PROCESS PLANT OPERATIONS AND CONTROL

International Teaching PROCESS PLANT OPERATIONS AND CONTROL

0623000005
DIPARTIMENTO DI INGEGNERIA INDUSTRIALE
EQF7
SMART INDUSTRY ENGINEERING
2021/2022

OBBLIGATORIO
YEAR OF COURSE 1
YEAR OF DIDACTIC SYSTEM 2021
SECONDO SEMESTRE
CFUHOURSACTIVITY
1PROCESS PLANT OPERATIONS AND CONTROL - MOD 1
770LESSONS
2PROCESS PLANT OPERATIONS AND CONTROL - MOD 2
220LESSONS
Objectives
KNOWLEDGE AND UNDERSTANDING
FUNDAMENTALS, STRUCTURE AND SECTIONS OF A PROCESS PLANT.
CONCEPTS OF MACROSCOPIC MATERIAL AND ENERGY BALANCES, APPLICATION TO PROCESS PLANT OPERATIONS.
PROCESS VARIABLES MEASURED BY INSTRUMENTATION IN A PROCESS PLANT.
TECHNO-ECONOMIC PERFORMANCE OF A PROCESS PLANT: YIELD TO PRODUCT, ENERGY EFFICIENCY, OPERATING COST, PROFIT.
PROCESS SIMULATION HYBRID METHODS FOR THE CREATION OF A DIGITAL TWIN OF A PROCESS PLANT.
ADVANCED METHODS OF AUTOMATIC DIGITAL PROCESS CONTROL, FIRST PRINCIPLES AND/OR DATA-DRIVEN MODEL-BASED CONTROL.

APPLYING KNOWLEDGE AND UNDERSTANDING – ENGINEERING ANALYSIS
ABILITY TO ANALYSE SIMPLE PROCESS FLOWSHEETS AND TO DETERMINE MAIN MATERIAL STREAMS AND HEAT DUTIES.
ABILITY TO ANALYSE STEADY STATE AND DYNAMIC OPERATING CONDITIONS OF A PROCESS PLANT.
ABILITY TO ANALYSE PROCESS VARIABLE DATA, ERROR DETECTION AND DATA RECONCILIATION.
ABILITY TO RECOGNISE THE KEY PROCESS VARIABLES TO CONTROL FOR THE OPTIMISATION OF PROCESS, ECONOMIC AND ENVIRONMENTAL OBJECTIVE FUNCTIONS.

APPLYING KNOWLEDGE AND UNDERSTANDING – ENGINEERING DESIGN
ABILITY TO ESTIMATE MAIN MATERIAL STREAMS AND HEAT DUTIES IN A PROCESS PLANT
ABILITY TO MODIFY PROCESS VARIABLES TO ACHIEVE THE ECONOMIC OPTIMISATION OF THE PROCESS.
ABILITY TO SELECT THE PROCESS CONTROL STRATEGY AND TECHNIQUE.
ABILITY TO CHOOSE THE MODELLING APPROACH TO DEVELOP THE DIGITAL TWIN OF A PROCESS PLANT AND OF A CONTROL SYSTEM.

MAKING JUDGMENTS - ENGINEERING PRACTICE
ABILITY TO CHOOSE THE OPERATING CONDITIONS OF A PROCESS PLANT AND TO OPTIMISE THE PROCESS CONTROL FOR THE MAXIMUM ECONOMIC PROFIT.

TRANSVERSAL SKILLS -COMMUNICATION SKILLS
ABILITY TO COMMUNICATE IN TECHNICAL LANGUAGE ON TOPICS RELEVANT TO PROCESS PLANT OPERATIONS AND CONTROL IN INTERDISCIPLINARY INDUSTRIAL ENVIRONMENT. ABILITY TO READ AND UNDERSTAND TECHNICAL DOCUMENTS ON PROCESS PLANT.

LEARNING SKILLS – TRANSVERSAL SKILLS
ABILITY TO APPLY THE LEARNED CONTENTS TO CONTEXTS OTHER THAN THOSE PRESENTED IN THE COURSE. ABILITY TO EXPAND THE KNOWLEDGE ON THE TOPICS BY MEANS OF ADDITIONAL LEARNING MATERIALS.

