🏆 DCS & SIS Integration | APC/MPC | Batch ISA-88 | SIL 3 | ATEX

ARG Smart Petrochemical

Integrated Process Control & Safety Systems - 1,000 KTA Olefin Complex

1M+
I/O Points
SIL 3
Safety Level
ISA-88
Batch Control
<100ms
DCS Scan
99.9%
Availability
850°C
COT
-165°C
Cold Box
45+
Control Systems
🔄 فرآیند

زنجیره فرآیند پتروشیمی

🛢️
خوراک
Naphtha/Gas
→
🔥
کراکر
850°C
→
❄️
کوئنچ
Quench
→
🗼
تقطیر
Fractionation
→
⚗️
تفکیک
C2/C3/C4
→
🧪
پلیمر
Polymerization
→
📦
گرانول
Pelletizing
→
🚛
انبار
Storage
📐 Live Process Flow Diagram - 1,000 KTA Olefin Complex
✓ All Systems Online Normal Operation 145 t/h C2H4
FEED Naphtha/Ethane 450 t/h Preheat 550°C STEAM CRACKER 8 Furnaces F-101 F-102 F-103 F-104 COT: 845°C S/HC: 0.45 Yield: 32.5% TLE Quench 350°C Quench Tower 40°C CGC 5-Stage Compressor 1 2 3 4 5 32.5 bar COLD BOX Cryogenic Sep Demethanizer -100°C Deethanizer -20°C C2 Splitter 99.95% -162°C C2H4 Ethylene 145 t/h C3H6 Propylene 85 t/h PE REACTOR Polyethylene Loop/Gas 42 t/h PP REACTOR Polypropylene Spheripol 38 t/h EXTRUDER Pelletizing Twin Screw Underwater 80 t/h STORAGE PE Silo PP Silo Bagging Refrigeration C2/C3 Cascade C3 C2 UTILITIES Steam CW Power HP/MP/LP 30K m³/h 150 MW Flare
845
°C COT
32.5
bar CGC
-162
°C Cold Box
145
t/h C2H4
85
t/h C3H6
42
t/h PE
38
t/h PP
32.5%
Yield
⚙️ Equipment Control

سیستم‌های کنترل تجهیزات

کنترل موتور، ولو، پمپ و کمپرسور

⚡
Motor Control
کنترل موتور
📐 Start Sequence
1. Check Permissives (all OK)
2. Pre-lube timer (if required)
3. Start command to MCC
4. Monitor run feedback
5. Running confirmation
🎯 I/O Signals
DI
Running FB
DI
Fault/Trip
DO
Start Cmd
AI
Current (A)
⚠️ Protection
Overload (49) | Overcurrent (50/51)
Ground Fault (51G) | Thermal (26)
⏱️ Timers
Start timeout: 10-30s
Anti-jog delay: 15-30 min
🔄
VFD Control
درایو فرکانس متغیر
📐 Speed Control
Speed_SP = PID_OUT × (Max - Min) + Min
Ramp Up/Down rate configurable
Torque limit protection
🎯 Parameters
AO
Speed Ref 4-20mA
AI
Speed FB
AI
Torque %
DI
At Speed
⚙️ Features
Auto/Manual speed | Min speed limit
Flying start | DC braking
🔧
Control Valve
ولو کنترلی
📐 Positioning
AO = PID_Output (0-100%)
Position FB = AI (4-20mA)
Deviation alarm if |SP-FB| > 5%
🎯 I/O Signals
AO
Position SP
AI
Position FB
DI
Open LS
DI
Closed LS
🔧 Characterizer
Linear | Equal % | Quick Open
Cv calculation for sizing
⏹️
On/Off Valve (XV/SDV)
ولو قطع/وصل
📐 Sequence
OPEN: Energize SOV → Wait → Check ZSO
CLOSE: De-energize → Wait → Check ZSC
Fail position: FC (Fail Close) or FO
🎯 I/O Signals
DO
Open Cmd
DI
ZSO (Open)
DI
ZSC (Closed)
DI
Fault
⚠️ Alarms
Travel time exceeded | Position disagree
SOV fault | Actuator fail
💧
Pump Control
کنترل پمپ
📐 Start Sequence
1. Check suction valve OPEN
2. Check level > LLL
3. Start motor
4. Open discharge valve
5. Monitor flow > Min
🎯 Protection
FALL
Low Flow Trip
PSLL
Low Suction
TAHH
Bearing Temp
VAHH
Vibration
🔄 Standby Auto-Start
If Running pump trips → Start Standby
Duty rotation scheduling
🌀
Compressor Control
کنترل کمپرسور
📐 Control Modes
• Suction Pressure Control
• Discharge Pressure Control
• Flow Control
• Load Sharing (Parallel)
🎯 Anti-Surge
Surge Line
h = f(Q²)
Control Line
+10% margin
ASV
Recycle valve
Response
<100 ms
⚠️ Trip Conditions
High discharge temp | Low lube pressure
High vibration | Surge count > 3
🔥
Heat Exchanger
مبدل حرارتی
📐 Temperature Control
TIC controls outlet temp
by adjusting heating/cooling medium
Q = U × A × LMTD
🎯 Control Scheme
PV
Outlet Temp
MV
Steam/CW valve
FF
Feed flow
Bypass
3-way valve
📊 Monitoring
Fouling factor | ΔP trend
Approach temperature
📊
Vessel Level Control
کنترل سطح مخزن
📐 Strategies
• Self-regulating: Simple PID
• Integrating: Tight control needed
• Surge tank: Averaging level
• Interface: Two LTs required
🎯 Alarms
LAHH
High-High
LAH
High
LAL
Low
LALL
Low-Low Trip
⚙️ Level Types
Displacer | DP | Radar | GWR
Redundant voting for SIS
📋 Sequence Control

