1. Polymer Property Online Predictive Models
PiControl Solutions LLC has the ability to calculate polymer properties, such as melt index, density and/or MFR. The calculations run every minute and are displayed on the DCS/PLC screen. As soon as new lab values are detected, the model predictions get auto-updated to account for the error between the lab and the model values corresponding to the time of lab sample collection. PiControl applies powerful automation and programming internally, inside the existing DCS/PLC to provide the best, most user-friendly operator interface.
2. Steady State Polymer Property Control
By using the predictive models for melt index, density and/or MFR, PiControl Solutions LLC implements powerful closed-loop controllers for controlling melt index, density and/or MFR by automatically manipulating the appropriate raw material feeds. Control action is smooth and optimized for tight and stable control.
3. Transition Sequence Control
PiControl Solutions LLC uses its revolutionary DCS-based APC (advanced process control) technology to provide powerful automatic controls for product transitions. The operator just specifies the new grade number or name and PiControls Solutions LLC technology automatically do transitions from the current melt index, density and/or MFR to the new targets. PiControl Solutions LLC technology is totally unique and completely unparalleled and unprecedented in terms of simplicity, ease of operator use, understanding, maintenance and intervention.
4. Production Rate Control and Maximization
PiControl Solutions LLC DCS-based APC (advanced process control) technology can be used to control production tightly at a given target. The DCS-based APC (advanced process control) technology also provides the capability to automatically maximize the production rate subject to any process, economic or equipment constraint. The DCS-based APC (advanced process control) technology includes methodology for identifying closed loop dynamics between the catalyst feed with production rate and all relevant important constraints that need to be considered. The DCS-based APC (advanced process control) controller determines the optimal path to move as fast (but in a stable manner) to the desired (target) production rate while satisfying the constraints. PiControl Solutions LLC also provides specialized DCS-based APC (advanced process control) technology for handling process non-linearity. The internal based APC (advanced process control) controller parameters are automatically adjusted based on process non-linearity, completely transparent to the operator.
5. Optimal Temperature and Pressure Control
PiControl Solutions LLC uses multivariable closed-loop process identification and controller tuning optimizer and simulator to identify multivariable closed-loop process dynamics and then determines the optimal tuning parameters to control the reactor temperature and pressure optimally with minimal oscillations. Use of this multivariable closed-loop process identification and controller tuning and optimization technology has resulted in truly spectacular and totally unprecedented results, proven in large commercial polymer plants.
6. Optimal Composition Cascade Control
PiControl Solutions LLC multivariable closed-loop process identification and controller tuning optimizer optimally tunes all the primary and secondary control loops required for closed-loop composition control. Stability and improvement in the process control quality of these control loops in turn improves the process control quality of other control loops – temperature, pressure and quality and has a beneficial impact on the overall process which in turn improves overall plant profits.
7. Online Oscillation Detection and Adaptive Control
PiControl Solutions LLC uses online process control performance quality monitoring and detection software product to detect oscillations in a real-time online manner. Detecting oscillations in chemical processes is often rendered difficult because of varying levels of random noise and process drift. Unlike competitor PiControl Solutions LLC software uses its proprietary TAD (True Amplitude Detection) algorithm to unambiguously and precisely detect real oscillations without ever getting confused by noisy squiggles that make other technologies far less reliable and usable. This distinguishing control technology allows PiControl Solutions LLC to provide genuine adaptive control automatically and reliably and helps to reduce or dampen oscillations that can easily develop in many polymer processes.
8. Pressure Setpoint Optimization
PiControl Solutions LLC uses special online optimization technology to determine the optimal component partial pressures for key components in gas phase polymer reactors. This enables the plant to optimize raw material losses in the flare/recovery systems while improving catalyst consumption efficiency. PiControl Solutions LLC online optimization technology is general purpose non-linear constrained reduced medium optimizer and may be used for any other optimization applications specific to any plants or process needs.
