{"id":2416,"date":"2018-12-11T07:10:04","date_gmt":"2018-12-11T06:10:04","guid":{"rendered":"https:\/\/staging.blogs.yokogawa.de\/chemical-pharma\/uncategorized\/assistance-systems-2-electronic-stability-control\/"},"modified":"2022-06-17T09:28:30","modified_gmt":"2022-06-17T07:28:30","slug":"assistance-systems-2-electronic-stability-control","status":"publish","type":"post","link":"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/assistance-systems-2-electronic-stability-control\/","title":{"rendered":"Assistance systems \u2013 2. Electronic stability control"},"content":{"rendered":"<p>We started the <a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/de\/assistenzsysteme-1-unsere-taeglichen-kleinen-helferlein\/\">series<\/a> by taking a look at a few of the <strong>assistance systems<\/strong> incorporated into modern automobiles, during which we discovered that car drivers and plant operators have several <strong>things in common<\/strong>. Another very important aspect they share is that assistance systems render neither plant operators nor car drivers superfluous. In both cases, they provide valuable support and give the human driver or operator <strong>more time<\/strong> to concentrate on <strong>more essential tasks<\/strong>. Parallel to this, <strong>efficiency, safety and availability are improved<\/strong>.<\/p>\n<p>However, there is also one vital <strong>difference<\/strong>. Broadly speaking, any assistance system is suited for any car. This is due to the fact that both cars themselves and the way they\u2019re driven are basically always the same.\u00a0<strong>Process plants<\/strong>, on the other hand, not only differ considerably from one another; they also tend to be far <strong>more complex<\/strong> to operate. That explains why, in contrast to cars, a specific assistance system is only suitable for a specific plant. And even with two plants of the same type, a cost-benefit analysis never hurts.<\/p>\n<p>This and future installments of our mini-series will be devoted to a <strong>group of assistance systems<\/strong> which share a number of common features, and indeed are often used <strong>together<\/strong>, but which can also operate completely <strong>independently<\/strong> of one another. We\u2019ll be examining how these systems work, how they\u2019re integrated and how they\u2019re employed. The group in question consists of the following three assistance systems:<\/p>\n<ul>\n<li><strong>APC\u00a0\/\u00a0MPC \u2013 Advanced Process Control\u00a0\/\u00a0Model (Multivariable) Predictive Control<\/strong><\/li>\n<li><strong>RTO \u2013 Real Time Optimization<\/strong><\/li>\n<li><strong>Digital Twin<\/strong><\/li>\n<\/ul>\n<p>The title provides a telltale clue: the subject of this post is an assistance system that in many ways is reminiscent of the ESC in cars. APC\u00a0\/\u00a0MPC has been around in refineries and in the chemical &amp; petrochemical industries since the eighties.\u00a0APC\u00a0\/\u00a0MPC could be described as a veteran among assistance systems in the process industry.\u00a0Today, you can find it in power stations, cement works and other industrial plants. Like ESC, APC\u00a0\/\u00a0MPC generally does what it\u2019s designed to do unobtrusively, and in most cases we\u2019re not even aware quite how many times our \u201cstability\u201d has been improved and we\u2019ve been prevented from \u201cskidding\u201d out of control.<\/p>\n<h2>APC?\u00a0MPC? \u2013 A definition<\/h2>\n<p>APC (Advanced Process Control) started out as the <strong>generic heading<\/strong> for a broad range of techniques and technologies implemented within industrial <strong>process control<\/strong> systems. You could say it refers to anything more complex than a standard PID controller. One such technology is MPC, which stands for <strong>Model<\/strong> Predictive Control or <strong>Multivariable<\/strong> Predictive Control. The term APC is nowadays (incorrectly) popularly used by most people as a synonym for MPC. It makes no difference whether they\u2019re talking about \u201cmodel\u201d or \u201cmultivariable\u201d predictive controls because MPC solutions are normally both. Strictly speaking, therefore, M2PC (Multivariable Model Predictive