کنترل توالی

Startup, Shutdown & Emergency Sequences

▶️
Unit Startup Sequence
توالی راه‌اندازی
📐 Steps
S01: Verify utilities available
S02: Purge with N2 (5× volume)
S03: Leak test (hold pressure)
S04: Start aux systems
S05: Introduce feed
S06: Establish circulation
S07: Heat up (controlled rate)
S08: Transfer to normal ops
🎯 Transitions
Auto
On completion
Manual
Operator confirm
Timed
After delay
Conditional
On PV value
⏹️
Normal Shutdown
خاموشی عادی
📐 Steps
S01: Reduce feed rate (ramp)
S02: Reduce firing/heating
S03: Stop feed completely
S04: Depressure to flare
S05: N2 purge
S06: Cool down
S07: Isolate and drain
S08: Safe for maintenance
🎯 Considerations
Rate
50°C/hr max
Catalyst
Passivation
Vessels
Drain/Purge
Duration
8-24 hours
🚨
Emergency Shutdown (ESD)
خاموشی اضطراری
📐 ESD Levels
ESD-0: Total plant (fire/explosion)
ESD-1: Process unit
ESD-2: Equipment group
ESD-3: Single equipment
🎯 Actions
Feed
XV Close
Fuel
Trip + Purge
Machines
Trip all
Depress
BDV Open
⚠️ Triggers
Manual pushbutton | F&G confirmed
PAHH | TAHH | Multiple trips
💨
Depressuring (BDV)
تخلیه فشار
📐 Design Basis
API 521: Reduce to 50% in 15 min
or 7 barg in 15 minutes
whichever is lower
🎯 Components
BDV
Blowdown Valve
RO
Restriction Orifice
KO Drum
Liquid removal
Flare
Safe disposal
🔥 Fire Case
Automatic on F&G Zone confirm
Manual from CCR or field
🔬 Analyzers

سیستم آنالایزر

Online Process Analyzers

📊
Gas Chromatograph
کروماتوگراف گازی
📐 Principle
Separation by boiling point
Carrier gas: He, H2, N2
Detector: TCD, FID, FPD
🎯 Applications
Feed
Composition
Product
Purity
BTX
Aromatics
Cycle
5-15 min
🌬️
O2 Analyzer
آنالایزر اکسیژن
📐 Types
• Paramagnetic (flue gas)
• Zirconia (in-situ, hot)
• Electrochemical (ambient)
• Laser (TDLAS)
🎯 Applications
Combustion
2-3% excess
Inert
<0.5%
Safety
LEL calc
Response
1-10 sec
⚗️
pH / Conductivity
پی‌اچ و هدایت
📐 pH Control
Nonlinear: gain varies 10× per pH
Neutralization curve mapping
Multiple reagent dosing
🎯 Maintenance
Calibration
Weekly
Cleaning
Auto/Manual
Reference
Check Ω
Life
6-12 months
🌿
CEMS
پایش آلاینده‌ها
📐 Parameters
O2, CO, CO2: NDIR
NOx: Chemiluminescence
SO2: UV Fluorescence
Particulate: Opacity/Laser
🎯 Requirements
Uptime
>95%
RATA
Annual
QA/QC
Daily CGAS
Report
EPA/Local
🏭 واحدها

