ensuring apc optimization with profit suite

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2015 Honeywell Users Group Europe, Middle East and Africa Ensuring APC Optimization with Profit Suite Richard Salliss, Honeywell

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Page 1: Ensuring APC Optimization with Profit Suite

2015 Honeywell Users Group

Europe, Middle East and Africa

Ensuring APC Optimization with Profit Suite

Richard Salliss, Honeywell

Page 2: Ensuring APC Optimization with Profit Suite

2 © 2015 Honeywell International All Rights Reserved

Profit Optimization Suite Overview

Profit Optimization Suite Roadmap

How is Honeywell advancing optimization?

The UOP connection…

Optimization Case Studies

Agenda

1

2

3

4

5

Page 3: Ensuring APC Optimization with Profit Suite

3 © 2015 Honeywell International All Rights Reserved

Profit Optimization Suite

Profit Controller

Minimum Effort Move

Past Future

Assumed Values

CV

Predicted

Unforced

Response

MV

Control Funnel

Optimal Response

Setpoint

Profit Sensor Pro

Profit Stepper

*Optimum

Profit Optimizer: Real-time, Dynamic

Optimization

Control Performance Monitor

Page 4: Ensuring APC Optimization with Profit Suite

4 © 2015 Honeywell International All Rights Reserved

Profit Optimization Suite

• One Consistent technology platform ‒ MPC and Real Time Optimization

‒ Flexible Modeling environment

‒ Unmatched operational awareness

‒ Lowest lifecycle cost

Seconds Hours/Days

Profit Loop Experion

Profit Controller (C300/ACE)

Profit Suite - Profit Controller

- Profit Sensor

- Profit Stepper

Profit Optimizer (DQP

Multi-Unit

Optimization)

Profit Executive (SuperDQP

Multi-Asset

Optimization)

Continuum of Control Solutions

Single Variable

Linear Control

Multiple-Variable Non –Linear

Control and Optimization

Profit CPM (Control Performance Monitor)

Page 5: Ensuring APC Optimization with Profit Suite

6 © 2015 Honeywell International All Rights Reserved

• CAB Prioritized enhancements

• Profit Suite Engineering Studio ‒ Profit Optimizer integration

‒ Enhanced DMCplus conversion tools

‒ Support for Predict Back

• Updated CV Move Function Block (account for

subcontrollers)

Profit Suite R431 – Proposed Scope

Page 6: Ensuring APC Optimization with Profit Suite

7 © 2015 Honeywell International All Rights Reserved

• Platform & Infrastructure Compliance

• Profit Optimizer Enhancements ‒ APC Vendor Agnostic

‒ Operator Guidance for optimization

• Honeywell User Experience ‒ Engineer/Operator Feedback

‒ CAB Prioritized enhancements

• APC monitoring / benefits sustainment improvement ‒ Improved support for BGP Performa

‒ Mobility and alignment with CPM and BGP Performa

• Operator Training Tools ‒ Automate/simplify model builds for USO training

infrastructure

Profit Suite R440 – Proposed Scope

Page 7: Ensuring APC Optimization with Profit Suite

8 © 2015 Honeywell International All Rights Reserved

• Most APC applications have two components ‒ Constraint control

‒ Optimization

• Key to successful application ‒ Design for responsive control action

‒ Use optimizer to take economic advantage of degrees of freedom

• Small scope applications are straight forward ‒ Distillation column, reactor, furnace

‒ Good control and Opt scope inherent

‒ Few design issues

• Large scope Applications are more challenging ‒ Multiple columns, Multiple equipment processing unit

‒ Trade off typically requires choosing either good control or optimization scope