Control) would be more accurate. The software frequently ships with a whole package of <strong>tools &amp; functions<\/strong> like <a href=\"https:\/\/www.yokogawa.com\/solutions\/products-platforms\/solution-based-software\/optimization\/advanced-process-control-platform-for-advanced-control-and-estimation\/\"><strong>PACE<\/strong><\/a> \u2013 Yokogawa\u2019s APC\u00a0\/\u00a0MPC solution. PACE is an acronym for \u201cPlatform for Advanced Control and Estimation\u201d, in other words apart from APC\u00a0\/\u00a0MPC and all of their accompanying tools &amp; functions, it also includes software for estimating parameters that are either not measurable or not instantly available \u2013 a kind of <a href=\"https:\/\/en.wikipedia.org\/wiki\/Soft_sensor\"><strong>soft sensor<\/strong><\/a> function.<\/p>\n<h2>APC\u00a0\/\u00a0MPC \u2013 The \u201celectronic stability control\u201d<\/h2>\n<h3>It\u2019s infuriating!<\/h3>\n<p>It\u2019s infuriating \u2013 the liquid level in a column sump is simply not <strong>stable<\/strong>: it goes <strong>up and down<\/strong> like a drunken sailor!\u00a0The <strong>process control system (PCS) and the plant operator<\/strong> are spending all their time struggling to get it under control to the extent that the plant at least keeps going without constantly <strong>tripping an alarm<\/strong>. There\u2019s virtually no remedy we haven\u2019t already tried: tuning the control loops in the PCS, optimizing the instrumentation, searching for process or control correlations that could be at the root of the problems \u2013 and so the list goes on. I wouldn\u2019t go so far as to claim that none of this has helped a bit but, all in all, these improvements still haven\u2019t produced a satisfactory result. What\u2019s more, even if we succeed in identifying correlations (such as the dead time between the measurement at the inlet and the column sump), we can\u2019t be certain of their precise effect.<\/p>\n<h3>Undesirable consequences<\/h3>\n<p>The utilization of PCS and operator capacity is already disappointing enough, but a glance at production performance and product quality is likely to be even more so \u2013 for several reasons:<\/p>\n<ol>\n<li>Operation at maximum or minimum <strong>throughput<\/strong> is not possible because the strong <strong>fluctuations<\/strong> will regularly trip an alarm.<\/li>\n<li>Furthermore, <strong>quality variations<\/strong> must probably be reckoned on. That\u2019s bad enough if you have a final product downstream of the apparatus, but even worse if there are also intermediate products needing to be processed. In this case, the <strong>poor \u201cstart\u201d<\/strong> has impacts on the entire <strong>production chain<\/strong>.<\/li>\n<li>Increased <strong>wear and tear<\/strong> on the plant is inevitable because it is permanently operated near to the <strong>limit<\/strong> and sometimes beyond.<\/li>\n<\/ol>\n<p>When it comes to efficiency, safety and availability, therefore, skepticism is justified. But what is there can we do about it?<\/p>\n<h3>The solution \u2013 \u201cElectronic stability control\u201d<\/h3>\n<p>This is where the benefits of <strong>APC\u00a0\/\u00a0MPC<\/strong> really start to unfold: <strong>multivariable and model predictive<\/strong>.<br \/>\n(I hope the APC\u00a0\/\u00a0MPC gurus among you will pardon the occasional simplification here.)<\/p>\n<h4>Multivariable<\/h4>\n<p><strong>Multivariable<\/strong> signifies in this context that all variables identified (possible) can be incorporated into the APC\u00a0\/\u00a0MPC, even if we\u2019re not absolutely sure about the <strong>correlations<\/strong>. The APC \/ MPC provides us with the means to <strong>analyze<\/strong> these correlations and constitutes a <strong>very helpful<\/strong> approach.\u00a0The APC\u00a0\/\u00a0MPC is not interested either in the process technology or in any control correlations, which we couldn\u2019t always describe to it with any certainty anyway. It simply looks at what happens at the <strong>output<\/strong> if something changes at the <strong>input<\/strong>.