PLANT

WIDE
CONTROL
Totok Ruki Biyanto, Ph.D
PLANTWIDE CONTROL
The plantwide control theory is about choosing
which variables to measure, which variables to
manipulate, which variables to control, and which
links to make between them. Two different ways
to approach this is available, that is a
mathematically oriented approach (control
structure design) and a process oriented
approach.
SKOGESTAD’S PLANTWIDE
CONTROL PROCEDURE

• This method includes

starting with the economic
objective of the plant and
to design a control scheme
that implements the optimal
operation.
• Skogestad’s method consists
of two parts, a top-down
analysis and a bottom-up
design

Control Hierarchy
 PLANT WIDE CONTROL METHODS
Skogestad Method Luyben Method Proposed Method

Top-Down 1. Objective Function 1. Objective Function

(luyben - exclude
1. Objective Function 2. Identify Degrees of economy)
Freedom
2. Identify Degrees of 2. Identify Degrees of
Freedom and 3. Energy Freedom
Important Management
Disturbances System 3. TPM - Where to Set the
Production Rate
3. Primary Controlled 4. TPM - Where to Set (Inventory Control)
Variables the Production Rate
(Inventory Control) 4. Economical Controlled
4. TPM - Where to Set Variable = Primary –
the Production Rate 5. Quality Control Skogestad = Quality -
(Inventory Control) Luyben
6. Inventory Control
Bottom Up 5. Process Integration and
7. Check Component
1. Regulatory Control Balance Control = Regulatory –
Layer (Secondary Skogestad = Inventory -
8. Control Individual Luyben
Controlled Variables)
Unit Operation
2. Supervisory Control 6. Supervisory Control
Layer 9. Optimization Layer Layer = Control
individual - Luyben
3. Optimization Layer
7. Optimization Layer
PLANTWIDE CONTROL
INTRO COURSE: CONTENTS
Overview of plantwide control (W1)
Plant Model (W2)
Selection of primary controlled variables based on economic : The link
between the optimization (RTO) and the control (MPC; PID) layers
- Degrees of freedom (W3)
- Optimization (W4)
- Self-optimizing control (W5)
- Applications (W5, W6)
- Many examples (W5, W6)
Where to set the production rate and bottleneck (W7)
Design of supervisory control layer
- Decentralized versus centralized (MPC) (W9)
- Design of decentralized controllers: Sequential and independent design (W10)
- Pairing and RGA-analysis (W11)
Case studies (W12-W15)

Book :
Luyben “Plantwide Control Process”
Skogestad “Economic Plantwide Control : Automated controlled variable selection for a
reactor-separator-recycle process”
Gade Pandu “Plantwide Control Recent Developments and Applications”
MEASUREMENT
v2

(BERNOULLI)
v1
P1 P2

h2

h1

Kesetimbangan Energi
𝐸𝑝 = 𝑚. 𝑔. ℎ
1
𝐸𝑘 = . 𝑚. 𝑣 2
2
𝑚.𝑔.ℎ 𝐸𝑝
𝑃 = 𝜌. 𝑔. ℎ = = 𝑉
𝑉
1 2 = 𝑚.𝑔.ℎ= 𝐸𝑝
𝑃= 𝜌𝑣1
2 𝑉 𝑉
Persamaan Bernoulli
1 1
𝑃1 + 𝜌1 . 𝑔. ℎ1 + 𝜌1 𝑣1 2 = 𝑃2 + 𝜌2 . 𝑔. ℎ2 + 𝜌2 𝑣2 2
2 2
MEASUREMENT
v2

(BERNOULLI)
v1
P1 P2

h2

h1

1 1
𝑃1 + 𝜌𝑣1 = 𝑃2 + 𝜌𝑣2 2
2
2 2
1
𝜌 𝑣1 2 − 𝑣2 2 = 𝑃2 − 𝑃1
2

2(𝑃2 − 𝑃1 )
𝑉=
𝜌

2(𝑃2 − 𝑃1 ) Book : Tony R. Kuphaldt

𝑉=𝐶
𝜌 Lesson in Industrial Instrument
MEASUREMENT
Persamaan Kontinuitas 𝐴1 𝑣1 = 𝐴2 𝑣2

