How to view advanced control?
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Friends, some companies are now starting to adopt APC (Advanced Process Control). Has anyone come across it? How is it working? What do the operators say?
What exactly is it? Have only seen this noun
Due to my work, I was previously familiar with this thing; in practical use, there isn’t really any significant difference. Personally, I think the algorithms are more complex, the scope of calculations is wider, and feedforward control plays a more prominent role. However, it’s essentially just an improvement in the tool itself. The effectiveness of its use depends a lot on the person using it. I’m not a professional, so these are just my personal opinions
This is a precursor to staff cuts! ! ! ! ! !
First, your raw materials need to be relatively stable; second, the modeling (control algorithms) must be suitable for your actual manufacturing process; and lastly, the operators need to be familiar with the process and possess the necessary skills. For example, in a distillation tower, it is necessary to stabilize the materials surrounding it before implementing advanced control measures; there are specific parameters to be met, which is equivalent to imposing a strict constraint on the operators. Let’s look at the benefits: some people like it, while others find it troublesome. @jiaguoyun
APC is a good thing; it’s not being used very well at the moment. There is a reason for this; I have conducted research on the atmospheric and vacuum distillation units of Sinopec. There are two main reasons: limited test data on the properties of the raw materials and the products. APC enables automatic adjustment and fine-tuning of production parameters based on real-time laboratory analysis data. Currently, model predictions are used to provide parameters for APCs; in other words, it relies on guessing, and this is less accurate than what an operator can determine based on experience. How can such a method work effectively? Additionally, there are no costs associated with implementation and maintenance. The implementation cost for an APC set abroad is around 3 million, while in China it’s only about 800,000; moreover, the subsequent maintenance costs are zero. You can imagine that even the best people can’t do anything about this.
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Not now; some companies have already started to adopt APC. As for how well it works, it’s the same as with DCS, SIS, or various hardware devices: those who know how to use it can utilize it effectively, while those who don’t consider it to be complete nonsense. It’s something that the French have been using since the 1960s and 1970s, so it must be effective. But this also needs to be viewed dialectically; it’s not perfect, it has both disadvantages and advantages. The key is to determine whether it’s suitable – not all devices or production processes are appropriate for it, and thorough research must be conducted before implementing it.