Home Plant PLCs, Advanced process control improves refinery, chemical

/ Automation / PACs / plant operations

Advanced process
control improves
refinery, chemical
plant operations
Next-generation advanced process control
(APC) shatters processing barriers for
process facilities.
BY HIROSHI WAKASUGI AND SANJAY
VENUGOPAL AUGUST 7, 2019

To survive challenging conditions, process

industry firms, including in the downstream oil &
gas industry are actively seeking opportunities to
optimize their entire supply chain. The
economics of national operating companies are
vastly different from international downstream
organizations. Yet all are seeking ways to
increase production margins, improve safety
performance, and maximize equipment and plant
reliability.

Feedstocks and energy are the major costs

items, so downstream companies must view the
entire supply chain to optimize feedstock usage
while shopping for the best value without
compromising quality. Likewise, downstream
companies strive to lower energy consumption
and minimize waste, such as octane giveaway in
transportation fuels. One option downstream
companies are pursuing to improve their
By using this website, youcompetitive
agree to ourposition is implementing
use of cookies. This may include personalization of content and
automation/optimization projects, with advanced
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
 process control (APC) being a critical component
of these efforts.

Tools to innovate

Automation and optimization strategies focus on

how to schedule operations to produce high-
demand transportation fuels, and petrochemical-
and chemical-based products, while improving
yields and conserving energy. Especially in
petrochemical and chemical manufacturing,
being a cost leader is an advantageous position,
and cutting costs requires limiting process
disturbances and downtime.

Since the 1980s, companies have applied various

automation/optimization programs, including
early APC systems, to attain better control of
manufacturing costs and improve daily
operations. First-generation APC programs
suffered from numerous problems, including:

They were tedious to develop with available

computer/software and field instrumentation
technologies.
The APC software programs were difficult to
maintain due to process/feed/grade changes.
Early APC models did not function well with
nonlinear processing conditions.
The systems required frequent attention and
maintenance from control engineers.

Newer APC technologies are addressing these

issues, and delivering other improvements as
well.

Over the past 20 years, APC applications have

benefited greatly from the new computational
power of PCs, more sophisticated “smart” field
instrumentation and wireless technologies.
Leading-edge computer capabilities and software
can support complex simulation models,
enabling APC programs to push operations
closer to processing/equipment constraints. At
the heart of this development is the ability to
By using this website, youmore
agreeclosely control
to our use processing
of cookies. operations.
This may The
include personalization of content and
continuing development of multivariable control
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
 (MVC) accurately defines processing conditions
and is thus a key component of APC.

Improved MVC supports predictive control via

dynamic process models. This enables:

Maximization of process capacity ─ pushing

process/reaction constraints under safe
conditions
Minimization of downtime and increased
unit/equipment availability
Freeing of operators’ time so they can
complete other vital tasks
Reduction of product giveaway (minimizing
waste/off-spec product generation)
Optimization of energy use across process
units and entire plants.

MVC is one of the two main components of APC;

the other one is enhanced regulatory control
(ERC). Figure 1 is a graphical representation of
benefits delivered by these components per
expenditure of capital cost. Optimization also
delivers significant benefits, but it not considered
part of APC.

As Figure 1 shows, the APC components with the

greatest benefit/cost ratio are ERC and MVC.
Next-generation APC technologies are driving
down costs in these two areas. An example is the
platform for advanced control and estimation
(PACE), co-developed by Shell Global Solutions
(Shell) and Yokogawa, with similar products
available from other vendors, with all these
products here referred to as next-generation APC.

Next-Generation APC
As mentioned earlier, MVC and ERC are the key
components of a successful APC strategy. Next-
generation APC combines these two
components into one software application
(Figure 2).

The most successful APC installations take a

holistic view of the plant to develop complex
plant-wide applications within the same
workspace and sequenced by multi-processors.
By using this website, you agree to our use of cookies. This may include personalization of content and
MVC models can be linear, linear dynamic or
ads, and traffic analytics.
nonlinear.Review our reactions
Process Privacy Policy
andfor more
unit information.
operations ACCEPT
 require using different models to create MVC
models. Better modeling of the process vastly
improves the overall control performance of the
APC. Especially in the design stage, inclusion of
additional measurement or process data is very
useful for generating better models.