INVESTIGATION SKILLS – TRANSVERSAL SKILLS
ABILITY TO DERIVE INFORMATION AND DATA FOR THE OPERATIONS AND CONTROL OF PROCESS PLANT FROM TECHNO-SCIENTIFIC DOCUMENTS AND FROM SIMULATION AND CONTROL SOFTWARE.
Prerequisites
FOR THE SUCCESSFUL ACHIEVEMENT OF THE PREFIXED OBJECTIVES, MATHEMATICAL KNOWLEDGE IS REQUIRED ON LINEAR AND NON-LINEAR ORDINARY DIFFERENTIAL EQUATIONS, THE LAPLACE TRANSFORM OF LINEAR DYNAMICAL SYSTEMS, THE CONCEPT OF FEEDBACK CONTROL, PRINCIPLES OF OPTIMIZATION AND LINEAR PROGRAMMING.
Contents
INTRODUCTION TO PROCESS PLANT: PROCESS CLASSIFICATION, PLANT HIERARCHICAL STRUCTURE AND PROCESS SECTIONS, PROCESS STREAMS AND UTILITIES, PROCESS VARIABLES, PROCESS UNITS (TH. 5H)

MASS AND ENERGY BALANCES: MASS BALANCES ON OPEN SYSTEMS AT STEADY STATE AND UNDER TRANSIENT CONDITIONS, RECAP OF THE FIRST PRINCIPLE OF THERMODYNAMICS, ENERGY BALANCES, BALANCES ON PROCESSES WITH CHEMICAL REACTIONS (TH. 8H, EX. 5H)

INTRODUCTION TO UNIT OPERATIONS OF CHEMICAL ENGINEERING: MIXING, SEPARATION, REACTION, HEAT TRANSFER, DESIGN AND OPERATING VARIABLES, DEGREES OF FREEDOM, DESIGN AND RATING EQUATIONS, PRODUCT YIELD AND RECOVERY, ENERGY EFFICIENCY. (TH. 6H, EX. 3H)

TECHNICAL DOCUMENTATION OF PROCESS PLANT: BLOCK DIAGRAMS, PROCESS FLOW DIAGRAMS (PFD), PIPING AND INSTRUMENTATION DIAGRAMS (P&ID), SYMBOLS AND CONVENTIONS, CLASSIFICATION OF PIPING AND INSTRUMENTATION, PLANT UNIT AND INSTRUMENTATION DATA SHEETS, MAIN OPERATING CONDITIONS, MEASUREMENT LOGICS, CONTROL AND INTERLOCK SYSTEM. (TH. 8H, EX. 4H)

ECONOMIC ANALYSIS OF PROCESS PLANT: RECAP OF ECONOMIC ANALYSIS PRINCIPLES, CAPITAL COST AND OPERATING COST, PROFITABILITY INDICATORS, ECONOMIC OPTIMISATION (TH. 6 H, EX. 2H)

PROCESS SIMULATION AND OPTIMISATION TECHNIQUES: DIGITAL-TWIN OF A PROCESS PLANT, SIMULATION BASED ON FIRST PRINCIPLES, SEQUENTIAL-MODULAR APPROACH AND EQUATION-ORIENTED APPROACH, MASS AND ENERGY BALANCES SOLUTION, DESIGN AND RATING OF PROCESS UNITS, SENSITIVITY ANALYSIS AND OPTIMISATION METHODS, DATA-DRIVEN SIMULATION, SIMULATION HYBRID METHODS (TH. 5H, LAB. 9H).

PROCESS DATA RECONCILIATION: CLASSIFICATION OF THE MEASURED PROCESS VARIABLES, DETECTION, IDENTIFICATION AND ESTIMATE OF GROSS ERRORS, ESTIMATE OF NON-MEASURED OR UNMEASURABLE PROCESS VARIABLES, DATA RECONCILIATION TECHNIQUES (TH. 6H, ES. 3H)

RECALLS ON MATLAB®¸ INTRODUCTION TO ITS CONTROL TOOLBOX AND SISOTOOL® DESKTOP (TH. 0H, EX./LAB. 3H).

RECAP OF REPRESENTATION OF DYNAMICAL SYSTEMS IN THE DISCRETE TIME DOMAIN. THE FEEDBACK LOOP WITH DISCRETE REGULATORS (PID, FUZZY CONTROLLER) (TH. 4H, EX./LAB. 1H).

PRINCIPLES OF ADVANCED PROCESS CONTROL TECHNIQUES (TH. 2H, EX./LAB. 0H).

THE MODEL PREDICTIVE CONTROL (MPC) IDEA AND IMPLEMENTATION. EXAMPLES APPLIED TO PROCESS INDUSTRY (TH. 7H, EX./LAB. 3H).