9. Online Dew-Point and Enthalpy Calculations
PiControl Solutions LLC provides technology for online dewpoint calculations, enthalpy calculations, heat-balance-or-mass-balance-based production rate calculations or any thermodynamic and kinetic calculations as needed by the plant or process.
10. Finishing/Compounding Train Advanced Control
PiControl Solutions LLC provides special DCS-based APC (advanced process control) technology to provide online rate maximizing and constraint pushing type advanced process control (APC) on the finishing/compounding trains. This section of the plant is full of mechanical equipment – transfer line blowers, solids transfer, extrusion equipment, pelletizers, cutters etc. PiControl Solutions LLC carefully examines the whole process and comes up with a custom design to stabilize, optimize the operation along with train throughput maximization.
11. Reactor to Extruder Throughput Integration
The upstream polymer reactor and the downstream extruder train are like two different plants. Matching the production rate from the reactor and the extruders can be challenging and if not done well, can result in lower efficiency (lost production). PiControl Solutions LLC provides integration between the reactor and extruder train which improves operational efficiency which in turn translates to higher profits.
12. Laboratory Information Management System
PiControl Solutions LLC PiLims OPC-based software product allows the laboratory technician to enter lab data onto a server-type computer and then the data gets automatically transferred to the DCS using OPC protocol.
The PiLims system provides label printing option, comments/notes recording to enter any useful operator/technician notes highlighting the laboratory samples. The lab data can also be trended to allow inspection of historical data. This feature is useful for laboratory data analysis, management and process troubleshooting.
13. Daily Controller Quality Performance Monitoring and Reporting
PiControl Solutions LLC online process control performance quality monitoring and detection software product monitors all of the important PID controllers, cascade PIDs, constraint override type PIDs, low/high selector type PIDs and also certain model-based, custom or advanced process controllers (APCs). Every day, it generates a report on all the controllers showing 25 different control criteria. In addition to these criteria, inside the report, every controller tag is assigned a grade from 0 (worst performance) to 100 (best performance). There is also a custom diagnostic message generated for all controller tags. The grade, diagnostic, and message assists the plants control engineer or technician to focus on the malfunctioning controllers in the whole plant. The end result is improved control quality and timely proactive fixing of control problems.
14. Fast Data Monitoring and Shutdown Debugging
Using the PiLogger OPC-based software product, PiControl Solutions LLC provides debugging and root-cause investigation of equipment shutdowns and plant/process operating problems. The PiLogger product can scan tags at the rate of milliseconds and keep a recent history of data on critical tags. The most recent 2-3 days of data is always saved in history in the form of a circular file. After an incident has occurred, fast-scanned data with 2-3 days of history provides invaluable insights into trying to analyze the problem. PiLogger also helps to identify the first-out which tells the first and foremost event that caused the process problem or equipment shutdown.
15. Process Engineering Online Analysis Tools
Many process engineers, operations experts and research engineers develop and implement various Excel-based spreadsheets to calculate important process calculations. PiControl Solutions LLC provides consulting services to convert all custom applications into online OPC-based software that reads live data directly from any DCS/PLC or external server using OPC. All calculations, rigorous, complex, iterative etc. can be implemented on a server. Calculations can be displayed on the server or may be displayed on a DCS screen or a PLC-PC HMI screen.
16. Expert System Operator Advisory
Many new plants are being built today. Many new and inexperienced technicians, operators and engineers enter the control rooms and plants every year. PiControl Solutions LLC specializes in capturing technical knowledge and wisdom from experienced personnel and then programming a custom Expert System Rule-Based Advisory X. It can be programmed with sophisticated and smart rules that will display special alerts to the operator when the conditions triggering that rule are satisfied. Any complex/smart message needing timers, multiple nested logic and backward logic propagation can be implemented. It helps to capture the knowledge, wisdom and skills of experienced operators, technicians and engineers and then save it permanently for online use and benefits of new personnel. Loss of people through retirement and promotions does not lead to a total loss of skills and knowledge of those individuals.
