MEMO 3 – PLANTWIDE CONTROL PHILOSOPHY

Plantwide Control Philosophy

The plant-wide control philosophy was constructed based on the top-down approach (Luyben, 1997). The ultimate control
objective is to comply to the production specification and capacity desired, which is a film-grade LDPE with a purity
99.96% at a rate of 150,000 tonnes/annum. Furthermore, in determining the controller type or system design that should be
applied, the guidelines by Seborg et. Al (2011) is referred to. Other small objectives and constraints are specified in Table
X.1, Table X.2, and Table X.3. The safeguard procedures in Table Y.1, Table Y.2, and Table Y.3 consists of three levels
of control. The levels 2 and 3 act as a backup control system respectively in excessive pressure build up and emergency
cases. Finally, a Process & Instrumentation Diagram is constructed as displayed in Appendix X.

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Table X.1 : Top-down approach (Fermentation Unit) Table X.3 : Top-down approach (Polymerization Unit) > AIC, FT absorber
LE > LT > To avoid exceeding liquid
MS-101
Controlled Manipulated Controlled Manipulated LICA level in molecular sieve
Valve Controller Type Valve Controller Type EAB-102
Variable (CV) Variable (MV) Variable (CV) Variable (MV)
CM-101 outlet gas Stream 4 V-1 Feedback T-201 liquid level Stream 51 V-31 Feedback D-101
Stream 11 C-202 outlet D-101 Reflux
Stream 10 V-2 Feedback Stream 52 pressure - Feedback Drum
composition pressure
Stream 13 Stream 53 & 57 C-203 outlet D-101 Reboil
Stream 12 V-3 Feedback - Feedback D-101
composition pressure pressure
EAB-102 pressure Purge V-4 Feedback Stream 53 & 57 V-32 & Feedback & Bottoms To relief pressure build-up
Stream 53 & 57 Product in case of pressure of
EAB-102 liquid flowrate V-33 Ratio Level 2 PSV
Stream 15 V-5 Feedback RE-101 pressure control system
level Stream 54 E-203 utility
V-34 Feedback RE-101 failure
Stream 15 temperature flowrate
Stream 14 V-6 Feedback Reflux Drum Table Y.3 : Safeguard Procedure (Polymerization Unit)
composition Stream 58 E-204 utility
V-35 Feedback RE-101
D-101 liquid level Stream 16 V-7 Feedback temperature flowrate
Reboil
D-101 Reboiler R-201 reactor Cooling jacket utility Safeguard Equipment Safeguard Objective/explanation
D-101 temperature V-8 Feedback V-36 Feedback RE-101
utility stream temperature flowrate Level Instrument
Bottoms
D-101 Reflux Drum D-101 Condenser Peroxide injection Product LE > LT > To maintain adequate
V-9 Feedback V-37 & Feedback & T-201
pressure utility stream (stream 55 & 59) Stream 55 & 59 LICA liquid level in tank
V-38 Feedback EAB-102
D-101 Reflux Drum flowrate Activated upon emergency To maintain set pressure
Stream 19 V-10 Feedback Level 3 D-101 SIS, BDV PT > PIC >
liquid level Stream 64 E-205 utility shutdown C-202 outlet of the primary
V-39 Feedback RE-101 M
D-101 Liquid D-101 Liquid Reflux temperature flowrate compressor
V-11 Ratio
Reflux flowrate stream V-203 pressure Stream 65 V-40 Feedback To maintain set pressure
PT > PIC >
RE-101 liquid level Stream 21 V-12 Cascade V-203 liquid level Stream 67 V-41 Feedback C-203 outlet of the secondary
Table Y.2 : Safeguard Procedure (Dehydration Unit) M
RE-101 Reboiler V-204 pressure Stream 68 V-42 Feedback compressor
RE-101 temperature V-13 Feedback To maintain set
utility stream V-204 liquid level Stream 70 V-43 Feedback E-203 TT > TICA
RE-101 Reflux RE-101 Condenser Stream 66 E-206 utility Safeguard Equipment Safeguard Objective/explanation temperature
V-14 Feedback V-44 Feedback Level Instrument To maintain set
Drum pressure utility stream temperature flowrate
LE > LT > To maintain adequate E-204 TT > TICA
RE-101 Reflux Stream 69 E-207 utility T-101 temperature
Stream 20 V-15 Feedback V-45 Feedback LICA liquid level in tank Level 1 To maintain reactor (highly
Drum liquid level temperature flowrate R-203 TT > TICA
RE-101 Liquid RE-101 Liquid PT > PIC > To maintain set pressure exothermic) temperature
V-16 Ratio P-201
Reflux flowrate Reflux stream M outlet of the pump To maintain set
To maintain optimum E-205 TT > TICA
MS-101 liquid level Stream 23 V-17 Feedback temperature
