Training Services

Advanced Process Control

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 Introduction

n Process Design vs. Process Control

– Objectives
– Tools
– Data

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 Introduction

n Process Design vs. Process Control

– Process Design
— Objectives
Ÿ Capital vs. energy
Ÿ Equipment sizing

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 Introduction

n Process Design vs. Process Control

– Process Design (continued)
— Tools
Ÿ Steady state
Ÿ Engineering calculations
Ÿ Off-line optimization
— Data
Ÿ Specifications
Ÿ Simulations

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 Introduction

n Process Design vs. Process Control

– Process Control
— Objectives
Ÿ Maximum return from real-time
operations
Ÿ Capture engineering knowledge

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 Introduction

n Process Design vs. Process Control

– Process Control (continued)
— Tools
Ÿ Dynamic control tools
Ÿ Advanced process control
Ÿ Optimization - steady state
— Data
Ÿ Instrument systems
Ÿ Laboratory

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 APC Example

n Naphtha Hydrotreating Unit

– Actual problem
– Energy flows
– Problems occur at different times
– With basic controls, operator must solve the
problems
– Economic incentives

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 APC Example
Process Overview
F
3105 To C-1

Hydrogen Addition
and Preheat CW

TA TA < T B
T
3510 D-102
C-101

E-201 TB
F
Naphtha Hydrotreating F 3503
Preheat 3502
F-100 Furnace
D-101 H 2S Reactor L
H 2 from D-7 F
3501
3501

T
3511 L To Depropanizer
High
3500
Temperature E-101R
DPIC-501

HVN to E-20

Naphtha Hydrotreating Unit

H 2S Stripper Heat Duty Controls
E-100 F
3504
E-102

Reactor Charge to E-4

H 2 from K-1
Platforming Reactor F-200
Furnace

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 APC Example
Heat Exchanger Detail
NHT Unit H 2S
Stripper - Existing
Preheat/Reboil T C-101
Controls 3510

E-201

F
NHT Unit
3502
Preheat
F-100
D-101

T
3511

E-101R
DPIC-501

F
E-100 3504

E-102

Reactor Charge to Hydrogen from K-1 Compressor

E-4 and F-200

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 APC Example
Observations

n Loss of reboiler temperature control

n Loss of tower feed temperature control
n What set point for E-101R differential
pressure controller (DPIC-501)?
n Maximize heat recovery for economic benefit

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 APC Example
General Control Issues

n Observations on control problems

– Why do controllers go out of control?
– What must be done to keep them in control?
– What variables can be measured?
– What variables can be manipulated?

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 APC Example
Solution

n Naphtha Hydrotreating Unit - Solution

– Key to solution - control of the E-100 bypass
— All the issues revolve around how much
heat is available to the reboiler circuit
(although a side issue is DPIC-501)
— Automate with simple controller
— Determine how to set the controller set
point

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 APC Example
Solution (continued)

n Naphtha Hydrotreating Unit - Solution

– Setting controller set points
— Each controller has an objective
— Each set point is an opportunity
— With new control hardware, more
information can be brought into the
control system

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 APC Example
Bypass Control
NHT Unit H 2S Stripper -
Resolution of the Reboiler
and Feed Temperature T C-101
Control Problems 3510

E-201

F
NHT Unit
3502
Preheat
F-100
D-101

T T
3500 3511

E-101R

Split
Range

A B

F
E-100 3504

E-102

Reactor Charge to Hydrogen from K-1 Compressor

E-4 and F-200

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 APC Example
Bypass TIC Set Point
NHT Unit H 2S Stripper -
Constraint Control for
T3500 Set Point T C-101
3510

SP = 95% Open E-201

VPC
3510
F
NHT Unit 3502
High Signal
Limits H/L SS Selector

SP
VPC
T 3511 T
3500 SP = 5% Open 3511
(Valve A)

Split
Range

E-101R
A B

F
E-100 3504

E-102

Reactor Charge to Hydrogen from K-1 Compressor

E-4 and F-200

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 APC Example

n Naphtha Hydrotreating Unit - Observations

– Note the differences between process control
and process design
— Objectives
— Tools
— Data

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 APC Example
(continued)

n Naphtha Hydrotreating Unit - Observations

– Note the differences between basic control and
APC
— Problems are not tuning problems
— DPIC is a poor design
— Other controls adequate
— Controls incomplete