Optimization – Control Engineer’s Dilemma

Page 8: Ensuring APC Optimization with Profit Suite

9 © 2015 Honeywell International All Rights Reserved

SS Controller Targets Feasible SS Controller Targets

SS

Model

• Build SS model for Optimizer ‒ Linear, NL, large scale

‒ Represents plant behavior

‒ Define objective function

• Calculate SS targets to

determine the end goal

• Realize the operating value by

dealing with dynamics ‒ Ensure feasibility

‒ Prevent constraint violations

‒ Push plant to SS

• Update the model, objective

function and dynamic

compensator ‒ Compensate for changing

conditions

• Repeat cycle

Traditional Optimization Overview

SS Optimizer

Economics and Ranges

SS Targets

Process

Dynamic Compensator

Limits

Process Changes

Feasibility

Feedback

LP Override Target Ramp Rates

Without Profit Optimization,

the LP Override must be engineered to provide

feasible SS controller targets and a realistic ramp

rate to the MPC controller

MPC Controller

Ramped Path

Page 9: Ensuring APC Optimization with Profit Suite

10 © 2015 Honeywell International All Rights Reserved

• Profit Optimization Suite provides best of both big and

multiple small applications ‒ Model pairing for good local control

‒ Global objective function to fully utilize degrees of freedom

‒ Reduce impact of week and less certain models

• A robust solution ‒ Flexes with changing process conditions

Accepts what can realistically be achieved and rejects what can’t

‒ Ensures feasible optimization path across entire process

scope

• Easy-to-use optimization/coordination solution ‒ Accommodates both SS and dynamic optimization schemes

Solving The Dilemma

Page 10: Ensuring APC Optimization with Profit Suite

11 © 2015 Honeywell International All Rights Reserved

Honeywell’s Layered Optimization

• Dynamic application

• Multi-unit optimization

• Non-linear optimization

Profit Optimizer coordinates

the economics of multiple

Profit Controllers for multi-unit

plant-wide optimization

Profit

Controller

Profit

Controller

Profit Optimizer

Profit

Controller

Economics and Ideal

Target Values

Disturbance

Values

Control

Variables

Manipulated

Variables

Product Value

Optimization

RMPCT

Algorithm

Page 11: Ensuring APC Optimization with Profit Suite

12 © 2015 Honeywell International All Rights Reserved

Profit Optimizer

Profit Optimizer

Profit Controller 1

Global Economics and Ranges

SS MV Targets

Gains

MV Economics

Process 1

Profit Controller 3

Process 3

Profit Controller 2

Process 2

Limits

Optimal

Dynamic Path

Local Feasible SS MV targets

QP Override 1 QP Override 2 QP Override 3

Feedback

SS

Model

Profit Bridge

Gains

Interface block

Other Controller 2

Ensures Optimal Dynamic Global Path

Page 12: Ensuring APC Optimization with Profit Suite

13 © 2015 Honeywell International All Rights Reserved

Multi-Unit Dynamic Global Coordination

$

Cont

50%

$

Cont

30%

$

Cont

20%

Dynamic Paths

Dynamic Paths

20-30% additional benefits over unit-based optimization

Page 13: Ensuring APC Optimization with Profit Suite

14 © 2015 Honeywell International All Rights Reserved

-5 -4 -3 -2 -1 0 1 2 3 4 5-5

-4

-3

-2

-1

0

1

2

3

4

5

x1

x2

Minimization of the JAE function

Start Point

Solution

1

6 5

4 3 2

7

• Profit Optimizer will be enhanced to include ‘Hessian

Updating’ which will ‒ allow optimizer to use

‘rate-of-change’ information

compared to simple gain updating

‒ allow faster convergence on the

optimum solution and improved

ability to deal with process

non-linearities

‒ provide additional benefits of around 10%, depending on

process non-linearities

• Profit Optimizer will be deployable across all major

APC solutions on the market, not just Profit Controller

R440 Optimization Enhancements

Page 14: Ensuring APC Optimization with Profit Suite

15 © 2015 Honeywell International All Rights Reserved

Plant-wide Optimization

Key Challenge:

Plantwide economics

Local economics

Optimal feasible

Control & Optimization

Schedule & Optimization

Production Planning

Business Planning

Planning

(Months)

Scheduling (Day/Weeks)

Integration Scheme? How?

App -1 App -2 App -3 App -n

Real Time Dynamic Optimization - DQP (hr)

How to get the solution layers to stay consistent

and reach the global optimum jointly?

