Regulatory Control Stabilization

As raw material costs increase this is drawing increasing attention towards improvement of process efficiency, all industries now recognize Regulatory Control Stabilization to be the baseline step for all process efficiency initiatives. In depth evaluation is required to improve the effectiveness of the regulatory control loops and achieve regulatory control stabilization (e.g. control configuration, PID tuning, instrumentation).

Regulatory control stabilization and PID loop tuning are also pre-requisites for advanced process control (APC) implementation. Yokogawa's decades of hands-on experience as a global supplier of process automation solutions has provided a wealth of knowledge and understanding in regulatory control loops, both before and after APC implementation.

Customer Challenge

Quality, Efficiency, and Operators Workload Significantly Impact Profitability

Problematic control loops negatively affect many aspects of your plant. PID setup and tuning without a proper methodology leads to trial-and-error tuning, leaving the total regulatory control strategy sub-optimized and lacking a consistent control objective across all control loops (e.g. averaging level control).

Plant safety is paramount to the continuance of production operations and all process industries now recognize the importance of regulatory control stabilization as the baseline for plant safety. To achieve stability, plants must evaluate and improve the effectiveness of regulatory control loops (e.g. control configuration, PID tuning, instrumentation).

Also, control loops operated in manual mode require careful monitoring and overall have poor performance. They will lead to an increase in operators’ workload and are unable to maintain the consistent safety, product quality, and economical efficiency of your plants.

Our Solutions

Regulatory Control Optimization to Enable Improved Production

Yokogawa's regulatory control stabilization service is a packaged service product including necessary engineering and consulting services to stabilize safety, improve efficiency, and reduce operators’ workload.

Tune VP is designed to estimate the optimized P, I, D tuning parameters for the PID controllers reside in FCS of CENTUM DCS system. This application provides an effective and easy to use solution for PID controller tuning with the following key features:

  • Online open and closed loop model identification and simulation
  • Prevalent and effective model identification algorithm
  • On demand P, I, D recommendation based on flexible SV or MV step test
  • Auto detection of operational change for P, I, D recommendation opportunity
  • Easy use by non control specialist
  • Loop tuning history report and PID log book

Customer Benefits

Economical Efficiency Now, Optimization Opportunities for the Future

The benefits of APC are vast. Companies can enjoy near immediate benefits in economic efficiency and safety, while several optimization opportunities are possible for the future. More specifically:

  • Economical Efficiency through reductions in energy consumption
  • Improvements in product quality through process stabilization
  • Operators’ Workload is improved by automating troublesome control loops and reductions in Reduce painful manual-mode board operation
  • Improvements in HSE (Health, Safety, Environment) are realized by avoiding plant upset with well-stabilized controls and a conservation environment with low-emission control
  • Prepare for APC implementation allows for further optimization in the future

Enabling Technology

TuneVP

TuneVP is designed to estimate the optimized PID tuning parameters for various PID controllers such as CENTUM DCS, Foundation Fieldbus Controllers, GE Fanuc PLCs, etc.

Process dynamic response data obtained from step testing or normal operational setpoint value (SV) or manipulated output value (MV) change are collected via OPC interface. Transfer function model is derived from MV and PV (process variable) data relationship. Based on the model, IMC tuning method is used to calculate the optimized PID parameters, in tandem with the closed loop PID controller response simulation.

 

Temperature Control Stabilization

Process:  BTX plant

Purpose:  Reduce the fluctuation of tray temperature in distillation column

Benefits:  Stabilize product quality and reduce the number of operator intervention (MV change in manual mode)

Averaging Level Control

Process:  De-ethanizer

Purpose:

  • Reduce the fluctuation of de-ethanizer feed which is generated by improper level control tuning of de-butanizer accumulator
  • Stabilize the tray temperature and product quality (C2 in propane) of de-ethanizer

Benefits:  Stabilize product quality (C2 in propane) and increase propane yield

Operating Ratio Improvement in Closed Loop

Process:  Chemical plant

Purpose:

  • Reduce the number of control loop operations (e.g. SV/MV change, mode change)
  • Increase the operating ratio in auto mode (closed loop) of control loops

Benefits:

  • Reduce operators’ workload
  • Reduce loop operations for 13 tags by 40% (3,700 à 2,200 operations)

*Deliverable of a full Service Report at the final stage

Overview:
  • Yokogawa's operational performance program bench mark service enhanced the automation performance at the chemical plant.
  • Operator stress was dramatically reduced by identifying the causes of excessive manual interventions.
Industries:

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