Process Solutions

Profit Controller Design

Considerations

Process Solutions

Designing An RMPCT Controller

Functional design
Preliminary plant test /PID tuning
Application design
Final plant tests
Identification - modeling
Off-line controller build/simulation
Commissioning
Trouble Shooting
Operator & engineer training

Process Solutions

Functional Design
Define Process Control Objectives
Economics
Operation
O
ti

Specify:
Manipulated Variables (MVs)
Disturbance Variables (DVs)
Controlled Variables (CVs)

Identifyy and Assess:

Missing Instrumentation
Basic Regulatory
g
y Control Performance

Process Control Objectives

Process Solutions

Understand the process and its operation in detail

No shortcuts here
Discuss with process operators and engineers
Observe
Ob
the
h process

Understand the problems

O
Operational
ti l problems,
bl
process problems,
bl
or control
t l problems
bl
Find out how operators typically handle problems

Understand operating objectives of the process (unit)

Unit objectives, performance criteria
Integration with other process units

Define the control objectives

Be reasonable
Get buy-in from users (review with operations)

Control Expectations

Process Solutions

What should we expect the controller to do for us ?

Key
y process
p
parameters within limits subject
p
j to noise level
Minimize movement in MVs
Steady State optimization
Stabilize process (downstream units)
Allow operator to perform other tasks

What
Wh t should
h ld we nott expect:
t
Cannot solve physical equipment limitations
Control of Model Based Control Variables depends on
accuracy of model (Inferential or Engineering Model)
Control of Analyzer based Control variables depends on
analyzer
l
reliability
li bili

Set / Revise the control expectations accordingly

Process Solutions

Process Economics
Understanding the economics of the unit is
essential to designing
g g ggood controls
Discuss with operations, planners and schedulers
What are feedstocks,
feedstocks products ?
What is the economic aim. Maximize feed, product
value,
l conversion,
i energy efficiency?
ffi i
?

Process Solutions

Process Operation
Process operation is best understood by
Operators,
p
superintendents
p
and pprocess engineers
g

Know how the planners targets are turned into

daily operating objectives
Understand the process limits and constraints
(often very plant specific)
Operations objectives may conflict with planning
objectives
bj ti
Resolve this. get the key people in the same room

Process Solutions

Examples of Process Limitations

Overloading
Design
g capacity
p y limitations

Flooding
Jet flooding
flooding, causes poor separation

Heat Exchanger Limitations

Pinch
Fouling
Overhead
O h dC
Cooling
li (Summer)
(S
)

Process Instrumentation
Sensors should function correctly
minimum noise
responsive

Quick responding
Minimum deadtime

representative and accurate

precise

Valves in working order

minimum hysteresis
free moving

Where ppossible,, fix anyy problems

p

Process Solutions

Process Solutions

Equipment Limitations

Plant design capacity in general

Rotating equipment loading (amps)
Valve openings (pressure drops)
Heat exchanger performance
Heater design limitations (TMT, Q)

Process Solutions

Regulatory
R
l
Control
C
l Strategy
S
1
((Platform for RMPCT))
Break regulatory PID control cascades ? (e.g. top
temperature to reflux flow)
does the loop reject disturbances
does the loop work well

Use commonly used metrics e.g. ITSE, ITAE

C
Compare
to minimum
i i
variance
i
performance
f
Use a commercially available package for evaluation

does the loop respond fast relative to RMPCT

Regulatory controllers can reduce model matrix

d it
density

Process Solutions

Regulatory
R
l
Control
C
l Strategy
S
2
(platform for RMPCT))
(p
Break regulatory level control loops ?
Is there sufficient level control inventory ?
Is the level control valve adjusting the feed to another
unit ?
Do we need to stabilize the feed to the downstream
unit ?

for quality control reasons

pushing the unit closer to constraints

Step testing more difficult

Can calculate models for many level configurations

Process Solutions

Regulatory Controller Tuning

Tune regulatory controls preferably before pre-step
tests and certainlyy before main step
p test
Dynamics of regulatory controls are embedded in
matrix model
Poor regulatory controller tuning leads to poor
performance of MVPC
Consistent regulatory controller tuning leads to
optimum
ti
performance
f

Process Solutions

Controller Scope 1
Decide on boundaries between RMPCT controllers
One bigg controller coveringg multiple
p units, e.g.
g
FCCU reactor/regenerator and main fractionator and
light-ends columns
Separate controllers for

Reactor/regenerator
M i fractionator
Main
f ti t
Light-ends columns

Process Solutions

Controller Scope 2
One large controller
Enables unit wide optimization in control matrix
Handles common constraints between sub-units

