Nic Castelijns
Advanced Control, Optimization, and Monitoring
1
Confidentiality Notice
The information contained in this presentation is highly sensitive
and confidential material that is regulated under non-disclosure
agreements between Honeywell and its users
This information should not be passed outside of Honeywell or
customer companies
Under no circumstances should this be shared with third parties
not covered under appropriate non-disclosure agreements
directly with Honeywell, International.
Concepts and specific technologies in this presentation are either
patent-protected, patent pending, or under international patent
review
Operations Excellence
*ARC 2012 Report - Advanced Process Control and On-line Optimization (APC) 2012
Vision Statement
To make the most efficient use of each and every molecule by
bringing Advanced Control & Optimization to every process.
12
Real-Time Optimization
Dynamic Unit-based Optimization
Dynamic Multi-Unit Optimization
Benefit Sustainment
Operator Engagement
Monitoring
Visualization
Steady State,
UniSim Steady State
Non-linear Process
Modeling
Models
Multi-unit Coordination
Profit
& GlobalOptimizer
Optimization
Multivariable
Control
Profit Controller
Profit
Controller
Express
& Unit
Optmization
CPM
Application
Profit
Monitoring &
Expert
Diagnostics
Profit SensorPro
Advanced
Regulatory
Profit
Toolkits
Control
& Soft
Sensing
Profit Loop, OperTune
Base Level Regulatory Control
Loopscout
UOP
Process Design,
Best Practices,
HPS Sales, Projects,
Services
Measurement
& Control
Devices
UniSim Optimize
Dynamic,
Non-linear
w/Process
RigorousModels
Models
Profit Design
Studio
Design &
Profit
Simulation
Stepper
Possible analogies
Thermostat in your house
Cruise control
Management of people processes
14
15
Race Strategy
Overall Optimization
20
Design
Implement
Sustain
Operate
Maintain
Repair
Deploy
Design Evaluate process and operating objectives
Implement Create and install controller
Operate Gather operations input and train the operators, test
Sustain
Operate Use the controller to generate benefits
Maintain Ensure ongoing and improved generation of
benefits
Repair Fix controller if no longer meeting operating objectives
22
Deploy Design
Best-in-class Engineering Environment
Workflow Driven Environment
Knowledge capture and up-skilling tools
Ethanol
24
Optimizer only
Improved bumpless model
update for Profit Optimizer
31
Workflow-oriented design
Role-driven options
Embedded Knowledge
Management
Project Lifecycle Support
Data collection & import
Data manipulation & exclusion
Empirical modeling (linear and
nonlinear)
Simulation
Deployment
34
37
Automate re-identification
Lab + analyzer bias for all types
Bias analyzer with Lab
Automate lab entry
Dynamic Subspace (DSS) model
enhancements
Deploy Implement
Best-in-class Engineering Environment
Workflow Driven Environment
Knowledge capture and up-skilling tools
Virtualization Support
38
Seed ID information
On-the-fly Variable Addition
Collect only variable type
Variable sequencing and queuing
Execution
39
40
New
Install and configuration
enhancements
44
Runtime Scripting
Updated environment (Microsoft
support)
Documentation
Workflow driven
Embedded data dictionaries
46
Deploy Operate
Best-in-class Engineering Environment
Workflow Driven Environment
Knowledge capture and up-skilling tools
Internal simulation
47
Design
Implement
Sustain
Operate
Maintain
Repair
Deploy
Design Evaluate process and operating objectives
Implement Create and install controller
Operate Gather operations input and train the operators, test
Sustain
Operate Use the controller to generate benefits
Maintain Ensure ongoing and improved generation of
benefits
Repair Fix controller if no longer meeting operating objectives
49
52
R430:
SITRAN Trends
Process Impact View
Multi-Controller View
What-If Analysis
Localization
53
Sustain Maintain
Design for Maintainability and Migration
State of the art Performance Monitoring
Regulatory layer
Multivariable control layer
Optimization
CPM Lite
PID only (suitable for MVs)
CPM Enterprise
PID and MPC
57
Financial Performance
Plant Performance
Decreased revenue,
increased costs
Yields, conversions,
separations, etc
Physical Equipment
Reactors, compressors, heat
exchangers, etc.
Poor equipment
performance
58
POOR CONTROL
Differentiators
DCS and APC vendor independent
Universal data connectivity
Integrated all-in-one package
o Regulatory loop performance monitoring
o Advanced control performance monitoring
o PID loop tuning
59
Fix it
Something mechanical
Investigate further
Common oscillations
Controllers not in normal mode
Expert Guidance
60
62
KM
e M s
M s +1
Gain Mismatch
Model
Controller
Phase Mismatch
y
Plant
K P P s
e
P s +1
63
Limit Tracking
High Limit Activation + Low Limit Activation
Benefits (% of Original)
12
18
Time (Months)
65
Tuning Recommendations
Remote Serviceability enhancements
Improved automation for setup and
configuration of performance
monitoring trends and displays
67
Seed ID information
On-the-fly Variable Addition
Collect only variable type
Variable sequencing and queuing
Execution
69
Profit Suite
Easy modeling tools
linear and non-linear
71
Race Strategy
Overall Optimization
72
MES Integration
CPM Evolution
Supply Chain Management
Solutions
Real-time Business Optimization
Boundary Management/OLI
What is the real operating space
available
MES Framework
Leverage SOA, OPC-UA
infrastructures;
Intuition platform
74
R412
R411
R410
75
R430
2012
2012
1H
2H
1H
1H
1H
64 bit support
PHD/UPS upgrade
SQL upgrade
DMC conversion tool
1H
2015
2H
2H
R412
Simpler Install
UOP Isomar and Tatoray
Performance Module Toolkits
Advanced Energy Solutions
Profit Suite Engineering
Studio
R411
80
2H
2H
R410
2014
1H
1H
2H
R430
Easier to
connect
Matrikon OPC
Easier to install
Patch type
install
R413
Easier to configure
Profit SensorPro templates
Profit SensorPro connections
R440
2H
1H
2012
1H
2H
2H
1H
2013
1H
2H
2H
CPM R563
1H
2014
1H
2015
2H
1H
2H
1H
2H
CPM R571
Control
Performance
Monitor
CPM Lite
81
CPM R570
CPM R600
Questions?
www.honeywell.com/ps
83
BACKUP SLIDES
84
85
Enhancing
Controller Engine
Optimizer Engine
Maintenance Solutions (Profit Stepper, Expert, etc.)
Visualization
UniSim Optimize
Providing
Simplified Installation and deployment
Updated System and Microsoft Compatibility
86
Past
Future
Optimal Response
CV
Setpoint
Predicted
Predicted
Unforced
Unforced
Response
Response
Control Funnel
MV
Assumed Values
T=0
CPM Lite
87
CPM Lite
2014
88