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AN INDUSTRIAL APPLICATION
Serdar Kemalolu Emre zgen Kuzu
Dila Gke zgur etin
Turkish Petroleum Refineries Corporation, Izmit 41780
Turkey
Abstract: This paper reviews the application of a model predictive controller algorithm to a crude oil
unit in Izmit Refinery of Turkish Petroleum Refineries Corporation as a summary of nearly eight months
of practical study. The controller is designed to control the crude heating via process flows followed by
furnace heating and distillation column with product strippers. After a process overview, the fundamental
control loop considerations are discussed. Steps of determining inferred qualities and step test response
tests are outlined. The controller design considerations, constraint handling and economic variables are
presented. Finally, a comparison of before and after commissioning in the kerosene quality and rate is
tabulated as well as simulation results of the system response for different set point changes in the
product qualities.
Keywords: Advanced process control, multivariable predictive control, crude distillation processes,
model identification.
1. INTRODUCTION
Model predictive control (MPC) strategies have found a wide
range of applications from refineries to food processing and
become a standard control algorithm for process industries. In
1999 nearly five thousand applications were reported with an
increase of about 80 % in the following years (Qin and
Bagdwell, 2003). MPC algorithm utilizes an explicit process
model to optimize an open loop performance objective to
constraints over a future time horizon, based on current
measured variables and the current and the future inputs
(Rossitier, 2003).
Turkish Petroleum Refineries Corporation (TUPRAS) is the
largest industrial enterprise in Turkey. TUPRAS controls all
of Turkeys refining capacity with operating four refineries
with a total annual process capacity of 28.1 million tons
crude oil. TUPRAS Izmit Refinery is the biggest refinery of
four with annual refining capacity of 11.0 million tons of
crude oil.
After privatization in 2006, implementation of advanced
process control (APC) applications were initiated to increase
operational excellence with many other projects. In this
paper, an APC application to one of the crude units in Izmit
Refinery is presented. After the process overview, base layer
control strategies developed to sustain healthy layer for APC
studies are explained. The main elements of the controller,
controlled, manipulated and disturbance variables are
discussed. Following the methods for obtaining inferred
qualities, response tests and dynamic modelling strategies are
outlined. The dynamic models obtained during tests are used
in the commercial MPC algorithm SMOCPro. The control
strategies, economic concerns and commissioning issues are
1.
4. CONTROLLER COMISSIONING
4.1 Controller Design
The dynamic models from observed plant data were used to
design the controller. Shell Multivariable Optimizing
Controller, SMOCPro is used to implement predictive
controller in TUPRAS Izmit Refinery Crude Unit.
SMOCPro, a part of the Process Control Technology Package
(PCTP) of Shell Global Solutions International BV, and its
algorithm was summarized by Qin and Bagdwell (2003) :
min
u ( n )... u ( n + C 1)
i =1
y ( n + i ) r ( n + i ) w1 + u ( n + i 1) w 2
(1)
j =1
0,35
0,18
Before APC
Crude Oil Gravity =32,46 API
Kero/Feed Ratio (mean)= 14,7%
0,30
0,16
0,12
0,20
0,10
0,15
0,08
11 % Kerosene Yield
Improvement
WSRN/FEED Mean
Days
WSRN/FEED Ratio
KERO/FEED Mean
65
60
55
50
45
40
35
30
25
20
15
10
0,06
5
0,10
0
0,14
0,25
KERO/FEED Ratio
42
Kerosene Flash Point (C)
WSRN/FEED
After APC
Crude Oil Gravity =32,43 API
Kero/Feed Ratio (mean)= 16,4%
KEROSENE/FEED
40
38
Difference : 0.47 C
36
After APC
Standard Deviation = 1.163
34
Before APC
Standar Deviation = 1.34
4.4 Results
Over a two months period of controller running, the overall
throughput of desired products increased significantly. Figure
2 shows the decrease in the naphtha yield, whole straight run
naphtha (WSRN), and increase in the kerosene yield for a
five weeks period of pre-commissioning and four weeks
period of post-commissioning of the controller. The crude oil
density was assumed to be constant, 32.46 and 32.43 API
Sample
180
5660
175
170
165
160
5640
Heavy Diesel Pumparound (m3/hr)
High Limit
PV
Low Limit
155
5620
5600
5580
5560
5540
5520
5500
150
0
100
200
300
400
500
600
700
800
900
100
200
300
400
41.5
1.34
41
1.32
600
700
800
900
600
700
800
900
600
700
800
900
600
700
800
900
1.3
Column Pressure (kg/cm2)
40.5
500
Time (min)
Time (min)
40
39.5
39
38.5
38
37.5
1.26
1.24
1.22
1.2
1.18
Low Limit
PV
37
1.28
1.16
High Limit
1.14
36.5
0
100
200
300
400
500
600
700
800
900
100
200
300
400
151
370
150
Coulmn Top Temperature (C)
372
368
366
364
362
High Limit
PV
Low Limit
360
100
200
300
400
500
600
700
800
149
148
147
146
145
144
358
0
900
100
200
300
400
500
Time (min)
Time (min)
339
326
338
322
320
High Limit
PV
Low Limit
318
316
314
312
324
500
Time (min)
Time (min)
337
336
335
334
333
332
331
330
310
329
308
0
100
200
300
400
500
600
700
800
900
Time (min)
100
200
300
400
500
Time (min)
1910
1900
1890
1880
1870
1860
1850
Loop Description
MV
CV
10
11
700
12
650
13
14
15
16
17
18
5. CONCLUSIONS
19
HADPA Flow
20
21
1830
1820
1810
1800
0
100
200
300
400
500
600
700
800
900
Time (min)
1020
1000
Heavy Diesel Rate (m3/hr)
DV
1840
980
960
940
920
900
880
0
100
200
300
400
500
600
700
800
900
Time (min)
600
550
500
450
400
350
300
0
100
200
300
400
500
600
700
800
900
Time (min)
REFERENCES
Andersen, H.W. and Kummel, M. (1992). Evaluating
estimation of gain directionality Part 2: a case study of
binary distillation, Journal of Process Control, 2, 67-86.
Rossitier, J.A. (2003). Model based predictive control A
practical approach, CRC Press, London.
Qin, S.J. and Badgwell, T.A., (2003). A survey of industrial
model predictive control technology, Control
Engineering Practice, 11, 733-764.