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February 21, 2016 Reliance Technology Group – APC / RTO 1
Process Engineering GroupProcess Engineering Group
APC maintenanceAPC maintenance
Viknesh RajaViknesh Raja
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Scope
Responsibilities
Methods to identify performance degradation
Causes of performance degradation
APC maintenance actiities
Flo!chart of APC maintenance
February 21, 2016 Reliance Technology Group – APC / RTO 2
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February 21, 2016 Reliance Technology Group – APC / RTO "
Responsibilities
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Responsibilities
#op management$ Attention, focus and isibility%
APC engineers$ Monitor and report performance, configure changes, updatecustom calculations and soft sensors, tune APC parameters and &eep the modelin good fidelity !ith plant behaior and desired ob'ecties% Conduct internal ande(ternal audits%
Plant)C#* engineers$ *et proper control ariable +C- limits, rela( C limits
based on the plant and e.uipment &no!ledge of constraints, chec& that the APCis moing the plant to right constraints based on the operational or economicob'ecties and report any discrepancies to APC group%
Plant instrument engineers$ /eep the base leel P loop performance in goodshape, ma&e sure all APC ariables are lie and !or&ing in APC enironment,
report and !or& !ith APC group to incorporate any configuration and tuningchanges into APC%
Panel officers$ /eep the controller 3, rela( all M limits and report to plantengineers or APC group for any difficulty in doing so% Ma&e sure that the Climits are &ept as per the plant engineer)APC engineer guidelines%
February 21, 2016 Reliance Technology Group – APC / RTO 4
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February 21, 2016 Reliance Technology Group – APC / RTO 5
Methods to identify performancedegradation
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PREDER: ependent ariable prediction error%
This value is the difference between the predicted and the actual controlled variable
values, calculated as "prediction - actual".
AVPRER: ependent ariable filtered aerage prediction error%
This value is the heavily-filtered average of the absolute value of the prediction error.Use it to determine, on average, how big errors are in the model.
ACPRER: ependent ariable accumulated error +integrated alue of PRR-
When this value is trending upward, a disturbance (or model error) that is decreasing the
actual dependent variable value is occurring.
When this value is trending downward, a disturbance that increases the actual
dependent variable value is occurring.
Prediction error plots are custom configured using dummy CVs.
February 21, 2016 Reliance Technology Group – APC / RTO 6
CV Prediction Errors
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Prediction error(1
ACPRER (Dependent !ariable accumulated (integrated prediction error
"#is entry is t#e integrated !alue of prediction errors (predicted minusactual since t#e last prediction initiali$ation.
C#anges in t#is !alue indicate eit#er a mismatc# bet%een t#e model
predicted response and t#e actual process response& or t#at an
unmeasured process disturbance #as occurred.
'onitoring ACPRER is recommended o!er PREDER as time correlated
controller disturbances (prediction errors are better detected by obser!ing
t#e integrated !alue.
"#is !alue ultimately represents t#e current bias& since t#e last prediction
reset& t#at must be added to t#e model predicted dependent !alue to matc#
t#e response of t#e process.
February 21, 2016 Reliance Technology Group – APC / RTO 7
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Prediction error(
)#en t#is !alue is trending up%ard& a disturbance (or model error t#at is
decreasing t#e actual dependent !ariable !alue is occurring. )#en t#is !alue is
trending do%n%ard& a disturbance t#at increases t#e actual dependent !ariable!alue is occurring.
"#e controller updates ACPRER during eac# cycle. ACPRER gets reset to t#e
current cycle*s PREDER !alue %#ene!er one of t#e follo%ing conditions
occurs:
(a t#e dependent !ariable predictions are initiali$ed (PRD+,D - 1.
(b t#e absolute !alue of ACPRER becomes greater t#an ///./ (to a!oid
e0ceeding any numerical tolerances for t#e system.
