a tool module developed for pro/ii and dynsim applied to...

2014 Software Global Customer Conference - September 30 - October 2

A Tool Module Developed for PRO/II and DYNSIM

Applied to Process Plant-wide Control Structures

Design at PETROBRAS Projects

Prof. Dr. Heleno Bispo Prof. Dr. Sidinei Silva

Chemical Engineering Department Federal University of Campina Grande – Brazil Herbert Campos Gonçalves Teixeira

PETROBRAS Research and Development Center - CENPES


• Introduction

Petrobras use PRO/II for process

design in its project.

The static simulation results feeds

Comos and there are several tools that

use the process data for equipment

sizing.

But How Petrobras design control

structures?

There was not any tools.


What is the challenger?

HDT


Petrobras and UFCG present you a tool for Plant Wide Control using

Self-optimizing methodology

From base case, a case

Study varying all

combinatory disturbance

is automatically done

(plant flexibilty)

During Basic design, one PRO/II

simulation is elaborated Grids with

results are

obtained Use an Add in,

BRPWC tool, for

automatically

select the best

CVs and pair

MVs

Translation

Adjustment tool of

the PRO/II to

Dynsim convertion

All control strategies are

validated in Dynsim model

and feedback the basic

engineering design

PID tuning tool are

used to adjust

automatically all

controllers for equal

performance

evaluation


Self-optimizing Control

The set point constants cs

results in a "nearly optimal

operational", i.e., an

acceptable loss L for the

expected implementation

errors n disorders.

( , ) ( , ) ( )opt

sL d n J c n d J d

Acceptable loss!

Self-optimizing Control


How Easy Is Build a Tool to Work With PRO/II ?

• PRO/II uses COM Technology to enable the user get or input data into *.prz file!

• Full documentation with real examples;

• Easy to understand and use;

• Open to personal application with PRO/II;

• Various languages for applications;

Component

Object Model

(Microsoft) Working in

background!


GUI of BRPWC Tool


GUI of BRPWC Tool

Worksheet with plantwide control tool after selection of MVs, CVs and disturbances.


GUI of BRPWC Tool

Worksheet with plantwide control tool after selection of MVs, CVs and disturbances.

Worksheet with results of

all increments and

decrements generated by

the tool used.

Worksheet with

the gain matrix of

the increments of

VMs.

Worksheet with

the results of the

gain matrix of the

disturbances.

Worksheet sets of

variables and their

minimum singular

values.

Results of Sets

of CVs


Challenger Two…

Optimization...

Define the optimal operation:

-minimizing the cost function!

Hard Work!

Plantwide by Self-

optimizing Control

methodology


Solution: Build One Reduced Model


Our first solution: Build One Reduced Model

Inputs of

User!

Possible CVs

depends of

inputs!

Our Solution

was very slow...


Final Solution: Use PRO/II Case Study

Case Study

Export

“*.INP” file By add-in,

modify

“*.INP” file to

write all

combination

desired

Import

modified

“*.INP” file

from

PRO/II

Run

Simulation


Validation With Dynsim

Build the control structure

with the best set of

controlled variables.


Translation Adjustment Tool - TAd (PRO/II DynSim )


• Motivation

Once the set control structure designed by BRPWC toolbox:

• The dynamic simulations for design validation will be necessary;

• The test, which need to start in a steady-state given by PRO/II model, will analyze the optimal control structure given by the plantwide control methodology;

• To avoid rebuilding static model in a dynamic environment, the translate procedure from PRO/II model to DynSim need to be used;

• And, most importantly, start it up from current steady-state equilibrium point.


Translation

• Introduction

• Standard Translation Process

Stationary

SIM4ME

SQL

Startup

Dynamic


Start up in a

previously

specified steady

state

TAd Tool

• Adjustment Process by Tad Tool:

• Introduction


Pressure

Node

Pressure

Node

Pressure

Node

Pressure

Node

Flow

Device

→ Primary (Pressure Nodes);

→ Secondary (Flow Devices).

