Laboratory for Automation and Measurement

In January 2017 we have finished one year-long project at the INA Rijeka Refinery which included: • Detail analysis, diagnosis and optimization of control loops at 3 groups of plants ( GP-1 , GP-2 and GP-3 ); • Installation and implementation of the modern monitoring and diagnostics system, identification and control loop tuning and simulation software. 350 control loops were analyzed and diagnosed. Based on the historical data control loop models were identified. Ultimately, the control loops were tuned using a high-level optimization tool and their performance was tested in the control room. As the results 12 newly configured and 32 reconfigured control loops increase automation level of the plants. 30 control loops are switched from manual to auto mode.  In 54 control loops we reduced or eliminated oscillation thus increasing the overall plant stability. Sensor or valve problems were detected on 37 control loops. It is estimated that the number of alarms is reduced by 50 %. Finally, variability of the products properties and quality measures are reduced.

The project of laboratory batch reactor automatization and optimisation was carried out during 2015 at the PLIVA R&D department. The aim of the project was to design modern process control system for easy, safe and flexible experimentation. Developed batch process control system will enable safe and efficient process control, accurate and repeatable experimentation as well as continuous data acquisition for later analysis of experimental results. More details (pdf)

We have just initiated large-scale project with the aim to provide monitoring, analysis and tuning of more than 350 control loops at the Rijeka Refinery process units. Control loop audit will include diagnostics of the field instrumentation and control valves, define sources of variability and oscillation, and poor control loop performance. The analysis will be foundation for control loops optimization which will result with decreased number of control loops in manual mode, reduced variability of controlled variables and more stable operation. Additionally, the implementation of the advanced software package will provide a possibility to perform controller tuning education and on-site optimisation. It is expected after project completion increased productivity, decreased equipment failures and prolonged service time, as well as increased process safety. All mentioned is a good base for advanced process control real application.

Cooperation between Pliva Hrvatska d.o.o and Faculty of Chemical Engineering and Technology, University of Zagreb started with the project of laboratory batch reactor modification and modernization within the Research and development department. The purpose of the project was to fully automate and modernize the experimentation procedure in the laboratory mixed batch reactor with vacuum distillation column and pumping system. The whole project starting from conceptual idea, through design and program support was successfully designed and applied. The modification and modernization procedure was consisted of measuring and control devices procurement and implementation, control strategy configuration, control loop tuning, SCADA system installation and design and laboratory batch reactor start-up and testing. After initial testing, operators where educated how to run safely modern batch reactor control system. Designed batch system includes all important process control characteristics such as safe and stable process control, accurate and repeatable experiments, robust system to different process conditions, continuous measurement and data acquisition.