February 21, 2016 Reliance Technology Group – APC / RTO 8
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Prediction error(
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Prediction error(2
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CV Prediction Error Plot (effect of o!erride
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'odel cur!es (!isual inspection
Smoot#ness of model cur!es and !erification %it# process insig#t
"#e model cur!es of APC must accurately represent t#e process c#ange
"#e model cur!es s#ould be interpreted as t#e c#ange in t#at particular CV
corresponding to a unit c#ange in t#e 'V 3eeping all ot#er 'V455s
constant
"%o aspects of t#e model cur!es s#ould be loo3ed at6ain
Dynamics
)#en bot# t#ese aspects are accurate t#e cycling of t#e controller %ill
reduce and t#e control action %ill become smoot# and accurate
"#e final steady state !alue of t#e cur!e is denoted as 6A+, "#e part of t#e cur!e leading to Steady state !alue is called t#e D7,A'+CS
February 21, 2016 Reliance Technology Group – APC / RTO 12
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'odel cur!es (!isual inspection(
February 21, 2016 Reliance Technology Group – APC / RTO 1"
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'odel cur!es (!isual inspection(
February 21, 2016 Reliance Technology Group – APC / RTO 14
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Causes of Performanceegradation
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Causes of Performance Degradation
Process c#anges:
E8uipment degradation& ,e% Constraints
'a9or c#ange in operating regime (5eed product spec& flo%s etc ,e% operational ob9ecti!es& or increased unmeasured disturbances
+nstrumentation issues:
Deficient P+D loop tuning& Control !al!e or ot#er issues
Control loop configuration c#anges
;perator understanding:
'V Pinc#ing Conflicting CV Constraints
+nconsistent ob9ecti!es Deficiency in "raining
APC +ssues:
'odel design& Controller fidelity and Soft sensor accuracy issues
"uning <ogic problems
February 21, 2016 Reliance Technology Group – APC / RTO 16
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February 21, 2016 Reliance Technology Group – APC / RTO 17
Causes of Performance Degradation (process(1
E8uipment degradation& ,e% Constraints
E8uipment degradation can cause c#anges in t#e be#a!ior of t#e plant
(=> fouling& column fouling& catalyst degradation
+n certain cases t#e e8uipment may be ta3en offline for
ser!icing4maintenance acti!ities (furnace deco3ing
,e% process constraints (control !al!e pressure drop& S;R !s E;R
operations limit t#e mo!ement of 'Vs and CVs
"o ensure good performance of APC necessary action must be ta3en
1. C"S engineer s#ould analy$e and record t#e c#anges in
prediction error (ACPRER 4specific error calculations in CC5
and inform t#e APC engineer.
. APC engineer must c#ange t#e model to ma3e it robust enoug#to #andle t#is. +n some cases model may need to be c#anged or
additional logic may need to be added to ensure t#at t#is
be#a!ior is captured
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February 21, 2016 Reliance Technology Group – APC / RTO 18
Causes of Performance Degradation (process(
'a9or c#ange in operating regime (5eed product spec& flo%s etc
Due to ne% guidelines from t#e management t#e operating parameters may
need to be c#anged
"#ese can include c#anging t#e t#roug#put& feed& product specs& product
ratios etc.
