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Training Class by Dr. George Cheng

Flare Control System Design to Comply with EPA RSR-63.670 Rules

Date: April 4, 2018 (Wednesday)
Time: 8AM - 10PM
Place: JW Marriott Hill Country Resort
23808 Resort Pkwy, San Antonio, TX 78261


The deadline for refineries to comply with EPA RSR-63.670 rules is approaching. Flares must maintain a minimum combustion zone net heating value of 270 Btu/scf. In addition, for air assisted flares, the combustion zone net heating value dilution parameter must be above 22 Btu/sq.ft. In order to achieve these goals, flare control systems are critical.

Technically, flare control is very difficult because: (1) The vent gas flow can change widely; (2) The heating value in vent gas can change widely and quickly; (3) Nitrogen is often used as purge gas to maintain positive pressure in the vent pipe, making the process more complex; (4) There are large and varying time delays in the heating value control loops, and (5) The heating value process is extremely nonlinear in different operating conditions. Flares are difficult to control using conventional PID controllers. Model-based control can be costly to develop and maintain.

CyboSoft is offering a field-proven flare control solution with its CyboCon Model-Free Adaptive (MFA) control software. In this training session, we will show how to design control systems for a steam assisted flare and an air assisted flare. We will run real-time control simulations to compare the performance when controlling combustion zone net heating value with different methods under varying operating conditions.

CyboSoft’s Flare Process Modeling and Control Similation Software will be used in this class to demonstrate the following results: (1) A flare process is under good control where the combustion zone net heating value is above 270 But/scf under varying operating conditions; (2) A flare process may not meet the 270 But/scf requirement due to poor steam control; and (3) A flare process is not controlled well due to slow GC data.

In the Q&A session, we can discuss: (1) RSR-63.670 regulations relating to control system design considerations, (2) Vent gas heating value measurement, (3) 15-min data block calculations, (4) How to integrate a flare control system with an existing DCS, and (5) implementation of MFA flare control systems for your specific applications.

 
     
     
 
Dr. George S. Cheng is the CTO of CyboSoft and CyboEnergy with headquarters in California USA. He is the originator and developer of Model-Free Adaptive (MFA) control theory, a revolutionary breakthrough in control technology. MFA is the only commercially successful advanced control method that does not require mathematical models. No other comparable technology possesses all the attributes of MFA.

In 2017, CyboSoft released a Flare Control System Design Guide to help refineries comply with EPA RSR-63.670 rules. CyboSoft offers a field proven MFA flare control system based on its off-the-shelf CyboCon MFA Control Software to control the key variables such as the combustion zone heating value for steam assisted flares and air assisted flares.

CyboSoft is the leader in control tech serving the worldwide process control, building control, and equipment control markets. CyboSoft’s MFA control products have been widely deployed in various industries and application areas. CyboSoft received the 2007 Frost & Sullivan "North America Technology Leadership Award" in the field of Industrial Automation.

Dr. Cheng is a frequent public speaker and an author of numerous articles and book chapters in the field of automatic control and renewable energy. He is a Fellow of ISA and senior member of IEEE.

 
     
     
  Model-Free Adaptive Control and CyboCon Software  
     
 
Item Description
Objectives • Learn Model-Free Adaptive (MFA) control methodology and technology, MFA control products including CyboCon software, CyboCon CE instrument, and embedded MFA controllers.
Who should attend • Engineers, managers, operators, and other professionals.
Class length • 1 to 2 days depending on the materials covered.
• Advanced class – 2 days with application specific topics.
Benefits • Significant technical and financial rewards for your company and your personal career
Ordering Info. Register online or call 916-631-6313 to register.
• Ask for group discount
Place • Rancho Cordova, California, or customers site.
Instructor(s) • Professional(s) from CyboSoft.
What is included • The attendees will receive an evaluation copy of one of the following products: CyboCon software, MFA Control Toolset for LabVIEW, or other embedded MFA control products.
Language • Class can be taught in English or Chinese.
 
     
     
  Training Content  
 
Subject
Details
1. Introduction and objectives

 

2. Model-Free Adaptive (MFA) control

Definition, concept, and structure.
Issues of modeling, identification, control design, tuning, and stability.
Comparison of MFA and other control methods.
3. Hands-on simulation of MFA control systems. Performance comparison with PID controllers SISO MFA vs. PID.
Nonlinear MFA vs. PID.
Anti-delay MFA vs. PID.
MFA pH vs. PID.
Anti-delay MFA pH vs. PID. Robust MFA vs. PID.
MIMO MFA. FB/FF MFA vs. PID.
4. Configuration of MFA controllers Selected controllers in CyboCon software, CyboCon CE instrument, MFA Control Toolset for LabVIEW, etc.
5. System implementation Interface, Safety Watchdogs, and Commissioning.
6. Real application discussions Process, control problems, control objectives.
Selection of MFA controller(s).
Hands-on configuration of MFA controllers(s).
7. Business and Economics Optional discussion of return-on-investment (ROI) estimation.
8. Summary Training summary and outline of next steps.
 
     
     
     
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