Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

Research Article 12

Control of the Fractionator Top Pressure for a Delayed Coking Unit in

Khartoum Refinery
Salah Eldeen F..Hegazi 1, Gurashi Abdallah Gasmelseed 2 , Mohammed M .Bukhari 3
1

Department of Chemical Engineering,Faculty of Engineering ,Jazan University,Saudi Arabia .

Email :salahhegazi2003@yahoo.com
2
Department of Chemical Engineering, Faculty of Engineering, University of science &technology -SudanEmail :gurashigar@hotmail.com
3
Department of Chemical Engineering, Faculty of Engineering, University of Bengahzi Libya
(Received November 02, 2014; Accepted February 28, 2015)
Abstract
-The control of the fractionator top Pressure for
delayed coking unit in Khartoum refinery, by keeping
it in certain limits is essential to adjust disturbances
which lead to deviation from the desired values. The
aim of this paper is to select the suitable controller and
the appropriate tuning method. The control loop is
designed depending upon controllability and
performance. The column top pressure cascaded with a
reflux rate. The mathematical model for the loop was
determined
using
MATLAB
toolbox
system
identification by designing Graphical User Interface
(GUI). The same was used to identify the transfer
function for each loop. Having identified the transfer
functions, the loop was closed and the characteristic
equation was obtained from the overall transfer
function using Routh-Hurwitz together with the direct
substitution method to get the ultimate gain and
ultimate period, from which the adjustable parameters
were determined using Z-N criterion. These were used
to investigate the offset upon a unit step change in the
set point using proportional only (P), proportional
integral (PI) and proportional integral derivative
controller (PID).The controller that gave the minimum
offset is found to be proportional integral derivative
controller ( PID) and has been selected. The procedure
is repeated using Root-Locus and Bode criterion. In
each case the controller that gave the lowest offset was
selected. The three methods of Routh, Roots Locus and
Bode were compared according to their offset and
found to be within good accuracy. However, for good
initial estimate of the adjustable parameters, it was
recommended to apply proportional gain (kc=2.5,
integral time (
=0.75min ) and derivative time(
for system tuning, with respect to
the PID controller. Having closed the loops in
conventional system, the same was transformed to
digital computer control. The analysis of the offset
investigation and system stability were performed on
(Z-domains). The results are in agreement with
conventional analysis.
Index terms: Delayed coking, Roots Locus, Bode ,
tuning, conventional.

I.

INTRODUCTION

Control of Delayed coking unit Coker

Many oil refineries have nowadays integrated or are
planning to develop a fairly complex unit called Delayed
Coking Unit (DCU). The purpose of DCU is upgrading
petroleum residue by thermal cracking[1] Most aspects of
the DCU have been addressed previously modeling and
simulation
optimization
process
control
[2];
[3];[4],[5;[6];[7],[8];[9].
Delayed coking is one of the most difficult
refinery units to operate and control. The unit takes
vacuum residue (fresh feed), heats it and injects it into the
main fractionator bottom, where it is mixed with an
internal reflux recycle of heavy cracked material. The total
fresh and recycled feed is then heated in the coker furnace
to a high cracking temperature. Coke remains in the drums
and is periodically removed. That is the main reason for
the coker being a difficult unit to operate. Twice daily
filled coke drums are switched off for coke removal and
empty drums are connected. The drum that was just filled
then goes through a cycle of steaming out, cooling,
opening, coke removal, closing, steaming and pressure
testing, heating and finally reconnecting to the furnace and
fractionator. [10]
Al-fula crude is pumped from the surge tanks unit through
several heat train exchangers and into the fractionator. The
flow rate of coker feed is controlled upstream of the
exchangers by the flow controller leading to the
fractionating tower. Coker feed is preheated through three
heat exchangers prior to entering the fractionator.
Controlling the temperature of the Product quality is
controlled by throttling the amount of reflux pumped back
to the tower at various control points.[11]
Problem Statement
During the operation of the delayed coking unit
in Khartoum refinery, the pressure at the top of coking
tower is raise in severe leads to breakout the valve and
lack of control. The adjustment of the operating top
pressure of the delayed coking unit in its desired value by

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)
selection the best techniques of control is the aim of this
paper.
Paper objectives
General Objectives
To develop a mathematical model using graphical
user inter-phase (GUI). In order to test the
performance of delayed coking unit at Khartoum.
Refinery.
To control of the process using controller that gives
the best performance .
To compare between the performance and best
selection tuning method.