\u00a0Dead times and other correlations that are sometimes invisible or difficult to verify are no longer anything to worry about. Classic PID control loops tend only to know one input and one output, so we also have to explain the \u201ccontext\u201d. This is adequate for the majority of control tasks (though not all) because otherwise we\u2019d have more APC\u00a0\/\u00a0MPCs than PCSs.<\/p>\n<h4>Model predictive<\/h4>\n<p>The APC\u00a0\/\u00a0MPC simultaneously \u201ccreates\u201d a <strong>\u201cmodel*\u201d<\/strong> from these variables and correlations. This does more than simply map the relationships between the different variables; it also lets us <strong>\u201ctake a peek into the future\u201d<\/strong> (predictive). These two capabilities allow the APC\u00a0\/\u00a0MPC to orchestrate the relevant control loops in our PCS.<\/p>\n<p>Of course, it\u2019s still the PCS that ultimately controls the plant, so it needs to be kept \u201cin good shape\u201d. It\u2019s just that it now has a system in the background that stops it from losing its \u201cstability\u201d and \u201cskidding\u201d out of control. There isn\u2019t normally any direct <strong>interaction<\/strong> with the plant operator.\u00a0The APC\u00a0\/\u00a0MPC works permanently in the background and accesses the PCS directly.\u00a0It could thus be described as an <strong>online closed loop<\/strong> which is responsible for direct actions, similar to the ESC.<\/p>\n<h3><img decoding=\"async\" class=\"wp-image-7469 alignleft\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/app\/uploads\/sites\/8\/2022\/06\/APC-Curve-Reduced_EN-300x210.png\" alt=\"\" width=\"484\" height=\"339\" \/>Applications<\/h3>\n<p>The two classic tasks of an APC\u00a0\/\u00a0MPC are first of all that outlined above, namely to <strong>stabilize<\/strong> the plant at a specified operating point. Second, the plant must be moved from one operating point to the next and <strong>\u201cforeseeable changes\u201d<\/strong> compensated as efficiently as possible. These could be <strong>grade changes<\/strong> in a <strong>polymer plant<\/strong>, for instance, or plant components which are <strong>switched<\/strong> in a <strong>delayed coker<\/strong> (as a result of periodic decoking).\u00a0Both of these are highly complex processes where it helps to have the correlations between different variables taken into account automatically and to always look a short distance ahead into the future.<\/p>\n<p>APC\u00a0\/\u00a0MPCs are basically suitable for all <strong>continuous<\/strong> and <strong>semi-continuous<\/strong> processes. With <strong>batch processes<\/strong>, a lot depends on the process specifics, and the APC\u00a0\/\u00a0MPC sometimes also needs to be backed up by other solutions such as an \u201cautomated driving system\u201d.\u00a0 APC\u00a0\/\u00a0MPCs are used for many types of plant in many different <strong>sectors of industry<\/strong>, for example in refineries, chemical &amp; petrochemical plants, power stations, cement works, wastewater treatment facilities, fertilizer plants, liquefied gas installations, pulp &amp; paper mills etc.<\/p>\n<h3>Challenges and benefits<\/h3>\n<p>The <strong>challenges<\/strong> associated with any APC\u00a0\/\u00a0MPC are inherently <strong>complex<\/strong>. As described above, they are often linked to process and control correlations which are difficult to get to grips with using conventional PCSs. Other boundary conditions arise, for instance, due to regulations (<strong>environment<\/strong>) or economic requirements (<strong>competition<\/strong>), especially if these change. A very large number of variables and conditions interact with one another here.\u00a0An APC\u00a0\/\u00a0MPC helps the plant operator keep them under control. Parallel to this, <strong>efficiency, safety and availability are improved<\/strong>.<\/p>\n<p>APC\u00a0\/\u00a0MPCs generate the most \u201cmoney\u201d in the three categories <strong>yield<\/strong>, <strong>capacity<\/strong> and <strong>energy<\/strong>. In the case of yield, this is mainly reflected as a 10 to 20 percent <strong>reduction<\/strong> in <strong>quality variability<\/strong>. A 3 to 5 percent <strong>increase in throughput<\/strong> means increased capacity while on the <strong>energy<\/strong> side, electricity and fuel consumption <strong>savings<\/strong> of between 3 and 5 percent are possible. The latter also leads to a reduction in emission levels. (Source: IEEE 2011: Control in the Process Industries).