How to Use Valve Position Control to Optimize Process Efficiency and Capacity

The following tip is from the ISA book by Greg McMillan and Hunter Vegas titled 101 Tips for a Successful Automation Career, inspired by the ISA Mentor Program. This is Tip #97.

oil valve

There are many opportunities for process optimization by valve position control (VPC). Table 1 summarizes common examples of the use of VPC for increasing process efficiency and capacity. Efficiency is increased by reducing energy and raw material costs for a given production rate. Capacity is increased by increasing feed rates for a given efficiency. Table 2 is a summary of key PID features that make the implementation of VPC easier and more effective at achieving process objectives and dealing with process disturbances.

Optimization

VPC PID PV

VPC PID SP

VPC PID Out

Minimize Prime Mover Energy

Reactor Feed Flow PID Out

Max Throttle Position

Compressor or Pump Pressure SP

Minimize Boiler Fuel Cost

Steam Flow PID Out

Max Throttle Position

Boiler Pressure SP

Minimize Boiler Fuel Cost

Equipment Temperature PID Out

Max Throttle Position

Boiler Pressure SP

Minimize Chiller or CTW Energy

Equipment Temperature PID Out

Max Throttle Position

Chiller or CTW Temperature SP

Minimize Purchased Reagent or Fuel Cost

Purchased Reagent or Fuel Flow PID Out

Min Throttle Position

Waste Reagent Or Fuel Flow SP

Minimize Total Reagent Use

Final Neutralization Stage pH PID Out

Min Throttle Position

First Neutralization Stage pH PID SP

Maximize Reactor Production Rate

Reactor or Condenser Temperature PID Out

Max Throttle Position

Feed Flow or Reaction Temperature SP

Maximize Reactor Production Rate

Reactor Vent Pressure PID Out

Max Throttle Position

Feed Flow or Reaction Temperature SP

Maximize Column Production Rate

Reboiler or Condenser Flow PID Out

Max Throttle Position

Feed Flow or Column Pressure SP

Maximize Ratio or Feedforward Accuracy

Process Feedback Correction PID Out

50% (Zero Correction)

Flow Ratio or Feedforward Gain

Table 1 – Examples of Optimization by Valve Position Control

Concept: Valve position control (VPC) can be quickly implemented for small process optimization opportunities. An integral-only structure has traditionally been used for VPC to eliminate interaction. However, an integral-only controller is difficult to tune, can get into limit cycles, and can be too slow to prevent running out of valve; that is, a valve is on the flat part of its installed characteristic and is close to an output limit. The key PID features shown in Table 2 enable the use of PI control.

Feature

Function

Advantage 1

Advantage 2

Direction Velocity Limits

Limit VPC Action Speed Based on   Direction

Prevent Running Out of Valve

Minimize Disruption to Process

Dynamic Reset Limit

Limit VPC Action Speed to Process Response

Direction Velocity Limits

Prevent Burst of Oscillations

Adaptive Tuning

Automatically Identify and Schedule   Tuning

Eliminate Manual Tuning

Compensation of Nonlinearity

Feedforward

Preemptively Set VPC Out for Upset

Prevent Running out of Valve

Minimize Disruption

Enhanced PID

Suspend Integral Action until PV Update

Eliminate Limit Cycles from Stiction Backlash

Minimize Oscillations from Interaction Delay

Table 2 – Key PID Features for Valve Position Control

Details: Use valve position control on valves that are the constraints to improving the capacity or efficiency of a unit operation. For loops that manipulate utility flows, use a maximum throttle position for the VPC setpoint. For expensive fuels and reagents, use a minimum throttle position for the VPC setpoint. To increase efficiency, use the VPC output to maximize a less expensive or waste fuel or reagent, minimize a prime mover (e.g., compressor or pump) discharge pressure, or maximize a chiller or cooling tower outlet temperature. To increase capacity, use the VPC output to maximize a feed rate to a fedbatch or continuous operation. Use an enhanced PID with a threshold limit to ignore inconsequential changes in valve position and to stop limit cycles.

Use directional setpoint rate limits with external-reset feedback (Tip #72) to reduce interactions and provide a slow approach to an optimum and a fast getaway; movement away from the optimum for disturbances; to prevent running out of valve (valve close to output limit or on flat part of installed characteristic). Use a feedforward summer in the VPC to provide preemptive action. Use adaptive tuning to help the VPC deal with nonlinearities and changing objectives. Review the application with the process engineers. Train Operations in the use of the VPC. Work in the control room with the operators to improve tuning and make sure the VPC does not cause any operational problems.

101 Tips for a Successful Automation CareerWatch-outs: Just one abnormal condition, one bad batch, or one increase in off-spec will likely prevent the VPC from ever being used again. The VPC should start with very narrow output limits to restrict what the VPC can do. Only after the VPC is tuned and confidence is gained should the output limits be widened. The VPC will have to be retuned to deal with nonlinearities as the limits are widened. If you do not have external reset feedback (e.g., dynamic reset limit), you may have to use an integral-only structure for the VPC to prevent interaction.

Exceptions: If unmeasured disturbances are too fast and disruptive, VPC is not feasible. If the optimum setpoint is a function of operating conditions rather than simply valve position, model predictive control is a better optimization solution.

Insight: Valve position control can be implemented in a matter of hours to start optimizing the efficiency or capacity of a unit operation.

Rule of Thumb: Use valve position control with key PID features to maximize production rate and to minimize energy use and raw material costs for a unit operation.

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