02 apc project run through

7/21/2019 02 APC Project Run Through

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APC Project Scope

Pre-Project Activities

Kick-Off

Functional Design

Pretest Activities

Plant Test

Model Building

Coissioning ! Tuning

Benefit anal"sis# Docuentation

Sustained Perforance

February 21, 2016 Reliance Technology Group – APC / RTO 3



Pre-Project Activities

APC PC setup

• APC $ngineer-Offline PC-Online PC-DCS

C%M%O&OPC setup

Soft'are (DMCPlus) Setup

Data collection

PFDs# P!%Ds# DCS grap*ics and Process description

Preliinar" Functional design docuent (FDS)




February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation5

+o, esponsi,ilities

Preliminary Benefit Analysis for APC CTS

CS !om"atibility to a!!e"t Set"oints from APC

Controller

#T$%&nst'Site%&nst

CS !om"atibility to !ommuni!ate (it) APC ser*ers #T$%&nst'Site%&nst

CS !a"a!ity to +et loae by aitional lo+i!s for APC #T$%&nst'Site%&nst

APC -nline ser*er Pro!urement #T$%&nst'Site%&nst

APC offline ser*er Pro!urement .-"tional butre!ommene/

#T$%&nst'Site%&nst

&nterfa!e to lin CS an APC Ser*er #T$%&nst'Site%&nst

Soft(are loain+ in APC -ffline an -nline ser*er #T$%&nst'Site%&nst ' #T$ APC

stablis)in+ !ommuni!ation bet(een -nline an CS #T$%&nst'Site%&nst ' #T$ APC

Startin+ ata Colle!tion #T$%&nst'Site%&nst ' #T$ APC



• Plant or CTS person e.plains t*eprocess along 'it* operatingp*ilosop*"

• Current constraints restrictingsectional or plant t*roug*put

• eactor operation procedure 'it*respect to severit"# selectivit" and

safet" aspects• /a, data for soft sensors• Scope of t*e controller and

e.pectations fro plant and CTSpersonnel

• Project sc*edule and et*odolog"#contact person# and tea e,ers

• 0ard'are# soft'are setup and T1connectivit"

• Milestones


Kick-off



%t defines t*e entire control scope for DMC and ensures t*at

• All significant interactions in t*e plant are included• T*e econoic o,jectives to ,e ac*ieved are 'ell defined

/ists out t*e M2s# C2s and D2s of t*e unit and t*e total M2-C2 atri.

%t defines M2-C2 Control P*ilosop*" including

• Ai of t*e control sc*ee for eac* e3uipent and section• Bot* C2 control ," M2s and M2 utili4ation for ot*er C2s

DCS /ogics to ,e incorporated for APC Custo Calculations for APC

February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation

Functional Design



• Correct kno'n deficiencies in %nstruentation5egulator" controls

• Filter 6ois" Signals

• P%D Configuration finali4ed in DMC7 econfigure '*ere re3uired

• %nstall kno'n Soft sensors calculation in DCS

• DCS calculation ,locks

• %dentif" %nstruents&egulator" Controllers to ,e e-ranged

• Make preliinar" odel and identif" t*e direction and step c*anges in M28s and effect on

C28s


Pretest Activities



P%D Tuning• Stick" valve identification• Anal"sis of P%D loops (SP# P2 ! OP) and identif"ing loops to ,e

tuned• Calculating P%D paraeters• Tuning loop 'it* ne' P%D paraeters


Pretest Activities



Preparedness for t*e Plant Step Test•Constraints t*at prevented t*e particular M2s to ,e c*anged ,e"ondits a.iu step si4e9•P%D controller configuration during pretest # plant test and in DMCcontroller s*ould ,e sae9•Constraints t*at ,ecoe active7 full opening or full closing of valves#

out of range orifices# colun flooding etc9•Finali4e a sta,le P%D configuration•Move all M2s# D2s and utilities B/ valves : to ; ties


Pretest Activities



• Ai for <= to <> steps in eac* M2• ?se a.iu step si4e• C*eck for an" constraints t*at ,ecoe active and in ne.t step ai to avoid

t*e constraint• /ook for percepti,le c*ange in t*e ain C2 for t*e step carried• /ook for an" uneasured distur,ance (i9e9 Tags not included in t*e clc)

creeping into t*e step test ," o,serving une.plaina,le c*anges in C2• 6ote do'n an" P%D configuration c*anges ade ," PO7 Auto to local#