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 APC Concepts

n Relationship of control problems

and control strategies
– Problems
— Dynamics
— Nonlinearity
— Variable limits
— Disturbances
— Interactions

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 APC Concepts
(continued)

n Relationship of control problems and control

strategies
– Strategies
— Tuning
— Split range
— Linearization
— Feedforward
— Cascade
— Override/Constraint
— Inferential calculations
— Decoupling
— Multivariable Predictive Controller (MPC)

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 APC Concepts
Control Tool Chart
Process Control - Problem/Technique Matrix
Process Control Technique
Problem

PID Split Nonlinear Process Cascade Override/ Feedforward Inferential Multivariable, Decoupling
Tuning Range Controller Linear- Constraint Predictive
ization Control
Dynamics
- Deadtime √ √ √
- Stability √ √ √ √

Nonlinearity
- Gains √ √ √
- Dynamics √ √

Variables
- MV
- Limits √ √ √
- Disturb. √

- CV
- Unmeas. √
- Limits √ √
- Interact. √ √ √

- DV √ √ √ √
changes

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 APC Concepts
(continued)

n Relationship of control problems and control

strategies
– Definitions
— CV - controlled variable
Ÿ Measurement (controller input)
Ÿ Target (set point)

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 APC Concepts
(continued)

n Relationship of control problems and control

strategies
– Definitions (continued)
— MV - manipulated variable
Ÿ “Handle” on the process
Ÿ Typically, control valve (controller output)
— DV - disturbance variable
Ÿ Upsets to the process
Ÿ May or may not be measurable before upset

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 APC Concepts
(continued)

n Relationship of control problems and control

strategies
– Problems
— Dynamics
— Non-linearity
— Variable limits
— Disturbances
— Interactions

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 Process Dynamics

Dynamic characteristics of the process response

to changes in manipulated or disturbance
Exothermic Reaction
variables (MVs or DVs)

Endothermic Reaction
CV
Deadtime

MV Controller in Manual

Time

TIC
MV: Flow Rate of Fuel Gas
CV: Reactor Outlet Temperature

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 Dynamics
Controller Tuning

For a PID Controller,

 t 

∫
 
Controller Output = G e + (1 / T i) e dt - T d   
de
 o  dt  

 

where: G = Controller gain
e = Error (difference between SP and CV)
Ti = Integral time constant
Td = Derivative time constant

Controller output is proportional to the error, the time

integral of the error, and the rate of change of the error.
G, Ti and Td are the controller tuning parameters.

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 Dynamics
Cascade Control

The effects of
disturbances in the
manipulated flow stream
such as pressure changes
are measured and
controlled so that the
important controlled
variable (reactor outlet
Set Point
temperature) is not upset.
FIC

Secondary Controller
Primary Controller

TIC

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 Dynamics
Feedforward Control

Feedback
Signal
Σ
Feedforward
Signal

Set Point
FIC

TIC

Disturbances, such as changes in feed rate, are measured

and control action is taken before the important controlled
variable (reactor outlet temperature) is upset.

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 Dynamics
Multivariable Predictive Control (MPC)
TT
LIC

FIC FIC

Targets:
Top Composition
MPC
TT
Bottom Composition
FIC
LIC
Composition

FIC

By design, the Multivariable Predictive Controller (MPC) handles many of the problems
encountered in process control. Feedforward control action is easily added to the
controller to improve the control system’s dynamic response to disturbances.

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 APC Concepts

n Relationship of control problems and control

strategies
– Problems
— Dynamics
— Non-linearity
— Variable limits
— Disturbances
— Interactions

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 Non-Linearity

n What is “non-linearity?”
– “Linearity” addresses the relationship
between controller and process gains
– The gain is the ratio of the change in output
caused by a change in input
– Most controllers are linear - once they are
tuned, the gains are constant
– Most processes are not linear
n How the controls deal with this problem is
the subject of this section

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 Non-Linearity
(continued)

— Example - exothermic reactor

— Control applications
Ÿ Process linearization (example - pump)
Ÿ Gain scheduling (example - pump)
Ÿ MPC

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 Non-Linearities
Process Linearization

PI FIC

Because the pump’s head (discharge pressure) drops as the flow increases, the change in flow for a change in valve
flow area is not the same at high flow rates as it is at low flow rates. This is a nonlinear process if the flow area
and valve travel have a linear relationship - “ a linear control valve characteristic.” Controller tuning determined
at high flow rates may be unstable at low flow rates.

