01 APC Overview CTS

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February 21, 2016 Reliance Technology Group – APC / RTO 1

Process Engineering GroupProcess Engineering Group

Advanced Process ControlAdvanced Process Control

5 Days Training5 Days Training

Fareed KhanFareed Khan

April 03, 2012April 03, 2012





+at i" APC-

APC at RI

)o/ APC +or"-

APC 'onitorin$ & 'aintenance

Introduction to RTO

#

APC Introduction



APC Control Hierarchy

Planning & Scheduling

Optimization

LP - CLP

APC APC

DCS

Empirical & Dynamic model

Rigorous & Steady state

(Plant ide!

Simple & Steady state

(Site & Enterprise ide!

msec

min

hrs

"onths & days

#nstrument & Plant

%

"ultiple or single loop no "odel





6

Real Time ptimisation

Reactor Te!erature

Profit RTO

F*oatin$ O!tia

Con"traint"

afety :ui!ent ua*ity

APC

First principles Model Steady State Model Nonlinear (QP !ptimi"er



True!conomic

ptimum

"alve Positions

Temperature

Compressor Speed

Column # P

Pressure

Purity

$

perator%sPre&erred

perating

Region

#'Cplus

perating

Region

$

4

APC Control

#egression Model $ynamic Model %P !ptimi"er



T

R!( #uty

Side )L*

F

T P

#rum Pres

Side Comp +,-.

vd Temp

)!!#

T

D

A

F

F

∆P

F

)!!#

(tm Comp +-.

'" / Parameters that perator

change

C" / Parameters that peratorcontrols

)) / #isturbance variable to the

unit

#CS Control / #istillation To0er

Control "alve

1uality Constraints

A

!2uipment Constraint

Sa&ety ConstraintsSa&ety "alve

Control "alve

Simple P&$ Model !'erride %ogic

P

vd Pres

A

vd Comp +,-.





Prediction using Plant 'odel

A""ue" inearity and u!er!o"ition

10



'odel Prediction / Linearity and Superposition

inearity H Abi*ity to u*ti!*y ' oeent

u!er!o"ition H Abi*ity to add cure"

Possible when the dynamic equations are

represented by Linear differential equations like

Laplace Transforms

Co!o"ite Cure for 1 & 0.( unit of ' oeent

( 1 # 1 & 2.( J0.( J1.( 0.(



!rror Correction



ptimi3ation at steady state

Manipulated aria!leCurrent alues

Controlled aria!lePredicted "teady "tatealues

Econo#ic $n%or#ation

Manipulated aria!le "teady "tate Targets

Controlled aria!le&perating 'i#its

Controlled aria!le"teady "tate Targets

Manipulated aria!le

&perating 'i#its

"teady"tate

'inear Progra#

1#



'ove Plan 4eneration

1%


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'ove Plan 4eneration !5ample



#'Cplus Control Structure

16

:conoic"Co"t" on 'ani!u*ated ariab*e"

teadytateO!tiiation

'odu*e

ynaicContro*'odu*e

ACOBA: < CiIO

C < Proce"" Inforation y"te

e!endentariab*ea*ue"

Inde!endentariab*e a*ue"

'ani!u*atedariab*e a*ue"

et!ointOut!uta*ue"

iit" and Tar$et"Tunin$

Con"tant"

ynaic Prediction" 'Tar$et"

teadytate

Prediction"

CTar$et"

O!erator Contro* :n$ineer

Prediction'odu*e



'odel !2uation

δ C" A K ∆I

Calculate

∆

∆

∆

∆

=

∂

∂

∂

∂

∂∂

∂

%

#

2

1

%%%%

#%%%

2#%%

12#%

12#

12

1

4

6

(

%

#

2

1

I

I

I

I

aaaa

aaaa

aaaa

aaaa

aaa

aa

a

CF

CF

CF

CF

CF

CF

CF

$

Prediction 'ode Contro* 'ode

Calculate Calculate

Identification 'ode

14



Recap

17

APC i" a # "te! Proce""L

1. Predict teady tate 89

2. O!tiie at Predicted

#. Generate a 'oe P*an to reac

'iniie $ie a/ay in ua*ity, eui!ent & afety con"traint"

'iniie oeent" in et!oint"

