifying section
is lower than the vapour flow in the stripping section because of the
condensation into the liquid.
The following Figures showed 2 other feed conditions: case (b) for saturated
liquid (left) and case (c) for vapour-liquid mixture (right):

And the following Figures showed 2 other feed conditions: case (d) for saturated
vapour (left) and case (e) for superheated vapour (right):

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Sub cooled feed or superheated feed can be controlled (see Figure below) by
preheating (left) or de superheating (right) the feed prior to column entry:

A superheated bottom feed can be cooled by injecting a quench stream as shown

in the Figure below.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

An Example of Distillation Column Control:A typical distillation column has a combination of different control loops. The
control system of a particular column is designed to meet that column's
particular process requirements. An example is shown in the Figure below.

There are several control loops associated with the distillation column:
Temperature:
1. Overhead condensation (Fin-fan)
2. Overhead column (Reflux)
3. Feed preheat
4. Column bottom (Reboiler steam)
Pressure:
1. Overhead accumulator (Off gas)
Level:
1. Overhead accumulator (Distillate product)
2. Column bottom (Bottoms product)
Flow:

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

1. Column feed

In this distillation column, the material balance (MB) loops consisted of

the following:

Feed flow control loop (which sets the throughput, i.e. production rate)
Bottom level control loop (which controls the column level)
Accumulator level control loop (which regulates the product flow by regulating
the overhead accumulator level)
Off gas pressure control loop (which controls the column pressure)

The energy balance (EB) control loops are the following:

Boiler temperature control loop (which control the column bottom temperature
by controlling the steam input to the reboiler)
Feed preheater temperature control loop (which controls the feed inlet
temperature)
Overhead condenser temperature control loop (which regulates amount of
cooling in the column)
External reflux temperature control loop (which controls the temperature at the
top of the column)
In this example, the main influence on the heat input to the column is the steam
flow to the reboiler. Heat also enters the system via the preheater. Heat balance
is achieved when the heat input from the reboiler and preheater is removed by
the condenser.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

(Note that there is also a balance between the energy in the feed stream and
product streams, but this balance does not have much effect on the overall
energy balance)
In this type of control system, the material balance control loops react to the
changes in the column's energy balance.
For example, a change in the reboiler steam flow will lead to a series of changes
in the column; and the column's control system react to this change in order to
maintain the material balance and energy balance. Sample plant picture
An increased steam flow to the reboiler means an increase in heat input which
will result in increased vaporisation in the reboiler and an increased bottom
temperature. There will be an increased vapour flow and temperature throughout
the column. The liquid level in the bottom of the column decreases as more
liquid is being boiled-off, and the bottom product rate decreases. Hence, a
change in the EB leads to a change in the MB.
Increased vapour flow to the top will cause a higher temperature at the top of
the column, and the temperature (reflux) controller will increase the reflux flow
back to the column. Increased reflux flow will condense the additional vapour in
the column.
The larger amount of vapour also requires additional cooling in the overhead
system and this is handled by the temperature control that increases the fan
speed of the overhead condenser. This will increase the heat removal and tends
to restore the EB. Increased condensation leads to increased liquid flow into the
overhead accumulator (reflux drum). The accumulator level controller responds
by increasing the outflow of top product. This increased outflow of materials from
the top will offset the decreased in outflow from the bottom, hence the MB is
restored.

Concentrations of the top and bottom product streams are affected as well higher bottom temperature will results in more heavy components being
vaporised from the bottoms product.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

This can be illustrated using a multi-component separation of 8 products: C1, C2,

C3, C4, C5, C6, C7 and C8+. The main separation is between 2 key components:
the light key (C4) and heavy key (C5). This is shown in the Figure below.

If the bottom temperature is too high, more of the heavy key (HK) will be
vapourised from the bottom product. The vapour thus had become heavier due
to the presence of the HK. The final boiling point (FBP) of the top product will be
higher but the initial boiling point (IBP) did not change.