13
Different tuning methods are used for investigating the
system stability.
Frequency Dynamic System Analysis of the top pressure
Data for pressure control
Table (3.1): Operating records for Column top pressure
and reflux rate

Specific Objectives
To determine the transfer function from model using
system identification.
To determine the optimum parameters; Kc, I and D .
To tune the feedback controllers used in delayed
coking unit.
To compare the accuracy of Bode criteria, Root Locus
method and Routh test.
II. MATERIALS AND METHODS

Pressure, MPa

Reflux flow(T/h)

0.093

68

0.095

68

0.0109

74

0.0111

73

0.011

73

0.0114

74

0.0113

74

0.0114

74

Transfer functions of the Top pressure and the reflux

rate

System Identification
System Identification is the art and science of building
mathematical models from measured input-output
data. To examine the measured data, and create new
data sets from the original one by various
preprocessing .Then the models will be estimated
using the obtained data.

1.
2.
3.
4.

Identification: get the system transfer function

Get the closed loop characteristic equation of the
system.
Investigate offset for the system by calculation using
Routh to get ultimate gain (Ku) ,ultimate period (Pu),,
usepropotional gain (Kc,),integral time ( ) and
derivative time ( ) from Z-N table.
Get the system performance using P,PI and PID,
upon a unit step change in set point.
5-Repeat step1 to step3 for other loops.
Compare the performance
Select the controller that gives the best performance.

To keep the pressure of the column at designed

value through controlling the reflux rate of the column, the
MATLAB software

supported with GUI (system

identification) the transfer function was obtained. The

transfer function in z-domain is:

The same is transformed into S-domain:

The System Performance for Closed Loop:

P-Controller
For closed loop transfer function using Pcontroller only:
(3)
Routh-Hurwitz Method

5. Repeat using Bode Method and Root Locus method.

Select for each the controller that gives the best
performance.
III.
RESULTS AND DISCUSSION
Control of the column top pressure
The top pressure of the fractionator of the delayed coking
unit (DCU) in Khartoum Refinery is the primary control
loop and the reflux flow rate is the secondary control
loop. The MATLAB tool box system identification by the
Graphical User Interface was used to determine the model
and the transfer functions of the cascade control loops.

The characteristic equation is

+(6.7 + 0.35 K) + (25 -4.5 k) S +33.6 +5.05k=0
(4)
Routh Array :
S3

S2

6.7+0.35k

S1

(25 - 4.5k) -

25 4.5 k
33.6+5.05k

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)
S0

33.6+5.05k

14
putting

25 - 4.5 k -

s=i.w(6)

=0

-I

The ultimate gain Ku = 4.1

The characteristics equation is
+(6.7 + 0.35 K) + (25 -4.5 k) S +33.6 +5.05k=0
(5)

w=4.3 rad/sec, The ultimate period Pu=2/=1.46

min
Using Ziegler Table; Kc=2.1 for P-controller only.
The step response curve is illustrated inFigure(3.1)
below

Fig.(3.1):The final value of closed loop response of the system using P-controller only
The Offset for Closed Loop Transfer Function
The Transfer function is:

)
The offset = 0.24 1 = -0.76

S2

6.7+0.35k

S1

(25 - 4.5k) -

S0

33.6+5.05k

33.6+5.05k

25 - 4.5 k -

=0

PI-Controller
For closed loop transfer function using PI-controller

Using Z-N table; Kc=1.85 and

=1.2

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)
3.8 The Offset for Closed Loop Transfer Function
R(t)=1.0(14)
R(s) =

