Topics
DeltaV Embedded Advanced Control Advantage DeltaV Advanced Control Product Suite
Experience / Examples
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Improve Quality
Reduce Variability Predict Lab Measurements
PlantWeb Benefits
Increase Throughput
Continuously Push Limits Protect Multiple Constraints
Reduce Costs
Maximize Efficiency and Reduce Energy Costs Accurate Quality Control to Reduce Inventory and Product Rework Stabilize Control to Reduce Equipment Wear and Incident Risk
APC Impact
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Enable the average process engineer to quickly deploy state-of-the-art Advanced Control to improve plant performance.
DeltaV Makes Advanced Control Easy!
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10
11
12
Functional Design Det. Design, Config & Staging Step Tests & Model ID Traditional APC Technology Commissioning
Performed on-site
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Start Commissioning
End Commissioning
100%
Traditional APC
% On-line Time
More than 50% of APC applications are turned off within the first 2 years after installation.
time
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Yr 1
Yr 2
Process changes
New constraints or limits Different control objectives Different process dynamics
Control Foundation
Without This
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Monitor Performance
Advanced Control
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Intelligent
Performance Monitoring Inspect with InSight Process Model Calculations Advanced Control Predict / Neural / Fuzzy
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% On-line Time
time
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Ease of Use
Intended for process control engineers Minimum APC consulting required
Sustained Performance
Built-in tools to optimize regulatory control performance Accounts for health of field devices
Reduced Cost
Faster project implementation Easier to maintain
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Topics
Experience / Examples
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DeltaV Predict/Pro Model Predictive Control (MPC) with embedded optimization for small and large applications. DeltaV Neural On-line property estimation for process measurements normally only available from lab analysis. DeltaV Simulate/Pro Off-line training and engineering environment. Run DeltaV on your laptop!
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DeltaV Predict/Pro Model Predictive Control (MPC) with embedded optimization for small and large applications. DeltaV Neural On-line property estimation for process measurements normally only available from lab analysis. DeltaV Simulate/Pro Off-line training and engineering environment. Run DeltaV on your laptop!
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DeltaV InSight
Poor control costs your company money. DeltaV InSight provides a cost effective way to improve control performance:
Gain process insight with embedded learning Easy to Use Out of the Box
No Configuration Required Adapts to system configuration changes
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Evaluate
Validate Compare Diagnose
Improve
Advise Tune Adapt
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Never before has a Control System provided embedded learning algorithms for every control loop; enabling intelligent monitoring, diagnostics, and advanced tuning.
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DeltaV InSight
Bringing it all together:
Performance Monitoring Loop Diagnostics Embedded Learning Adaptive Tuning Adaptive Control
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New interface provides seamless transition between loop diagnostics and tuning.
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Embedded Learning Runs in the Controller Fast Data Capture Small Communications Load Runs in Background
InSight monitors each control block to detect changes to SP (or OUT in manual), called a Trigger Event. InSight captures response data and calculates a dynamic process model for each Trigger Event. Models are stored in a database for use in loop diagnostics and adaptive tuning. Users may modify default values for SP or OUT move size required for a Trigger Event in the Learning Set-up Display.
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Learning may be enabled in Control Studio during configuration, or Learning may be enabled in DeltaV Explorer Learning may also be enabled and disabled ONLINE using DeltaV InSight Learning is available on DeltaV and Fieldbus PID blocks
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Explorer tree allows easy navigation of control hierarchy Overview display summarizes performance for System, Area, Units and Modules Abnormal Control Conditions indicated for Problem Loops:
Control Service Status: Incorrect mode Limited control output Bad/Uncertain input Control Performance Status: Standard Deviation Variability Index Oscillation Index Tuning Index
Quickly identifies loops that have recommended tuning Tuning display filter will only indicates loops with:
Significant improvement in variability (e.g., >20%) High model confidence Currently have high variability
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Device Alerts are reported through InSight Asset Displays Overview provides graphical display for Asset Alerts of System, Area, and Modules Asset Display identifies Asset Alerts including: Asset Failed Maintenance Soon Advisory Communications Failed Easily Launch AMS Device Manager in Context to access detailed diagnostics
Right-Click
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On-demand Tuning
Steps control output to identify tuning Same as old TUNE
Adaptive Tuning
No Testing Uses Process Learning during normal operations
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Simulate
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InSight automatically calculates dynamic models from operator changes Model Quality and Learning Status Tuning criteria and desired speed of response Tuning Recommendation No Testing Required
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Models automatically stored in a model database Various plot options to analyze impact of operating conditions on process models Average of selected models may be utilized to establish the recommended tuning
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Closed loop simulation of setpoint and disturbance changes for recommended tuning
Select New Tuning Simulation for both Speed vs Robustness Adaptive and On-
demand Tuning
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Process gain and dynamics may change as a function of operating conditions such as valve position or feed rate.
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Customized Reports
Add production KPIs in customized reports via Excel and DeltaV Reporter
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Easy As PID
DeltaV Explorer
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Simulated Response
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FLC
FLC
PID
PID FLC
FLC
PID PID
Notice at both SP change and at load disturbance the FLC output change is more dramatic than PID. Resulting in faster return to SP. Also notice as PV approaches SP, the FLC exhibits less overshoot.
