The APC control system plant maintenance and solution
Category:
Smart Factory Integrated Solution
Better Your Technology
Our goal:Maintain the investment rate above 95%, realize the sustainability of APC benefits, and real-time and visualize economic benefits.
Current Situation, Problem
APC technology has been widely used in many large petrochemical enterprises in China by virtue of improving automation level, achieving card quality control of product quality, and improving the economic benefits of the device.
At present, the common problem in the factory is the lack of APC maintenance concept, which leads to the APC application rate becoming lower and the control effect getting worse. The current common APC operation problems are as follows:
First, APC troubleshooting
Communication interruptions, operator error, server failure, design flaws in controller logic, etc. can cause APC failure. When the controller is not available, it will affect the device's investment rate and normal production, and will directly affect the quality of the product.
Second, changes in working conditions
Changes in conditions and processes such as plant expansion, equipment renewal, raw material replacement, and new product development have resulted in the initial APC models and parameters not meeting current production needs.
Third, hardware and software updates
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Aging of server hardware can cause software to run slowly or even collapse. Hardware upgrades are often accompanied by software upgrades. Many chemical calculations and models need to be re-established.
Therefore, it is necessary for the factory to establish the correct APC maintenance concept. Maintaining APC and equipment maintenance is also important for stabilizing the normal production of the factory and continuously creating benefits.
Solution
In view of the current APC maintenance problems in the factory, Bangye Technology provides the following solutions:
First, the professional team is stationed in the factory
Maintenance personnel stationed in the factory can respond in time to ensure that APC is used normally. In view of various APC problems, maintenance personnel should have the ability to PID tuning, model identification, controller parameter modification and optimization design.
Second, the implementation of maintenance work content
24h response failure, standard operation, job ticket signature
Regular inspections and continuous operation
Submit maintenance reports and benefit reports regularly
Controller debugging, optimizing model parameters
Re-adjust the control matrix with process modification
Maintenance work example
The bottom temperature (controlled variable) of the rectification column of a plant gas separation unit is regulated by the hot oil flow rate (operating variable). The temperature fluctuation of the hot oil after the reform of the upstream device becomes large and difficult to stabilize, resulting in large temperature fluctuation at the bottom of the tower and poor control effect. The temperature curve is shown in Figure 1:
After analyzing the historical data, it is found that the change of hot oil flow and temperature will affect the temperature of the bottom of the tower, but the temperature that affects the bottom of the tower is the energy transfer between the temperature and flow of the hot oil and the temperature of the bottom of the tower. The thermal oil flow rate and temperature are then chemically calculated to obtain the Q of the hot oil energy. Replace the operating variable with Q, re-establish the model, overcome the thermal oil temperature fluctuation interference, and achieve smooth control of the tower bottom temperature. The standard deviation of the temperature at the bottom of the tower after maintenance is reduced by 45% compared with that before maintenance. The improvement effect is shown in Figure 2:
Maintenance work effect
During the APC maintenance period of a refining and chemical company, Bangye Technology responded to the fault handling 35 times in the first quarter, most of which were long-term unmaintained APC faults of the controller.
After the maintenance work was carried out, the total number of fault responses decreased to 11 times, the frequency of failures decreased by 70%, and the automation level was greatly improved.
Maintenance benefit
The advantage of APC maintenance work is to ensure the safe and stable production of the equipment, to continuously optimize the model and parameters of the controller, to continuously track the processing problems, to submit complete suggestions and implement, so that the economic benefits continue to maintain a high level. At present, Bangye Technology has carried out APC maintenance work in several factories, and both have achieved very good results.
With a professional APC team and rich project maintenance experience, Bangye Technology will always be committed to APC project execution and maintenance, and realize the visualization, sustainability and optimization of the plant APC benefits.
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