5or e0ample 5CC at ?'D can be run in t%o modes
Propylene mode
6asoline mode
Due to t#ese c#anges t#e optimi$ation function may not be !alid. =ence t#e
follo%ing action s#ould be ta3en
C"S engineer must be a%are of t#ese c#anges and must inform t#e
APC engineer t#e ne% optimi$ation ob9ecti!es and t#e lostoptimi$ation potential
APC engineer s#ould ma3e t#e re8uired c#anges in t#e calculations4
costing functions to ensure t#at t#e ne% optimi$ation ob9ecti!es are
ac#ie!ed
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February 21, 2016 Reliance Technology Group – APC / RTO 19
Causes of Performance Degradation (process(
,e% operational ob9ecti!es& or increased unmeasured disturbances
APC can predict CV mo!ement %#en it is modeled accurately %it# all
t#e related 'Vs or 55s
@nmeasured disturbances (ambient temperature c#ange %ill cause
une0pected c#ange in t#e CV prediction
Smoot# and small disturbances are compensated for by APC
Sudden and large disturbances can degrade t#e performance of t#e
controller
"#e follo%ing action needs to be ta3en
C"S engineer s#ould identify suc# disturbances by obser!ing
t#e prediction error of t#e concerned CVs and inform t#e APC
engineer APC engineer s#ould model t#e ne% disturbance or incorporate
a %ay of measuring t#is disturbance so t#at t#e CV prediction
become more accurate leading to better model fidelity and better
performance
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February 21, 2016 Reliance Technology Group – APC / RTO 20
Causes of Performance Degradation (+nstrumentation(1
Deficient P+D loop tuning& Control !al!e or ot#er issues
APC acts as a super!isory control& #ence base control (P+D loop #as to be
maintained to ensure t#at APC performs at its best
'aintaining good base le!el control is !ery important to APC
"#ere can be many issues %it# base le!el control %#ic# can affect APC
performance
Stic3y !al!es
5aulty transmitters
+naccurate P+D loop tuning
Suc# instrumentation issues can deteriorate APC performance drastically
"#e follo%ing action must be ta3en to ensure t#at t#ese issues do not affect APC
performance
"#e C"S engineer must monitor all P+D loops on a regular basis andmust analy$e and record t#e results
"#e instrumentation4APC engineers of t#e plant are responsible for
ensuring t#at all P+D loops are %ell maintained
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February 21, 2016 Reliance Technology Group – APC / RTO 21
Causes of Performance Degradation (+nstrumentation(
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February 21, 2016 Reliance Technology Group – APC / RTO 22
Causes of Performance Degradation (+nstrumentation(
Control loop configuration c#anges
APC is modeled assuming a certain control loop configuration
Any c#anges made to t#ese configuration needs to be reflected in APC
Control loop configuration includes t#e follo%ing
C#ange in P+D algorit#m due to migration of DCS
C#ange in !al!e or transmitter types4models
rea3ing cascades
Reconfiguring split range controls
C#anging t#e %ay read4%rite are #andled by t#e DCS
"#e C"S engineer must 3eep trac3 of t#e different configuration c#anges
and must bring t#em to t#e attention of t#e APC and instrumentation
engineer
"#e instrumentation and APC engineer are responsible for ma3ing t#e
re8uisite c#anges to APC to ensure good performance
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February 21, 2016 Reliance Technology Group – APC / RTO 2"
Causes of Performance Degradation (;perator(1
'V Pinc#ing Conflicting CV Constraints
Pinching is t#e process of ma3ing t#e upper limit e8ual to t#e lo%er limit for 'Vs
in APC
Pinc#ing pre!ents APC from ma3ing any mo!ement to 'Vs t#ereby restricting
t#eir mo!ements
Conflicting CV limits can #inder APC mo!ement
E; conc and C; conc #ad a common 'V (o0ygen. All t#e ot#er #andles for C;
conc %ere #itting limits as defined by t#e operator. E; column Delta P(CV %as
being constrained at t#e upper limit. "o maintain t#e limit on E; column Delta P
APC %as cutting t#e ; to t#e unit t#ereby cutting plant t#roug#put.
;nce t#e DeltaP limit %as increased t#e plant t#roug#put increased
"#e C"S engineer is responsible for indentifying suc# conflicting limits and
informing t#e operator and APC engineer
"#e operator must rela0 suc# limits after consultation %it# APC engineer
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February 21, 2016 Reliance Technology Group – APC / RTO 24
Causes of Performance Degradation (;perator(
+nconsistent ob9ecti!es Deficiency in "raining
Conflict of interest bet%een dept can cause conflicting mo!ements in
APC
Comfort le!el of certain operator maybe be #ig#er compared