Persamaan Tekanan Hidrostatis 𝑃1 − 𝑃2 = 𝜌ℎ𝑔

1
Persamaan Bernouli pada pipa datar 𝑃1 − 𝑃2 = 𝜌 𝑣2 2 − 𝑣1 2
2
1
𝜌𝑔ℎ = 𝜌 𝑣2 2 − 𝑣1 2
2

𝐴1 𝑣1 2 2
2𝑔ℎ = ( ) −𝑣1
𝐴2

𝐴
2𝑔ℎ = (( 1)2 −1)𝑣1 2
𝐴2

2𝑔ℎ
𝑣1 =
𝐴
( 1 )2 −1
𝐴2
S-CURVE DAN FOPDT

∆𝑃𝑉
𝐾=
∆𝑀𝑉

𝑌 𝜃 + 𝜏 = 0.632∆
𝑌 𝜃 + 𝜏/3 = 0.283∆
𝜏
𝑡28% = 𝜃 +
3
𝜏 = 1.5(𝑡63% − 𝑡28% )

𝜃 = 𝑡63% − 𝜏
TUNING PID

1 𝑑𝑒
𝑂𝑢𝑡𝑝𝑢𝑡 = 𝐾𝑝(𝑒 + න 𝑒 𝑑𝑡 + 𝜏𝑑 )
𝜏𝑖 𝑑𝑡

𝑑𝑒
𝑂𝑢𝑡𝑝𝑢𝑡 = 𝐾𝑝𝑒 + 𝐾𝑖 න 𝑒 𝑑𝑡 + 𝐾𝑑
𝑑𝑡
 TYPICAL INSTRUMENTATION
LOOP

On/Off  PLC

Ball,Valve, Buterfly Valve

, etc
Switch
 TYPICAL INSTRUMENTATION
LOOP
Contimous  PID, Fuzzy
Logic, ANN, GA, Etc.

Globe valve, needle Valve,

Sensor and Cage Valve, Etc
transmitter
STEAM DRUM LEVEL CONTROL
ANALYTICAL CONTROL
TEMPERATURE CONTROL
TANK
PFD
P&ID
CONTOH
APLIKASI PWC

PADA PLANT
DISTILLATION COLOUMN
DISTILLATION COLOUMN
LIQUEFIED PETROLEUM GAS
FACILITY(LPGF)
WHRPG
𝐶𝑂2 CAPTURE
𝐻2 𝑆 REMOVAL UNIT
135-H-05
Condenser 3519
3517 3517

135-V-09
KO Drum
3514
3518
135-V-07
135-H-02
Amine
Amine
RegeneratorP-65
Exchanger P-53 135-V-11
3510 3506 Reflux Drum
4519
3501 3514

3511
3612
3514 4520

135-P-04 135-H-03
Reboiler

135-V-06 135-V-10
Amine Flash Drum
Contactor 135-V-02
Surge Vessel

3510
135-P-01
 TEG DEHYDRATION UNIT
3601
3612

3604
4325
136-V-23 136-H-06
KO Drum 136-H-08 E-41 Vent Exchanger
3611
Hot TEG 3615
Exchanger 4523

3602
136-V-16
Flash Drum

E-40
3609
3616 4524
136-H-10
3614 TEG Reboiler
3803
136-V-04 4111
TEG Contactor 136-H-21
136-H-07 Cold TEG
Cooler Exchanger
3617
3606 136-V-22
Stripping Gas
Column
136-V-18
3619
Accumulator
Vessel

3618

136-P-10
COOLED REACTOR
ETHYENE GLYCOL PLANT
HDA PROCESS
TENNESSEE EASTMAN PROCESS
THANK YOU

ANY QUESTIONS?