Markand Joshi

2014
Sustained Performance Program for Aspentech DMCplus controllers, KNPC MAA refinery Kuwait:
To provide expert engineering services for continuous monitoring and improvement of DMCplus application on long-term basis for sustained optimal benefits thereon.
KNPC Mina Al-Ahmadi (MAA) refinery has implemented Multivariable Predictive Controllers, in most of the process units, using the following AspenTech software packages:
• DMCplus as the Multivariable Predictive controllers
• AspenWatch as DMCplus controller performance analysis and reporting tool
• Production Control Web Server (PCWS) to monitor Controller performance
• AspenIQ is used for inferential development and online bias update.
• LIMS to IQ: Interface application to fetch LIMS data to Aspen IQ.
• Aspen SmartStep for automated Step Testing.
Process units, having existing DMCplus controllers, connected to respective DCS are as shown below:
Honeywell DCS: FCC, HCR, VR, ARD, HP, LPG, PRU, Alkylation and MTBE.
Invensys DCS: CDU-4/5, ARD, New GOD, CCR-1/2, Gas Trains-1/2/3, ERU, SRU/TGT and Boilers.

IOCL Vadodara DHDT & Hydrogen Unit APC implementation:
Two controllers are designed, one controller for DHDT and one controller for Hydrogen unit.
Hydrogen balancing across the supplier and consumers.
DHDT Diesel yield maximization with respect to Flash point and Energy optimization.




2013
IOCL Vadodara Delayed Coker Unit APC implementation:
SYDEC technology licensed by Foster Wheeler used for DCU plant.
Three controllers are designed in DCU. One controller for Fractionators and other one controller for light end recovery section, two controllers designed for Heater section which include feed maximization and pass balancing controller.
Toolkits developed for coke weight calculation, Drum outage calculation and drum change over toolkit.
Feed maximization objective achieved using coke drum outage calculation toolkit.
Fractionators’ profile controlling improved during Drum change over using drum change over toolkit.
IOCL Vadodara VGO-HDT APC implementation:
Process is licensed by M/s. UOP, U.S.A for VGO-HDT Plant.
Three controllers are designed in VGO-HDT. One controller is for reactor section to control reactor profile, energy optimization by reduction of standard deviation in hydrogen/hydrocarbon ratio.
Two controllers for fractionators and light end section to control product quality, for product value optimization and energy optimization.
Honeywell’s First controller implemented by using OPC tunneller. Communication of APC server to OPC server established through firewall using Matrikon OPC tunneller. APC controller tested and commissioned successfully. Benefit like diesel maximization, Product value optimization and tight control on reactor profile has achieved through controller successfully.

2012
IOCL Vadodara Linear Alkyl Benzene Plant APC implementation:
Process is licensed by M/s. UOP, U.S.A for LAB Plant.
Three controllers are implemented in Paraffin plant (front end) to maximize Heart cut flow by minimization of standard deviation of C10 paraffin loss from stripper column and C13 loss from rerun column bottom. Energy optimization objectives also included.
Four controllers are implemented in LAB Plant (Back end) to optimize energy consumption, maximize LAB production by minimization of product quality give away.
Program developed to minimize effect of disturbance generated during online Detal reactor change over for catalyst regeneration.
APC controllers tested and commissioned successfully. Benefit like Heart cut maximization, minimization of product quality give away, energy optimization and benzene column profile tight control achieved by the APC.
IOCL Vadodara Hydro-cracker unit APC implementation:
Process is licensed by M/s. Chevron Research Co., U.S.A for Hydrocracker with two stages Hydro cracking which helps maximization of middle distillates and improved quality.
Two controllers are implemented for two reactors to better control reactor temperature profile and maximize reactor conversion with minimum energy usage.
One controller is implemented for fractionator and one controller is implemented for vacuum column for product value optimization.
One controller is implemented for Debutanizer and de-ethanizer section for tight control of LPG and Light naphtha product quality and to maximize LPG yield by minimization of standard deviation in Light Naphtha RVP.
APC controllers tested and commissioned successfully. Benefit like tight control of reactor temperature profile, maximum reactor conversion, minimum product quality variation/energy usage and maximum yield are delivered by the APC.
2011
IOCL Vadodara CDU-3 & CDU-4 unit APC implementation:
Distillation of low sulfur and high sulfur crude.
Heater Pass Balancing on DCS level by developing CL program for Pass balancing.
Two APC controllers implemented one controller is for Main Fractionators column and second controller cover Pre-fractionation Column and stabilizer.
APC controllers tested and commissioned successfully. Benefit like tight control of heater pass delta flow and temperature, minimum product quality variation/energy usage and maximum yield are delivered by the APC.
IOCL Vadodara Motor Spirit Up-gradation unit APC implementation:
Process is licensed by M/S UOP, USA for MSQU with the design throughput of 850 TMTPA.
One controller is implemented in FCC gasoline splitter unit to maximize light and Heart cut gasoline production and energy minimization.
One controller is implemented in naphtha Hydrotreater section to minimize energy consumption and to improve reactor profile control.
One controller is implemented in reformate splitter section to maximize light reformate RON by minimization of variation in heavy reformate.
APC controllers tested and commissioned successfully. Benefit like light and heart cut gasoline maximization, RON maximization and energy saving achieved successfully.

2010
IOCL Vadodara FCC unit APC implementation:
Process is licensed by M/S UOP, USA for FCCU with the design throughput of 6000 M3/day. Main products are Gasoline, LPG, Heavy Naphtha, and LCO.
One controller implemented in Reactor-regeneration section to control reactor and regenerator temperature profile, cyclone velocity. Minimization of air venting, Maximize unit throughput maintaining cyclone velocity.
Two controllers implemented in Main fractionator column, and Gas concentration unit to Maximize LCO and gasoline production by maintaining product quality.
APC controllers tested and commissioned successfully. Benefit like Preheat temp maximization, minimization of Air venting achieved successfully, maximum throughput are delivered by the APC controllers. Regenerator section cyclone temp standard deviation reduced. Product value optimization achieved.
LCO and Gasoline yield increased after APC implementation.
IOCL Panipant AMC & Remodelling Project:
Site Resident Engineer for Maintenance and Remodelling Project of Advanced Process Control in HCU, CDU and FCC unit of IOCL Panipat Refinery.
Remodelling of Existing APC controller.
Up gradation of APC software from R205 to R400.
Tuning of Base layer PID controller as well as Advanced regulatory controller if adversely affecting APC controller performance.
Inferential Property monitoring, Validation, updating and performance reporting.
KPI Reports Development to monitoring APC application.
Tuning of all functioning controller to maintain all control strategy in line to improve controller on stream factor.
March 2008 to Dec 2009
LCM (Life Cycle Management) Project, IOCL-Refinery.
Site Resident Engineer for Maintenance of Advanced Process Control in CDU, Feed Preparation Unit, FCCU.
Tuning of Base layer PID controller as well as Advanced regulatory controller if adversely affecting APC controller performance.
Inferential Property monitoring, Validation, updating and performance reporting.
KPI Reports Development to monitoring APC application.
Tuning of all functioning controller to maintain all control strategy in line to improve controller on stream factor.
Conducting In-house operator training programs on APC.
Benefit Audit of all running controller.
To maintain latest software specification.

Process Monitoring and APC application support