Robu"t de"i$n for different o!eratin$ !oint", and ab"orb In"truent >oi"e, une;!ecteddi"turbance, and 'ode* :rror

'iniie Co"t and 'a;iie Ca!acity

$esired eha'ior in the Controlled and Manipulated )aria*les to e+pected and

une+pected distur*ances, Model errors and noisy measurements



Applications

&&

Changes to process

6 e2uipment7

operating philosophy7

resources7 and

mar8et conditions

a&&ect per&ormance

e$radationTie

o"tProfit

# e g r a d a

t i o n o & A p p l i

c a t i o n

P e r & o r m

a n c e P r i o r i t i

6 a t i o n

Lo0 e&&ort changes can

o&ten be made to the

applications to sustain and

enhance (ene&its

R e c o v e r

y o & P e r

& o r m a n c e

T r o u b * e " , o o t &

o * 2 e

u"tained and :nancedPerforance8Continuou" I!roeent9

! n h a n c e

m e n t o &

A p p l i c a t

i o n

P e r & o r m

a n c e : n ,

a n c e

Tie

Annua*

Profit" 8M'9

A!!*ication"Coi""ioned

!conomic (ene&its

are optimi3ed 0hen

applications are

achieving their

design potential

' a 5 i m i 3

e " a l u e

o &

A p p l i c a

t i o n

' a ; F a * u e &

: f f i c i e n c

y

APC Li&ecycle



APC 'aintenance

20

Process changes

Instrumentation issues

perator understanding

APC Issues

Clarity o& Roles

:ui!ent de$radation, >e/ Con"traint" 'ajor can$e in o!eratin$ re$ie 8Feed & !roduct "!ec, f*o/" etc9

>e/ o!erationa* objectie", or increa"ed unea"ured di"turbance"

' Pincin$ & Conf*ictin$ C Con"traint" Incon"i"tent objectie" & eficiency in Trainin$

eficient PI *oo! tunin$, Contro* a*e or oter i""ue" Contro* *oo! confi$uration can$e"

Pane* Officer, In"truent en$ineer, P*ant & CT en$ineer & APC $rou! Conf*ictin$ Objectie"N PO" cofort " CT con"traint !u"in$

'ode* de"i$n, Contro**er fide*ity and oft "en"or accuracy i""ue"

Tunin$ & o$ic !rob*e"





'anipulated "ariables

22



Controlled "ariables

2#





February 21, 2016 Reliance Technology Group – APC / RTO 2(

1. APC H Adanced Proce"" Contro*

2. :O H :uation Oriented "iu*ation

#. ' H euentia* 'odu*ar "iu*ation

%. RTO H Rea* Tie O!tiiation

(. ARP' H Autoated Ri$orou" Perforance 'onitorin$

6. RO'eo H Ri$orou" On*ine 'onitorin$ :uation Oriented

4. PT H P*ant Troub*e ootin$

7. PC H P*ant Ca"e tudie"

Introduction to RT



26 02<21<16

*hy RT9

Feed Rate

Profit

APC 8PI'9

Con"traint" :ui!entafety

ua*ity

O!tiu at Con"traint

Dynamic Plant Model Regressed Model from plant data Optimum always at constraints Linear Objectie ! "onstraints #LP$



27 02<21<16

*hy RT9

Reactor Te!erature

Profit RTO

F*oatin$ O!tia

Con"traint" :ui!ent

afety

ua*ity

%undamental Model from first principles&teady &tate Plant Model Optimum floating 'onlinear Objectie ! "onstraints #(P$'eeds &teady &tate Detection


APC



Types o& Simulation S' +TS.

euentia* 'ode o*er" 8'9 H A"!en P*u" , PRO II, )==, Ref"y" , PetroI'

)eed

Product

4ive inputs Calculate outputs

)nitiali*ation is easy

'eeds different soling algorithm for each equipment "an sole differential equations for Reactors&oles one by one and proceedsDifficult to sole for recycle streams and heat integrationMore difficult to optimi*e&till more difficult to respect constraints




Types o& Simulation / !