The offset =0.28-1= -0.72

The step response curve

is

Fig.(3.2): The final value of closedresponse of the system using PI-Controller

r(t)=1.0 (19)
PID-Controller
R(s) =
(20)
For closed loop transfer function using PID-controller

From Z-N table; Kc=2.5,

,
The Offset for closed loop transfer function for PID
controller
The step response curve is illustrated in Figure (3.3)

,The offset =1-1= 0.0

illustrated

below

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

16

Fig.(3.3): The final value of closed response of the system using PID-Controller using Routh test.

Fig.(3.4): The final values for different type of controllers using Routh test

Fig.(3.5): The final values and overshoots for different type of controllers using Routh test.

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)
For the system performance using Routh test as a
tuning method and proportional controller. Figure(3-1)
illustrates the offset =-0.76.Using PI controller reduce
the offset to -0.72 illustrated in Figure(3.2).
Adding derivative controller to PI eliminates the offset
to
zero
according
to
Figure(3.3).The
overshoot=28.6%.Due to elimination of the offset the
is PID controller is selected.
Controller Tuning Using Root-Locus Plots

17
To determine the ultimate gain and ultimate period from
the root locus, this can be realized by the following
methods:
Using the close loop transfer function

And OLTF is given as:

The
OLTF=

(24)

Draw the roots locus using MATLAB software

Fig.(3.6): Root- Locus Analysis for controlling top pressure of the column
Expand equation
= (31)
+(6.7 + 0.35 KC) + (25 -4.5 kC) S +33.6 +5.05k=0
(25)
Putting
s=i.w (26)

Equating the imaginary part to zero gives:

Equating the real part to zero gives
The equation becomes:
(28)
Substituting into equation (28)
=4.1

Using Ziegler Table; Kc=2.1 for P-Controller.

The transfer function is:

r(t)=1.0 (30)

The offset =0.24-1= -0.76

The step response curve is illustrated Fig.(3.7)

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

18

Fig.(3.7):The final value of closed loop response of the system using P-controller only.
PI-Controller
For closed loop transfer function using PI-controller

Then; Kc=1.85 and =1.2

3.15 The Offset for Closed Loop Transfer Function
r(t)=1.0 (35)
The offset =0.28-1= -0.72
The step response curve is illustrated in Figure(3.8)

Fig.(3.8):The final value of closed loop response of the system using PI-Controller
PID-Controller
The Offset for Closed Loop Transfer Function for
For closed loop transfer function using PID-controller
PID controller
r(t)=1.0
(40)
R(s)=
Taking Kc=2.5,

(41)

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

The offset =1-1= 0.0

The step response curve is illustrated in figure below

Fig.(3.9): The final value of closed loop response of the system using PID-Controller

Fig.(3.10): The final values for different type of controllers using Root Locus method.

Fig.(3.11):The overshoot of closed loop response of the system for different type of controllers using Root-Locus
method.

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

20
For the system performance using Root Locus as
tuning method and proportional controller. Figure.(3.7)
illustrates the offset = -0.76.
Using PI controller reduce the offset to -0.72 illustrated
in Figure.(3.8)
Adding a derivative controller to PI eliminates
the offset to zero according to figure(4-9).The
overshoot using PID is 28.6% illustrated in

Figure.(3.11).Due to elimination of the offset the best

selection is PID
3.19 Controller Tunning Using Bode Method
The OLTF=
Using MATLAB commands for plotting bode diagram
as illustrated in Figure.(3-12) below

Figure (3.12):Bode diagram for controlling toppressure of the column

The results of MATLAB are:
(45)

=2.43 min
M=
(47)
Log AR=log kc+log
(48)
Log AR=log kc+log
AR=1;
Ku=3
Using Ziegler Table ;Kc=1.5 for P-Controller.
3.17 The Offset for Closed Loop Transfer Function for P-Controller only:
The Transfer function is:

r(t)=1.0 (50)
R(s)= (51)

