Solutions for

Control Loop
Optimizing
Oil & Gas
Performance
Operations
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.

Debutan ize r
Sub-Optimal Control-Loop Performance Factors
LC0204 LC0205 PCSP0204 PCSP0204A

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 FC0204 FC0205
control loops and cause improper functioning. Factors that typially contribute to TC0203 FC0221 FC1361
suboptimal control loops are: CX0205 FC0234

TC0204
Equipment Wear/Aging LC0206 FC0222 FC0208

Changes in Operating Conditions CX0204 TC1203 TC2020 PC0205 FC0235 FC0234

Modifications to Plant CX0205

TC0209 FC0202 FC0209

Varying Unit Loads

Regenera to r
This lack of properly functioning control loops disrupts plant operation and affects
productivity, thus requiring continuous monitoring and improvement of control loops LC0204 LC0205 PCSP0204 PCSP0204A
throughout the plant/facility’s lifetime.

FC0204 FC0205

TC0203 FC0221 FC1361

CX0205 FC0234

No Control Feedback Steps to Improve Control TLoop

C0204
Performance LC0206 FC0222 FC0208

Action Control Action

CX0204 TC1203 TC2020 PC0205 FC0235 FC0234

Fuel Flow INTECH follows a systematic approach Cto X 0 2improve

05 control loop performance based
on the DMAIC process, and which consists of seven steps as defined by our solution
TC0209 FC0202 FC0209

vendor partners, who are also industry standard leaders.

Steam Flow 1 Disturbance Disturbance
Disturbance
Continuous Improvement

Flow Increase
from Fuel
Generator No Flow Change Control
Steam Improve
Flow
Hardware
Flow Drop
Flow Drop & Recovery Establish Measure Compare of Optimize Optimize
Steam Flow 2 Philosophy Performance Diagnose Controllers & Maintain
Target

Manual Control PID Control

Existing Mode Modify
Objectives
Differences in Manual & PID Control
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 INTECH’s solution acquires real-time data INTECH’s Process Analyzer helps find,
automatic loop performance reports, via OPC and a time-series of data for explore, and understand plant-wide
event-triggered reports & shift schedule analyses. OPC read rate is user-defined so oscillations & their interactions with
based reports via email. These reports can that Loop Analysis does not overload the multiple plant/process variables. This
also be accessed, customized and shared OPC server or underlying systems. helps ensure operation at 100% capacity.
online and over the cloud.

Operation / Safety / Quality Limit

Symptoms of Control Loop
Lower maintenance cost from Malfunction
reduced variations

Poorly configured control loops are a serious

damper to productivity and lead to issues like:

Unnecessary and excessive alarms

Set Point Frequent process upsets
Reduced output and quality
Increased operator loading
Reduced operator loading Increased output variations
from reduced alarms and Stiction, non-linearity or hysteresis in
more robust controls
control elements
Poor Loop Performance Improve Controls Operating Closer to Limits
Gradual decrease in overall
to Reduce Variations productivity
Poor Loop Performance and Impact of INTECH’s CLPO

Classical Optimization Method

Controllers are tuned during commissioning Noise & Interference
PI/PID parameters are initially set based on experience Damage to equipment
Reduced
Setpoint changes are made to test performance oscillations &
Increased and assets
Problem control loops are mostly tuned via trial & error protection
disturbances
Plants may run for their lifetime with sub-optimal controls Error Span
Optimal
productivity & Valve Reversals &
INTECH’s Real-Time Optimization operations Hysteresis

Control Valve Traversals

Control Strategy Design
Leading to reductions in
Control Element Performance Overloaded operators and
Controller Tuning according to Specific Objectives excessive intervention
Continuous monitoring of under-performing loops
Model-based process configuration Benefits of Control Loop Optimization
 What Our Customers Say...
“I would like to commend INTECH's on-site INTECH personnel have the correct skills & “After successful commissioning I would
team for going beyond individual primary knowledge to enable them to carry out all express my satisfaction at duly meeting
responsibilities, exhibiting a diverse skill set tasks and additional works… full training the project schedule. The work was done in
to progress towards project completion.” and familiarization of Control Loop tuning most professional manner and we shall
software has been carried out to our favourably consider your company for
complete satisfaction. future work.”

Project Supervisor Central Maintenance Coordinator Sr. Engineer

End User EPC OEM

Americas Asia Middle East Africa

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