Ruslan Zakirzyanov

Ruslan Zakirzyanov

Large-scale chemical plants rely on distributed process control systems (PCS) comprising numerous processing units, communication modules, and I/O devices interconnected via industrial networks. The design of a cost-efficient and reliable hardware architecture under partial uncertainty in plant parameters remains a challenging combinatorial optimization problem. This paper proposes a formal model for distributed control system hardware architecture synthesis. A hybrid ant colony-based metaheuristic framework is developed to construct feasible hierarchical architectures. The proposed approach is validated on a large-scale sulfuric acid plant control system case study. Plant parameters are identified from operational data, system stability is analyzed, and a controller synthesis is performed based on the optimized architecture. The results demonstrate the feasibility of the approach and confirm that the obtained architecture satisfies structural and dynamic performance requirements.

Ruslan Zakirzyanov

Metaheuristic algorithms are currently widely used to solve a variety of optimization problems across various industries. This article discusses the application of a metaheuristic algorithm to optimize the hierarchical architecture of an industrial distributed control system. The success of the algorithm depends largely on the choice of starting conditions and algorithm parameters. We examine the impact of parameter selection on the convergence of a modified ant colony algorithm and provide recommendations for tuning the algorithm to achieve optimal results for a specific industrial problem. The findings presented in this article can also be applied to other combinatorial optimization problems.

Ruslan Zakirzyanov

Automated process control systems (APCS) are widely used in modern industrial enterprises. They address three key objectives: ensuring the required quality of manufactured products, ensuring process safety for people and the environment, and reducing capital and operating costs. At large industrial enterprises, APCSs are typically geographically distributed and characterized by a large number of monitored parameters. Such systems often consist of several subsystems built using various technical means and serving different functional purposes. APCSs usually have a hierarchical structure consisting of several levels, where each level hosts commercially available technical devices with predetermined characteristics. This article examines the engineering problem of selecting an optimal software and hardware structure for a distributed process control system applied to a continuous process in the chemical industry. A formal formulation of the optimization problem is presented, in which the hierarchical structure of the system is represented as an acyclic graph. Optimization criteria and constraints are defined. A solution method based on a metaheuristic ant colony optimization algorithm, widely used for this class of problems, is proposed. A brief overview of the developed software tool used to solve a number of numerical examples is provided. The experimental results are discussed, along with parameter selection and possible algorithm modifications aimed at improving solution quality. Information on the verification of the control system implemented using the selected software and hardware structure is presented, and directions for further research are outlined.