۲۴ زیرسیستم پتروشیمی

🔥
کراکر حرارتی
Steam Cracker
شکست مولکولی هیدروکربن‌ها در دمای بالا
Temp
850°C
Residence
0.1-0.5s
Steam/HC
0.3-0.6
Yield C2
30-35%
RadiantConvectionTLE
❄️
کوئنچ و فشرده‌سازی
Quench & Compression
سردسازی سریع و فشرده‌سازی گاز کراکر
Stages
4-5
Pressure
35 bar
Power
50 MW
Anti-Surge
Active
Oil QuenchWater QuenchCGC
🧹
تصفیه گاز
Gas Treatment
حذف CO2، H2S، آب و ناخالصی‌ها
Caustic
NaOH 10%
Amine
MEA/DEA
Dryer
Mol Sieve
H2O
<1 ppm
Caustic WashAminePSA
🗼
برج‌های تقطیر
Distillation Columns
جداسازی محصولات بر اساس نقطه جوش
Demethanizer
-100°C
Deethanizer
-20°C
Depropanizer
+15°C
Trays
80-120
C1C2C3C4+
🧊
سرمایش
Refrigeration
تأمین سرما برای جداسازی در دمای پایین
Ethylene
-101°C
Propylene
-40°C
COP
2.5-3.5
Cascade
3-Level
Propylene RefEthylene RefCascade
⚗️
C2 Splitter
اتیلن/اتان
جداسازی اتیلن از اتان با خلوص بالا
Purity
99.95%
Trays
120-150
Reflux
4-5
Press
20 bar
High PurityRecycle
🧪
پلیمریزاسیون
Polymerization
تولید پلی‌اتیلن و پلی‌پروپیلن
PE
HDPE/LDPE
PP
Homo/Copo
Catalyst
Z-N/Metaloc
Cap
400 KTA
SlurryGas PhaseSolution
🔄
اکسترودر
Extruder & Pelletizer
تبدیل پودر پلیمر به گرانول
Cap
50 t/h
Pellet
3-4 mm
Power
5 MW
Type
Twin Screw
UnderwaterStrandAdditive
📦
انبار و بارگیری
Storage & Loading
ذخیره‌سازی محصولات و بارگیری
Tanks
50+
Spheres
LPG
Silos
Polymer
Jetty
Marine
Tank FarmSpheresLoading
🔥
کوره‌ها و بویلر
Furnaces & Boilers
تأمین حرارت و بخار فرآیند
Fired Heater
150 MW
Steam
HP/MP/LP
Efficiency
92%
BMS
SIL 3
RadiantHRSGBMS
⚡
کمپرسورها
Compressors
فشرده‌سازی گاز فرآیند و رفریجرانت
CGC
50 MW
Propylene
15 MW
Ethylene
8 MW
Type
Centrifugal
Anti-SurgeDry Gas SealVFD
💧
آب و پساب
Water & Wastewater
تصفیه آب و پساب صنعتی
Demin
500 m³/h
Cooling
30K m³/h
WWT
200 m³/h
ZLD
Optional
ROEDIDAFMBR
🔥
فلر
Flare System
سوزاندن گازهای اضطراری و اضافی
HP Flare
500 t/h
LP Flare
200 t/h
Height
120 m
Recovery
FGRU
HPLPGroundFGRU
🌿
محیط زیست
Environmental
پایش و کنترل آلاینده‌ها
CEMS
Real-time
VOC
<50 ppm
NOx
<100 ppm
ISO
14001
CEMSLDARScrubber
🛡️
ایمنی
Safety Systems
سیستم‌های ایمنی و اضطراری
SIS
SIL 2/3
F&G
SIL 1
ESD
Level 0-4
IEC
61511
SISF&GESDHIPPS
🖥️
DCS
Distributed Control
سیستم کنترل توزیع‌شده
I/O
500K+
Controllers
200+
OWS
50+
Redundancy
Hot
HoneywellYokogawaDeltaV
⚡
برق و ابزار دقیق
E&I
سیستم‌های برق و ابزار دقیق
Substation
132/33kV
MCC
6.6/0.4kV
UPS
N+1
Analyzer
GC/FTIR
HVMVLVAnalyzer
📊
APC
Advanced Process Control
کنترل پیشرفته و بهینه‌ساز
MPC
DMC+
RTO
Real-time
Inferential
Soft Sensor
Benefit
3-5%
MPCRTODMCRMPCT
🔄 Control Loops