On the other hand, the IBP of the bottoms product will be higher, because the
bottoms product has been depleted of the HK and become heavier. The FBP of
the bottoms product is not affected by the bottom temperature increase.

Other possible disturbances

This example illustrated just one of the many disturbances that can upset the
smooth operation of a distillation column. Besides the reboiler example, which
could be due to controller malfunctioning, other disturbances, can also occur. The

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

following list is not exhaustive, but only serves as a reference of what possible
events that can disrupt the smooth operation of a plant.

Reboiler and other heat exchangers: fouling of heat transfer surfaces, tube
leaks, etc
Charge heater: loss of fuel gas and/or fuel oil (e.g. due to low fuel gas pressure
trip)
Overhead condenser: loss of cooling water or loss of power supply (for air-fin
coolers)
Pumps: overload trip, loss of power, cavitations, etc
Control valves failure: e.g. loss of instrument air, jammed valve, faulty
positioners, etc.
Faulty instruments: wrong signals transmitted false alarms, etc.
Feed changes: feed rate, lower boiling components, contaminations, etc.
Tower internals: e.g. flooding, weeping, channelling, etc.

Drum Level Control Systems

Drum Level Control Systems are used extensively throughout the process
industries and the Utilities
to control the level of boiling water contained in boiler drums on process plant
and help provide a
constant supply of steam.
If the level is too high, flooding of steam purification equipment can occur.
If the level is too low, reduction in efficiency of the treatment and recirculation
function.
Pressure can also build to dangerous levels.
A drum level control system tightly controls the level whatever the disturbances,
level change, increase/decrease of steam demand, feedwater flow variations.

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Document Title:

In the process industries, boiling water to make steam is a very important

procedure.
The control of water level is a major function in this process and it is achieved
through a water steam interface established in a cylindrical vessel called the
drum which is usually lying on its side and located near the top of the boiler.
Maintaining the correct water level in the drum is critical for many reasons. A
water level that is too high causes flooding of the steam purification equipment;
resulting in the carry over of water and impurities into the steam system. A
water level that is too low results in a reduction in efficiency of the treatment and
recirculation function. It can even result in tube failure due to overheating from
lack of cooling water on the boiling surfaces. Normally drum level is expected to
be held within 2 to 5cm of the set-point with some tolerance for temporary load
changes.

Components Affecting Drum Water Level:Under boiling conditions, steam supporting field products such as bubbles exist
below the water/steam level interface. These bubbles have volume and therefore
displace water to create a misrepresentation of the true water level in the drum.
Another effect upon drum level is pressure in the drum. Because steam bubbles
compress under pressure (if the drum pressure changes due to load demands),
the steam bubbles expand or contract respective to these pressure changes. A
higher steam demand will cause the drum pressure to drop, and the steam
bubbles to expand to give the appearance of a water level higher than it truly is.
This fictitious
higher water level causes the feed water input to be shut down at a time when
more water is really required. A surge in water level as a result of the drum
pressure decreasing is called 'swell'. A water level decrease due to drum
pressure increase is called 'shrink'.

Level Control Strategies:

Figure 1 depicts three types of drum level control strategies with typical
applications for each. While single-element drum level control is acceptable for
steady boiler load conditions; as load changes become more frequent,
unpredictable, or severe; this type of level control cannot respond quickly
enough to compensate. More
information must be included and processed to predetermine the amount of
water to be added to the drum to compensate for load changes. The addition of
elements (flow and transmitter devices) enables the controller to predict the
amount of water added to the drum to maintain drum level set-point

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Single-Element Drum Level Control:

