Process Control

Project Execution Using the Stage Gate Process

Conference Presentation
Southwest Process Technology Conference
Friday, October 4, 2013 - 1:00pm-3:30pm
In recent years more and more projects are being executed effectively using the “Stage Gate” process. This presentation provides an overview of the...

The Renaissance of the North American Energy Sector

Conference Presentation
Southwest Process Technology Conference
Friday, October 4, 2013 - 1:00pm-4:00pm
Until just a few years ago, the widespread view was the U.S. was a mature oil and gas province with production in general decline. However, with the...

Process Control in Ethylene Plants: A Historical Perspective

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Thursday, May 2, 2013 - 8:00am-8:30am
Process control has been the cornerstone of automation technology in ethylene plants for the past several decades. Stiff global competition combined...

LNG Technology Development at Air Products

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Wednesday, May 1, 2013 - 12:00pm-12:30pm
This presentation will trace the beginning of MCR (mixed components refrigerant) and use of Coil Wound Heat Exchanger, from helium recovery to the...

Nonlinear APC Solution for Polypropylene Plants

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Wednesday, May 1, 2013 - 8:30am-9:00am
Abstract A Nonlinear Model Predictive Control Solution has been implemented on the two Polypropylene Lines at Saudi Polyolefins Company (TASNEE)...

Non-Invasive Closed Loop Step Testing Technology for MPC Applications

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 30, 2013 - 4:00pm-4:30pm
Multivariable Predictive Control (MPC) is the most widely used advanced process control technology in the process industries. For instance, there are...

Balancing Act - Simple Techniques for Steam Header Controls

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 30, 2013 - 10:15am-10:45am
An industrial steam distribution system with multiple headers, turbines, boilers, and reducing valves is managed with header control strategies that...

Take the Guess Work Out of Testing Your Safety Instrumented System

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 30, 2013 - 10:15am-10:45am
Key Words Process Safety, IEC 61508, Programmable Electronic Systems, Architectural constrains, Periodic Automatic and Manual Testing, Safety...

Abqaiq Plant Virtual Plant RTO Implementation

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 29, 2013 - 4:00pm-4:30pm
Abqaiq Plant Virtual Plant RTO Implementation Abstract Abqaiq Plant is the largest worldwide crude stabilization plant with $200MM energy consumption...

Fundamentals of Model Based Loop Tuning

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 29, 2013 - 2:30pm-3:00pm
There are many methods to tune PID controllers. This presentation provides a tutorial on tuning PID process controllers using Internal Model Control...

A Unified PID Control Methodology to Meet Plant Objectives

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 29, 2013 - 1:30pm-2:30pm
Plant objectives for basic and advanced regulatory control can be quite diverse. PID control plays an important role in maximizing safety,...

Amine Treating: A Technology Review and Tutorial

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 3, 2012 - 12:00am
Removal of H 2 S and CO 2 from gas streams and liquid hydrocarbon streams is important in many industrial processes. Solutions of aqueous amines have...

MPC Revamp of Two Naphtha Crackers, Lessons Learned and Relearned

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 3, 2012 - 12:00am
Braskem is the 8th largest petrochemical company in the world and the biggest producer of polymers in the Americas. The Braskem Triunfo site includes...

Relief Design for Laboratories and Pilot Plants

Conference Presentation
Global Congress on Process Safety
Tuesday, April 3, 2012 - 12:00am
Relief evaluation and system design for laboratories and pilot plants presents unique challenges to the relief designer. Relief devices designed for...

APC2: Aligning People with Control

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 3, 2012 - 12:00am
Advanced Process Control (APC) can take on many flavors and levels of sophistication. On the digital control systems (DCS), advanced regulatory...

Eliminating Difficult Start Ups with State Based Controls

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 3, 2012 - 12:00am
Some processes are just difficult to start up. Every year, significant production is lost due to start up delays, product quality issues after...

Opportunities and Challenges for Advanced Biofuel Industry

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 3, 2012 - 12:00am
Biofuels have been criticized for leading to rise in food costs. Advanced biofuels steer clear of this controversy as they are produced mostly from...