لوپ‌های کنترل

انواع لوپ‌های کنترلی مورد استفاده در پتروشیمی

🎛️
Simple PID Loop
کنترل تک‌حلقه‌ای
📐 PID Algorithm
OUT = Kp×e + Ki×∫e.dt + Kd×de/dt
e = SP - PV
🎯 Tuning Parameters
Kp (Gain)
0.5 - 5.0
Ti (Integral)
30 - 300 s
Td (Derivative)
0 - 30 s
Cycle Time
100 - 500 ms
📋 Examples
• Flow Control (FC) - Fast
• Level Control (LC) - Slow
• Pressure Control (PC) - Fast
• Temperature Control (TC) - Slow
🔗
Cascade Control
کنترل آبشاری
📐 Structure
Master (Outer): TC → SP_inner
Slave (Inner): FC ← SP from Master
Inner loop 5-10× faster than Outer
🎯 Example: Furnace
Master
TIC-101 (COT)
Slave
FIC-102 (Fuel)
Outer τ
120 sec
Inner τ
10 sec
⚙️ Mode Transfer
Master A/M → Slave tracks SP
Bumpless transfer required
⚖️
Ratio Control
کنترل نسبتی
📐 Algorithm
SP_controlled = Ratio × PV_wild
Ratio = Controlled / Wild
🎯 Example: Air/Fuel
Wild Stream
Fuel Gas
Controlled
Combustion Air
Ratio
10:1 - 15:1
O2 Trim
2-3% Excess
🔥 Cross-Limiting
Air leads on increase
Fuel leads on decrease
⚡
Feedforward Control
کنترل پیش‌خور
📐 Concept
FF = -Kd/Kp × Disturbance
OUT = FF + FB (PID)
🎯 Example: Heat Exchanger
Disturbance
Feed Flow
Controlled
Outlet Temp
Manipulated
Steam Flow
Lead/Lag
Dynamic Comp
📊 Benefits
Faster disturbance rejection
Reduces peak deviation 50-90%
↔️
Split Range Control
کنترل تقسیم‌بازه
📐 Configuration
OUT 0-50%: Valve A (Cooling)
OUT 50-100%: Valve B (Heating)
Gap/Overlap at 50%
🎯 Example: Reactor Temp
CV1
Cooling Water
CV2
Steam
Split Point
50%
Dead Band
2%
⚙️ Characterizer
Linear or custom curve
Reverse acting option
🔀
Override / Select Control
کنترل انتخابی
📐 Logic
OUT = MIN(PID1, PID2) or
OUT = MAX(PID1, PID2)
High/Low Selector
🎯 Example: Compressor
Normal
Flow Control
Override 1
Anti-Surge
Override 2
Max Power
Selector
Low Select
⚠️ Anti-Windup
External reset on override
Bumpless transfer back
🚀 Advanced Control