;perator training is !ery important to t#e performance of APC as t#ey
%ill be t#e ones %#o %ill be operating t#e plant on a minute by minute
basis <ac3 of operator training leads to lo% confidence& conflicting limits and
a lac3 of %illingness to s%itc# on t#e controller
"#ese can deteriorate plant performance and lead to s%itc#ing off of t#e
controller
"#e C"S engineer must ensure t#at all operators are trained %ell and#a!e t#e re8uired 3no%ledge to run APC
Any inconsistent ob9ecti!es must be discussed and resol!ed bet%een
t#e APC4C"S engineer4instrumentation and operator
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February 21, 2016 Reliance Technology Group – APC / RTO 25
Causes of Performance Degradation (APC(1
'odel design& Controller fidelity and Soft sensor accuracy issues
APC can perform to best of it ability if t#e model #as a good accuracy
)#en t#ere is e0cess cycling in t#e 'V mo!ements t#is can be due to an
issues %it# controller fidelity
"#e robustness of t#e model and controller fidelity is ensured using
different tools li3e
R6A
SVD
Condition number
Soft sensors are t#e tools using %#ic# t#e APC measures feed4product
specs
"#ese #a!e to be calibrated and updated regularly so t#at t#ey reflect
true product specs
Suc# soft sensors are modeled usually in ASPE, +B as and %#en
re8uired
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February 21, 2016 Reliance Technology Group – APC / RTO 26
Causes of Performance Degradation (APC(
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February 21, 2016 Reliance Technology Group – APC / RTO 27
Causes of Performance Degradation (APC( "uning <ogic problems
APC #as many tuning parameters t#at need to be tuned to ensure #ig#
performance
Some of t#ese tuning parameters are
Ran3s
'a0 mo!e
'o!e suppression
'a0 SS step
ECEs
SS Cost
Cost Criteria
"#e C"S engineer must notice %rong mo!ement& cycling or e0cessi!e
mo!ement in 'Vs or lac3 of control of CVs to t#e notice of APC engineer
"#e APC engineer %ill perform t#e re8uisite analysis and %ill ma3e t#e
re8uired c#anges to t#e tuning parameters
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February 21, 2016 Reliance Technology Group – APC / RTO 28
APC maintenance acti!ities
APC P f C l l ti
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APC Performance Calculations
1% :P Performance ; M < C based Performance nde( Calculations
2% Controllability ; C :imit iolation Calculation < APC #uning
"% Model Fidelity ; C Prediction error trending Calculation < Model Mismatch
February 21, 2016 Reliance Technology Group – APC / RTO 29
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APC Performance Degradation
Annual Profits
Controller
Switched On
Controller
Switched Off
Time
Degradation
Time
Degradation of Controller Performance
LostProfit
February 21, 2016 Reliance Technology Group – APC / RTO "0
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APC 'aintenance (1
Performance +nde0es:
;n "ime days
'VCP+s Reports CV <imit Violations
CV Prediction errors
Reports 5ormats
Controller Performance Reports
Plant Performance Report Site Performance Report
R+< Performance Report
CV <imits :
Safety <imits
E8uipment <imits
Buality <imits
February 21, 2016 Reliance Technology Group – APC / RTO "1
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APC maintenance (
CV 'onitoring is more in!ol!ed and re8uires:
no%ledge of Process and "ec#nology
no%ledge of ;perations no%ledge of plant constraints
CV and 'V mo!ements:
Correctness of Economic Direction
Correctness of direction %rt safety& 8uality and !iolation 'odel fidelity to #old on constraints
Correct cost and tuning
Correctness of priority %rt on safety& e8uipment constraints and 8uality
February 21, 2016 Reliance Technology Group – APC / RTO "2
R+< @ ti + d ;,DA7S
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R+< @ptime +nde0 ;,DA7S
+1440 Minutes per ay = 60- DA75AC > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
?Controller Run #ime in *econds +C#:3#- @
1 ;,DA7S > 3A* B ;;;;;;;;;;;;;;;;;;;;;;;
+AFAC-
Adantages < isadantages$
1%AFAC > number of runs in a day
2%Counts the total number of days from commissioning
"%Can be reset
f C
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R+< Performance +nde0 'VCP+
+3et 3umber of Ms D 0%5=Ms at :imits B 0%5=Ms at ngg :imits-
'VCP+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;(
100
+3et 3umber of Ms -
Adantages < isadantages$1%Ms at limits are debited by 50E +M are free to moe in one direction-
2%*uperfluous Ms are subtracted +:i&e Ms on standby e.uipment-
"%Can account for Cost and Min moe Ms
4%More pleasant results$ 50E for all Ms at constraint