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 Non-Linearities
Process Linearization (continued)
Pump Discharge Pressure
Flow

Valve
Open Area Installed Flow
Characteristic
Discharge
Pressure Valve Open Area

Controller Output

PI FIC

Equal % Valve Characteristic

With an “equal percentage valve,” the nonlinear valve characteristic compensates for the
nonlinear process characteristic. Controller tuning is more “robust.” No matter what
the flow rate is, the control loop performs well.

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 Non-Linearities
Controller Gain Scheduling

Controller
Gain

Flow Rate
Controller Gain vs. Flow

Gain
PI Filter FIC

Linear Valve Characteristic

If a linear valve must be used, another way to linearize the overall system is needed. Because the
process gain decreases at higher flow rates because the pump’s discharge pressure drops, higher
controller gain is needed as flow rate increases. The filter is added to smooth the noisy flow signal.

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 APC Concepts

n Relationship of control problems and control

strategies
– Problems
— Dynamics
— Non-linearity
— Variable limits
— Disturbances
— Interactions

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 MV Limits and Disturbances

n MV Limits
– Control applications
– Split range (example - furnace firing)
– Control at the limit (example - distillation)
Ÿ Valve position control
Ÿ Tuning
– MPC
n MV Disturbances
– Cascade (example - reboiler)

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 MV Limits
Split Range

100% A B C
Valve Opening

FI 0
0 100%
Refinery A PIC Output
Fuel Gas
FI PIC FIC

Propane B

FI
Fuel Gas Header
To Other Users
Purchased C
Natural Gas

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 MV Limits
Controlling at the Limits

What should be
the SP value? PIC

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 MV Limits
Valve Position Controller

SP = 95% Open, Integral-only controller

VPC

PIC
Cooling Water
Temperature

Valve Opening

Tower Pressure

Time

The “valve position controller” (VPC) slowly adjusts

the set point of the pressure controller to keep the water
valve at the limits of its control range. This limit is
assumed to be 95% valve open. As the cooling water
temperature decreases, the pressure controller set point
is reduced to save energy.

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 MV Disturbances
Cascade Control

TIC

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 MV Disturbances
Cascade Control

Because the MV
disturbances are handled
by the secondary
controller, it is usually
possible to tune the
primary controller with
higher gain resulting in
Set Point better performance.
FIC

Secondary Controller
Primary Controller
TIC
The effects of disturbances in the manipulated flow
stream such as pressure changes are measured and
controlled so that the important controlled variable
(reactor outlet temperature) is not upset.

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 CV Limits and Inference

n CV Limits
– Variables held within limits
– Override or constraint controls (example -
TWT)
n CV Inference
– Alternative to direct measurement
– Property estimation
— Rigorous
— Neural networks

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 CV Limits
Override/Constraint Control

TIC

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 CV Limits
Override/Constraint Control
(continued)
Tube Wall Temperature
Controller

Low SS TIC
Signal
Selector

Transfer Line
Temperature
Controller
TIC

As long as the tube wall temperature is below its limit, the transfer line temperature
controller manipulates the furnace firing rate. However, if the tube wall temperature
exceeds its limit. the tube wall temperature controller will “override” the transfer line
temperature controller to reduce firing. Unlike a shutdown, the transfer line
temperature will only drop enough to keep the tube wall temperature at its limit.

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 APC Concepts

n Relationship of control problems and control

strategies
– Problems
— Dynamics
— Non-linearity
— Variable limits
— Disturbances
— Interactions

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 Disturbances

n Unmeasured Disturbances
– Feedback control
– Tuning - Aggressive
– MPC
n Measured Disturbances
– Feedforward control
– MPC
n Special Case - Level Control

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 Unmeasured Disturbances
Feedback Control
One of the best features of feedback control is that no matter
what disturbances cause the controlled variable to deviate from
the set point, the controller will try to bring the CV back to the
target. In this example, the disturbances might come from
changes in the charge rate and composition, changes in the fuel
composition and header pressure, changes in the reactor catalyst
activity or internal flow, and even changes in air temperature
and soot build-up on the heater tubes. To get better performance
the disturbances causing the worst problems could be measured
and control action taken before the disturbance upsets the
Transfer Line Temperature. This is feedforward control.

