Solutions for
Optimizing
Oil & Gas
Operations
Control Loop
Performance
Optimization
Introduction
INTECH’s Control Loop Performance Optimization (referred to as CLPO) is an
operations improvement framework to optimize and streamline plant performance,
which contributes to smoother process operation and higher overall productivity.
INTECH’s applications add value through role based security, event triggered KPI’s
and multi variable loop and process analysis. INTECH provides advanced diagnosis,
tuning, performance optimization and routine monitoring of control loops as part of
its focus on lifetime asset and facility performance. This ensures timely identification
and rectification of control problems before they adversely affect process profitability.
This also makes sure that benefits of optimal loop performance do not diminish over
time.
Sub-Optimal Control-Loop Performance Factors
Of the four elements that make up a control loop, i.e. process, measurement,
controller and control element, changes in any one can affect the performance of
control loops and cause improper functioning. Factors that typially contribute to
suboptimal control loops are:
Debutan ize r
LC0204
LC0205
PCSP0204
FC0205
FC0204
TC0203
FC0221
FC1361
CX0205
TC0204
Equipment Wear/Aging
Changes in Operating Conditions
Modifications to Plant
Varying Unit Loads
PCSP0204A
CX0204
TC1203
TC2020
LC0206
FC0222
FC0208
PC0205
FC0235
FC0234
TC0209
FC0202
FC0209
CX0205
This lack of properly functioning control loops disrupts plant operation and affects
productivity, thus requiring continuous monitoring and improvement of control loops
throughout the plant/facility’s lifetime.
Regenera to r
LC0204
LC0205
PCSP0204
PCSP0204A
FC0205
FC0204
TC0203
FC0221
FC1361
CX0205
No Control
Action
Feedback
Control Action
Fuel Flow
Steam Flow 1
Disturbance
Disturbance
Disturbance
C0204
Steps to Improve Control TLoop
Performance
CX0204
TC1203
TC2020
FC0222
FC0208
PC0205
FC0235
FC0234
TC0209
FC0202
FC0209
INTECH follows a systematic approach Cto
control loop performance based
X 0 2improve
05
on the DMAIC process, and which consists of seven steps as defined by our solution
vendor partners, who are also industry standard leaders.
Flow Increase
from Fuel
Control
Improve
Hardware
Flow Drop
Flow Drop
& Recovery
Manual Control
Existing Mode
PID Control
Steam Flow 2
Target
Differences in Manual & PID Control
FC0234
LC0206
Continuous Improvement
Generator No Flow Change
Steam
Flow
FC0234
Establish
Philosophy
Measure
Performance
Compare of
Diagnose
Optimize
Controllers
Modify
Objectives
Optimize
& Maintain
Why do you need Control Loop Performance Management?
Control Loops are an integral part of any automated process and define how efficiently a plant, facility, fileds or sub-system operates.
Poor control loop performance can go undetected indefinitely and adversely affect productivity, having a negative impact on bottom line.
INTECH’s Loop Tuning helps identify origins of poor control loop performance and facilitates their remediation. It analyzes loops for
problems like hysteresis, stiction, process non-linearity, and poor tuning; it then identifies and models processes’ dynamic response to
calculate suitable loop PID controller settings. It also provides a choice of tuning objectives, and simulates loops’ response to visualize
effects of parameter changes prior to applying them.
Custom Reporting Solution
Loop Monitoring
Process Analysis
INTECH’s custom reporting solution gives
automatic loop performance reports,
event-triggered reports & shift schedule
based reports via email. These reports can
also be accessed, customized and shared
online and over the cloud.
INTECH’s solution acquires real-time data
via OPC and a time-series of data for
analyses. OPC read rate is user-defined so
that Loop Analysis does not overload the
OPC server or underlying systems.
INTECH’s Process Analyzer helps find,
explore, and understand plant-wide
oscillations & their interactions with
multiple plant/process variables. This
helps ensure operation at 100% capacity.
Operation / Safety / Quality Limit
Lower maintenance cost from
reduced variations
Symptoms of Control Loop
Malfunction
Poorly configured control loops are a serious
damper to productivity and lead to issues like:
Unnecessary and excessive alarms
Frequent process upsets
Reduced output and quality
Increased operator loading
Increased output variations
Stiction, non-linearity or hysteresis in
control elements
Gradual decrease in overall
productivity
Set Point
Reduced operator loading
from reduced alarms and
more robust controls
Poor Loop Performance
Improve Controls
to Reduce Variations
Operating Closer to Limits
Poor Loop Performance and Impact of INTECH’s CLPO
Classical Optimization Method
Controllers are tuned during commissioning
PI/PID parameters are initially set based on experience
Setpoint changes are made to test performance
Problem control loops are mostly tuned via trial & error
Plants may run for their lifetime with sub-optimal controls
INTECH’s Real-Time Optimization
Control Strategy Design
Control Element Performance
Controller Tuning according to Specific Objectives
Continuous monitoring of under-performing loops
Model-based process configuration
Noise & Interference
Reduced
oscillations &
disturbances
Increased
protection
Optimal
productivity &
operations
Damage to equipment
and assets
Error Span
Valve Reversals &
Hysteresis
Control Valve Traversals
Leading to reductions in
Overloaded operators and
excessive intervention
Benefits of Control Loop Optimization
What Our Customers Say...