5%Measures the effectieness of controller as designed6%ased on the performance of the :P optimiGer in the APC
7%Historical reference and highlighting unusual day;to;day highs or lo!s
8%alues can be reported for a controller or plant or site or een R:
9%Current, daily, monthly aerages can be easily calculated
10%Ieneric and transparent, easy to implement < easy to interpret
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February 21, 2016 Reliance Technology Group – APC / RTO "5
PC)S Screen
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February 21, 2016 Reliance Technology Group – APC / RTO "6
'A,AC" is used to detect t#e position of 'V:
- ot# limits clamped& -+nacti!e
1-At upper limit& -At lo%er limit
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February 21, 2016 Reliance Technology Group – APC / RTO "7
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R+< Performance A!erages
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R+< Performance A!erages
For controllers that e(ecute eery minute$
+MP=14"9 B MCP- +MP=+AFAC;1- B MCP-
Daily 'VDP+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
+1440 Minutes per day- AFAC
+MMP=+1440="0;1- B MCP-
'ont#ly 'V'P+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
+1440="0 Minutes per Month-
+MCP1=M1 B MCP2=M2 BJ-
Plant 'VPP+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
+M1 B M2 BJ-
+MPP1=M1 B MPP2=M2 BJ- Site 'VSP+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
+M1 B M2 BJ-
+M*P1=M1 B M*P2=M2 BJ-
R+< 'VRP+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
+M1 B M2 BJ-
R+< CV Violation Performance +nde0 V;+= V+;<
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R+< CV Violation Performance +nde0 V;+= V+;<
For a controller running eery minute$
V;+ > ?C Aboe High limit by a defined tolerance +0 or 100-@
+H=14"9 B -
V;+= > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
+1440 Minutes per day-
Adantages < isadantages$
1%Can be defined separately for lo!er < upper limit iolation
2%Can indicate Model #uning issues for a good fidelity controller "%mportant Cs can be trac&ed for unacceptable iolation
4%Aerages are 1st order lags
5%Plot needs to be lin&ed, default plots are not aailable in MC
CV <imit Violation F per day (/./ "olerance
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February 21, 2016 Reliance Technology Group – APC / RTO 44
CV <imit Violation F per day (/./ "olerance
R+< Performance enefit 'VP+
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R+< Performance enefit 'VP+
?MMP D +85 ; 50-@ 'VP+ > ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ( 100
50
Adantages < isadantages$
1%"5E MCP > Gero profit, 85E MCP > 100E profit
2%85E performance is base line, higher alues gies better than design
numbers%
"%All Ms are !eighted e.ually
4%Reflects percentage of baseline benefit achieed by the controller
R+< 'V Performance +nde0 G features
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R+< 'V Performance +nde0 features
ased on 'anipulated Variables 'Vs 'onitors Acti!e Constraint of 'Vs
Penalty of H/F if an 'V is targeted at lo%er or upper limit Performance of H/F %ill result if all 'Vs are ;, but all targeted at upper4lo%er limit <o%er t#an H/F could result if 'Vs are pinc#ed& or 3ept ;55
Performance +nde0 Ranges:
Ireater than 85 (cellent et!een 75 D 85 ery Iood et!een 65 D 75 Iood et!een 50 ; 65 Fair :ess than 50 Poor
endor soft!are li&e Aspen < Matri&on can also be used
C based similar performance inde( can also be calculated, !ould improe performance of controllers !here
redundant or multiple Ms for same C are present%
February 21, 2016 Reliance Technology Group – APC / RTO 46
Reports 5ormats
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February 21, 2016 Reliance Technology Group – APC / RTO 47
Reports 5ormats
Conflicting ;b9ecti!esI P;s comfort !s C"S constraint pus#ing
R+< Performance Report
Site Performance Report
Plant Performance Report
R+< 'V Performance +nde0 J "o be reported by CE; APC (R"6
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February 21, 2016 Reliance Technology Group – APC / RTO 48
p y (
R+< 'V Performance +nde0 J "o be reported by site APC
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February 21, 2016 Reliance Technology Group – APC / RTO 49
p y
R+< 'V Performance +nde0 G "o be reported by site C"S
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February 21, 2016 Reliance Technology Group – APC / RTO 50
p y
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February 21, 2016 Reliance Technology Group – APC / RTO 52
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