How do you integrate real-time optimization (RTO) with regulatory control?
Answer
RTO integration hierarchy: RTO (steady-state economic optimization, minutes to hours cycle) provides setpoints to APC layer, which provides setpoints to regulatory (DCS/PLC) layer. Design considerations: execution frequency matching, constraint handling consistency, model consistency between layers, steady-state detection before RTO execution, feedback from actual to update RTO models. Interface: RTO writes setpoint targets to MPC CVs or directly to PID setpoints with feasibility checking. Implement range limits, rate limits, and operator override capability. Validate economic benefits through production accounting.
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