Estudo da automação de trocadores de calor do tipo casco e tubos
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(2) Dados Internacionais de Catalogação-na-publicação (CIP) (Biblioteca Central da Universidade Federal do Espírito Santo, ES, Brasil). F519e. Fiorillo, David de Almeida, 1982Estudo da automação de trocadores de calor do tipo casco e tubos / David de Almeida Fiorillo. – 2010. 125 f. : il. Orientador: José Denti Filho. Dissertação (Mestrado em Engenharia Elétrica) – Universidade Federal do Espírito Santo, Centro Tecnológico. 1. Permutadores térmicos. 2. Controle de temperatura. 3. Logística. 4. Automação. 5. Termodinâmica. 6. Controladores PID. I. Denti Filho, José. II. Universidade Federal do Espírito Santo. Centro Tecnológico. III. Título. CDU: 621.3.
(3) DAVID DE ALMEIDA FIORILLO. ESTUDO DA AUTOMAÇÃO DE TROCADORES DE CALOR DO TIPO CASCO E TUBOS. Tese submetida ao programa de Pós-Graduação em Engenharia Elétrica do Centro Tecnológico da Universidade Federal do Espírito Santo, como requisito parcial para a obtenção do Grau de Mestre em Engenharia Elétrica. Aprovada em 22 de Dezembro de 2010.. COMISSÃO EXAMINADORA. Prof. Dr. Jose Denti Filho - Orientador Universidade Federal do Espírito Santo. Prof. Dr. Marcelo Lucas Pereira Machado Instituto Federal de Educação, Ciência e Tecnologia do Espírito Santo - Ifes. Prof. Dr. Alessandro Mattedi Universidade Federal do Espírito Santo.
(4) “Seja ecologista de tua natureza interna e tu serás ecologista da natureza externa.” (José Tadeu Fiorillo) “Viver é a coisa mais rara do mundo. A maioria das pessoas não faz mais do que existir.” (Oscar Wilde).
(5) Agradecimentos. Agradeço a Edimilson Caetano Vitorino pelas informações e motivações para este trabalho.. Ao CNPq pelo apoio financeiro concedido, sem o qual esta pesquisa não teria sido possível.. Ao Professor e Doutor João Luiz Marcon Donatelli do departamento de mecânica da UFES, pois sem seu conhecimento e orientação este trabalho não seria possível.. Ao experiente engenheiro Ivanor Martins da Silva por facilitar a busca pelas soluções de modelagem apresentadas neste trabalho.. Ao engenheiro e amigo Márcio Frisso pela coleta de dados de processo.. Ao engenheiro Bruno Veturim pelas discussões técnicas.. Ao orientador José Denti Filho pela orientação..
(6) Resumo Este trabalho foi motivado a partir da experiência do autor, enquanto engenheiro de automação de uma indústria de transporte de petróleo e derivados, atuando na melhoria do controle de temperatura de óleo pesado de um trocador de calor do tipo casco e tubos. Associados aos problemas inerentes dos sistemas térmicos industriais como a inércia, resistências e capacitâncias térmicas, tempo morto e histereses, encontram-se também as limitações devido ao subdimensionamento ou superdimensionamento destas plantas. Portanto, controladores clássicos monovariáveis são pouco eficazes na regulação de e diminuição da variabilidade de teperatura de óleo, podendo assumir valores de até ± 60 ºC em torno do setpoint. Neste trabalho são investigadas estratégias para o controle de temperatura aplicado ao trocador de calor na realização da tarefa de regular a temperatura de saída de óleo sob variações de carga (vazão de óleo e alimentação de vapor). Primordialmente, são levantadas informações sobre os mecanismos termodinâmicos que regem o funcionamento do trocador. Em seguida, é proposta uma modelagem baseada em parâmetros físicos, como, dimensões, vazões de entrada e saída de óleo e vapor e massa de aço do casco e tubos. São apresentados e comparados resultados da modelagem proposta com dados reais de um trocador. A principal contribuição do estudo foi a proposição de uma associação de estratégias de controle para regular a energia consumida pelo trocador, baseada na realimentação de fluxos de vapor e de entrada de óleo. As informações de vazão, pressão e temperatura foram unificadas na variável energia e associada a técnicas de controle PID feedback, feedforward e preditor de Smith. O arranjo foi capaz de compensar variações de cargas tanto da vazão óleo como da linha de vapor, reduzindo a variabilidade para ± 10 ºC. O método de controle de energia e associações de estratégias foi confrontado com o método clássico PID feedback monovariável, que além de diminuir o desgaste do atuador foi capaz diminuir o desperdício de energia em até 69% . Ao final do trabalho, são apresentados resultados da simulação do controlador proposto sobre a modelagem e arranjo de instrumentação para aplicação do método abordado..
(7) Abstract This work was motivated from the author's experience as an automation engineer for the transportation industry of petroleum and derivatives, working on improving the temperature control of heavy oil from a heat exchanger shell and tube type. Associated with the inherent problems of industrial thermal systems such as inertia, resistance and thermal capacitance, hysteresis and dead time, there are also limitations due to oversizing or undersizing these plants. Therefore, singlevariable classic controls are ineffective in regulating and reducing the variability of teperature oil, and may take values up to ± 60 º C around the setpoint. This work investigates strategies for controlling the temperature applied to the heat exchanger in accomplishing the task of regulating the temperature of the oil output under load (flow of oil and steam power). Basically, it bring up information about the thermodynamic mechanisms governing the operation of the exchanger. Then, we propose a model based on physical parameters such as dimensions, input and output flows of oil and steam and steel mass of the hull and tubes. Are presented and compared the results of proposed model with real data from an exchanger. The main contribution of this study was to propose a combination of control strategies to regulate the energy consumed by the exchanger, based on the feedback flow of steam and oil inlet. Information flow, pressure and temperature were unified in the variable power and control techniques associated with PID feedback, feedforward and Smith predictor. The arrangement was able to compensate for variations in load as much oil as the flow of steam lines, reducing the variability up to ± 10 ° C. The method of controlling power and strategies of associations was confronted with the classical PID feedback monovariable that besides reducing the wear of the actuator was able to reduce energy waste by up to 69%. At the end of the paper presents simulation results of the proposed controller on the modeling and instrumentation arrangement for implementing the method discussed..
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