Advanced Process Controls (APC) and Real Time Optimization

Where Advanced Process Controls (APC) and Real Time Optimization Fits into the Project Lifecycle

Typically, Advanced Process Controls (APC) and Real Time Optimization implementation takes place during the normal steady state phase of a unit’s life-cycle. Plant owners are increasingly looking to expedite the benefits of Advanced Process Controls (APC) implementation by introducing it at the conclusion of the guarantee period and having it functional within three-six months after the plant becomes operational.

Process industries utilize a huge and interconnected set of technologies and processes. The key challenge for operators of refining, chemical and petrochemical plants is to maintain processes at their optimal operating point while simultaneously maintaining multiple safety margins at acceptable levels.

KBR implements model-based feed-forward multivariable control systems that monitor thousands of systems simultaneously and in real-time. Advanced Process Controls (APC) and Real-Time Optimization link planning, scheduling and management functions and offers an advance proactive view of all plant systems; allowing operators to push production limits without jeopardizing equipment limitations.

Without any modification of physical plant hardware, KBR’s Advanced Process Controls (APC) offers both tangible and intangible benefits.

The Benefits of Advanced Process Controls (APC) Include:

• Improved production by reducing the safety buffers needed to ensure limits for product quality and equipment integrity are not breeched
• Minimized energy consumption for maximal plant throughput
• Stabilized plant operation through minimized fluctuation of key process variables
• Improved responsiveness to changing economic and regulatory conditions through easy review and modification of operating objectives
• Less variability in the feedstock to downstream units
• Improved operator effectiveness by focusing attention on the key unit performance indicators
• Improved process safety as the APC system acts as an early-warning system
• Better understanding of overall unit operation

KBR has extensive Advanced Process Controls (APC) experience implementing all major commercially available software systems and can assure seamless delivery on time and on budget.

Real Time Optimization (RTOPT)

The global marketplace for refining, chemical and petrochemical products has placed increased pressure on facility operators to remain both competitive and profitable. This fast-paced environment forces operators to use real-time plant data to continuously evaluate and alter operating conditions in order to maximize economic productivity.

RTOPT is a complex, rigorous model-based system that optimizes plant operations and complements an APC installment and improves performance by adjusting a series of process variables in order to increase profitability and minimize operating costs.

RTOPT Provides:

• Better troubleshooting and engineering analysis
• Identification of abnormal equipment operation
• Availability of reconciled material and energy balances
• Better understanding of the process and operation
• Model-based optimization solution
• First-principle engineering models
• Integration with existing models