Manage intermediate and final:

• Inventory (volumes)

• Properties (quality)

• Timeline (just in time)

Page 15: Ensuring APC Optimization with Profit Suite

16 © 2015 Honeywell International All Rights Reserved

Stra

igh

t-Ru

n a

nd

/or B

len

din

g

Blending Components

Straight-run products

APC model has a greater resolution but limited scope

• It captures essential unit or area operating constraints

• Optimizes unit production to possible detriment of plant

Plant-wide Optimization

Refinery Model – An APC View

Page 16: Ensuring APC Optimization with Profit Suite

17 © 2015 Honeywell International All Rights Reserved

Stra

igh

t-Ru

n a

nd

/or B

len

din

g

Blending Components

Straight-run products

Feed

y

y

y

p

p

p

nn

2

1

2

1

Product

The model has a high level of abstraction

• It captures essential material and energy balances in holistic view of the refinery

• It leaves out many unnecessary or even obscuring details for the economic optimization

Refinery Model – A Planner’s View

Plant-wide Optimization

Page 17: Ensuring APC Optimization with Profit Suite

18 © 2015 Honeywell International All Rights Reserved

App 1-1

App 1-2

App 1-3

App 1-n

DQP -1

App 2 -1

App w -1

App m-1

App m-p

DQP -m

A copy of yield model

+ economics from

planning/scheduling

Master Optimizer

Master MPC Controller

SDQP

Returned values can

include the predicted

yields and proxy limits

Manage intermediate and final:

• Inventory (volumes)

• Properties (quality)

• Timeline (just in time)

Manage:

• Unit operation

• Limits

• Constraints

Profit Executive is the “Integration Scheme”

Page 18: Ensuring APC Optimization with Profit Suite

19 © 2015 Honeywell International All Rights Reserved

Profit Executive Components

Planning Execution

Optimizer What-If steady state analysis using

current operating conditions

Controller Dynamic operating plan moves provided

to simulator

Optimizer Generates optimal steady state operating

plan based on actual costs

Controller Moves plant toward optimal while

accounting for immediate constraints

Predictor Computes yield/property model biases

using operating data

APC Extensions Bounds optimization problem based on

APC constraints

Page 19: Ensuring APC Optimization with Profit Suite

20 © 2015 Honeywell International All Rights Reserved

UOP-HPS Integrated Solutions for APC Process Models Example - Hydrocracking

Performance

Calculations

System data Process

models

• Mass balance

• Catalyst space velocity

• Catalyst life

• Catalyst average bed

temperatures

• %HDS, %HDN, gross and net

conversion

• H2 consumption

• H2 partial pressure

• As-produced product yields

• Product yields at standard cut

points

• Product TBP cut points

• Process data

• Lab data

• Online analyzers

• Yield

• Activity

• Deactivation

• Product quality

Economically optimize

manufacturing complex:

• Unit product rates

• Unit product qualities

• Provides operating

responses for optimum

Practical constraints:

• Catalyst temperatures

• Equipment design

• Cycle length

System

Constraints

Leverages process expertise for attainable optima

Page 20: Ensuring APC Optimization with Profit Suite

21 © 2015 Honeywell International All Rights Reserved

Optimization Case Studies

Page 21: Ensuring APC Optimization with Profit Suite

22 © 2015 Honeywell International All Rights Reserved

• Profit Optimizer coordinates Profit Controllers (APC controllers) to

maximize profit by solving collaborative optimization problem

• Scope: coordinate Profit Controllers of FCC and HFA units

• Optimization task: maximize most valuable product yield for different

scenarios (gasoline / alkylate / propylene) with compliance to each

Profit Controller constraints

Multi-unit Optimization Case Study

Profit Controller-1

Profit Optimizer (DQP)