(TH.: THEORY; EX./LAB.: EXERCISE/ LABORATORY PRACTICE)
Teaching Methods
LECTURES ARE IN ENGLISH AND LECTURE SLIDES ARE ALL IN ENGLISH.
ATTENDANCE AT THE LECTURES IS STRONGLY RECOMMENDED.
TEACHING INVOLVES THEORETICAL LECTURES CONDUCTED BY THE LECTURER WITH EXTENSIVE USE OF COMPUTERIZED SLIDES AND ANIMATIONS, EXERCISES CARRIED OUT BY THE LECTURER ON THE BLACKBOARD AND COMPUTER LAB CLASSES CONDUCTED BY THE LECTURER INTERACTIVELY WITH THE STUDENTS, USING APPROPRIATE LEARNING SOFTWARE. EACH STUDENT IS ASSIGNED A USERNAME AND A PASSWORD, ALLOWING ACCESS IN THE COMPUTER CLASSROOM TO NETWORKED PCS PROVIDED WITH MATLAB® LICENSE AND ITS TOOLBOXES. EACH STUDENT CAN INSTALL AND USE THE LICENSE OF THE UPDATED VERSION OF MATLAB® OF THE UNIVERSITY, BY DOWNLOADING IT FROM HTTPS://WEB.UNISA.IT/SERVIZI-ON-LINE/MATLAB-X-UNISA.
Verification of learning
THE ASSESSMENT OF THE ACHIEVEMENT OF THE LEARNING OUTCOMES WILL BE CARRIED OUT IN AN ORAL EXAMINATION WITH A VARIABLE DURATION BETWEEN 30 AND 45 MINUTES. GENERALLY, THE EXAMINATION WILL INCLUDE TWO QUESTIONS ON TECHNICAL AND ECONOMIC ISSUES OF PROCESS PLANT OPERATIONS AND ONE QUESTION ON PROCESS CONTROL. THE LATTER MAY ALSO INVOLVE A SHORT HANDS-ON SESSION BY MEANS OF MATLAB ON DISCRETE OR ADVANCED PROCESS CONTROL.

TO PASS THE EXAM THE STUDENT MUST DEMONSTRATE THE ABILITY TO UNDERSTAND AND KNOW HOW TO APPLY THE MAIN CONCEPTS AND METHODOLOGICAL TOOLS ELUCIDATED IN THE COURSE. THE FINAL MARK, OUT OF THIRTY (THE MAXIMUM IS THIRTY CUM LAUDE), DEPENDS ON THE MASTERING ABILITY OF THE COURSE CONTENTS OBJECT OF THE EXAM, TAKING INTO ACCOUNT THE QUALITY OF THE ORAL REPORTING AND THE JUDGMENT ABILITY DEMONSTRATED. IN PARTICULAR, THE KNOWLEDGE OF THE METHODS FOR SOLVING MASS AND ENERGY BALANCES IN PROCESS PLANTS AND OF THE BASIC PRINCIPLES OF ADVANCED CONTROL DISCUSSED IN THE COURSE IS A NECESSARY CONDITION TO PASS THE EXAM. THE STUDENT ACHIEVES THE EXCELLENCE WHEN HE/SHE IS ABLE TO USE THE KEY CONTENTS IN AUTONOMY TO FIND OPTIMAL OPERATING CONDITIONS OF THE PROCESS PLANT AND THE RELEVANT CONTROL STRUCTURE ALSO IN CASE STUDIES WITH SIGNIFICANT DIFFERENT FEATURES WITH RESPECT TO THOSE COVERED IN THE COURSE.
Texts
SLIDES, BOOK EXCERPTS AND TEACHING AIDS PROVIDED BY THE LECTURERS.

CONSULTATION TEXTBOOKS
BEQUETTE B.W., PROCESS CONTROL: MODELING, DESIGN AND SIMULATION, PRENTICE HALL, 2003.
FELDER R.M., ROUSSEAU, R.W. BULLARD L.G., ELEMENTARY PRINCIPLES OF CHEMICAL PROCESSES, 4TH GLOBAL EDITION, WILEY, 2016.
HIPPLE J., CHEMICAL ENGINEERING FOR NON-CHEMICAL ENGINEERS, WILEY, 2017.
MAGNANI G., FERRETT P., ROCCO P., TECNOLOGIE DEI SISTEMI DI CONTROLLO, 2 ED., MCGRAW-HILL LIBRI ITALIA, 2003.
ROMAGNOLI J.A., PALAZOGLU A., INTRODUCTION TO PROCESS CONTROL, 3RD EDITION, CRC PRESS, 2020.
TOGHRAEI M., PIPING AND INSTRUMENTATION DIAGRAM DEVELOPMENT, WILEY, 2019.
More Information
ALL COURSE SLIDES, ADDITIONAL NOTES AND EXAMPLES OF EXAM QUESTIONS ARE MADE AVAILABLE BY THE LECTURERS ON THE MICROSOFT TEAMS® PLATFORM OF THE UNIVERSITY OF SALERNO.

LECTURE TIMETABLES ARE AVAILABLE AT HTTPS://EASYCOURSE.UNISA.IT/
  BETA VERSION Data source ESSE3