• Methodology

(Stationary Simulation)

(Dynamic Simulation)


1

2 3

1 – Mass and Energy Balances:

2)()()(

2)(

).(

2222 D

rrhrrhr

hrarcsenr

rhA

LhAVliquid

2 – Geometry:

3 – Valve Position:

massrefcritv

ref

RPC

WOP

.00075379.0 ,

VLT

VVV

LLL

TVVLLT

ViLi

i

T

VLT

vvv

vn

vn

Pvnhnhu

nynxn

nnn

• Methodology


TAd

1 – Inventory updating;

2 – Adjusment of the valve

position (liquid path).

1

2

• Adjustments

SQL

SQL

.dyn

.dat

1

Cycle

• Methodology


Solution

FLASH.DIA (m) 0.5 To DynSim STATIC

FLASH.LEN (m) 2 To DynSim STATIC

FLASH.VOL (m3) 0.392699 To DynSim DYNAMIC

vL/vT 0.5 Given by user

vL (m3) 0.19635 Calculated here

vV (m3) 0.19635 Calculated here

nL (kg-mol) 1.361715 Calculated here

nV (kg-mol) 0.117774 Calculated here

xi yi

H2 0.003551 0.156221

N2 0.000579 0.060248

METHANE 0.003776 0.228617

CH 0.977661 0.545833

BENZENE 0.014433 0.009081

hL (kJ / kg-mol) 35942.5

hV (kJ / kg-mol) 35568.8

rhoL (kg-mol / m3) 6.93516

rhoV (kg-mol / m3) 0.599818

P (kPa) 2352.17

T (K) 471.645

MWL 83.4926

MWV 52.3177

FLASH.MT (kg-mol) 1.479489 To DynSim DYNAMIC

FLASH.M[H2] (kg-mol) 0.023234 To DynSim STATE

FLASH.M[N2] (kg-mol) 0.007884 To DynSim STATE

FLASH.M[METHANE] (kg-mol) 0.032067 To DynSim STATE

FLASH.M[CH] (kg-mol) 1.395581 To DynSim STATE

FLASH.M[BENZENE] (kg-mol) 0.020723 To DynSim STATE

FLASH.UT (kJ) 52208.84 To DynSim STATE

FLASH.L (m) 1 To DynSim DYNAMIC

FLASH.LFRAC 0.5 To DynSim DYNAMIC

FLASH.FLASH.H (kJ/kg-mol) 6.430838 To DynSim DYNAMIC

FLASH.FLASH.LF1 0.920396 To DynSim DYNAMIC

FLASH.FLASH.MW 81.01094 To DynSim DYNAMIC

FLASH.FLASH.R (kg-mol/m3) 3.767489 To DynSim DYNAMIC

FLASH.FLASH.U (kJ/kg-mol) 35288.42 To DynSim DYNAMIC

FLASH.FLASH.VF 0.079604 To DynSim DYNAMIC

FLASH.T (K) 471.645 To DynSim DYNAMIC

S2.F (kg-mol/hr) 18.0895

ds_S2.AREF 0.6

S2.P (kPa) 2357.848 Calculated here

tl_SRC2.P (kPa) 2345.47

ds_S2.DP (kPa) 12.37839 Calculated here

S2.W (kg/s) 0.419539 Calculated here

S2.RMASS (kg/m3) 579.0345 Calculated here

ds_V2.CV 10.95686 To DynSim STATIC

• Translating options:

• Methodology

No controllers need!


Translating

• Methodology


• Graph Theory

• Methodology

• Procedure Automatization


→ Incidence Matrix

→ Adjacency Matrix

→ Flowsheet's Paths

• Example 1

• Tad Tool


• Example 2

• Tad Tool


PID Controllers Tuning Tool


• Tuning Tool developed in VBA Platform;

• SimSci DynSim® processes models;

• Classical methods for PID Controllers.

• Introduction


Step 2:

• Tuning tool operating:

Step 1:

• Excel Engine and Cross

Reference setting:

• Tool Evaluation

• Controller tune interface


• Automatic step test for the tuning and parameters calculation:

• Tool Evaluation


A tool have been developed for Plant Wide Control structure selection

Case Study

• Conclusions


• The plantwide control strategy design tool results, not only in

a set of optimal Control structures, but in several tools that help us to

speedup the usage of dynamic simulation during plant design phase

and OTS design.

• The obtained results have demonstrated a powerful and

promising tool to analysis and control of processes assessment of

actual plants.

• Conclusions


Thank you

Questions?

Acknowledgement

a tool module developed for pro/ii and dynsim applied to...

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