Cascade to decascade# anual operation of ,"pass of control valves

• 6ote do'n an" anual valve operation# regeneration# flus*ing# line ups#offspec processing# an" operational or aintenance procedure ,eingcarried out during step test

• @atc* continuousl" t*e %P:< trends and look for une.plained ,e*avior inC2s and M2s

• un fe' ,ase cases interittentl" to c*eck for accepta,le odels ,eforestep test is stopped


Plant Test


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Plant Test Forat



• Make Model file and controller nae• Setpoint# Output and Meas vector list in DPP• M2# C2 ! D2s list in DPP• Calculated and DCS Soft sensor vector list in DPP• %dentif" ,ad slices 'it* reasons arked• All M2s vs 2alve output case• All M2s vs All control C2 case• All Sectional M2s vs control C2 case '*ere re3uired

• %ndividual C2 cases are ade• Cross correlation anal"sis• $valuate case prediction• Build Final Model7 C*oose Model Curves and Curve Operations• $valuate Model prediction 1A and condition nu,er7 1A<= and

C6<=e for :.: atri.


Model Building



Model Building-%port 2ectors



Data slicing

•Bad Data invalidates t*e data set 7

- Process pro,le&upset

- Coputer pro,le (C%M%O )

- 0ard'are &%nstruentation Failure

- 2alve Saturation

- At"pical distur,ance


Model Building



Building cases

• %nclude all independent varia,les t*at ipact Dependent varia,les in t*e

case

• Onl" sallest su,-set of good data is used - data t*at is good for all

varia,les in t*e case


Model Building




Model Building-Auto correlation




Model Building-Cross correlation




Model Building-Prediction



•C*oosing odel curves

• C*oosing appropriate odel curves fro cases (Sign# D"naics# 1ain)

• $valuate Model prediction

• 1A ! S2D ! Condition nu,er anal"sis7 1A<= and C6<=e for :.:

atri.

• Build final odel to ,e used for controller


Model Building



CCF

• %port Model and define options for Coposite# $T8s and

Su,controllers• Develop CCF7 Define C28s# M28s# FF8s# and Su,controllers# @atc* dog

countdo'n

• Provide C2# M2#FFEs Description

• Develop online calculations

• Provide Perforance %nde. Calculations ! Controller c"cle tie

• Provide %nterittent Anal"4er (1C)

•CCF Custo logic for M2 *and s*ake

• DCS custo logic for M2 0and S*ake


Model Building




CCF



• For M28s7 Define Move Suppression# Ma. Move# Ma. SS Move# M2 cost

• For M28s7 C*eck all lo'er and upper liits specif" critical and 'ind upstatus9

• For C28s7 Define ?pper and lo'er liit ranks# SS and d"naics $C$8s

and C*eck all lo'er and upper liits also c*eck critical flags9


Offline controller siulation and tuning



Simulation (ino(, "ant !ontroller moel


Siulation



• Plant O,jectives and Constraints

• Controller odel revie'

• Soft Sensors revie'

• CCF Configuration

• Siulation

• Make DCS /ogics ! APC grap*ics in Plant


Model evie' Meeting



• Plant revie' of t*e odel# control p*ilosop*" and siulations

• Open loop Coissioning and inforal operator training

• DCS /ogic c*ecking CCF /ogic c*ecking• %nstall and evaluate inferential predictors

• %nstall operator interface

• M2 step si4es#

• Move Sup c*eck

• C2 anks and $C$ c*eck• /iits c*eck ," Plant

• Controller Prediction error and Direction C*eck

• Closed loop coissioning

• Online fine tuning and onitoring

• Operator and engineer training


Controller coissioning



•


PC@S



•


1CS



• Process Description

• Control P*ilosop*"

