Confidential level 2: Protected

TEC SPECIAL COURSE (2006)

INSTRUMENTATION DESIGN

ADVANCED PROCESS CONTROL

TECHNOLOGY

Hisashi Murata
Instrumentation Design Department

Confidential level 2: Protected

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

Confidential level 2: Protected

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)

Confidential level 2: Protected

1.2 Specific Example of Application Service

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)

Confidential level 2: Protected

1.2 Specific Example of Application Service

Feedforward Control of Heat Exchanger (2/3)
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

Confidential level 2: Protected

1.2 Specific Example of Application Service

Feedforward Control of Heat Exchanger (3/3)
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

Confidential level 2: Protected

1.2 Specific Example of Application Service

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

Confidential level 2: Protected

1.2 Specific Example of Application Service

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

Confidential level 2: Protected

1.3 Method of Incorporation

Process
Computer
Operator
Station

Operator
Station

Gateway

Engg
Station

Control
Station

Control
Station

Control
Station

Control
Station
Control Room
Field

Confidential level 2: Protected

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

Confidential level 2: Protected

1.4 Multivariable Model-based Predictive

Control Mechanism

Utility Function

LP (Linear Programming)

Dynamic Characteristic Model

(Model based prediction &
output calculation)

Model Identification
Software

DCS

Confidential level 2: Protected

1.4 Multivariable Model-based Predictive

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)

Confidential level 2: Protected

1.4 Multivariable Model-based Predictive

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.

Confidential level 2: Protected

1.4 Multivariable Model-based Predictive

Control Mechanism
MV2
d2
CV2
F(x)

c2
: Optimum
Operation Point

CV1
c1

d1

Example of incorporated LP

MV1

Confidential level 2: Protected

1.4 Multivariable Model-based Predictive

Control Mechanism
CV1

CV2

MV1

MV2

Example of incorporated
dynamic characteristic model
(This model is developed based on operation data.)

1.5 Engineering Flow

Confidential level 2: Protected

(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

1.5 Engineering Flow

Confidential level 2: Protected

(e.g.Multivariable model based predictive control in EPC LSTK

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.

1.5 Engineering Flow

Confidential level 2: Protected

(e.g.Multivariable model based predictive control in EPC LSTK

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.

Confidential level 2: Protected

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

Confidential level 2: Protected

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

Confidential level 2: Protected

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

Confidential level 2: Protected

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

Confidential level 2: Protected

2.2 Introduction of Case Examples of

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

<Recent Job/Proposal results>

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

Confidential level 2: Protected

2.2 Introduction of Case Examples of

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.
<Recent Job/Proposal results>
PKPE (BA-0546) : Intelligent P&ID (responding with
PITS)
ONGC (DA-0955)

Confidential level 2: Protected

2.2 Introduction of Case Examples of

Job/Proposal in TEC

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

Confidential level 2: Protected

2.2 Introduction of Case Examples of

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
<Recent Job/Proposal results>
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)

Confidential level 2: Protected

2.2 Introduction of Case Examples of

Job/Proposal in TEC

OAS (Offsite Automation System)

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

Confidential level 2: Protected

2.2 Introduction of Case Examples of

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.
<Recent Job/Proposal results>
FOSS (EB-0245) Field operator supporting system by
Ministry of Economy, Trade and Industry
CMMS Proposal (DF-0123/0124) in Iran, CCC-F (DA0952)

Confidential level 2: Protected

2.2 Introduction of Case Examples of

Job/Proposal in TEC

Explanation of case examples of PKPE Proj.

(Refer to separate documents distributed)

Confidential level 2: Protected

Q&A