Applying dynamic advanced process control models in processes at Bashneft Oil Company refineries

UDK: 65.011.56
DOI: 10.24887/0028-2448-2021-6-108-112
Key words: dynamic advanced process control (APC), process optimization, virtual analyzer, multi-parameter controllers, digital plant
Authors: S.I. Nedelchenko (Bashneft PJSC, RF, Ufa), M.S. Gayfullin (Bashneft PJSC, RF, Ufa), E.S. Golovina (Samaraneftekhimproekt JSC, RF, Samara), Yu.A. Ergomyshev (Samaraneftekhimproekt JSC, RF, Samara), V.A. Lavrentiev (Samaraneftekhimproekt JSC, RF, Samara), A.V. Komogorov (Samaraneftekhimproekt JSC, RF, Samara)

The article describes the advanced process control (APC) systems, their advantages, design features, and operating principles. APC is a technology that reduces fluctuations in production variables, which allows the process unit to operate stably and optimally, closer to its limitations (maximum productivity, product quality, technological limitations). APC is the most important element among automated business management systems, because exactly at this level the problem of optimal process management begins to arise and be solved. Besides the direct economic effect, the implementation of the APC brings many indirect improvements by reducing the number of unit regime upsets and saving energy. However, like any high-tech system, the APC needs constant monitoring, modernization, and maintenance. For timely and on-line adjustment of control system models, support teams are needed, which allow the regular modernization of system models and components with a significant increase in their efficiency, in a short time and with minimal costs. As a case, we consider the history of implementation and development roadmap for APC systems at the refineries of Bashneft PJSC and provide in-house designed improvements to APC at the enterprises of Bashneft. In order to establish a unified approach for estimating the technological and economic effects of APC business projects, methodological guidelines were developed while implementing APC technological installations. The need for development of APC and their integration with resource management and planning systems for building a new digital plant as part of global digital transformation of the economy is noted.

References

1. Lu Joseph Z., Closing the gap between planning and control: A multiscale MPC cascade approach, Annual Reviews in Control, 2015, V. 40, pp. 3–13.

2. Nedel'chenko S.I., Gayfullin M.S., Golovina E.S. et al., Criteria for choosing a process control system (In Russ.), Neftyanoe khozyaystvo = Oil Industry, 2020, no. 2, pp. 90–93.

3. Seleznev A.Yu., Possible refinery application processes to improve operation efficiency (In Russ.) Neft'. Gaz. Novatsii, 2020, no. 4 (233), pp. 35–42.

4. Zakharkin M.A., Kneller D.V., Applications of advanced process control techniques (In Russ.), Datchiki i sistemy, 2010, no. 10, pp. 57–71.

5. Camacho E.F., Bordens
C., Model predictive control, London: Springer-Verlag, 2004, 405 p.

The article describes the advanced process control (APC) systems, their advantages, design features, and operating principles. APC is a technology that reduces fluctuations in production variables, which allows the process unit to operate stably and optimally, closer to its limitations (maximum productivity, product quality, technological limitations). APC is the most important element among automated business management systems, because exactly at this level the problem of optimal process management begins to arise and be solved. Besides the direct economic effect, the implementation of the APC brings many indirect improvements by reducing the number of unit regime upsets and saving energy. However, like any high-tech system, the APC needs constant monitoring, modernization, and maintenance. For timely and on-line adjustment of control system models, support teams are needed, which allow the regular modernization of system models and components with a significant increase in their efficiency, in a short time and with minimal costs. As a case, we consider the history of implementation and development roadmap for APC systems at the refineries of Bashneft PJSC and provide in-house designed improvements to APC at the enterprises of Bashneft. In order to establish a unified approach for estimating the technological and economic effects of APC business projects, methodological guidelines were developed while implementing APC technological installations. The need for development of APC and their integration with resource management and planning systems for building a new digital plant as part of global digital transformation of the economy is noted.

References

1. Lu Joseph Z., Closing the gap between planning and control: A multiscale MPC cascade approach, Annual Reviews in Control, 2015, V. 40, pp. 3–13.

2. Nedel'chenko S.I., Gayfullin M.S., Golovina E.S. et al., Criteria for choosing a process control system (In Russ.), Neftyanoe khozyaystvo = Oil Industry, 2020, no. 2, pp. 90–93.

3. Seleznev A.Yu., Possible refinery application processes to improve operation efficiency (In Russ.) Neft'. Gaz. Novatsii, 2020, no. 4 (233), pp. 35–42.

4. Zakharkin M.A., Kneller D.V., Applications of advanced process control techniques (In Russ.), Datchiki i sistemy, 2010, no. 10, pp. 57–71.

5. Camacho E.F., Bordens
C., Model predictive control, London: Springer-Verlag, 2004, 405 p.


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