FH-201 FT > FIC intake of air and natural LE > LT > To maintain liquid level
gas into fired heater V-203 LICA and pressure in HP
To maintain optimum heat PT > PICA separator
Table X.2 : Top-down approach (Dehydration Unit) HX-201 TT > TIC
exchange rate LE > LT > To maintain liquid level
Table Y.1 : Safeguard Procedure (Fermentation Unit) To maintain optimum heat V-204 LICA and pressure in LP
Controlled Manipulated E-201 TT > TIC
Valve Controller Type exchange rate PT > PICA separator
Variable (CV) Variable (MV) Safeguard Safeguard PT > PIC > To maintain set pressure
Equipment Objective/explanation C-201 To maintain HP recycle
T-101 liquid level Stream 24 V-18 Feedback Level Instrument M outlet of the compressor E-206 TT > TICA
temperature
Stream 25 pressure P-201 outlet pressure - Feedback To maintain optimum To maintain optimum heat To maintain LP recycle
Stream 28 E-204 TT > TIC E-207 TT > TICA
Stream 26 V-19 Feedback CM-101 FT > FIC water intake into exchange rate temperature
temperature combustor To maintain optimum heat T-201 To relief pressure build-up
Stream 32 HX-202 TT > TIC
Stream 30 V-20 Feedback To maintain optimum Level 1 exchange rate R-203 in case of pressure of
temperature CE-101 FT > FIC Level 2 PSV
sulfuric acid into clarifier To maintain adequate V-203 pressure control system
Stream 27 E-201 utility PT > PIC
V-21 Feedback To maintain optimum yeast pressure of separator V-204 failure
temperature flowrate F-101 FT > FIC
intake into fermenter V-201 To maintain adequate T-201
K-201 outlet LE > LT >
Stream 34 pressure - Feedback To maintain absorber liquid level in separator R-203 Activated upon emergency
pressure PT > PIC LICA Level 3 SIS, BDV
pressure tank V-203 shutdown
Stream 36 E-204 utility LE > LT > To maintain absorber To maintain optimum heat V-204
V-22 Feedback EAB-102 HX-203 TT > TIC
temperature flowrate LICA liquid level exchange rate
Stream 39 To maintain optimum To maintain adequate
Stream 37 V-23 Feedback FT > FIC PT > PIC
temperature water intake into absorber pressure of separator
V-201 pressure Stream 40 V-24 Feedback To boilup/bottoms product V-202 To maintain adequate
V-201 liquid level Stream 44 V-25 Feedback FT > FIC LE > LT >
flowrate of absorber liquid level in separator
Stream 43 LICA
Stream 41 V-26 Feedback To maintain absorber tank
temperature Level 1 TT > TIC
temperature To maintain optimum
V-202 pressure Stream 47 V-27 Feedback FT > FIC
To maintain reflux drum water intake into absorber
V-202 liquid level Stream 45 V-28 Feedback D-101 PT > PIC AB-201
pressure To maintain absorber
PT > PIC
Stream 48 flowrate Stream 48 V-29 Feedback FT > FIC, LE To maintain distillate pressure
AB-201 pressure Stream 50 V-30 Feedback > LT > LICA flowrate from reflux drum T-101
FT > FIC, AT To reflux flowrate into R-201 To relief pressure build-up
> AIC, FT absorber R-202 in case of pressure of
Level 2 PSV
FT > FIC, LE To boilup/bottoms product V-201 pressure control system
> LT > LICA flowrate of absorber V-202 failure
To maintain absorber AB-201
TT > TIC T-101
temperature
RE-101 To maintain reflux drum R-201
PT > PIC R-202 Activated upon emergency
pressure Level 3 SIS, BDV
FT > FIC, LE To maintain distillate V-201 shutdown
> LT > LICA flowrate from reflux drum V-202
FT > FIC, AT To reflux flowrate into AB-201

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Page 3 of 5
Appendix X: Process & Instrumentation Diagram

Drawn By: Darvin Manimaran, Rafael Damar Arjanggi and Heshveena Sivalingam Title: P&ID (Green Polyethylene Production)
Checked By: xxxxxx Sheet No: 1/1 Filename: P&ID-01 Location: Chon Buri, Thailand
Drawing: Revised - 05
Consultant: IndoMalaya Engineering

Client: Curtin Malaysia Sdn. Bhd.

Date: 26th August 2018

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References
Luyben, William L, Björn D Tyréus, and Michael L Luyben. (1999). Plantwide Process Control. New York: McGraw-Hill

Seborg, Dale E., Thomas F. Edgar, Duncan A. Mellichamp, and Francis J. Doyle III. (2011). Process Dynamics and Control. United States
of America: John Wiley & Sons, Inc.

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