Maximize productivity and minimize cost by advanced control (Expert optimizer)

Advanced Control System (Expert Optimizers) in Industrial Processes.

In an Industrial process control system, the main objectives of any process are to stabilize the process operation to achieve the maximum production figures, get the highest quality, maximize efficiency, and minimize costs and expenses.

 
Normally the automatic control system does this work at a certain level and limited achievement. but there is more. An advanced control system (Expert optimizer) is one of the advanced tools used at a high level in automatic control systems. It plays a significant role in this area by applying advanced techniques to optimize the main parameters of any industrial process.

Advanced Control (Expert Optimizer)

The expert optimizers can be used in different modules based on the type of process such as production process, supply chain, energy management, and asset performance. In this article, we will go through the expert optimizer to understand what is the expert optimizer, explain the expert optimizer's benefits, how it works, and what applications are using it.

What is the expert optimizer?

An Expert optimizer is a complicated tool that uses and utilizes modern equations and mathematical models to optimize any process. These advanced tools are created and configured to add more advantages to the existing control system. Expert optimizer identifies and analyzes the measured data by system sensors like temperature and pressure sensors.

It is used to maximize productivity, maximize product quality, and minimize costs and expenses. The expert optimizer also uses a machine learning approach, fuzzy logic, and artificial intelligence in one application. The outcome of the expert optimizers has significant improvements in process efficiency and performance.

In expert optimizers, many advanced graphical and trend display tools are used to monitor and follow up on the process optimization performance and report for any errors or unstable conditions to enhance and utilize the maximum system performance and the highest level of optimization to increase productivity and reduce maintenance cost.

What are the benefits of the Expert optimizers?

• Increase productivity.
• Decrease the specific energy consumption (specific heat and power consumption).
• Increase the product quality by lowering the standard deviation.
• Minimum payback of project investment.
• Long-term stability of process and equipment.
• Reduced equipment depreciation and wear.
• Minimized downtime by avoiding unstable operations.
• Reduced maintenance costs as a result of minimum downtime and maximum production.

How does an expert optimizer work?

Expert Optimizer performance

The optimization process passes through certain stages starting with operation without optimization and ending with full optimization. These stages are the instability stage where the process is controlled manually, decreasing instability and increasing the set-point, and finally, the steady operation with full optimization.

Without optimization (manual operation).

In this stage, the human operation takes place and is involved in the process’s control. in the manual control stage, the operator behaves like a controller, and the process is controlled by open loop control without any computers. It depends on the evaluation and the judgment of the human. As per the figure, The process performance in the manual stage has the following properties:

• System and process operation is unstable.
• Low performance and low productivity because of the slow response and less accuracy.
• The cost increases because It requires more labor.
• The error percentage increases because the operator normally cannot handle the small change in measured values which causes the continuous oscillation around the set-point.

During optimization.

In this stage, the operation mode changed from manual and open-loop control to an automatic mode. The controller seeks to achieve the set point and takes actions based on the measured values by the system instrumentation. In this stage, the process operation has the following:

• The level of instability and the system becomes more stable with low oscillation.
• The performance and efficiency of the process operation are increased.
• The system stability enables the system to increase the set-point which leads to productivity increases.
• The operation stabilization of the system decreases the energy losses through the system and decreases the specific fuel and electrical power consumption. That means decreasing in operation costs and production increases. 

After optimization.

The objective from this stage is to keep the achievement that exists during the optimization stage with maximum productivity, highest quality, lowest cost, and finally maximum performance and accuracy. It also maximizes the system stability and minimizes the final (steady state) gap between the setpoint and the actual value.

What are the Expert Optimizer’s Control strategies?

In the Expert Optimizer, there is a toolkit containing several control strategies used to develop the process operation’s performance. These control strategies are capable of handling tough operation conditions. It develops a new level of optimization and robust control techniques like fuzzy logic control, Neural networks, and Model predictive control.

What is the Fuzzy logic control strategy?

Fuzzy logic control is one control system type that deals with imprecision and uncertainty through a fuzzy logic and mathematical approach. In fuzzy logic control, the input and output values are represented by linguistic variables away from numerical values, to allow more flexibility in complex and uncertain situations by executing rules.

What are the Neural Networks?

One of the types of AI (Artificial Intelligence) is the neural network. It imitates the human brain’s function. It uses the deep learning process where the system recognizes the relationships and patterns between all interconnection nodes or neurons.

These neurons process the received input signals and generate output signals to other neurons. The neural network could be applied in auto-vehicles, financial forecasting, and medical applications like medical diagnostics because of the decision-making based on a huge amount of data collected.

What is the Model Predicted Control?

The Model Predictive Control (MPC) predicts the behavior of any system in the future and makes a decision based on the system model and past and current status. It is considered one of the successful control strategies used in industrial processes for performance optimization.

What are the Expert Optimizer’s applications?

1. Manufacturing and industrial processes to optimize production, quality, and cost.
2. Multi-fuel application to optimize fuel consumption and cost
3. Energy Management Strategies to optimize energy consumption and efficiency.
4. Transportation for routes, traffic optimization
5. Healthcare applications to optimize disease diagnosing and treatment planning.
6. Customer Service to improve customer satisfaction.
7. Finance for risk assessment and help in decision-making.

 

What are the Steps to apply Expert optimizers in any project?

• Study the process condition to determine the feasibility and potential of optimization.
• Prepare the complete plan and the project strategy.
• Design the best solution matching the process based on the data collected.
• Implement and integrate the new system into the existing process operating system.
• Operate the commissioning of the system.
• Perform a PGT (performance guarantee test) to confirm the project-agreed achievements.
• Follow-up and monitoring of the system performance.
• Check for System upgrades and improvements to maximize benefits.

Summary.

Advanced control like expert optimizer is one of the automation tools in the manufacturing and industrial processes that is used to optimize the process performance to a higher level. It increases productivity, maximizes product quality, and reduces the operating cost.

Advanced control (Expert optimizers) could be used in many applications like Manufacturing, Transportation’ Healthcare applications, and Customer Service. The project will go through certain stages like studying, project implementation and commissioning, and evaluation.