Advanced Process Control Technology

Confidential level 2: Protected
TEC SPECIAL COURSE (2006)

INSTRUMENTATION DESIGN
ADVANCED PROCESS CONTROL

TECHNOLOGY
Hisashi Murata
Instrumentation Design Department
Contents of Lecture
1. Advanced Process Control Technology
1.1 What is Advanced Process Control?
1.2 Specific Example of Application Service
1.3 Method of Incorporation
1.4 Multivariable Model-based Predictive Control Mechanism
1.5 Engineering Flow
2. Other In-plant IT System
2.1 Vertical Integration of Instrumented Control System and
Information
2.2 Introduction of Case Examples of Job/proposal in TEC
1.1 What is Advanced Process Control ?

What is APC (Advanced Process Control) ?
<In a broad sense>
Control to increase the added value of a plant
(Control not meaning Regulatory Control)
Although it is not control, the surveillance loop on operation
support may also be included.
<in a limited sense>
In many cases, it means MPC(Multivariable Model-based
Predictive Control)
What is Regulatory Control?

The minimum control to operate a plant (to ensure the
performance)

Feedforward Control of Heat Exchanger (1/3)
Steam flow rate Ws
Load
T2 Setting
Temp.
FIC
TIC
Time
Weak to a load change

Outlet temp. T2
Liquid flow rate Wp
Heat exchanger
Inlet temp. T1
Fig. 1.2.1 Control of heat exchanger (Feedback control)

Steam flow rate Ws
T2 Setting
FIC
TY
Note:
TY: Calculation of Ws set
value (with the formula below)
Ws=Cp/Hs*Wp*(T2-T1)
Cannot be completely
consistent with the target value.
Outlet temp. T2
Liquid flow rate Wp
Heat exchanger
Inlet temp. T1
Fig. 1.2.2 Feedforward control of heat exchanger

T2 Setting
Steam flow rate Ws
TIC
FIC
TY
2
TY
1
Note:
TY1: Calculation of Ws set value
(with the formula below)
Ws=Cp/Hs*Wp*(T2-T1)
TY2: Selective control of
TIC(feedback control) and
TY1(feedforward control)
Outlet temp. T2
Liquid flow rate Wp
Heat exchanger
Inlet temp. T1
Fig. 1.2.3 Combination of feedforward control and feedback control

Multivariable Model-based Predictive Control (1/2)
<Objectives of control>
A) Stable operation of equipment around distillation columns
Coping with the variation (flow rate, composition, etc.) of feed

liquid
Coping with any external disorder (e.g. temperature of CW)

B) Energy saving
Maximization of the heat efficiency of Re-boiler / Condenser

C) Improvement of the product yield, increase in volume of run
Minimization of Give-Away of column-top and column-bottom

products (reducing margins to required specifications as much
as possible)
Maximization of production

Multivariable Model-based Predictive Control (2/2)
PIC
PT
MPC
TI
TT
FI
FIC
LIC
TI
LT
FT
FT
TT
TT
TIC
FIC
FT
TI
TT
LT
LIC

Process
Computer
Operator
Station
Operator
Station
Gateway
Engg
Station
Control
Station
Control
Station
Control
Station
Control
Station
Control Room
Field
1.4 Multivariable Model-based Predictive

Control Mechanism
MPC
CV1
MV1
AI
1
FIC
1
CV2 MV2
TIC
2
DCS
Field
CV: Controlled Variable
MV: Manipulated Variable

Control Mechanism
Utility Function
LP (Linear Programming)
Dynamic Characteristic Model

(Model based prediction &
output calculation)
Model Identification
Software
DCS

Control Mechanism
1. Formula for dynamic characteristic model
MV1=A1(CV1)+B1(CV2)(Eq. 1)
MV2=A2(CV1)+B2(CV2)(Eq. 2)
(A*, B* : Predictive Model)
2. Restrictions on CV
c1 (const.)<=CV1<=d1 (const.)(Eq. 3)
c2 (const.) <=CV2<=d2 (const.)(Eq. 4)
(c*: Lower Limit, d* : Upper Limit)

Control Mechanism
3. Objective function (e.g. minimization of cost)
F(x)=e1*(MV1 )+e2*(MV2)(Eq. 5)
(e*: Cost factor, (MV* ): Rate of change in MV)
Within the restrictions, determine the

control and operational variables to
minimize the cost for each control
cycle.

Control Mechanism
MV2
d2
CV2
F(x)
c2
: Optimum
Operation Point
CV1
c1
d1
Example of incorporated LP
MV1

Control Mechanism
CV1
CV2
MV1
MV2
Example of incorporated
dynamic characteristic model
(This model is developed based on operation data.)
(e.g.Multivariable model based predictive control in EPC LSTK

Proj.)
1. Conceptual design
Objectives of control,
Determination of candidate
Control & operational
variables
4. On-site equipment
Installation / SAT
2. Arrangement and system

Architecture of Hardware/
Software
Determination of Control &

operational variables and
tunig parameters
Test of communication
with DCS
Mechanical control, starup,

Stable operation
5. Dynamic char.
Test 1 (pretest)
Dynamic char. Analysis
Installation effect estimation
& establishment of criteria for
performance test
7. Model identification
& verification
3. FAT
8. Model
implementation
6. Dynamic char. Test 2

(plant test)
Operation data collection
for model identification
& verification
9. Performance
test

Proj.)
<Points to notice in engineering>

1. ITB request is ambiguous
In Proposal Book, often expressed that to be optional or to limit the
scope
Note that the request may swell when a job is being executed.
2. Additional request on instruments
In PKPE Proj., a flowmeter and a valve are added at the time of job
execution. Particularly, pay attention to the addition of an analyzer.
3. Large quantity of work after mechanical commissioning
In the case of KR2 Proj., the mechanical commissioning was at the
beginning of 2000, and the work for APC has completed in Feb. 2004
(about 4 years after mechanical commissioning).
Pay attention to mechanical commissioning and takeover conditions.