The controller uses process models to control

constraints of the application. It can be
configured by specifying controlled variables
(CVs), disturbance variables (DVs), manipulated
variables (MVs) and intermediate process out
variables (POVs). The controller model structure
can be confirmed using a graphic model viewer
to provide clear visual information on CVs, DVs,
MVs, POVs and model relationships. The graphic
model viewer shows the control designer what
POVs impact which CVs, and if particular CV’s
are highly correlated with each other.

The estimator relates MVs and DVs to POVs.

POVs can also feed other POVs, which provides
more much flexibility in defining the relationship
amongst variables, and in particular, how
prediction errors are forecasted to other POVs.
Only later in the design process does the control
designer select POVs to become controlled
variables (CVs). Model identification using POVs
is often simpler and more robust as the control
designer is fitting a series of models among
POVs rather than an MV-to-CV relationship which
may have many process operations between
them.

A comprehensive simulation of the APC strategy

is achieved via several steps:

Defining the simulation sequence: Set the

processor execution and controller
configuration details
Creating scenarios to simulate: Identify model
disturbances or operator actions
Developing cases: Define one or more
scenarios to review
Conducting the simulation: Collect and store
simulation results for review
Comparing simulation results: Run simulation
for multiple scenarios, and review by
comparing simulation results.
By using this website, you agree to our use of cookies. This may include personalization of content and
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
Holistic APC development
 Early APC technologies needed to work with
other applications such as quality estimators and
user calculations. Next-generation APC improves
deployment of the control application via
sequenced multiple processors (controller,
estimator, and more). As illustrated in Figure 3,
the process MVs and DVs are jointly used by the
control and estimation layers.

Full estimation functionality is integrated into the

controller, with the estimator using non-linear
relationships. With this functionality, projections
from the estimation layer calibrate the control
layer, and gains in the control layer can be
updated automatically. Next-generation APC
enables the use of different model blocks in the
estimation and control layers. Control engineers
can configure a nonlinear model in the estimation
layer to handle the nonlinearities of actual
operations.

Nonlinear functions built by POVs mirror the true

nonlinear dynamics of processing conditions.
Such cross-utilization of data reduces application
development time and greatly improves control
capabilities. The graphic model viewer enables
visualization of cause-effect relationships among
MVs, DVs, POVs, and CVs ─ allowing the
engineer to review selected variables in a static
view.

As with any software installation, understanding

the lifecycle is essential for success. The lifecycle
phases for a next-generation APC
implementation are:

Design
Staged
Live
Archive

The design (time) phase uses a single workspace

for data management, process dynamics
modeling, and scenario-based simulations, while
the staged and live phases rely on the Run Time
components of Human-Machine Interface, Data
Repository and OPC Interface (Figure 4).

Preliminary control matrixes and model results

By using this website, you agree to our use of cookies. This may include personalization of content and
from the design time are shared by the run time
ads, and traffic analytics. Review
environment. Asour Privacy
part of thePolicy for more information.
Next-generation APC, ACCEPT
 two modes of operation are possible: Staged
(read-only) and Live (read and write). Running
two models in parallel allows the control engineer
to validate any modifications in the Staged model
before activating new control changes in the Live
version.

APC in Action
A chemical company had several initiatives in
progress at their plant in Spain. In 2016, the
company decided to implement an APC project
on a selected unit, with execution a joint effort
with Yokogawa.

The unit selected for this APC project was the

Cyclohexane (CX) distillation unit because it
displays the typical process characteristics in
which an APC value proposition can be applied:

High energy consumption

Operators faced with controllability challenges
Operation versus process constraints needs to
be managed.

Potential positive impact on process

performance was, in this case, the opportunity to
improve the selectivity of the reactor fed by the
Cyclohexane product from the distillation.

The “Platform for Advanced Process Control and

Estimation” is Yokogawa’s multivariable control
technology, jointly developed with Shell. This APC
platform was released in Q4 2015 and is
implemented worldwide, including on this project.

Process background
A simplified flow diagram of the process is
shown below in Figure 5.

