A Study on DDC (Direct Digital Control)-Based Integrated Control Architecture and Operational Optimization for Unconventional Oil Production Plants
This study proposes a distributed integrated control architecture based on Direct Digital Control(DDC) as an alternative to conventional centralized Distributed Control System(DCS) structures for a Canadian oil sands pilot plant, and theoretically analyzes its control characteristics and operational optimization potential. The target process consists of production and circulation, separation, water treatment, partial upgrading, and utility systems, and exhibits complex characteristics such as multiphase flow, high viscosity, time delay, strong coupling, and operation under extreme environmental conditions. In this study, an integrated control architecture combining independent DDC nodes for each process unit with a supervisory control layer is presented. A control model considering the coupling relationships among production, separation, water treatment, and upgrading processes is formulated, along with an objective function for energy optimization. Furthermore, through literature-based comparison and system architecture analysis, it is demonstrated that the DDC-based structure is suitable for oil sands pilot plants in terms of responsiveness, scalability, fault isolation, and energy efficiency.