Figure 2 depicts the control scheme for single-element drum level control. In this
configuration, only the water level in the drum is being measured (hence the
term " single element" ) . LT- 1 is an electronic differential pressure transmitter
with a high static pressure range. The high side of the transmitter is connected
to the bottom ofthe drum. Because of the drum's static pressure, the low side of
the transmitter is connected to the top of the drum above the water/steam
interface. This provides a reference for the transmitter by cancelling the static
pressure effect and allowing only the water hydrostatic head to be measured. A
constant head reservoir is required to maintain a consistent head in the
reference leg of the transmitter. This is often referred to as a ''wet leg" The
output of the electronic DP transmitter is the process Input for the MOD 30ML
Controller, (LC-1), and the
output is then compared to a drum level set-point. Any discrepancy between
setpoint and drum level causes an output from the MOD 30ML controller in
compensation. Because controller action is reverse, as the drum level Increases,
a resultant output signal will decrease to close the feedwater control valve. The
output of the Controller is fed to the feedwater control valve (FCV-1). If the
feedwater valve is pneumatic, an lP (current-to-pressure) converter is required to
change the Controller current output to accommodate the pneumatic valve.
Note that the response from the controller to the feedwater control valve is
reactive; i.e. feedwater is added only in response to a drop in drum level. This
type of control is acceptable if steam load changes are not dramatic because the
controller can respond well to steady demands. In applications where steam load
changes become
frequent and unpredictable, a reactive strategy is better suited. This type of
system requires more field devices for input.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Two-Element Drum Level Control System:A two-element drum level control system is capable of providing close adherence
of drum level to its set-point under steady-state conditions as well as being
capableof providing the required tight control during a transient. Its performance
during transient conditions permits its use on many industrial boiler applications.
Such
applications are characterized by adequately-sized drums used with load
changes of moderate rate and degree. These characteristics are usually found in
plants with continuous-type processes, and those with mixed heating and
processing demands. Caution should be exercised in its use on systems without
reasonably constant
feedwater pressure. The term 'two-element' is derived from two variables: steam
flow and drum level
influence on the feedwater valve position. It is often classified as a combination
'feed-forward-feedback' system because the steam flow demand is fed forward
as the primary index of the feedwater valve position. The drum level signal
becomes the feedback which is used to constantly trim the accuracy of the feedforward system and provide final control of the water/steam interface in the

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

drum. Refer to Figure 3 for the control scheme of a two-element drum level
control. Note the left side of the doted line is identical to that used in singleelement control.
Additional equipment required for two-element drum level control consists of a
steam flow measuring device, a differential pressure transmitter, a square root
extractor, a feedwater flow computer and a feedwater flow mode transfer
station. At first this may appear like a large investment in order to gain stable
drum level control, but as
you will see this is not necessarily true.
How it works:
Steam flow is measured by the steam flow transmitter (FT-1), its signal is fed to
the feedwater flow computer (FC-1) after processing through the square root
extractor (FY-1). As in the single-element level control, the drum level is
measured by the level transmitter (LT-1) and its signal is transmitted to the drum
level controller (LC- 1). In the drum level controller, the process signal is
compared to the drum level setpoint, where a required corrective output signal
to maintain the drum level is produced. This corrective signal is sent to the
feedwater flow computer. The feedwater flow computer combines the signal
from the two variables, and produces
an output signal to the feedwater control valve (FCV-1). Auto/Manual transfer of
the feedwater control valve is accomplished via FK-1. Nearly all of the load
change work is done by the feed-forward system, for example,
a pound of feedwater change is made for every pound of steam flow change. The
drum level control system is used for compensation only. It is expected that the
drum level will be maintained very closely to the set-point
value. This is true in spite of the low-to-moderate volume/throughput ratio and a
wide operating range. As a result, integral response (reset) is a necessary
function in the drum level controller. Using one MOD 30ML Controller, four of the
functions in the two-element control scheme are accomplished: level control (LC1), square root extraction (FY-1), feedwater flow computation (FC-1), and
feedwater flow mode transfer (FK-1). The
MOD 30ML Controller is a multi-functional controller providing level control for
LC-1. Utilizing the linearization block in the ML will provide the required square
root function to obtain a linear signal from the steam flow transmitter. A math
block in the Controller enables feedwater flow computations. Finally, a feedwater
flow transfer station is easily provided for with an operator-accessible
Auto/Manual button on the Controller display. Once in manual, the controller
output is ramped up or down by an operator using keys on the controller display.
Should a totalized steam flow be required, the MOD 30ML Controller provides an
eight-digit display of the totalized value.
FT-1 is an ABB electronic transmitter providing accuracy of 0.2% and is rugged
enough to handle static pressures up to 6000 PSI.