The scope of APC in this project includes stage 1

& 2 of the CX distillation. The CX is oxidized with
air in the presence of a catalyst, yielding the main
reaction products ON (Cyclohexanone) and OL
(Cyclohexanol). The reactor conversion is very
low, so most of the output stream is non-reacted
By using this website, youCX, which
agree is recycled
to our to the This
use of cookies. reactor
mayfrom the personalization of content and
include
distillation units. These units consist of several
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
distillation columns, with the main product the
 non-reacted CX. ON + OL is further processed in
other units to produce caprolactam. Caprolactam
is the precursor to Nylon 6, which is a widely
used synthetic polymer.

Objectives and challenges

The APC project’s main objectives were:

Control the long recycle impurities (% ON +

OL) as measured by an on-line analyzer. The
impurities should be minimized to ensure
good selectivity in the reactor. Before APC, this
variable was not under automatic control
because the analyzer is a chromatograph with
a sample period of 14 minutes, resulting in a
long lag time between process variable
updates, and consequently poor PID control
performance.
Maximize the short recycle and long recycle
streams to improve reaction selectivity and
reduce undesired by-products. This requires
additional energy in the form of more steam
required by the distillation columns, so
process constraints must be kept under
control when the recycle streams are high.

The second distillation stage has two columns in

a double-effect configuration. Controlling the
level in the bottoms of the second column at a
desired target by adjusting the first column
reboiler steam flow maintains unit mass balance
because the steam rate influences the addition of
fresh CX feed.

Plant operation is not straightforward for the

operator and requires a lot of attention. One
reason is the difficulty of controlling the above-
mentioned level because of a long response time
and a strong interaction between the first column
steam rate and the recycle rates. Before APC, the
level was controlled with a regular PID loop, but
the performance was not adequate. Another
difficulty for the operator is managing the unit
constraints since it is desired to maximize the CX
recycle rates, which requires frequent manual
adjustments.

By using this website, youMaximizing

agree to ourthe
userecycle will lead
of cookies. This to
mayincreased
include personalization of content and
column refluxes to maintain the purity of the
ads, and traffic analytics. Review our
recycle stream. Privacy Policy
Increasing forwill
refluxes more information.
drive the ACCEPT
 unit against some constraints. Setting a high
purity setpoint and increasing the recycle are
both desirable in terms of impact on the
selectivity, but a trade-off must be found between
the two. If one sets a lower purity setpoint, one
will be able to reach a higher recycle stream, and
vice versa. Proper targets and limits for the APC
were set based on observation of the actual unit
performance, and further optimization is an
ongoing process.

Project steps
The project was executed over a period of five
months, with the following sequence of activities:

Phase 1: Feasibility study and economic

evaluation.

Preliminary plant tests were carried out to verify

the unit responses. A first pass APC design was
developed. Expected economic benefits were
estimated in order to verify the viability of the
project.

Phase 2: APC implementation.

Base layer control checking to ensure proper

performance of regulatory controls for the
purpose of the APC, and fine tuning of some PID
loops. This ensured the foundation was sound
for the APC application

Step-testing: Step the relevant manipulated

variables to collect data on the actual dynamic
response. The data was then used to develop the
model required for the controller.

Controller design and simulation: Configure the

controller in a development system, test in
simulation, and prepare the controller for
implementation in the run-time control system

Commissioning: Closing of the APC loops, and

monitoring of performance and fine tuning

Post-Implementation study: Verification of

actually achieved benefits
By using this website, you agree to our use of cookies. This may include personalization of content and
All the above activities involved very close co-
ads, and traffic analytics.
operation Review our Privacy
between Policy company’s
the chemical for more information.
staff ACCEPT
 from their technology and operations department
and Yokogawa’s APC engineers.

Economic benefits
The achieved APC benefits were found to be in
line with the feasibility study estimates. The
benefits come from improved selectivity in the
reactor as a result of improved CX recycle purity
control and CX recycle flow maximization, both
made possible by the APC application.

General industry trends have resulted in

downsizing of technical staff at many
downstream sites, requiring outsourcing of some
complex and specialized projects, such as APC
implementations. Success when outsourcing an
APC project depends on the experience and
expertise of the selected APC consultant, so this
decision must be made with care.