Proj.)
<Points to notice in engineering>

4. Performance test may be requested.
Prepare actions to be taken for setting method of criteria (usually,
accomplishment of cost down of **$/Yr after introduction) and for
the event in which the required performance could not be attained.
Alternatively, It makes for software to function as installed into
the conditions of takeover, not promising the performance.
<ReferenceOn TN system>
Because ITB request is ambiguous and the quantity of work from

FEED is large, at the present, it is planned to cope with it in TECJ fundamentally.
Depending on individual Proj., if there is any part which can be
transferred to another Department, it is assumed that the work
will be transferred to the organization to be supplied with TN.
Contents of Lecture
1. Advanced Process Control Technology
1.1 What is Advanced Process Control?
1.4 Multivariable Model-based Predictive Control Mechanism
2. Other In-plant IT System
2.1 Vertical Integration of Instrumented Control System and
Information
2.2 Introduction of Case Examples of Job/proposal in TEC
2.1 Vertical Integration of

Instrumented Control System and Information System
(Decision-Making/Operation Timescale of Each System)
SSM : Sales & Service Management
Hierarchy
SCM : Supply Chain Management

ERP : Enterprise Resource Planning
Among
Enterprises
P/PE : Product and Process Engineering
SCM
MES : Manufacturing Execution System
SSM
APC : Advanced Process Control
Enterprise
DCS/PLC : Distributed Control System
ERP
/ Programmable Logic Controller
Plant
MES
Section
/Area
Equipment
OPTIMIZATION & APC
P/PE
DCS/PLC
Time
sec
min
hour
day
2.1 Vertical Integration of

Instrumented Control System and Information System
(Functions of MES)
Sales &
Service
Management
Operations /
Detailed
Scheduling
Resource
Allocation
and Status
Dispatching
Production Units
Enterprise
Resource
Planning
Supply
Chain
Management
Document
Control
Product Tracking
and Genealogy
Labor
Management
Product/
Process
Engineering
Performance
Analysis
Maintenance
Management
Quality
Management
OPTIMIZATION
&
APC
Process
Management
Data Collection
/ Acquisition
DCS/PLC
2.2 Introduction of Case Examples of

Job/proposal in TEC
PIMS (Plant Information Management System)

Plants operation data collection system
As an interface between the host system (including
MPC) and the instrumented control system (DCS
etc.), transactions of data will be executed
<Recent Job/Proposal results>
PKPE (BA-0546), KR2 (BA-0427), many proposals

Job/Proposal in TEC
LIMS (Laboratory Information Management

System)
Laboratory Analysis service system in plants
Provided with collection of analytic data and
workflow (work assignment, work approval,etc.)
management, and interface function with other
systems

PKPE (BA-0546): Interface with PIMS
ONGC (DA-0955), JCP (DA-0884), SAFCO4 (DA0822)

Job/Proposal in TEC
TIMS (Technical Information Management System)

Management system of plant equipment drawings
(also including Intelligent P&ID)
A sort of support system for plant maintenance work.
PKPE (BA-0546) : Intelligent P&ID (responding with
PITS)
ONGC (DA-0955)

Job/Proposal in TEC
In-plant LAN
In-plant LAN (Local Area Network)
PKPE (BA-0546): Extension of the existing LAN
ONGC (DA-0955), OPP (CC-0165), JCP (DA-0884),
SAFCO4 (DA-0822)

Job/Proposal in TEC
TSS (Training Simulator System)

System for operation training of Startup/Shutdown
Operation, Steady-State Operation, and Abnormal
State Operation
In many cases, these are Stand-Alone systems
AR4 (BA-0512), Ethylene TSS project in Japan (AA0665), KR2 (BA-0417), KVCM (BA-0432)
YAEG (DA-0994), SHEG (DA-0987), ONGC (DA0955), JCP (DA-0884)

Job/Proposal in TEC
OAS (Offsite Automation System)

System mainly for automation of Offsite Area
operation at refineries
Sometimes called OMS (Oil Movement System)
REFAP2 (BA-0539)Gasoline-diesel oil blending
system
KR2 (BA-0417): Automatic lineup system

Job/Proposal in TEC
Maintenance system
Plant maintenance work system
There are various types systems, and terms CMMS
(Computerized Maintenance Management System),
EAM (Enterprise Asset Management) and AMS (Asset
Management System) are often used.
FOSS (EB-0245) Field operator supporting system by
Ministry of Economy, Trade and Industry
CMMS Proposal (DF-0123/0124) in Iran, CCC-F (DA0952)

Job/Proposal in TEC
Explanation of case examples of PKPE Proj.

(Refer to separate documents distributed)
Q&A

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Confidential level 2: Protected

TEC SPECIAL COURSE (2006)