Profit Controller-2 Profit Controller-9

Production

plan

Optimization

target

Page 22: Ensuring APC Optimization with Profit Suite

23 © 2015 Honeywell International All Rights Reserved

FCC Reactor Temperature

Gasoline Butane-

butene Gasoline Propylene Profit

Date

Multi-unit Optimization Case Study

Page 23: Ensuring APC Optimization with Profit Suite

24 © 2015 Honeywell International All Rights Reserved

Optimization scheme

Results (change of yield %

to FCCU feed) Comments

Maximize gasoline yield

+0.6% gasoline

–0.2% propylene

–0.3% alkylate

Constrains: propylene yield, butan-butylene yield,

gasoline RVP, gasoline RON, olefins in butan-

butylene, min T of reactor

Maximize propylene yield

+0.15% propylene

+0.05 % alkylate

–0.1% gasoline

Constrains: gasoline yield, max T of reactor, gas

plant capacity

Maximize alkylate yield

+0.4% alkylate

–0.6% gasoline

propylene – no change

Constrains: gasoline yield, max T of FCC reactor,

max T of HFA reactor, alkylation capacity

Net profit maximization 78 000 Rubbles per day,

(= 28 mln. Rubbles per year) Constrains: all above

Multi-unit Optimization Case Study

Page 24: Ensuring APC Optimization with Profit Suite

25 © 2015 Honeywell International All Rights Reserved

Naphtha

Crude Light Distillate VGO Purchase - Column V

Unit C3/C4 to Poly/Alky

Heavy Distillate

A Vacuum LVGOl Gasoline

Light Gasoil to FCC Tower FCC

HVGO LCO

Heavy Gasoil to FCC A

Vacuum Bottoms to FCC HCO

Atmos Bottoms

Atmos Bottoms to FCC Slurry

Naphtha LCO from FCC

Crude

Unit Distillate Naphtha

Diesel

B HTR

Diesel

Atmos Bottoms Cloud = -5 ~-25C Blending

Sulfur = 0~10ppm

Final Product

Naphtha

Naphtha

Crude Light Distillate Diesel Cloud = -45 ~ -48C

Unit Unifiner Sulfur = 4-6ppm

Heavy Distillate

C

Atmos Gasoil

Debut Overhead

Light Naphtha Debutanizer

Hydro Heavy Naphtha

Atmos Bottoms Vacuum Light Vacuum Gasoil Cracker

Tower Light Distillate

C Heavy Vacuum Gasoil

Heavy Distillate (to FCC)

Vacuum Tower Bottoms Bottoms

HCO from FCC

Component

Tank A

Tank B

Component

FeedTanks 3

Fd tank 2

Feed

Tank 2

4%

1%

20%

10%

Gate-to-gate optimization of oil refinery distillate production

Plant-wide Optimization Case Study

Page 25: Ensuring APC Optimization with Profit Suite

26 © 2015 Honeywell International All Rights Reserved

0 50 100 150 200 250 300 350 400-5

-4

-3

-2

-1

0

1

2

3

4Incremental Changes in Crude Unit Feed Rate

Crude Unit 1 deltaFeed

Crude Unit 2 deltaFeed

Crude Unit 3 deltaFeed

Combined Crude deltaFeed

0 50 100 150 200 250 300 350 400-5

-4

-3

-2

-1

0

1

2

3

4Incremental Changes in Crude Unit Feed Rate

Crude Unit 1 deltaFeed

Crude Unit 2 deltaFeed

Crude Unit 3 deltaFeed

Combined Crude deltaFeed

Average crude

saving is ~ 0.5%

for meeting the

same product

demand.

This is worth

$22M/year

Plant-wide Optimization Case Study

Feed Cost Saving from Optimizing the Volumetric Gains

Page 26: Ensuring APC Optimization with Profit Suite

27 © 2015 Honeywell International All Rights Reserved

Pursue Profit with Honeywell’s Profit Suite

Unified Technology Single platform from Experion-embedded

to plant-wide control & optimization

Faster Realization

of Benefits Designed for minimal effort to

achieve the first Euro of

benefits and build to larger

benefits as ROI is justified

More Benefits Over Time The most comprehensive offering to

transform business needs and objectives

into real-time operations

Flexible

Licensing Honeywell’s flexible approach

to software licensing ensures

maximum returns and

protection of your investment

Layered Optimization Honeywell’s unique solution for

leveraging existing models and

increasing operator effectiveness

while driving max benefits

through large-scale

optimization

Page 27: Ensuring APC Optimization with Profit Suite

28 © 2015 Honeywell International All Rights Reserved

www.honeywell.com/ps

Questions?