In general, APC projects take about six to twelve

months for design and installation. A typical APC
project involves:

Feasibility study: During the study, process/base-

layer control and process flow diagram reviews
and recommendations are conducted across the
plant. Taking a plantwide view generates greater
opportunities for improved operations. The study
should also include a benefit analysis to show
exactly how the project will improve plant
operations.

Enhanced regulatory control: To be successful,

an APC project requires a solid foundation. Basic
loop tuning and enhancements are therefore
often necessary before APC installation.

APC implementation: As each downstream

facility is unique, a detailed APC design and
review is necessary. Generic APC solutions fail to
meet the fine details in controlling individual
process units and downstream facilities.
Applying a quality estimator to plant data allows
fine tuning of the APC strategy. Step-testing
generates a robust model to validate any plant
responses to constraints. Simulation and testing
By using this website, you agree to our use of cookies. This may include personalization of content and
are very important in finalizing the APC model
ads, and traffic analytics.
before liveReview our Privacy Policy
commissioning. for any
As with more information. ACCEPT
rollout
 requiring process changes, operator training and
documentation are essential.

Here are some of the key steps in APC

implementation:

Pre-test
Step-test
DCS interface engineering
Commissioning
Handover

Throughout each step, the consultant should

provide constant monitoring to advise operators
with respect to setting the right limits for the
controller variables, updating loop tuning
parameters as necessary, and updating models
to accommodate drastic changes in process
dynamics due to turnaround or equipment
changes.

Once the control system is activated, post

implementation reviews of the new APC
performance are highly recommended. Process
conditions constantly change; consequently,
audits and performance reviews confirm that the
APC strategy is adhering to the design goals.

Innovating for tomorrow

APC technologies have been available for more
than 30 years. As new hardware and software
innovations appeared, the power of APC was
quickly adopted by downstream companies.
There are many APC solutions available.
However, the application of APC has had
problems. Looking forward, APC users want:

Quickly deployable APC solutions requiring

less engineering time to construct and
maintain
Visualization tools that allow operators and
engineers to track and monitor process unit
operations while checking control variables
Integrated platforms for improved engineering
efficiency.

The selected next-generation APC technology

needs to meet these user requirements. The
By using this website, you agree to our use of cookies. This may include personalization of content and
graphic model viewer interface uses an
ads, and traffic analytics.
organized Review our Privacy
hierarchy Policy
for easy for more information.
visualization of ACCEPT
 process conditions and control-system status.
Operators and engineers can quickly access
relevant information and implement changes to
the APC when necessary.

By combining all these tools and functionality,

APC can be implemented and maintained to
deliver significant and sustainable improvements
to plant performance.

Do you have experience and expertise with the

topics mentioned in this content? You should
consider contributing to our CFE Media editorial
team and getting the recognition you and your
company deserve. Click here to start this process.

Hiroshi Wakasugi and

Sanjay Venugopal
Author Bio: Hiroshi Wakasugi
is the general manager of the
advanced process solutions
department at Yokogawa; Sanjay
Venugopal is an advanced
process control specialist at
Yokogawa.

Search Products And Discover

New Innovations In Your Industry
SEARCH

By using this website, you agree to our use of cookies. This may include personalization of content and
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
 Magazines and Newsletters

SUBSCRIBE
Sign Up Today!

By using this website, you agree to our use of cookies. This may include personalization of content and
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
 RELATED CONTENT
How to tune servo systems: Force control, Part 4:
Questions and answers
JOSEPH PROFETA

Advanced process control improves refinery,

chemical plant operations
HIROSHI WAKASUGI AND SANJAY VENUGOPAL

By using this website, you agree to our use of cookies. This may include personalization of content and
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
 RELATED CONTENT
How to tune servo systems: Force control, Part 4:
Questions and answers
JOSEPH PROFETA

Advanced process control improves refinery,

chemical plant operations
HIROSHI WAKASUGI AND SANJAY VENUGOPAL

CONTACT
CONTRIBUTE
TERMS OF USE
PRIVACY POLICY
DO NOT SELL

3010 Highland Parkway Suite 310

Downers
By using this website, you agree to our use Grove, IL
of cookies. 60515
This may include personalization of content and
(630) 571-4070
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT
 Copyright 2023

By using this website, you agree to our use of cookies. This may include personalization of content and
ads, and traffic analytics. Review our Privacy Policy for more information. ACCEPT