Individual controllers

Less diverse range of CV response times

Cannot handle common constraints between sub-units
More control over possible MV/CV pairings
Easier to step test - less time
Easier to commission
Higher service factor (Improved operator acceptance)

Choosing MV's
MV s (control issues)

Process Solutions

Independent of other MV's and DV's (exceptions)

Not only
y its moves,, but also its effects on CV's

Independent of other control schemes

Minimum requirement: one-way interaction
Tuning for inactive MIMO controllers can be risky

A good MV should have

Significant effects on some CV's
Predictable effect on all CV's (if none thats OK too)

Use
U ffor control
t l vs for
f optimization
ti i ti
Control

MV's with a fast,, strongg and ppredictable effect,, with a good

g
range
g to
move

Optimization usage

MV'ss with small effect and MV

MV
MV'ss with a less predictable effect

Choosing MV's (design issues 1)

Process Solutions

Write to SP vs OP
G
Generally
ll write
it to
t SP
Use the SP if the OP is a valve or is more non-linear than the SP
W
When
e thee OP
O iss also
so a constraint
co s

SP equation vs load response equation

Choose SP response equation
Tune PID for SP tracking, not for disturbance rejection
Remember configuration/tuning is imbedded in dynamic model

Set up proper windup handling

Must always propagate the MV windup back to the MV interface point

A
Avoid
id trim
i controls
l andd "too
"
big"
bi " valves
l
Avoid compound MV's

Choosing MV's (design issues 2)

Process Solutions

Be careful about discontinuities

Split range valves
Overrides

Consider linearizing when appropriate

MV linearization ((not yet

y possible)
p
)
Top temperature instead of reflux flow control
Duty control (can be a double
double-edge
edge sword)
Ratio control

Check shed
shed-modes
modes

Process Solutions

Choosing MV's (design issues 3)

Some are obvious
The operator
p
ppreviously
y used them

Some are less obvious

Because a regulatory controller SP is hardly ever
changed, does not mean it should not be a MV

Process Solutions

Examples of MV's

Reflux flow
Reboiler flow or dutyy
Tray Temperature
Overhead Pressure
Feed Temperature
Feed Flow
Compressor Speed
Heater Fuel Gas Pressure

Choosing DV's
DV s (control issues)

Process Solutions

Must be independent of other MVs and DVs

Significant effects on CV's
Reliable measurement
DV change must be independent of MV's and other
DV's

Sometimes desirable to specify as DV for selected

CVs and as MV for remaining CVs (be aware of
consequences in
i terms off sub-optimality)
b
i li )

DV's often cannot be moved independently

Does that violate the rule of independence?
What if some of them always come together?

Use only one of them

Choosingg DV's ((design

g issues))

Process Solutions

Be careful about DV's from recycle streams

Often not independent from the MV's
MV s

OK, if the recycling period >> the unit response time

Problematic, if the recycling period ~ the unit response
time
i

Causes many difficulties in the model identification

When you "step"

step the DV
DV'ss
Decoupling the effects of the DV's is the key

Be careful about inferred DV

DV'ss
Watch out for integrating DV's

Process Solutions

Examples of DV's
Feed flow
p
Feed temperature
Feed composition (analyzer)

Choosing CV's
CV s (control
(
l issues)
i
)

Process Solutions

Dependent on at least one MV

Controllability of that CV under all operations and all year
around
Build the relationship between the CV and the control
objective

For measured CV
CV'ss
Consider measurement noise, dead-time, and dynamics

For inferred CV
CV'ss
Replaces/complements on-line analyzer
First p
principle
p engineering
g
g model

Process Solutions

Choosing CV's (design issues 1)

Three main classes
regulated, (to improve unit stability)
restrained,
restrained (operational limits)
optimized, (economic benefit objective)

Consider linearity of the CV response

use logarithms for compositions for high purity specs.
be
b aware off di
discontinuities
ti iti

Level
Valve positions

Process Solutions

Ch i CV's
Choosing
CV' (design issues 2)

Current and future constraint requirements

Soft vs hard constraint specifications
Cl d l
Closed-loop
control
t l response time
ti
Be careful about parallel CVs:
Matrix conditioning number

Proper CV validation
Bad value check and handling
Frozen check
Rate of change check
High
g and low limit check

Process Solutions

I f
Inferential
ti l Calculations
C l l ti
1
If analyzer is not available, is unreliable or deadtime is pprohibitive consider use of inferential
calculation
Use a statistical modeling tool which includes
various techniques such as:
Linear models
Partial least squares
Neural Networks