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Three-Element Drum Level Control System:In most drum level control applications, the two-element drum level control will
maintain the required water/steam interface level even under moderate load
changes. However, If an unstable feedwater system exists exhibiting a variable
feed header-to-drum pressure differential, or if large unpredictable steam
demands
are frequent, a three-element drum level control scheme should be considered.
As implied from the previous information, this control strategy supplies control of
feedwater flow in relationship to steam flow.
The performance of the three-element control system during transient conditions
makes it very useful for general industrial and utility boiler applications. It
handles loads exhibiting wide and rapid rates of change. Plants which exhibit
load characteristics of this type are those with mixed, continuous, and batch
processing
demands. It is also recommended where normal load characteristics are fairly
steady; but upsets can be sudden, unpredictable and/or a significant portion of
the load.
How it works:

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI

Figure 4 shows the control scheme for three-element drum level control. To the
left of the dotted line, the instrumentation is the same as that for the twoelement drum level control, with one exception: the output of the feedwater flow
computer now becomes the set-point of the feedwater flow controller (FIC-2).
Equipment required
to complete our three-element drum level control scheme includes an additional
flow device (FE-2) and differential pressure transmitter (FT-2). The area to the left
of the dotted line in figure 4 functions the same as that of a twoelement drum
level control. We can pick up the operation for this scheme where the output
signal of the feedwater flow computer (the combination of steam flow and drum
level) enters the feedwater controller (FIC-2).
This in effect becomes the set-point to this controller. Feedwater flow Is
measured by the transmitter (FT-2). The output signal of the feedwater flow
transmitter is linearized by the square root extractor, (FY-2). This signal is the
process variable to the feedwater controller and is compared to the output of the
feedwater flow computer
(set-point). The feedwater flow controller produces the necessary corrective
signal to maintain feedwater flow at its set-point by the adjustment of the
feedwater control valve (FCV-1). As in the two-element drum level control
scheme, nearly all of the work necessary to compensate for load change is done
by the feed-forward system (i.e. a pound of feedwater change is made for every
pound of steam flow change). The drum level portion of the control scheme is
used only in a compensating role. Despite low-tomoderate volume/ throughput
ratio and a wide operating range, it is expected the drum level will be maintained
very close to set-point. Achieving this requires use of the integrating response
and reset in both the drum level and feedwater controllers. This application may
suggest that an additional controller is required for the feedwater flow controller,
however this Is not true. The MOD 30ML Controller is a multi-loop unit. An easilyconfigured feed-forward command in the MOD 30ML means no additional wiring
is required to have the drum level controller and feedwater controller working
together. Feedwater flow computations are effortlessly done in the maths block
of the controller, all square root functions are performed within. The feedwater
flow element (FE-2), is an ABB WEDGE unit. A reliable, rugged, yet
accurate measuring device that will be in service for many years. Many models
include the option of mounting the transmitter on the WEDGE itself, thus
eliminating the need for expensive lead lines, valves and flanges. The feedwater
flow transmitter (FT-2), is an ABB electronic differential pressure transmitter. If
the system is appropriately designed. FT-1. FT-2, and LT-1 may be the same type
of transmitter. This means stocking only one type of transmitter In the case of a
transmitter failure

Document Title:

Training on GET-Instrumentation

April 2014

*Type as the subject of email

Code: PI