Advanced Process Control Training Package

Fundamentals

R.Radhika

Presentation outline
APC Fundamentals Process control Simple Loops Control Strategies: Real Life example Some Control Strategies Control Hierarchy Problems for conventional controls MVPC Common Terms used in APC Things to note regarding APC Example of an APC controller

Process Control

Process : Process is any method of converting a raw material into end products Process Control : Methods that are used to control process variables when manufacturing a product Why Process Control?? Reduce Variability Increase Efficiency Ensure Safety

Simple Loops
Open Loops
HIC-1105 MV xxxx

FI-1101 m3/hr Crude 80 % Crude Naphtha Naphtha

Closed Loop

FIC-1101 SV xxxx m3/hr PV xxxx m3/hr

AL

FI-1101 m3/hr Naphtha Naphtha 80 % FIC-1101 SV xxxx m3/hr PV xxxx m3/hr AL LIC-1101 SV xxxx % PV xxxx % AL

Cascaded Loop

FI-1101 m3/hr Naphtha 80 % Naphtha

Control Strategies: Real Life example

Some Control Strategies

Basic Regulatory control PID control : PID control is most popular as a) It gives good performance for single loops b) It is applicable for wide range of processes by changing its tuning parameters
PID Error MV Hot Fluid Cold Fluid SP

+ Sensor

Steam

Condensate

Some Control Strategies

Feed forward Control Feed forward control is a control system that anticipates load disturbances and controls them before they can impact the process variable. For feed forward control to work, the user must have a mathematical understanding of how the manipulated variables will impact the process variable.

Fig. shows a simple feed forward loop in which a flow transmitter opens or closes a hot steam valve based on how much cold fluid passes through the flow sensor

Control Hierarchy

Advanced Process Control

Frequent Execution ( every 0.5 -5 min)

Setpoints

Data

Distributed Control System

Signals to Actuators Data

Rapid Execution (every 250 millisec)

FT
Process and Instrumentation

Problems For Conventional Controls

Instabilities resulting from Disturbances Dead times Interaction

Multiple Constraints

MVPC
APC can be referred to as Multivariable Model based Predictive Control Technology It utilizes a mathematical model representation of the process. The algorithm evaluates multiple process inputs, predicts the direction of the desired control variable, and manipulates the output to minimize the difference between target and actual variables
Model predictive control is an advanced control as it utilizes an explicit process model to predict the future response of a plant Looks at control scenario in totality & can adjust multiple parameters every minute (480 times per shift) as per agreed objectives to maximize productivity/profit This makes plant operation easier and enables pushing the operation towards optima to improve profitability It adapts quickly to process changes and rejects disturbances to impart stability and robustness in operation An operator has to only fix RANGES of various parameters and NOT adjust them continuously

Common Terms used in APC

:ManipulatedVariables
APC controller structure use three main types of variable

:Controlled Variables :Disturbance Variables

Screen shot of APC DCS graphics page

Things to note regarding APC

MV limits are hard limits ; not violated CV limits are soft limits ; may be violated In laymans language APC means varying the SPs/OPs of MVs (within the specified low/high limits) keeping a watch on the CVs i.e. whether they are within given limits APC may be visualized as a very sincere operator who varies the SPs/OPs of MVs once every minute to keep the CVs within the specified range Setting proper limits for the MVs/CVs is of utmost importance; responsibility rests with operator MV Limits must be wide to give room to APC controller to adjust & bring CVs within limits CV Limits can be preferably narrow to ensure strict (tighter) control It is very interesting to note that DCS level Auto cascade loop can coexist with APC loop; APC sits over & above DCS base loops giving added advantage

Things to note regarding APC

Inferentials/Inferred Property: is the on-line estimate of products (and intermediate streams) calculated from process parameters (pressure, temperature & flow) by combination of chemical engineering calculation and statistical techniques, when it cannot be measured online, or when it is measured on-line but infrequently, with significant delay or not reliably. Example of Inferred property: LPG weathering, Naphtha 95% point, SO/LO KV etc. Laboratory properties are available once in a shift and off-line (in Lab registers), so adjustments can be made only on judgement or thumbrules few times in a shift Inferred properties are available once in a minute and on-line (in the DCS system), so can be viewed in real time and directly used for control Regular lab update of inferentials is a must to retain their accuracy

Example of an APC controller

APC Main Fractionator controller of FCCU (Haldia Refinery)
Reflux flow

Col Ovhd Temp.

LCO Draw flow

+ + +

LCO Draw Temp. HCO Draw Temp,

LCO PA flow

HCO PA flow

+ -

Shed deck Temp. Slurry run down flow

ROT

Slurry PA opening

MV/CV/DV

Manipulated Variables (MV) The parameters that are adjusted or manipulated by Controller these variables as handles to affect the control. Controlled Variables (CV) Those parameters that need to be controlled for operational stability and improvement Disturbance Variables (DV) Those Variables that could cause a Disturbance to the plant but their control is not in our hand.

Process unit PFD: FCCU

DCS graphics: FCCU MF APC controller (MV page)

DCS graphics: FCCU MF APC controller (CV page)

DCS graphics: VDU-2 Heater APC controller

DCS graphics: VDU-2 Vacuum fractionator APC controller