Tüpraş operates four refineries with a total yearly crude oil processing capacity of more than 28 million tons, making it Turkey’s largest industrial company and one of the 10 largest refinery companies in Europe. Tüpraş refineries are equipped with advanced process control systems in addition to approximately 5900 proportional-integral-derivative (PID) control loops. If these loops are not regularly tuned to account for changes in process dynamics, the controllers are no longer able to catch desired set-point values in an optimal manner, reducing production while increasing safety risk and costs.
The Tüpraş R&D center chemical engineers, Mehmet Yagci and Gizem Kusoglu Kaya have developed an automated system for monitoring and identifying control-loop performance problems that saves the company an estimated $12 million to $20 million each year. The team used MATLAB® to accelerate the development and testing of the system’s core algorithms.
“MATLAB saved us a great deal of time in writing performance assessment and other algorithms,” says Mehmet Yagci, modeling and process control superintendent at Tüpraş. “With just a few lines of code we can estimate the performance of a control loop. We have complete confidence in the MATLAB functions that we use because we know they are thoroughly tested and widely used in industrial applications.”