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CLOSING THE GAP BETWEEN OPTIMIZATION AND OPERABILITY WITH RESILIENT ADVANCED PROCESS CONTROL

By: Publication details: Buenos Aires Instituto Argentino del Petróleo y del Gas, IAPG 2022Description: 16 pOnline resources: Summary: Advanced Process Controls (APC) are designed to yield a certain benefit but are demanding to sustain in the long term. Several factors such as wrong strategy philosophy, instrumentation maintenance and human factors may attempt against APC performance and endurance to dynamic situations. Even artificial intelligence analysis may not be enough against a wrong strategy. APCs are well known for pushing unit limits to its constraints and therefore delivering additional margins. Nevertheless, they have been around the industry for a long time and some consider them as "old" or well-known techniques which do not have much more to exploit. This study shows the roadmap applied on a Fluid Catalytic Cracking APC, with decreasing uptime year to year, in order to make Operations embrace the technology again. Advanced measurement calibration techniques and model structuring were used to gain overall robustness which led to higher uptime. Additionally, a thorough analysis in the process and comprehension of the human factor involved was held. Results showed that uptime was improved, and feed throughput increased by an additional 5% during the harshest season conditions. Additionally, process variance and product sent to flare system was minimized. This confirms that understanding the human factor role and harnessing specific techniques to ensure a resilient APC capable to withstand the disturbances of a continuously changing operation is the key to success.
Item type: Congresos (trabajos presentados)
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IAPG-Colección Not for loan 200067292

Advanced Process Controls (APC) are designed to yield a certain benefit but are demanding to sustain in the long term. Several factors such as wrong strategy philosophy, instrumentation maintenance and human factors may attempt against APC performance and endurance to dynamic situations. Even artificial intelligence analysis may not be enough against a wrong strategy. APCs are well known for pushing unit limits to its constraints and therefore delivering additional margins. Nevertheless, they have been around the industry for a long time and some consider them as "old" or well-known techniques which do not have much more to exploit. This study shows the roadmap applied on a Fluid Catalytic Cracking APC, with decreasing uptime year to year, in order to make Operations embrace the technology again. Advanced measurement calibration techniques and model structuring were used to gain overall robustness which led to higher uptime. Additionally, a thorough analysis in the process and comprehension of the human factor involved was held. Results showed that uptime was improved, and feed throughput increased by an additional 5% during the harshest season conditions. Additionally, process variance and product sent to flare system was minimized. This confirms that understanding the human factor role and harnessing specific techniques to ensure a resilient APC capable to withstand the disturbances of a continuously changing operation is the key to success.



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