P3-A Operational Trend for Excel- Guided Tour

1 Introduction

CTRL Designer LLC (CDL) is a leading provider of state-based control (SBC) (procedural control) based on ISA106 solutions to the process industries.

Its software portfolio and work processes help process control engineers develop an overall process control design and convert it automatically to the selected control system code. These solutions allow users to make smarter decisions to improve safety, reliability, efficiency, and sustainability.

The products are divided into phases:

• P1- Industrial Plant Assessment™ (IPA)
• P2- Level of Automation (LoA) [Service]
• P3- Operating Trends for Excel™ (OT)
• P4- Standard Operating Procedure Analyzer™ (SOP)
• P5-URS-to-FRS-Builder-for-Excel™ (URS)
• P6-FRS-Engine-for-Excel™ (FRS)
• P7-ACM-Engine-for-Excel™ (ACM)

The P3- Operating Trends for Excel™ (OT) is reviewed in this section.

2 P3-OT-Operational-Trends (OT)

As it is shown above, the P3-OT-Operational-Trends (OT) tool is used to develop:

• Develop OT for the Plant and its associated Units

• Develop OT for a selected Unit and its Equipments (Pump, Reboiler), Controllers, and Digital Outputs (Agitator, Block Valves).

The SOP document is used to develop OT. Standard Operating Procedure SOP normally written in a sequential format to communicate the operator’s activities.

The SBC will automate the majority of these activities and it is CRITICAL to review the SOP with operation before the development of URS or FRS to make sure the proposed SOP is implemented using SBC.

In this document the following is presented:

1. Guided Tour of a Plant Operational Trend
2. Guided Tout of a Unit Operational Trend
3. Step by Step How to develop OT

3 Guided Tour of a Plant Operational Trend

3.1 Purpose

The purpose of this section is to demonstrate a simple plant OT example

The design team provided us with a narrative fo the operation of this plant.

The objective of OT is to deliver the following:

1. Divide the plant to units

2. To review with operation

   • Visualization of Plant operation in time (Trends)
   • Visualization of Unit to Unit interaction in time (Dynamic)
   • Mode of Operation for the Plant PM and each of its associated Units
   • Steps for Plant PM

3. For URS engine

   • Trends
   • Dynamic
   • Plant PM Mode of Operation
   • Plant PM Steps
   • Each Unit UM Mode of Operation

3.2 Inputs

For this example (P3-OT-01-PM-RX-DIST-CDL.xlsx) we had received narrative from the design team.

This example is strored in the

• Folder: P3-OT-Operational-Trends

• File OT-03-Examples\P3-OT-01-PM-RX-DIST-CDL.xlsx

1. Start-up
   • Open the Feed to RX 8000 Wait until RX level is 75%
   • Run the RX until Temperature reaches 450 Deg C
   • Open Feed to Distillation 8000
   • Reduce feed to RX to 3000
   • Open Distillate to RX 5000 Recycle to Reactor
   • Open Bottom Product 3000
2. Run
3. Shut-Down
   1. Cut Feed and run distillation until the RX and Distillation levels are low 0 Prepare for shutdown
   2. Cut the Distillate and Bottom flow
   3. Cut Feed to Reactor

3.3 Tasks

3.3.1 Identify the Units

Based on the plant flow diagram and narrative the following units are identified.

1. RX: Reactor
2. DIST: Distillation

The plant flow diagram is shown below

3.3.2 Develop CDL Narrative

Based on the narrative provide above the following MV and CV are defined for the Reactor (RX) and Distillation (DIST)

Index	Tag	Range
1	MV1-RX Feed	10000
2	MV2-Dist Feed	10000
3	MV3- Top Product	10000
4	MV4- BTM Product	10000
5	CV1 - RX Level	100

The following CDL narrative is defined

Index	Narrative
1	Ramp the Feed to RX Unit (MV1-RX Feed) to 8000 Wait until RX Unit level (CV1 - RX Level) is 75%
3	Ramp the Feed (MV2-Dist Feed) to Distillation 8000
4	Reduce feed (MV1-RX Feed) to RX to 3000
5	Ramp Distillate feed (MV3- Top Product) to RX 5000 Recycle to Reactor
6	Ramp Bottom Product (MV4- BTM Product) to 3000
7	Run both RX and Dist Unit
8	Ramp Feed (MV1-RX Feed) to zero until the RX Level (CV1 - RX Level) reaches 10%
9	Ramp the (MV3- Top Product) and (MV4- BTM Product) to zero

Based on CDL OT Rules the following User MCD matrix is developed

Entering the value for each MV and CV yields to:

The command is followed by | and its value. This is stored in {User-MCD-Tasks} sheet.

3.3.3 Review Trends

The trends are displayed below:

3.3.4 Review The Mode Of Operation

The MofO are displayed below:

3.3.5 Dynamic

The Dynamic are displayed below:

3.4 Example 2 : Plant - Distillation - Reactor - 2-Distillations

This example is strored in the

• Folder: P3-OT-Operational-Trends

• File OT-03-Examples\P3-OT-05-PmDRTT-CDL.xlsx

3.4.1 Dynamic

This example dynamic diagram is shown below

3.4.2 Trends

This example trends is shown below

3.4.3 Mode of Operation

The mode of operation for the Plant and its unitsare shown below

3.5 Example 3 : Plant - Distillation - Reactor - 2Distillations

3.5.1 Dynamic

This example dynamic diagram is shown below

3.5.2 Trends

This example trends is shown below