“[We] commend INTECH’s knowledge of alarm
management, dedication, commitment and
effort. Most importantly, works have been
completed safely and INTECH has been able
to work successfully in our diverse
environment”
“INTECH personnel have the correct skills &
knowledge to enable them to carry out all
tasks and additional works… full training
and familiarization of Control Loop tuning
software has been carried out to our
complete satisfaction.”
“I commend you on your efforts in
customizing the business analysis
software for deployment for a Web Based
Alarm Management Dashboard. It meets
our objectives and has produced the
desired results.”
Central Maintenance Coordinator
Instrument Superintendent CM
Control & Automation Leader
EPC
End User
Americas
Asia
Middle East
INTECH Process Automation Perú S.A.C.
Av. República De Panamá N°3030 Oficina 7a
San Isidro, Lima, Perú
Tel: +511 606 6849
Cel: +51 982117562
PT INTECH Process Automation
Rukan Permata Senayan,
Blok C Nomor 5, 4th Floor,
Jalan Tentara Pelajar, Kebayoran Lama,
Jakarta Selatan, 12210 Indonesia
Tel & Fax: +62 21 579 49 444
INTECH Process Automation Inc. Br.
G-201 Al-salah Tower,
P.O. Box 4270, Al-khobar - 31952,
Kingdom Of Saudi Arabia
Tel: +966 13 8966052, +966 13 8966053
WORLD HQ
INTECH Process Automation Inc.
4903 W. Sam Houston Parkway N. Suite A-100
Houston, TX 77041, USA
Tel: +1 713 849 1000
Fax: +1 713 856 0785
Europe
INTECH Process Automation Sarl
168 Avenue Charles De Gaulle,
92 522 Neuilly-sur-seine Cedex, France
[email protected]
Central Asia
INTECH Process Automation LLP.
5A Erniyazova Str. Atyrau, Kazakhstan
Tel: +7 7122 32 01 16
Fax: +7 7122 32 00 52
INTECH Process Automation Pte. Ltd
600 North Bridge Road, #23-01
Parkview Square, Singapore 188778
Tel: +65 68289118
Fax: +65 68289112
Vendor Expertise
linkedin.com/company/intech-process-automation
facebook.com/Intechprocessautomation
Africa
INTERNATIONAL HQ
INTECH Process Automation FZCO
P.O. Box 61479, RA08ZC01,
JAFZA, DUBAI, United Arab Emirates
Tel: +971 4 8810056
Fax: +971 4 8810057
INTECH Process Automation (Shanghai) Co. Ltd.
Room 1605c, 16f Feidiao International Building,
No.1065 Zhaojiabang Road, Xuhui District,
Shanghai 200030 – P.R.C.
Tel: +86 21 2426 1951
Fax: +86 21 2426 1877
INTECH Process Automation Pvt. Ltd.
2nd Floor, Commercial Building #2
PCSIR Phase – II
Lahore 54782, Pakistan
Tel: +92 42 111 468 324, 3531 2509/11
Fax: +92 42 3531 4149
OEM
INTECH Process Automation Nigeria Ltd.
64b, Abacha Link Road, G.R.A. III,
Port Harcourt, Rivers State, Nigeria
Tel: +234 905 3992976
Liaisons Office,
Victoria Islands
Lagos, Nigeria
Tel: +234 805 9330560
[email protected]
INTECH Process Automation FZCO Br.
470, Italian City, Erbil, Iraq
Tel: +964 780 131 2198, +964 750 309 3766
North Africa Operations
Tel: +971 55 607 3230, +971 553768482
INTECH Process Automation Inc.
(Sucursal De Angola)
Casa Nº B07, Condominio Boulevard, Via Al16,
Talatona, Luanda - Republica De Angola
Tel: +244 222 720 471
Fax: +1 281 377 3455
[email protected]
[email protected]
Email: [email protected]
www.intechww.com
Standards & Certifications
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trademarks, brands, product and services marks and any use by INTECH should not be construed as an endorsement of INTECH or its services. The services described herein are provided
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