کنترل پیشرفته APC

Model Predictive Control & Real-Time Optimization

🧠
Model Predictive Control
MPC / DMC+
📐 Algorithm
min J = Σ(y-ysp)²×Q + Σ(Δu)²×R
subject to: y = G×u (Step Model)
umin ≤ u ≤ umax
🎯 Tuning
Prediction
P = 60-120
Control
M = 3-5
Sample
1-5 min
Model
60-120 steps
📊 Benefits
Handle MIMO interactions
Constraint optimization
+3-5% throughput
💰
Real-Time Optimization
RTO
📐 Objective
max Profit = Revenue - Cost
= Σ(Product×Price) - Σ(Feed×Cost)
- Utility Costs
🎯 Hierarchy
L4
Planning (days)
L3
RTO (hours)
L2
MPC (minutes)
L1
PID (seconds)
⚙️ Execution
Steady-state detection
Data reconciliation
Nonlinear optimization
📊
Inferential / Soft Sensors
Virtual Analyzers
📐 Model Types
y = f(T, P, F, ...)
• First Principles
• PLS / PCR Regression
• Neural Networks
🎯 Applications
Distillation
Composition
Reactor
Conversion
Polymer
MFI, Density
Cracker
Severity, Yield
🔄 Bias Update
Lab feedback correction
Analyzer validation
🤖
AI / Machine Learning
Neural Networks
📐 Architecture
Input → Hidden (ReLU) → Output
y = σ(W₂ × σ(W₁ × x + b₁) + b₂)
🎯 Applications
Predictive
Maintenance
Anomaly
Detection
Quality
Prediction
Process
Optimization
⚙️ Training
Historical data: 1-2 years
Validation: 20% holdout
📦 Batch Control

ISA-88 Batch Control

استاندارد کنترل فرآیندهای ناپیوسته

🏭
Physical Model
مدل فیزیکی
📐 Hierarchy
Enterprise → Site → Area →
Process Cell → Unit →
Equipment Module → Control Module
🎯 Example
Process Cell
Polymerization
Unit
Reactor R-101
EM
Agitator, Jacket
CM
Valve, Pump
📋
Procedural Model
مدل رویه‌ای
📐 Hierarchy
Procedure → Unit Procedure →
Operation → Phase
🎯 Example: Reaction
Phase 1
Charge A
Phase 2
Heat to 80°C
Phase 3
Add Catalyst
Phase 4
React 2 hrs
🔄
State Machine
ماشین حالت
📐 States
IDLE → RUNNING → COMPLETE
↓ HOLD ↔ HOLDING
↓ ABORT → ABORTED
↓ STOP → STOPPED
🎯 Commands
START
Begin batch
HOLD
Pause safe
STOP
Orderly stop
ABORT
Emergency
📝
Recipe Management
مدیریت دستور پخت
📐 Recipe Types
General → Site → Master → Control
Recipe = Header + Procedure +
Formula + Equipment Req.
🎯 Parameters
Process
Temp, Time
Formula
Amounts
Equipment
Unit selection
Version
Audit trail
🛡️ Safety Logic

منطق ایمنی SIS

Safety Instrumented Functions (SIF) per IEC 61511

🔒
SIF Structure
ساختار تابع ایمنی
📐 Components
Sensor → Logic Solver → Final Element
SIF = Initiator + Logic + Actuator
🎯 Voting
1oo1
Single sensor
1oo2
Any one trips
2oo3
Two of three
2oo4
Dual redundant
📊 PFD Calculation
PFDavg = λDU × TI / 2
SIL determined by PFD
📊
Cause & Effect Matrix
ماتریس علت و معلول
📐 Structure
Rows: Causes (Initiators)
Columns: Effects (Actions)
Cells: X = Direct, T = Time delay
🎯 Example: Reactor
TAHH
→ Feed XV, CW
PAHH
→ Feed XV, PRV
LAHH
→ Feed XV
LALL
→ Agitator, Pump
✅
Permissive & Interlock
مجوزها و اینترلاک
📐 Types
Permissive: Required to START
Interlock: Causes TRIP if lost
Both are safety functions
🎯 Example: Pump
Permissive
Suction valve open
Permissive
Level OK
Interlock
Low flow trip
Interlock
High temp trip
⏭️
Bypass Management
مدیریت بای‌پس
📐 Types
Maintenance Bypass: For testing
Process Bypass: Startup/Shutdown
Both require MOC approval
🎯 Requirements
Time Limit
8-24 hours
Approval
Shift Sup.
Indication
HMI Alarm
Log
SOE Record
⚠️ Compensating Measures
Manual monitoring required
Reduced capacity operation
🧠 منطق کنترل

