Untapped Advanced Control Capabilities in Modern Distributed Control Systems

Modern digital Distributed Control Systems (DCS) have become extremely powerful and capable platforms, even to the point of offering Model Predictive Control (MPC) functions within Level 1 process-connected devices. But, while DCS capabilities have increased substantially since their inception in the 1970s, much of their control capabilities remain untapped. This situation is exemplified by the wide-spread fact that many MPC implementations are designed to overcome regulatory control deficiencies. But such practices represent a gross waste of otherwise valuable resources, especially at the DCS, as well as MPC, level.

Observations made across multiple companies and sites indicates that one of the reasons for the poor utilization of DCS functional capabilities is the lack of investment by Industrial Management into staff training, in addition to the inadequate treatment given to process control in many engineering curriculums. With the above in mind, this case study presentation uses a real-world plant problem and illustrates how judicious use of process understanding and regulatory control DCS functions and capabilities provided the means to optimally operate a vital utility system for a large LNG facility.