engleski

Control loop optimization on FCC plant in INA Refinery Rijeka (pilot project)

Plant management is often unaware on the poor condition of the process control quality in the plant because of absence of easy methods to trend and quantify the control quality metrics. The first step in improving the plant control quality is to install online/offline control quality monitoring software. The second step is to analyze process data on poorly performing control loops and identify the system dynamics. The final step is to calculate the new and improved controller or APC tuning parameters. Following these three steps systematically can tremendously improve plant’s control quality and in turn, the plant’s profit margins. This case-study comprises control loop diagnostics, analysis and optimization within the INA Refinery Rijeka at the fluid catalytic cracking plant, particularly debutanizer column. During process control loop diagnostics and optimization procedure all control loops found in manual have been analyzed and finally switched to automatic control mode. Several control loops are tuned in consequence of increased stability of the entire plant. Moreover, excessive movement and fluctuation of control valve is reduced. The overall debutanizer’s control system performance is significantly improved which ultimately has a positive effect on product quality and energy consumption.

Control loop; process monitoring and diagnostics; controller optimization

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