TIC

MV: Flow Rate of Fuel Gas

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 Measured Disturbances
Feedforward Control

TIC

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 Measured Disturbances
Feedforward Control

Feedback
Signal
Σ
Feedforward
Signal

FIC

TIC

Disturbances, such as changes in feed rate, are measured and control

action is taken before the important controlled variable (reactor outlet
temperature) is upset.
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 Unmeasured Disturbances
Special Case - Level Control

FI

Emphasis on Emphasis on
LIC
level control flow control
FI
Level

Inlet Flow A highly tuned level controller

maintains the level much better, but it
passes flow disturbances directly on to
downstream systems. These
disturbances reduce the performance
Outlet Flow potential of downstream process
equipment.
Controller Retuned Time

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 APC Concepts

n Relationship of control problems and control

strategies
– Problems
— Dynamics
— Non-linearity
— Variable limits
— Disturbances
— Interactions

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 CV Interaction

n CV Interaction
– Blending Example
– Control Application
— Variable pairing selection
— Tuning
— Decoupling (example - crude fractionator)
— MPC

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 CV Interaction
(continued)
n Blending Example

Which valve
should each
controller
manipulate?

MV1

CV1 CV2
Mixer

MV2
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 CV Interaction
(continued)

n Blending Example

MV1
Mixer

CV1 CV2

Just as easily, CV1 could be paired with MV2

and CV2 with MV1. How would the control
engineer determine which pairing was better?
MV2

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 CV Interaction
(continued)

n Multivariable Predictive Controller

Alternatives to the MPC are
“decouplers” which cancel
the interaction between CVs.

MV1 MV2
Flow Target
MPC
Composition Target
CV1 CV2

Mixer

Flow Changes: both valves move

in the same direction

Composition Changes: both valves

move in opposite directions

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 MPC

n Basic Operation
– Prediction of a set of MV changes that will
cause the CVs to be at their targets at some
time in the future
– “Feedback” is achieved by periodically
recalculating the control moves

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 MPC
(continued)

n Models: Dynamic vs. Steady State

n Addressing Limits
– MV limits - add more “costly” MVs (example
- FCC oxygen)
– CV limits - “restructure” the controller to
permit other MVs to control the CV

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 MPC
(continued)

Note the deviation from target

CV1

CV2

CV3

MV1
What MV changes must be made at t = 0 to drive the
MV2 CVs to their set points at some time in the future?
MV3

t = -1 t=0
Time

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 MPC
(continued)
The MV changes are made at t=0 with the expectation that CV2
will move back to its target after an initial deadtime and that CV1
and CV3 will remain at their target values. After making the MV
changes, the controller waits for the next execution cycle.

CV1

CV2

CV3

MV1

MV2

MV3

t = -1 t=0 t=2
Time
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 MPC
(continued)
At t=2 after one time interval (which is typically less than the time expected for all the
CVs to reach their targets), the controller again samples the CVs. The actual CVs may
deviate from their expected values because the predictions are in error or because
other disturbances have upset the process as appears to have happened for CV2.

CV1

CV2

CV3

MV1

MV2

MV3

t = -1 t=0 t=1 t=2

Time

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 MPC
(continued)
No matter what caused the deviations from the CV targets, new control moves are
calculated and applied based on the dynamic response models which are part of the
controller. This sequence of control calculations is repeated indefinitely.

CV1

CV2

CV3

MV1

MV2

MV3

t = -1 t=0 t=1 t=2 t=3

Time
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 MPC
(continued)

CV1

CV2

CV3

MV1
Looking at the problem in another way, why can’t
MV2 a steady state optimization with steady state
process models be used to determine the new MVs?
MV3

t=0
Time

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 MPC
(continued)

CV1
A
?
CV2 B

C
CV3
MV1
...because past history does make
MV2 a difference in what MVs will be
calculated!
MV3

t=0
Time

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 MPC Controller

n Prediction of a set of MV changes that will

cause the CVs to be at their targets at some
time in the future
n Periodic recalculation of the control moves
based on dynamic response models
n No direct “pairing” of MVs and CVs as with
conventional process control tools

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 MPC Controller
(continued)

n Constraints, feedforward, and MV limits are

easily handled
n While the controller is “linear,” it is typically
far more “robust” (less sensitive to process
gain changes)

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 Summary

n Comparison Process Design and Process

Control
– Objectives
– Tools
– Data

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 Summary
(continued)

n Control Concepts
– Disturbance minimization
– Feedback and feedforward
– Control tools matched to control problems
– MPC is the first truly “digital” control tool
n Application of Engineering Knowledge to
Operations

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