• /ist of M2s and C2s• Custo and %G Calculation

• Custo M2 logics

• Safet" constraint ranks

• Stead" state gains7 odel curves

• Standard Calculation and logics

• DCS grap*ics

• PC@S snaps*ots


Docuentation



%P:<# $.cel# Po'ertools etc can ,e used

Basis7•%dentif" sources of ,enefits

•Decide '*at paraeters to ,e used to detect

,enefits

•Aplif" nu,ers ," using statistical paraeters

like C?S?M

•Select data for coparison ,efore and after APC

Material Balance 7•Keep aterial ,alance and adjust isatc* in input

or output

•?se soe sort of averaging to avoid effect of

d"naics

$conoics7

•Make sure t*at profit at one place is not a loss at

anot*er place

•?se actual prices and plant nu,ers

•Calculate ,enefits at regular intervals

Tools7

•?se %P:<# $.cel# Po'ertools# Minita, etc for anal"sis


Benefit Anal"sis



Anal"sis-$O and C? Section# 6agot*ane

Met*odolog"

•Material ,alance error closed ," adjusting c"cle gas purge9

•Stea generation credit is accounted in t*e profit9

•;HH *rs of %P:< data 'it* APC offline and inline is used to anal"4e t*e profit9

0ourl" averages are used9

•Data for lo' capacit" and plant upsets is reoved9

•Cuulative su (C?S?M) is used to trend and calculate profit9


Benefit Anal"sis- $.aple

P fit C t C d $O



ar!) 10, 200

Profit Coponent I Crude $O

Profit of 9<J crores&annu

Profit Coponent Stea generation



ar!) 10, 200

Profit Coponent I Stea generation

Profit Coponent $t*"lene t*roug*put



ar!) 10, 200

Profit Coponent I $t*"lene t*roug*put

/oss of :9;H crores&annu

Profit Coponent O."gen t*roug*put



ar!) 10, 200

Profit Coponent I O."gen t*roug*put

Profit Coponent Selectivit"



ar!) 10, 200

Profit Coponent I Selectivit"



ar!) 10, 200

Profit anal"sis

Sr9

6o9

Feed&Product

&?tilities

Average'it* APC

Offline

Average'it* APC

%nline

C?S?Mvalue for :>J

saples

Mass

Balance

Price Profit

MT & 0r MT & 0r MTMT &Da"

s &MT

Crores & Annu

< $t*"lene >9< H9== :;9: -:9<H ;==== -:9;H

: O."gen H9: H9>= :<9:< -<9: <<<< -=9=L

;Crude

$t*"leneO.ide

J9;H J9L ;=9:= :9LL ;J= 9<J

Steageneration

:>9J= :H9=J H9=H L9LL >=< =9<H

Total Profit 1.89 Crores per annum



• Controller onitoring and en*anceent

• Maintain on-going training efforts


Post Coissioning Sustained Perforance

# i t f APC P 9 t t b i Pl t




+o, esponsi,ilities

Preliminary Benefit Analysis for APC CTS

CS !om"atibility to a!!e"t Set"oints from APC

Controller

#T$%&nst'Site%&nst

CS !om"atibility to !ommuni!ate (it) APC ser*ers #T$%&nst'Site%&nst

CS !a"a!ity to +et loae by aitional lo+i!s for APC #T$%&nst'Site%&nst

APC -nline ser*er Pro!urement #T$%&nst'Site%&nst

APC offline ser*er Pro!urement .-"tional but

re!ommene/

#T$%&nst'Site%&nst

&nterfa!e to lin CS an APC Ser*er #T$%&nst'Site%&nst

Soft(are loain+ in APC -ffline an -nline ser*er #T$%&nst'Site%&nst ' #T$ APC

stablis)in+ !ommuni!ation bet(een -nline an CS #T$%&nst'Site%&nst ' #T$ APC

Startin+ ata Colle!tion #T$%&nst'Site%&nst ' #T$ APC

APC 7i!off Preliminary P)iloso")y is!ussion Site%-"'CTS'&nst ' #T$ APC

Ste" Test, oel Builin+ #T$ APC

CS lo+i! builin+ Site%&nst

FAT Commissionin+ Site%-"'CTS'&nst ' #T$ APC

Controller -nline tunin+ o!umentation benefit Analysis

#T$ APC

#e8uirement for APC Pro9e!t to be one in a Plant:

02 apc project run through

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