Advanced Process Control: From a PID Loop up to Refinery-Wide Optimization
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TOMATION IN INDUSTRY
Advanced Process Control: From a PID Loop up to Refinery-Wide Optimization P. L. Logunov∗ , M. V. Shamanin∗ , D. V. Kneller∗∗,a , S. P. Setin∗∗ , and M. M. Shunderyuk∗∗ ∗
LLC “LUKOIL-Nizhegorodnefteorgsintez,” Kstovo, Russia ∗∗ JCS Honeywell, Moscow, Russia e-mail: a [email protected] Received February 5, 2015 Revised February 5, 2015 Accepted May 25, 2020
Abstract—Advanced process control (APC) provides distributed control systems with wider functionality thus improving operations efficiency. At the same time, APC systems create a framework for higher-level optimization solutions. The paper outlines the key features and R advantages of Honeywell Profit Suite product family enabling effective and user-friendly design of layered optimization solutions. With a case study of a major Russian refinery it overviews the development and operation history of advanced control (AC) and optimization solutions from a PID loop up to a group of interrelated process units. Keywords: advanced process control (APC), model-based predictive control (MPC), dynamic optimization of several process units, PID control performance monitoring, APC performance monitoring DOI: 10.1134/S0005117920100100
1. INTRODUCTION Advanced process control (APC) is a key segment of industrial automation. Its main goal is to increase the profitability of existing distributed control systems (DCS) at process units Most of today’s DCS have some room for improvement, and APC offers a powerful tool to capture potential benefits. The term “APC” covers a wide variety of control technologies from relatively simple DCSembedded control schemes, such as PID cascades, feedforward, ratio, or lead-lag controls, etc., through science-intensive process optimization techniques. The latter may include adaptive or fuzzy control algorithms, quality estimators (QE, aka soft sensors, or inferential calculations), as well as model-based multivariable controllers. Over the past 30 years, multivariable control systems with embedded predictive models have been widely accepted in processing industries under the abbreviation MPC that stands for model predictive control. The MPC technology has been steadily proving its high potential for multivariable processes with strong interrelations and time lags. APC is frequently referred to in the narrower sense as MPC, and we will follow this convention further on. Some APC fundamentals may be found in [1, 2] with more details, case studies, and discussions in [3]. An APC system will be further referred to as special software for multivariable control of a process unit based on its predictive model. APC applications usually operate on dedicated servers integrated into DCS LAN; some vendors create them however, within native DCS in the form of one or more complex cascade controllers. 1929
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LOGUNOV et al.
APC systems of large process units are typically implemented as separate blocks, called multivariable controllers (or simply “controllers” software applications that should not be confused with conventional ha
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