:uation Oriented o*er" 8:O9 H A"!en 'O, Inen"y" O!era, )oney/e** >OA

)eed

Product

4ive outputsCalculate inputs

One soling algorithm for complete plant flowsheet +asy for recycle streams and heat integration+asy optimi*ation and constraint handling Difficult to initiali*e'eeds equation and ariable information'eeds special reactor model consideration&oles only algebraic equations




30 02<21<16

Summary S' 6 ! 'odels

:a"e of initia*iation

e"i$n PF "iu*ation

iu*ation "tudie"

O!tiiation

ata reconci*iation

)eat Inte$rated

Co!*ete !*ant ode* /it con"traint" :a"e of irrorin$ !*ant confi$uration

! S'



*hat is S' 6 !

' C*o"ed :uation"

? KA K'T

? < A K 'T

'T < 8? KA9

dF<d r i

Feature"L ,ere - formulation for one equation .ould needs - different soling

algorithm Only &imulation

:O O!en :uation"

0 ? KA K'T

Feature"L One formulation for one equation &ame equation for / &imulation

Parameteri*ation0 Data Reconciliation !

Optimi*ation 'eeds ariable information #const ! "alc$

February 21, 2016 Reliance Technology Group – APC / RTO #1



RT 'odeling

:uation Oriented A!!roac

ariab*e efinition !ar"e 'atri;

eriatie InforationE Fir"t Order H Dacobian

E econd Order )a""ian >ora*iation

Initia*iation

!*ine Co**ocation

P A*$orit teady tate etection

Ra!in$ 'etodo*o$y



Additional Re2uirement &or !

ariab*e efinition 8Con"t & Ca*c9L

0 # J%K1 J(K2 J4K#

0 2J 2J2K%

0 %J 3K1J#K%

06J(K1J%K#

1 1 1 0

0 1 0 1

1 0 0 1

1 0 1 0

!ar"ity 'atri;

Dacobian 'atri;( 5 ) 0

0 1 0 2

* 0 0 3

5 0 ( 0

In!ut ariab*e" need" to be defined a" con"tant"Out!ut ariab*e" need" to be defined a" ca*cu*ated

ariab*e" *ocation in an euation need" to be defined in a "!ar"ity!attern. On*y 2@ or *e"" non ero" are tere in !roce"" !*ant"Reduce" co!utationa* tie

irection reuired to "o*e te euation" in i" defined in a Dacobianatri;. Te"e are "*o!e" or !artia* deriatie"

A "econd order nuerica* deriatie inforation in a )a""ian atri;

February 21, 2016 Reliance Technology Group – APC / RTO ##



Additional Re2uirement &or Reactors in ! Reactor 'ode*" are ifferentia* :uation"

:O o*e" on*y A*$ebraic 'ode*"

ifferentia* :". are conerted to a*$ebraic :". by co**ocation

:;a!*eL

y *n8;9

dy<d; 1<;

at ;1, y 0

A""ue" a "o*ution euation a"L

y aJb;Jc;Q2

dy<d; bJ2c;

at ;1, dy<d; 1

& ;1.1, dy<d; 1<1.1

y1.%(%( J1.303K; 0.%(%(K;Q2!*ine 1 Co**ocation !*ine 2

February 21, 2016 Reliance Technology Group – APC / RTO #%





RT Se2uence

'ea"ureent a*idation

P*ant teady-

I!*eent O!tiiation !oint" 8Ra!er9 ineOut !eriod 30 inute"

O!tiiation Ca*cu*ation

Paraeter Ca*cu*ation

P*ant teady- +ait one 'inute

e"" tan 1 inute

1( inute

#0 inute

'ea"ureent"

:conoica*ue"

Contro**er iit"

Contro* and o!t.

tatu" Info.

e*ected P*ant

'ea"ureent"

e*ected P*ant'ea"ureent" andContro**er iit"

>o

>o






R 6 ;(C Li




Cor!orate RO'eo uite *icen"e inc*udin$ ARP', ?ti*itie", 'a"" ba*ance, 'IA>O, I'%':, ataba"e

% PRO II icen"e

Petro"i 6 u"er BC icen"e 10 BC Reactor ode*" inc*udin$ FCC, Reforer, )ydrocracer & )ydrtotreater"

60 BC Reactor u"er" inc*udin$ RO'eo u"er"

A'C, oft/are u!$rade and con"u*tancy a$reeent

?"a$e beyond 20 year" of *icen"e

Romeo 6 ;(C License



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01 APC Overview CTS