Troubleshooting Process Plant Control
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Troubleshooting Process Plant Control: A Practical Guide to Avoiding and Correcting Mistakes

Troubleshooting Process Plant Control: A Practical Guide to Avoiding and Correcting Mistakes


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About the Book

A practical and engaging guide to running process controls in petrochemical plants and refineries Process control is an area of study dealing with controlling variables that emerge in process plants, such as chemical plants, wastewater purification plants, or refineries. Existing guides to process control are numerous, but they tend to be associated with control engineering, which is more mathematical and theoretical. There is an urgent need for a more straightforward and concrete guide for practical use in petrochemical plants and refineries. Troubleshooting Process Plant Control meets this need with a work dedicated to real-life solutions and problem solving. Rooted in real-world examples and the career experience of the author, it largely avoids complex mathematics in favor of practical, well-established process engineering principles. Now fully updated to reflect the latest best practices and developments in the field, it is indispensable for process controllers in active plants of all kinds. Readers of the third edition will also find: New chapters on alarm disabling, spectrometer use, and reducing CO2 emissions Additional novel examples throughout Guidelines for using spectrometers to directly control reflux rates and steam flow to reboilers Troubleshooting Process Plant Control is ideal for practicing engineers and other technical professionals working in process facilities, as well as advanced students taking professional training courses in these fields.

Table of Contents:
ABOUT THE AUTHOR ix PREFACE TO THE THIRD EDITION xi INTRODUCTION xiii Chapter 1 Learning from Experience 1 Chapter 2 Process Control Parameter Measurement 11 Chapter 3 Dependent and Independent Variables 25 Chapter 4 Binary Distillation of Pure Components 33 Chapter 5 Distillation Tower Pressure Control 41 Chapter 6 Control of Aqueous Phase (Waste Water) Strippers 53 Chapter 7 Pressure Control in Multicomponent Systems 59 Chapter 8 Optimizing Fractionation Efficiency by Temperature Profile 67 Chapter 9 Analyzer Process Control 75 Chapter 10 Fired Heater Combustion Air Control 85 Chapter 11 Using Existing Controls to Promote Energy Efficiency 97 Chapter 12 Sizing Process Control Valves 105 Chapter 13 Control Valve Position on Instrument Air Failure 113 Chapter 14 Override and Split-Range Process Control 123 Chapter 15 Vacuum System Pressure Control 129 Chapter 16 Reciprocating Compressors 141 Chapter 17 Centrifugal Compressor Surge versus Motor Over-Amping 149 Chapter 18 Controlling Centrifugal Pumps 157 Chapter 19 Steam Turbine Control 165 Chapter 20 Steam and Condensate Control 177 Chapter 21 Control of Process Reactions 189 Chapter 22 Function of the Process Control Engineer 203 Chapter 23 Steam Quality and Moisture Content 213 Chapter 24 Level, Pressure, Flow, and Temperature Indication Methods 229 Chapter 25 Alarm and Trip Design for Safe Plant Operations 245 Chapter 26 Inverted Response of Process Parameters 255 Chapter 27 Nonlinear Process Responses 263 Chapter 28 Control Malfunction Stories 271 Chapter 29 Level Indication Problems in Vessels 279 Chapter 30 Calibration Specific Gravity for Level Control 285 Chapter 31 Flow Orifice Plate Cavitation 289 Chapter 32 Factors Causing Incorrect Process Parameter Measurements 293 Chapter 33 Optimizing Controls to Reduce Emissions from Sulfur Recovery Plants and Sour Water Strippers 299 Chapter 34 Positive Pressure in Fired Heaters—Effect of Wind 305 Chapter 35 A Lesson From Bhopal&mdashHazards of Ignoring Alarms 309 ABOUT MY SEMINARS 313 FURTHER READINGS ON TROUBLESHOOTING PROCESS CONTROLS 317 THE NORM LIEBERMAN VIDEO LIBRARY OF TROUBLESHOOTING PROCESS OPERATIONS 319 PROCESS CONTROL NOMENCLATURE USED IN PETROLEUM REFINERIES AND PETROCHEMICAL PLANTS 321 INDEX 327

About the Author :
Norman P. Lieberman is a practicing chemical engineer with 59 1/2 years of design, operation, and troubleshooting experience for refineries and petrochemical plants. He is well-known in the process industry for instructing technical process seminars, primarily for refineries and petrochemical plants.


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Product Details
  • ISBN-13: 9781394262939
  • Publisher: John Wiley & Sons Inc
  • Publisher Imprint: John Wiley & Sons Inc
  • Language: English
  • Returnable: N
  • Returnable: N
  • Weight: 771 gr
  • ISBN-10: 1394262930
  • Publisher Date: 15 Aug 2024
  • Binding: Hardback
  • No of Pages: 368
  • Returnable: N
  • Sub Title: A Practical Guide to Avoiding and Correcting Mistakes


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Troubleshooting Process Plant Control: A Practical Guide to Avoiding and Correcting Mistakes
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