02 APC Project Run Through
-
Upload
sreekanthmylavarapu -
Category
Documents
-
view
221 -
download
0
description
Transcript of 02 APC Project Run Through
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 1/42
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 2/42
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 3/42
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
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 4/42
Pre-Project Activities
APC PC setup
• APC $ngineer-Offline PC-Online PC-DCS
C%M%O&OPC setup
Soft'are (DMCPlus) Setup
Data collection
PFDs# P!%Ds# DCS grap*ics and Process description
Preliinar" Functional design docuent (FDS)
February 21, 2016 Reliance Technology Group – APC / RTO 4
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 5/42
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation5
+o, esponsi,ilities
Preliminary Benefit Analysis for APC CTS
CS !om"atibility to a!!e"t Set"oints from APC
Controller
#T$%&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
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 6/42
• 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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation6
Kick-off
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 7/42
%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
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 8/42
• 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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation
Pretest Activities
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 9/42
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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation
Pretest Activities
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 10/42
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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation10
Pretest Activities
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 11/42
• 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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation11
Plant Test
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 12/42February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation12
Plant Test Forat
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 13/42
• 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.
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation13
Model Building
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 14/42February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation14
Model Building-%port 2ectors
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 15/42
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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation15
Model Building
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 16/42February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation16
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 17/42
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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation1
Model Building
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 18/42
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation1
Model Building-Auto correlation
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 19/42
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation1
Model Building-Cross correlation
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 20/42
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation20
Model Building-Prediction
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 21/42
•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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation21
Model Building
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 22/42
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation22
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 23/42
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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation23
Model Building
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 24/42
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation24
CCF
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 25/42
• 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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation25
Offline controller siulation and tuning
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 26/42
Simulation (ino(, "ant !ontroller moel
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation26
Siulation
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 27/42
• Plant O,jectives and Constraints
• Controller odel revie'
• Soft Sensors revie'
• CCF Configuration
• Siulation
• Make DCS /ogics ! APC grap*ics in Plant
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation2
Model evie' Meeting
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 28/42
• 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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation2
Controller coissioning
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 29/42
•
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation2
PC@S
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 30/42
•
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation30
1CS
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 31/42
• 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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation31
Docuentation
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 32/42
%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:<# $.cel# Po'ertools# Minita, etc for anal"sis
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation32
Benefit Anal"sis
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 33/42
Anal"sis-$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
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation33
Benefit Anal"sis- $.aple
P fit C t C d $O
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 34/42
ar!) 10, 200
Profit Coponent I Crude $O
Profit of 9<J crores&annu
Profit Coponent Stea generation
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 35/42
ar!) 10, 200
Profit Coponent I Stea generation
Profit Coponent $t*"lene t*roug*put
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 36/42
ar!) 10, 200
Profit Coponent I $t*"lene t*roug*put
/oss of :9;H crores&annu
Profit Coponent O."gen t*roug*put
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 37/42
ar!) 10, 200
Profit Coponent I O."gen t*roug*put
Profit Coponent Selectivit"
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 38/42
ar!) 10, 200
Profit Coponent I Selectivit"
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 39/42
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
$t*"leneO.ide
J9;H J9L ;=9:= :9LL ;J= 9<J
Steageneration
:>9J= :H9=J H9=H L9LL >=< =9<H
Total Profit 1.89 Crores per annum
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 40/42
• Controller onitoring and en*anceent
• Maintain on-going training efforts
February 21, 2016 Reliance Technology Group – APC / RTO For Internal Circulation40
Post Coissioning Sustained Perforance
# i t f APC P 9 t t b i Pl t
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 41/42
February 21, 2016 Reliance Technology Group – APC / RTO 41
+o, esponsi,ilities
Preliminary Benefit Analysis for APC CTS
CS !om"atibility to a!!e"t Set"oints from APC
Controller
#T$%&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:
7/21/2019 02 APC Project Run Through
http://slidepdf.com/reader/full/02-apc-project-run-through 42/42