DCS-Layer Advanced Process Control Consortium

DCS-Layer Advanced Process Control ConsortiumDCS-Layer Advanced Process Control ConsortiumDCS-Layer Advanced Process Control Consortium



Sparse matrix MVC/MPC in DCS to unlock the highest possible ROI

DCS-Layer Advanced Process Control Consortium

DCS-Layer Advanced Process Control ConsortiumDCS-Layer Advanced Process Control ConsortiumDCS-Layer Advanced Process Control Consortium



Sparse matrix MVC/MPC in DCS to unlock the highest possible ROI

What is DCS-Layer APC

APC History

APC techniques for the petrochemical industry were first developed for pneumatic control systems (Foxboro) in conjunction with main frame computers (IBM 360) in 1960s. In 1970s, Honeywell developed function blocks in TDC 2000 that allowed APC strategies to be configured instead of programed in private digital networks. Advanced regulatory control was the golden standard to implement control and optimization solutions in 1980s. In 1984, DMC corporation was formed that accelerated widespread adoptions of multi-variable model-predictive controllers (MVC, MPC). While the sequential LP trade-offs and dynamic decoupling remain superior features in MVC/MPC, many smaller APC applications can be effectively implemented in modern DCS without MVC/MPC licenses. 

Modern DCS

In late 1990s, Foxboro IA released visual editors for building DCS loops (ICC Configurator). In 2000s, Honeywell Experion allowed visual connections of DCS function blocks (Control Builder). These flowsheet arrangements make creating APC schemes in DCS much more manageable. Advanced regulatory control (ARC) became unpopular in 1990s after the invention of DMC but resurfaced in modern DCS. Many petrochemical operators selectively decommissioned MVC/MPC and implemented equivalent APC functions in DCS.  Successful examples include dual-end composition controls for distillation column, feed maximization against shifting constraints in Olefins/NGL trains, and fired heater optimization against shifting limits. 

DCS-Layer APC vs. MVC/MPC

The commercial MVC/MPC continues to be an effective tool for complex APC. For example, a crude tower with 3 product draws can form a 3x3 dense matrix. The use of MVC/MPC allows efficient dynamic decoupling and optimization of trade-offs.  A fired heater with 4 passes can form a 12x4 dense matrix where multiple CV violations are managed by a LP optimizer.  A fractionation train can have DCS level loops disengaged and let MVC/MPC to handle long delays from the front to the back end. 


On the opposite side of the spectrum, many MVC/MPC applications have small core matrix without the need of rigorous LP, optimization of trade-offs, and dynamic coupling. For example, a deethanizer with two product specs may not need a commercial MVC/MPC at all. Planning and economic often determines the optimal targets for C3% at the overhead and C2% at the bottom where the need of trade-offs and LP in MVC/MPC becomes absent. The need of dynamic decoupling by MVC/MPC is frequently a mystery. The relative gain array (RGA) calculation for the 2x2 deethanizer may determine the need of decoupling to achieve stable operations. However, many unstable 2x2 are indeed stable when dynamics are included in RGA. The use of two independent DCS loops for controls of C3% and C2% proves to outperform Deep-Learning AI controllers. 


In summary, DCS-Layer APC is

•  Suitable for sparse matrix models with favorable dynamic RGA. 

•  Based on traditional ARC with additional MPC/MVC functions for relatively small APC. 

•  Proven to handle nonlinear gain/dynamics and transitions between S.S./ramp. 

•  Inherently model predictive controls without explicit presentation of models. 

•  User friendly due to the use of standard DCS features.

•  Free of MVC/MPC licenses. 

•  Based on MINLP PID tuning  that outperforms MPC/MVC for unmeasured disturbance rejections.


DCS-Layer APC Successes

Olefins/NGL  

"The DCS-Layer APC has been one of the greatest accomplishment this year and is worth >5 $MM/yr per application"


Refining

DMC projects are terminated and replaced with DCS-Layer APC applications in Honeywell Experion.


Chemical 

Nonperforming MVC/MPV controllers are decommissioned and replaced with DCS-Layer APC applications in Honeywell HPM.  "The additional uplift by the DL-APC is worth 1.1 $MM/yr" 

Neglected Insights

  • Unstable multivariable control loops identified by steady-state RGA can be closed-loop stable when dynamics (dynamic RGA) are considered.  Controls of dual-end fractionators  are  successfully implemented in modern DCS as two separate PID loops.


  • Spare matrix MVC can be more effectively implemented in modern DCS using standard DCS features without additional license or subscription fees.


  • Inferential properties can be installed in modern DCS using standard DCS features.


  • Open-loop feedforward is proven to be more effective and robust on Olefins/NGL trains than MPC or AI controllers.  


  • Hybrid AI models that combine traditional first-principle equations and deep leaning AI plant models can be used with MINLP to validate the structural design of DCS-Layer APC.


Top 10 Misinformation - Videos Coming Soon

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1. Flaws of steady-state relative gain analysis (RGA)

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2. Flaws of dynamic decoupling in MVC/MPC

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3. Misrepresentation of LP solutions

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4. Flaws of Deep Learning Spaghetti  Models

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5. Weakness of Deep Learning AI Controller

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6. Transitions Between S.S. & Ramp

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7. Flaws of IMC PID tuning

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8. Hidden PID Performance Curves

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9. Hidden MPC Characteristics in PID

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10. Neglected Nonlinear PID Features

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11. Neglected PID Tuning Parameters

Contact Us

Sparse matrix MVC/MPC embedded in DCS to unlock the highest possible ROI

We are independent APC practitioners interested in sharing insights about APC structural analysis and training.  We are specialized in formulating APC applications as MINLP problems and advise the most elegantly simple process control solutions ranging from simple PID loops to rigorous RTO.  In particular, we share know-how that helps convert  nonperforming sparse matrix MPC/MVC applications to the most profitable DCS-Layer APC.  

DCS-Layer APC Consortium

Alaska, United States

info@DL-APC.com

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