based reports via email. These reports can also be accessed, customized .... Email:
. Africa. INTE
Solutions for Optimizing Oil & Gas Operations
Control Loop Performance Optimization
Introduction INTECH’s Control Loop Performance Optimization (referred to as CLPO) is an operations improvement framework to optimize and streamline plant performance, which contributes to smoother process operation and higher overall productivity. INTECH’s applications add value through role based security, event triggered KPI’s and multi variable loop and process analysis. INTECH provides advanced diagnosis, tuning, performance optimization and routine monitoring of control loops as part of its focus on lifetime asset and facility performance. This ensures timely identification and rectification of control problems before they adversely affect process profitability. This also makes sure that benefits of optimal loop performance do not diminish over time.
Sub-Optimal Control-Loop Performance Factors Of the four elements that make up a control loop, i.e. process, measurement, controller and control element, changes in any one can affect the performance of control loops and cause improper functioning. Factors that typially contribute to suboptimal control loops are:
Debutan ize r LC0204
LC0205
PCSP0204
FC0205
FC0204 TC0203
FC0221
FC1361 CX0205
TC0204
Equipment Wear/Aging Changes in Operating Conditions Modifications to Plant Varying Unit Loads
PCSP0204A
CX0204
TC1203
TC2020
LC0206
FC0222
FC0208
PC0205
FC0235
FC0234
TC0209
FC0202
FC0209
CX0205
This lack of properly functioning control loops disrupts plant operation and affects productivity, thus requiring continuous monitoring and improvement of control loops throughout the plant/facility’s lifetime.
Regenera to r LC0204
LC0205
PCSP0204
PCSP0204A
FC0205
FC0204 TC0203
FC0221
FC1361 CX0205
No Control Action
Feedback Control Action
Fuel Flow
Steam Flow 1 Disturbance
Disturbance
Disturbance
C0204 Steps to Improve Control TLoop Performance CX0204
TC1203
TC2020
FC0222
FC0208
PC0205
FC0235
FC0234
TC0209
FC0202
FC0209
INTECH follows a systematic approach Cto control loop performance based X 0 2improve 05 on the DMAIC process, and which consists of seven steps as defined by our solution vendor partners, who are also industry standard leaders.
Flow Increase from Fuel Control
Improve Hardware
Flow Drop
Flow Drop & Recovery
Manual Control Existing Mode
PID Control
Steam Flow 2 Target
Differences in Manual & PID Control
FC0234
LC0206
Continuous Improvement
Generator No Flow Change Steam Flow
FC0234
Establish Philosophy
Measure Performance
Compare of Diagnose
Optimize Controllers Modify Objectives
Optimize & Maintain
Why do you need Control Loop Performance Management? Control Loops are an integral part of any automated process and define how efficiently a plant, facility, fileds or sub-system operates. Poor control loop performance can go undetected indefinitely and adversely affect productivity, having a negative impact on bottom line. INTECH’s Loop Tuning helps identify origins of poor control loop performance and facilitates their remediation. It analyzes loops for problems like hysteresis, stiction, process non-linearity, and poor tuning; it then identifies and models processes’ dynamic response to calculate suitable loop PID controller settings. It also provides a choice of tuning objectives, and simulates loops’ response to visualize effects of parameter changes prior to applying them. Custom Reporting Solution
Loop Monitoring
Process Analysis
INTECH’s custom reporting solution gives automatic loop performance reports, event-triggered reports & shift schedule based reports via email. These reports can also be accessed, customized and shared online and over the cloud.
INTECH’s solution acquires real-time data via OPC and a time-series of data for analyses. OPC read rate is user-defined so that Loop Analysis does not overload the OPC server or underlying systems.
INTECH’s Process Analyzer helps find, explore, and understand plant-wide oscillations & their interactions with multiple plant/process variables. This helps ensure operation at 100% capacity.
Operation / Safety / Quality Limit Lower maintenance cost from reduced variations
Symptoms of Control Loop Malfunction Poorly configured control loops are a serious damper to productivity and lead to issues like: Unnecessary and excessive alarms Frequent process upsets Reduced output and quality Increased operator loading Increased output variations Stiction, non-linearity or hysteresis in control elements Gradual decrease in overall productivity
Set Point
Reduced operator loading from reduced alarms and more robust controls Poor Loop Performance
Improve Controls to Reduce Variations
Operating Closer to Limits
Poor Loop Performance and Impact of INTECH’s CLPO
Classical Optimization Method Controllers are tuned during commissioning PI/PID parameters are initially set based on experience Setpoint changes are made to test performance Problem control loops are mostly tuned via trial & error Plants may run for their lifetime with sub-optimal controls
INTECH’s Real-Time Optimization Control Strategy Design Control Element Performance Controller Tuning according to Specific Objectives Continuous monitoring of under-performing loops Model-based process configuration
Noise & Interference Reduced oscillations & disturbances
Increased protection
Optimal productivity & operations
Damage to equipment and assets Error Span Valve Reversals & Hysteresis Control Valve Traversals
Leading to reductions in
Overloaded operators and excessive intervention
Benefits of Control Loop Optimization
What Our Customers Say... “[We] commend INTECH’s knowledge of alarm management, dedication, commitment and effort. Most importantly, works have been completed safely and INTECH has been able to work successfully in our diverse environment”
“INTECH personnel have the correct skills & knowledge to enable them to carry out all tasks and additional works… full training and familiarization of Control Loop tuning software has been carried out to our complete satisfaction.”