Advanced Control of Multiple Sulfur Recovery Units

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 2, 2012 - 12:00am
Sulfur Recovery in a Refinery entails collecting sour vent gases (containing H2S) from a number of sources, including Hydrotreaters, Hydrocrackers,...

Dynamic Simulation of Demethanizer and Chilling Train System

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 2, 2012 - 12:00am
The chilling train system is an important part of ethylene plant which is usually combined with demethanizer and a series of flash drums to separate...

Design and Process Control Issues In Nanomanufacturing

Conference Presentation
AIChE Annual Meeting
Monday, November 17, 2008 - 7:00pm
This presentation will raise awareness of some key process issues involved in answering the following primary question: in manufacturing products...

Account for Uncertainty with Robust Control Design - Part 2

December
2014
Instrumentation
Sachi Dash, J. Ward MacArthur, Konstantinos Tsakalis, Rakesh Joshi
Robust control can be applied to design controllers that can handle process uncertainty. Learn how to use identification experiments to obtain estimates of this uncertainty.

Account for Uncertainty with Robust Control Design - Part 1

November
2014
Instrumentation
Sachi Dash, J. Ward MacArthur, Konstantinos Tsakalis, Rakesh Joshi
The dynamic behavior of your process can never be modeled perfectly. However, process controllers can be designed to handle this so-called uncertainty.

CEP: Process Automation Corner - The U.S. Process Automation Enterprise Looks to the Future

March
2014
Process Automation Corner
Terry McMahon
The outlook is bright for the process automation enterprise in the U.S. through this decade and into the next. Process automation skills and know-how are honed through challenging projects and are perfected by maintaining these systems at peak efficiency. Without constant renewal based on new and different challenges, these skills tend to atrophy and become obsolete. Fortunately, after more than a decade of decline, the U.S. process industries are entering a period of highly advantaged resource and energy availability.

CEP: Process Automation Corner - Real-Time Analytics for Pharmaceutical Quality Control

December
2013
Process Automation Corner
Terry McMahon
When the U.S. Food and Drug Administration (FDA), under the leadership of Ajaz Hussain, then the Associate Director of the FDA’s Center for Drug Evaluation and Research (CDER), launched the Process Analytical Technology (PAT) Initiative a decade ago, it set in motion a multifaceted search for a more scientifically based approach to pharmaceutical manufacturing and quality assurance. Hussain’s call for more PAT in the industry’s manufacturing operations was really more of a challenge to current practices than a proscriptive program. The pharmaceutical industry has responded with a renewed emphasis on understanding the scientific basis of its processes, and toward that end has made significant investments in personnel and tools.

CEP: Process Automation Corner - Process Simulation and Process Control

September
2013
Process Automation Corner
Terry McMahon
Chemical engineers have been practicing process simulation since the advent of the profession in the early 20th century. It was called process design and inevitably involved simplifying assumptions, including that steady-state process conditions had...

Implement an Effective Loop Tuning Strategy

January
2013
Back To Basics
Timothy Olsen, Norman Ito
Use these loop tuning guidelines to improve process control and enhance product uniformity Many undergraduate chemical engineering programs teach the Ziegler-Nichols tuning methods, developed by John G. Ziegler and Nathaniel B. Nichols in the 1940s...

Advanced Process Control: Beyond Single Loop Control

June, 2010
This book fills the gap between basic control configurations (Practical Process Control) and model predictive control (MPC). For those loops whose performance has a direct impact on plant economics or product quality, going beyond simple feedback or cascade can improve control performance, or...

Design and Control of Distillation Systems for Separating Azeotropes

March, 2010
Hands-on guidance for the design, control, and operation of azeotropic distillation systems Following this book's step-by-step guidance, readers learn to master tested and proven methods to overcome a major problem in chemical processing: the distillation and separation of azeotropes. Practical in...

Optimize Process Regulation

December
2001
Instrumentation
Phillip D. Schnelle
Laboratory feedback proportional-integral control integrates statistical process control with automatic process control to minimize process variability.

Using Automation to Produce Quality Pharmaceuticals

October
2011
Instrumentation
Joseph S. Alford, P.E.
Automation can pay large dividends in the form of reduced process cycle times, lower operational costs, and more-consistent processes for manufacturing high-quality pharmaceutical products.