The offset =0.184-1= -0.186

The step response curve is illustrated in figure below

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

21

Fig.(3.13): The final value of closed loop response for the system using P-controller only
PI-Controller
For closed loop transfer function using PI-controller

Using from Z-N table; Kc=1.35 and =2.03

4-22 The Offset for Closed Loop Transfer Function
(55)

The offset =0.1682-1= -0.8318

The step response curve is illustrated in Figure(3.14)

Fig. (3.14): The final value of closed loop response of the system using PI-Controller
PID-Controller
For closed loop transfer function using PID-controller,
(61)
Taking Kc=1
,

3.24The Offset for closed loop transfer function for

PID controller

(60)

The offset =1-1= 0.0

The step response curve is illustrated in Figure(3.15)

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

22

Fig. (3.15): The final value of closed loop response of the system using PID-Controller

Fig. 3.16: The final values of closed loop response of the system using different types of controller applying Bode
criterion.

Fig.(3.17): The overshoot of closed loop response of the system using different types of controllers applying Bode
criterion.

Journal of Applied and Industrial Sciences, 2015, 3 (1): 12-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)

23
For the system performance using Bode criterion
as a tuning method and proportional controller.
Figure(3-13) illustrates the offset = -0.8318 .Using PI
controller reduce the offset to -0.186 illustrated in
Figure(3-14).
Adding a derivative controller to PI eliminates
the offset to zero according to figure(3.15).The
overshoot illustrated in Figure (3.17) is 0% According
to elimination of the offset the best selection is PID
using Bode method compared to Routh and Root Locus
method.
IV. CONCLUSION AND RECOMMENDATION
The delayed coking unit in Khartoum Refinery is
considered as one of the important unit for treatment of
the heavy crude oil (Al-fula crude ).The Graphical User
Interphase is used in identification and analysis the
control system. The dynamic performance of the system
is investigated ,the selection of the best mode of
controller is selected (PID-Controller). Different tuning
methods were used. These are : Ziegler, Bode, Nyquist,
Root Locus and Routh test.
From the control point of view, the delayed coking
process is a solution to the problem of decreasing
residual fuel demand. It also generates a variety of fuels
and in some cases a considerable amount of high
quality coke, while eliminating environmentally
unfriendly streams that often involve a disposal cost.
Implementing advanced process control and
optimization on a coking plant is quite a difficult task
but the results could be remarkable: energy savings,
maximized throughput, decreased CO emissions and
improved yields while increasing the overall profit of
the refinery.
Further work has to be done on the following:
1-Maximizing hot residue from crude distillation unit to
delayed coker.
2-Maximizing LPG production and fuel gas utilization.
3-Implementation of advanced process control.
4-Application of override control is essential for
controlling the base level.
ACKNOWLEDGEMENTS
The authors wish to thank the Faculty of Graduation
Studies in Gezira University, and Khartoum Refinery
Company for their help and support, this Paper.
5. References
[1] HessamVakilalroayaeietal, Dynamic behavior of
coke drum process safety valves during blocked outlet
condition in the refinery delayed coking unit,2012
[2] Elliott, J.D., "Optimize coker operations",
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[3] G Zahedi, A Lohi, Z Karami,A neural network

approach for identification and modeling of delayed
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Engineering ,2009
[4] Haseloff, V.& Friedman, Y.Z.&Goodhart, S.G.,
"Implementing coker advanced process control",
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[4] Chang, A.I.&Nishioka, K.&Yamakawa, T.,
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[6] Depew, C.A.&Hashemi, M.H.& Davis, J.,
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[7]Haseloff, V.& Friedman, Y.Z.&Goodhart, S.G.,
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[10] NurulHamizahBintiBaharan, ''Analysis of partial
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[11] Manual of Delayed Coking Unit at Khartoum
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