Inferential Calculations 2

Process Solutions

Develop
p / understand the models for calculations and the assumptions
p
behind them; most models are steady state models
Make sure that inputs with different dynamic are synchronized properly to
avoid adverse dynamic
dynamic. Consider dynamic compensation of the inputs
Draw a proper envelop for mass / energy balance calculations; the larger
the envelop, the more likely that signals with different dynamics will
affect the dynamic response
Consider a lab / analyzer update scheme in the model
Consider using SPC to track performance of inferential calculation
Regulatory controllers may have adverse effect on the calculation
Find that out and re-tune that controller before the final plant test

Process Solutions

Choosing Objective Function (LP) 1

J = min $ icost cv i + $ cost
mv j
j
x ss
i
j

Linear Program Optimization

Try to push to a corner of operating regime
Minimize utilities or other operating variables
Maximize most valuable product

Product Value Optimization (PVO)

Process Solutions

Choosing Objective Function (QP) 2

J = min
i $i cost (cvi yiss )2 + $j cost (mv j u ssj )2
xss
i

Quadratic Program Optimization

Use to keep
eep CV's/MV's
CV s/ V s aaround
ou d a desired
des ed opt
optimal
a soft
so t
target

Assumes the optimum MV/ CV values are known

Can be downloaded from rigorous model/optimizer

Difficult to prioritize CV QP terms against other LP

costs. Alternatively
Al
i l use soft
f bounds
b
d

Process Solutions

Choosing Objective Function 3

Add soft bounds for CV's and MV's
Cushion against
g
hittingg hard limits and wind-up:
p

CV constraint limit (Valve positions)

MV setpoint limits

Slowly bring integrating CVs within desired range

Drum levels CV's from 45 to 55 %

Open up product
d quality
li targets to relax
l MV
movement:

Consider using a narrow range instead of a fixed product

quality target

Process Solutions

Class Exercise
Debutaniser & Depropaniser Units
Define MV's, CV's, and DV's for one or two controllers

Process Solutions

Debutanizer

dPtop

Propane
F

Reflux
T

C3s/C4s

Reflux

%iC5
F

%iC4

Steam Reboiler

Steam Reboiler

dPbottom

Feed

%nC4

%C3
L
Q

Q
T
T

Butane

C5s

Depropanizer

Gas Plant 1
Feedstock
C2 to C8

Products

C2 andd lighter
li h to fuel
f l gas
C3 (Propane)
C4 (Butane)
C5+ (Heavier cut for further processing)

Product
P d Q
Quality
li S
Specifications
ifi i

Max. % nC4 in C5+

Max % iC5 in C4
Max.
Max. % C3 in C4
Max. % iC4 in C3

Process Solutions

Process Solutions

Gas Plant 2
Objectives
Maintain pproduct qqualities within specifications
p
Minimize energy consumption (steam)
Maximize feedrate

Process Constraints

Steam utilization
Off-gas from debutanizer
Flooding (both towers)
Depropanizer reflux drum level control valve position

Process Solutions

MVs

DVs

CVs

Process Solutions

Layered Approach to APC

First ensure basic controls work well
p
in order of complexity,
p
y
Consider optimization
cost and economic return:
1 Install RMPCT
2 Consider multi-unit optimization (DQP)

Optimization
p

Process Solutions

1st level of optimization is included in RMPCT

as product value optimization or by setting MV
priorities to push MV's in the right direction
sequentially
This
Thi provides
id optimization
ti i ti on a subb unit-wide
it id
basis
Only considers one sub unit on
on its own
own
It is sometimes worthwhile running a unit suboptimally so that other units can be run even more
profitably
fit bl
It is sometimes worth backing off upstream
because a downstream unit is limited

Downstream unit capacity limited so reduce

conversion target to relieve constraint

Process Solutions

Di t ib t d QP Approach
Distributed
A
h
Economic Objective

J = QP1 + QP2 + QP3 + ... + QPn

Distributed QP

App1
A
1
(QP1)

App
(QP2)

App3
A
3
(QP3)

App n
A
(QPn)

Economic objective function is sum of

individual RMPCT objective functions

Process Solutions

Profit Optimizer co-ordinates the economics of

multiple RMPCT controllers for Optimization across
J = QP1 + QP2 + QP3 + ... + QPn
many units
App1
(QP1)
x

x
x

App2
(QP2)

App3
(QP3)

Combined Constraints

App n
(QPn)

Process Solutions

Advantages with DQP approach

Quickly achieve 85+% of the total benefit
achievable with optimization
No
N steady-state
t d t t detection
d t ti needed
d d
No model validation and update
Easy to maintain the model
Can be expanded to 3rd level optimization later
if economically justified
Linearized 3rd level model gains extracted and
downloaded to lower layer. Lower layer
performs optimization