Control Logic & Models

🔥
کنترل کوره کراکر
Cracker Furnace Control
📐 COT Control
COT_SP = f(Feed, Severity, Yield)
Fuel = PID(COT_SP - COT_PV)
📥 I/O Points
TI-101
COT
FI-102
Feed Flow
PI-103
Coil ΔP
AI-104
O2 Excess
⚠️ Interlock
IF COT > 870°C → Trip Fuel
IF ΔP > 2.5 bar → Decoking
🛡️ SIF (SIL 2)
TAHH → Fuel Trip + Steam Purge
🌀
کنترل کمپرسور
Compressor Anti-Surge
📐 Anti-Surge
Surge_Line = f(ΔP, Q, RPM)
ASV = PID(Margin_SP - Margin_PV)
📥 I/O Points
PDI-201
Suction/Discharge
FI-202
Inlet Flow
SI-203
RPM
VI-204
Vibration
⚠️ Trip
IF Vibration > 100 μm → Trip
IF Surge Count > 3 → Trip
🗼
کنترل برج تقطیر
Column Control
📐 Dual Composition
L/D = f(Top_Comp_SP)
V/B = f(Bottom_Comp_SP)
📥 I/O Points
LI-301
Reflux Drum
PI-302
Column Press
TI-303
Tray Temp
AI-304
GC Analyzer
⚠️ Interlock
IF LAHH Drum → Close Reflux
IF PAHH → Open Relief
🧪
کنترل راکتور
Reactor Control
📐 Polymerization
MFI = f(H2/C2, Temp, Cat)
Density = f(Comonomer Ratio)
📥 I/O Points
TI-401
Reactor Temp
PI-402
Reactor Press
LI-403
Bed Level
AI-404
Gas Comp
🛡️ SIF (SIL 3)
TAHH/PAHH → Emergency Depress
📊 داشبورد

Plant Dashboard

🧪 ARG Petrochemical - Control Room
LIVE
🔥
842
COT °C
📊
32.5
CGC bar
🧪
145
C2 t/h
✅
32.5
Yield %
📦
38
PE t/h
🛡️
0
Trip
📈 تولید روزانه
🌡️ پروفایل دما فرآیند
📐 P&ID

Process Flow Diagram

Olefins Unit - Simplified PFD
Running
Standby
🛢️
Feed
150 t/h
🔥
Furnace
842°C
❄️
TLE
350°C
💧
Quench
40°C
🌀
CGC
35 bar
🧹
Caustic
10%
🧊
Dryer
<1ppm
🗼
Demethan
-100°C
🗼
Deethane
-20°C
🗼
C2 Split
99.95%
📦
C2 Tank
85%
🛡️ ایمنی

Safety Instrumented Systems

🔥
Burner Management
SIL 3
سیستم مدیریت مشعل کوره‌ها
  • Flame Detection (UV/IR)
  • Fuel Trip on Loss of Flame
  • Purge Sequence (5× Volume)
  • Light-off Permissive
⚠️
Fire & Gas
SIL 1
تشخیص آتش و گاز قابل اشتعال
  • Point Gas Detectors (LEL)
  • Open Path IR Detectors
  • Flame Detectors (UV/IR)
  • H2S Detectors (Toxic)
🛑
Emergency Shutdown
SIL 2
سیستم توقف اضطراری
  • ESD Level 0: Plant
  • ESD Level 1: Unit
  • ESD Level 2: Equipment
  • ESD Level 3: Process
💨
HIPPS
SIL 3
High Integrity Pressure Protection
  • 2oo3 Voting Logic
  • Fast Acting Valves
  • PST (Partial Stroke Test)
  • SFF > 99%
🔌 پروتکل‌ها

Standards & Protocols

🔗 Control Networks
PROFIBUS PAFoundation FFHARTWirelessHARTModbus
📊 Integration
OPC UAISA-88ISA-95APIMQTT
🛡️ Safety
IEC 61508IEC 61511NFPA 85API 556ISA 84
🧪 Process
API 610API 617ASME B31.3TEMANACE
🌿 Environmental
EPACEMSLDARISO 14001Reach
⚡ Electrical
IEC 60079ATEXNEC 500API 500Area Class
📈 ROI

Return on Investment

+8%
تولید
-5%
انرژی
+3%
Yield
-50%
Trip
<18
ماه ROI
99.5%
Availability