Process Technology II Introduction to Systems PDF

Process Technology II Chapter 1: Introduction to Systems Reading Objectives: 1. Describe how process industry facilities are divided into systems. 2. Describe how the systems concept is used in learning process technology, and how it is important in operating a plant safely. 3. Discuss h...

Process Technology II Chapter 1: Introduction to Systems Reading Objectives: 1. Describe how process industry facilities are divided into systems. 2. Describe how the systems concept is used in learning process technology, and how it is important in operating a plant safely. 3. Discuss how diagrams are used to describe a system and importance of diagrams to process technicians. 4. Discuss process control and the use of control diagrams to represent how a system is controlled. Reading Outline: I. Introduction to Process Systems a. Way of looking at how a group of components interrelate to perform a function (system concept or system thinking) II. Learning by Using the Systems Concepts b. Systems and the NAPTA curriculum i. Equipment and instrumentation cover components of a system (valves, heat exchangers, transmitters, etc) ii. Systems shows how those components interact to create different types of systems (distillation, refrigeration, water treatment, etc) iii. Intro to process establishes an overview of filed process technology iv. Chemistry and physics provide basic concepts needed to understand equipment and plant systems v. Safety, health, and environment emphasize issues involved in all job tasks remaining in compliance and regulations vi. Quality includes topics such as teams skills, quality tools, economics, and continuous improvement c. Importance of Systems vii. Must know why and how the plant functions the way it does viii. Knowledge provides foundation for recognizing porblems quickly and responding appropriately d. Systems Text Layout ix. Plant system can be divided into three major categories 1. Utility system 2. Auxiliary system 3. Process systems a. Separation systems b. Reaction systems III. Systems Diagrams e. Block Flow Diagrams x. Simplified diagram that shows major sections of system or plant facility with blocks with lines indicting how these sections are linked f. Process Flow Diagrams xi. Show main lines connecting major equipment in plant xii. Includes process lines, equipment, valves, controls, mass (material) balance and energy balance (energy in and out) g. Piping and Instrumentation Diagrams xiii. Detailed drawing xiv. Includes equipment, process piping instrumentation, control loops and pipe specifications with assigned line numbers 4. Utility flow diagram shows utilities h. Control Diagrams xv. Similar to process flow diagram but typically has abbreviated control loops xvi. Control diagrams shown on screens will typically display current process variables xvii. When operating control station typically work form control diagrams on computer or control screens xviii. When equipment needs repair or have to write a work permit, they may use P&IDs to confirm locations IV. System Controls i. Process variables are flow, level, temperature, pressure, and analytical composition j. Closed loops are loops that have feedback from the level transmitter k. Cascade control is an advanced control that uses two controllers, primary and secondary Quiz **Question 1** How do sub-systems work together in a larger system? They have no impact on each other They are interdependent and rely on each other They are not necessary for the functioning of the larger system They are completely independent of each other **Question 2** Why is it important to understand sub-systems in a larger system? All of the above It helps to identify potential issues It improves overall efficiency It allows for easier troubleshooting **Question 3** What should Process Technicians learn about each sub-system? The cost of the sub-system The history of the sub-system The location of the sub-system The terminology and process technology **Question 4** What is the system concept? A way to understand a work process A type of process A method for troubleshooting A type of equipment **Question 5** What is the purpose of breaking a system down into sub-systems? To improve overall efficiency All of the above To make the system easier to understand To identify potential issues **Question 6** What is the definition of a system? A single piece of equipment A collection of interrelated equipment and processes A collection of unrelated equipment and processes A group of processes that are not dependent on each other **Question 7** What should Process Technicians do once they understand all the sub-systems? Put the sub-systems together to understand the total system Only focus on the processes within the system Ignore the sub-systems and focus on the larger system None of the above **Question 8** What should Process Technicians do when faced with a complex system? Only focus on the processes within the system Break the system down into smaller sub-systems None of the above Ignore the sub-systems and focus on the larger system