<img decoding=\"async\" class=\" wp-image-7455 alignright\" src=\"https:\/\/www.yokogawa.com\/eu\/blog\/app\/uploads\/sites\/8\/2022\/06\/APC-Benefits-IEE-300x178.png\" alt=\"\" width=\"511\" height=\"303\" \/><\/p>\n<p>Added to this \u2013 though not as directly measurable in monetary terms \u2013 are the fact that <strong>less attention<\/strong> has to be paid by the plant operator, whose time is thus freed up for more important tasks, as well as the longer service life owing to the <strong>reduced wear and tear<\/strong>. The payback period for APC\u00a0\/\u00a0MPC project is typically between six and twelve months, though an ROI of just three months is not uncommon.<\/p>\n<h3>Summary<\/h3>\n<p>Modern APC\u00a0\/\u00a0MPC solutions are <strong>helpful tools<\/strong> for specific tasks where the aim is to achieve <a href=\"https:\/\/www.yokogawa.com\/solutions\/solutions\/approach\/operational-excellence-transformation\/\"><strong>operational excellence<\/strong><\/a>. The \u201cteething troubles\u201d in connection with <strong>implementation<\/strong>, <strong>use<\/strong> and <strong>maintenance<\/strong> are long gone. As a software solution, APC\u00a0\/\u00a0MPCs are ideally suited as part of <strong>digital production<\/strong> processes, in which they can share their capabilities and use data production-wide or even outside of production. This is why APC\u00a0\/\u00a0MPCs are predicted to become an increasingly important factor in <strong>Industry 4.0<\/strong>.<\/p>\n<p>&nbsp;<\/p>\n<p>*Model: In the context of an APC\u00a0\/\u00a0MPC, a model is a mathematical representation of the dynamic correlations between input and output variables. This model has nothing to do with the rigorous** process technology models of process simulation software.<\/p>\n<p>**Rigorous = Based on physical, chemical, mechanical, etc. principles<\/p>\n<hr \/>\n<blockquote class=\"wp-embedded-content\" data-secret=\"f944o4iAop\"><p><a href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/automation-en\/assistance-systems-1-our-little-daily-helpers\/\">Assistance systems \u2013 1. Our little daily helpers<\/a><\/p><\/blockquote>\n<p><iframe class=\"wp-embedded-content\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; clip: rect(1px, 1px, 1px, 1px);\" title=\"&#8220;Assistance systems \u2013 1. 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The level in the column sump is simply unstable and fluctuates like a drunken sailor. The process control system (PCS) and the plant operator are constantly occupied with keeping these fluctuations under control to such an extent that&hellip; <\/p>\n<p class=\"read-more\"> <a class=\"\" href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/assistance-systems-2-electronic-stability-control\/\"> <span class=\"screen-reader-text\">Assistance systems \u2013 2. Electronic stability control<\/span> Read More &raquo;<\/a><\/p>\n","protected":false},"author":125,"featured_media":2433,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_uag_custom_page_level_css":"","site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"","footnotes":""},"categories":[53,56],"tags":[162,410,121,224,139,165,73,215,411,167,133],"coauthors":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v20.13 (Yoast SEO v20.13) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Assistance systems \u2013 2. Electronic stability control - Chemical Pharma Blog<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.yokogawa.com\/eu\/blog\/chemical-pharma\/en\/assistance-systems-2-electronic-stability-control\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Assistance systems \u2013 2. Electronic stability control\" \/>\n<meta property=\"og:description\" content=\"It&#039;s desperate. The level in the column sump is simply unstable and fluctuates like a drunken sailor. The process control system (PCS) and the plant operator are constantly occupied with keeping these fluctuations under control to such an extent that&hellip;  Assistance systems \u2013 2. 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