DCS-Layer Advanced Process Control Consortium
Sparse matrix MVC/MPC in DCS to unlock the highest possible ROI
DCS-Layer Advanced Process Control Consortium
Sparse matrix MVC/MPC in DCS to unlock the highest possible ROI
Sparse matrix MVC/MPC in DCS to unlock the highest possible ROI
Sparse matrix MVC/MPC in DCS to unlock the highest possible ROI
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.
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.
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.
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"
1. Flaws of steady-state relative gain analysis (RGA)
2. Flaws of dynamic decoupling in MVC/MPC
3. Misrepresentation of LP solutions
4. Flaws of Deep Learning Spaghetti Models
5. Weakness of Deep Learning AI Controller
6. Transitions Between S.S. & Ramp
7. Flaws of IMC PID tuning
8. Hidden PID Performance Curves
9. Hidden MPC Characteristics in PID
10. Neglected Nonlinear PID Features
11. Neglected PID Tuning Parameters
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.
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