The World of Wireless

February
2010
News Feature
Matthew McKeon-Slattery
As wireless technologies have advanced, old limits have been overcome and new challenges have sprung up. Further growth is likely to be driven by specific application and cost-reduction needs. <br>

Tracing Process Problems

April
2002
Instrumentation
John E. Hoots
In water chemistry control, fluorescent tracing technology can quickly and effectively determine and deal with the root cause of a problem.

Reduce Thermal Risk in Industrial Synthesis

October
2001
Safety
Richard C. Wedlich 
Knowing the safe operating conditions for a reaction allows us to select appropriate safety measures and thereby lower both the likelihood and the severity of a thermal runaway.

Choose the Right Gas Sensor

September
2009
Instrumentation
Sandra Barnes
Selecting a sensor for continuous monitoring involves many considerations. This article discusses the types of sensors available, their applicability and limitations, and how to choose an appropriate sensor to protect people and equipment.

Practical Process Control: Tuning and Troubleshooting

December, 2009
Practical Process Control (loop tuning and troubleshooting). This book differs from others on the market in several respects. First, the presentation is totally in the time domain (the word "LaPlace" is nowhere to be found). The focus of the book is actually troubleshooting, not tuning. If a...

The Chemical Industry Phoenix

June
2012
Process Automation Corner
Terry McMahon
Seven years ago, I wrote a column for another publica­ tion entitled “The U.S. Chemical Industry: R.I.P.” This pillar of American economic strength, which a few years earlier was the leading exporter among U.S. manufac­turing sectors (with net exports of $15–20 billion annually), was shriveling due in large part to policy blunders and regula­tory mistakes.

Take the Tedium Out of Writing Process Descriptions

February
2001
Instrumentation
Michael J. Gentilcore
Setting up a special function and a shorthand system on a spreadsheet can improve the descriptions needed for implementing a process control system, while minimizing the monotony in writing them.

Applying Bus Technologies in Process Control

December
2002
Instrumentation
Ed Smigo
Fieldbus technologies have become increasingly popular in process control applications. This article highlights the practical applications and economics of various buses, so that an engineer can choose the best one for his or her process.

Easily Assess Complex Safety Loops

March
2001
Instrumentation
Lawrence  Beckman
Many safety instrumented systems rely on dissimilar redundant field devices, and this can complicate required analyses. These equations will enable field personnel to handle such situations readily.

Control and Optimize Nonlinear Systems

February
2003
Instrumentation
Roberto Z. Tantalean, Andrew C. Burden, Pradeep B. Deshpande
Turbocharging a contrained model predictive controller (CMPC) with fuzzy logic allows CMPCs to be applied over nonlinear systems

Tune Control Loops for Minimum Variability

January
2002
Instrumentation
Lanny A. Robbins
The Robbins tuning rules can reduce the variability of control loop response to about 60% of that observed with Ziegler-Nichols tuning rules.

Process Control for Microreactors

August
2001
Instrumentation
Don  Humbert, Lech  Znamirowski, Sarma Vrudhula, Olgierd A. Palusinski
Field-programmable analog arrays coupled with microreactor technology promise to change the way plants are built, as well as the methods by which their processes are designed and controlled.

Matching Your Process Constraints Using Dynamic Simulation

December
2003
Information Technology
Miquel A. Alos, Jose J. Macias-Hernandez, Iban Grau
A rigorous dynamic process simulator can be used to evaluate alternative control strategies for an exothermic reacting process in order to improve its safety and product quality.

Step into the Virtual Plant

February
2002
Instrumentation
Mark S Sowell III, Gregory K McMillan, Michael M Mansy
The ability to warehouse process and control system knowledge offers a vast potential for improved operations by sharing a common source of information and avoiding data duplication.

Use Model-Predictive Control to Improve Distillation Operations

January
2008
Instrumentation
Robert J. Conroy, Daniel R. Webb, Robert D. Rounding, Umesh Mathur
This methodology, based on steady-state and dynamic simulation, can be used to develop the necessary models— and avoid disruptive and costly step testing to the extent feasible.
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