“I commend you on your efforts in customizing the business analysis software for deployment for a Web Based Alarm Management Dashboard. It meets our objectives and has produced the desired results.”
Central Maintenance Coordinator
Instrument Superintendent CM
Control & Automation Leader
EPC
End User
Americas
Asia
Middle East
INTECH Process Automation Perú S.A.C. Av. República De Panamá N°3030 Oficina 7a San Isidro, Lima, Perú Tel: +511 606 6849 Cel: +51 982117562
PT INTECH Process Automation Rukan Permata Senayan, Blok C Nomor 5, 4th Floor, Jalan Tentara Pelajar, Kebayoran Lama, Jakarta Selatan, 12210 Indonesia Tel & Fax: +62 21 579 49 444
INTECH Process Automation Inc. Br. G-201 Al-salah Tower, P.O. Box 4270, Al-khobar - 31952, Kingdom Of Saudi Arabia Tel: +966 13 8966052, +966 13 8966053
WORLD HQ INTECH Process Automation Inc. 4903 W. Sam Houston Parkway N. Suite A-100 Houston, TX 77041, USA Tel: +1 713 849 1000 Fax: +1 713 856 0785
Europe
INTECH Process Automation Sarl 168 Avenue Charles De Gaulle, 92 522 Neuilly-sur-seine Cedex, France
[email protected]
Central Asia
INTECH Process Automation LLP. 5A Erniyazova Str. Atyrau, Kazakhstan Tel: +7 7122 32 01 16 Fax: +7 7122 32 00 52
INTECH Process Automation Pte. Ltd 600 North Bridge Road, #23-01 Parkview Square, Singapore 188778 Tel: +65 68289118 Fax: +65 68289112
Vendor Expertise
linkedin.com/company/intech-process-automation facebook.com/Intechprocessautomation
Africa
INTERNATIONAL HQ INTECH Process Automation FZCO P.O. Box 61479, RA08ZC01, JAFZA, DUBAI, United Arab Emirates Tel: +971 4 8810056 Fax: +971 4 8810057
INTECH Process Automation (Shanghai) Co. Ltd. Room 1605c, 16f Feidiao International Building, No.1065 Zhaojiabang Road, Xuhui District, Shanghai 200030 – P.R.C. Tel: +86 21 2426 1951 Fax: +86 21 2426 1877 INTECH Process Automation Pvt. Ltd. 2nd Floor, Commercial Building #2 PCSIR Phase – II Lahore 54782, Pakistan Tel: +92 42 111 468 324, 3531 2509/11 Fax: +92 42 3531 4149
OEM
INTECH Process Automation Nigeria Ltd. 64b, Abacha Link Road, G.R.A. III, Port Harcourt, Rivers State, Nigeria Tel: +234 905 3992976 Liaisons Office, Victoria Islands Lagos, Nigeria Tel: +234 805 9330560
[email protected]
INTECH Process Automation FZCO Br. 470, Italian City, Erbil, Iraq Tel: +964 780 131 2198, +964 750 309 3766 North Africa Operations Tel: +971 55 607 3230, +971 553768482
INTECH Process Automation Inc. (Sucursal De Angola) Casa Nº B07, Condominio Boulevard, Via Al16, Talatona, Luanda - Republica De Angola Tel: +244 222 720 471 Fax: +1 281 377 3455
[email protected] [email protected]
Email:
[email protected]
www.intechww.com
Standards & Certifications
* Notice: All registered logotypes, trademarks, brands, product and services marks used in this document are acknowledged as properties of their respective companies/owners and such companies/owners have not consented to their use by INTECH (Term INTECH is used for INTECH Process Automation Inc. and its affiliates). INTECH is not affiliated with these logotypes, trademarks, brands, product and services marks and any use by INTECH should not be construed as an endorsement of INTECH or its services. The services described herein are provided solely by INTECH. © 2016. All rights reserved by INTECH Process Automation Inc.