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DeltaV Fuzzy pH Control: Tighter control of effluent pH results in 8% decrease in amount of caustic used. Value = 720 GPD caustic; eliminated nuisance alarms
Before
(using DeltaV PID)
After
(using DeltaV Fuzzy)
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Past
Present
Future
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The Model Consists Of Step Responses That Show The Relationship Between Every Process Input And Output
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Graphical Configuration
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Process Steps
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Model Validation
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Control Variables
Manipulated Variables
Constraint Variables
Disturbance Variables
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APC Optimization
Often as simple as maximizing one variable to its most limiting constraints Throughput
Production Increase $$
APC
Throughput at limit
Operator Setpoint
Built-in LP Optimization
100% position
0% position
0% position
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100% position
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Current Values
Optimal Values
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Create virtual sensors for online measurements normally only available through lab analysis Easy to understand and use, cost effective General nonlinear modeling tool
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Select Inputs
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Crude Switch
09-Aug-03 00:00:00
11-Aug-03 00:00:00
13-Aug-03 00:00:00
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DeltaV Simulate
Configure your DeltaV system off-line on a single PC Check out control logic and operator interface using PC simulation Provides multi-user, global engineering and training environments Easy integration with dynamic process simulation packages such as mimic
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DeltaV Architecture
Control Design and Configuration are Independent of Hardware
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All features of the control system may be combined for execution on a single PC or multi-node network. Plant configuration may be utilized in this simulation environment with no change in configuration. Benefit: Reduce Costs in Engineering Maintenance Equipment
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Simulation capability with both virtual and real controllers (controllers optional)
Provides global engineering environment Multiple engineers on the same development system Provides multi-user training environment Multiple operators on the same or parallel sessions
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Multi-Node Environment
Operator Station
Professional Plus Application Station with mimic Simulator App Station
Supports mimic Process Simulator running in DeltaV Workstation Supports Third Party Process Simulators via standard OPC
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Supports mimic Process Simulator running in DeltaV Workstation Supports Third Party Process Simulators via standard OPC
Supports I/O simulation and Fieldbus emulation with virtual I/O module and mimic simulation
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Field Inputs
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Process Simulation
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Select the node(s) that you want to access (ProPlus and App Stations only)
Simulate an entire plant with both BPCS and SIS simulation together Simulate the same SIS logic that is implemented in the plant Great for Operator Training Systems (OTS) Easier Factory Acceptance Testing (FAT) for projects
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OPC I/F
Option 1: Run APC in Work Station
TDC3000 LCN
PLC Gateway APM HPM IOPs DeltaV Controller
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Topics
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Lucite International
Solutia, Inc. Canadian Forest Products Ltd. Baxter Petrotel-Lukoil
40
60 38 32 30
Jan-02
Jun-98 Apr-01 Apr-01 Jan-04
Petrogal
BASF Corporation Norske-Skog Canada Flint Hills Resources, LP Huntsman ICI
30
25 25 20 20
Feb-05
May-04 Jun-03 Jun-04 Oct-00
Husky Energy
Monsanto Company
20
20
Nov-04
Jul-03
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Naphtha
Hvy Kero
CV SP MV Lab Spec
Kero
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AGO
FC
Naphtha Kero
FC
Hvy Kero
FC
Crude
FC
AGO
Resid to VAC Column
Fuel Gas
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Crude Switch
09-Aug-03 00:00:00
11-Aug-03 00:00:00
13-Aug-03 00:00:00
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Variability Reduction
Before Average Atm Column SR NAPHTHA EP AGO EP OVERHEAD TEMP KERO DRAW TEMP HVY KERO TEMP AGO DRAW TEMP Vacuum Column WAX DIST 95% POINT VGO CHIMNEY TEMP WAX VAP TEMP H WAX VAP TEMP 349.55 636.32 253.18 362.59 459.37 528.14 St. Dev. 14.89 10.54 5.01 4.60 5.65 5.60 After Average 347.10 634.41 260.91 366.60 462.72 530.77 St. Dev. 4.30 6.22 1.80 1.86 2.60 2.55 Reduction in Std. Dev. 71.1% 41.0% 64.1% 59.5% 54.0% 54.5%
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are 25-50% Faster and Less Step Costly Tests than traditional APC Projects
Commissioning
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Fuel Flow
FT
Hot End
Excess Oxygen (controlled and constraint) Hood Draft Pressure (constraint) Kiln Stack Emissions (constraint)
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DeltaV MPC
Period Sept.3,2000 to Oct.15,2001 Sept.3,2000 to Apr.8,2001 Dec.17,2000 to Apr.8,2001 Sept.3,2000 to Jan.7,2001 Oct.15,2001 to Jan.8,2002
Average Specific Energy (filtered) (GJ/t) 9.15 9.62 8.78 10.20 8.22
Average Lime Average Product Mud Flow Flow (filtered) (filtered) (t/d) (t/d) 584.77 270.14 571.70 264.10 593.64 274.24 560.49 258.92 688.13 317.89
Specific Energy Standard Deviation (filtered) (GJ/t) 1.18 1.34 1.20 1.43 0.14
97.60%
Operator Increased Reduced Confidence Lime Variability 97.6% UPTIME! Production 89.5% 16-20%
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134.86
18.46
43.9 1.9
8.12 0.18
2.96
0.28
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TI
FI
FIC RSP
FT
+
TT
TI
Column
CV 1 CV 2 (OPTIM) AV 1 AV 2
TT
MV 1 MV 2
RTO
MPC
TI
EU/ SEC
DV
Steam
Reactor
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For the batch distillation process, the time to complete a cycle has now been reduced by an average of 3.35 hours. This is a 20% decrease in batch time which resulted in a throughput increase of 5.4%. This production increase equates to annual incremental revenue of just over US$2 million for this unit alone. Incremental production at this rate could defer the requirement to add capacity through plant capacity expansion. The capital expenditure that would have been required to provide this additional capacity is approx US$5MM
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Book was inspired by DeltaV Advanced Control Products. This book is available from ISA or may be ordered at EasyDeltaV.com/Bookstore The application sections include guided tours based on DeltaV Advanced Control Products CD provides an overview video for each section and examples. Copies of the displays, modules, and Simulation Cases are included.
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Summary
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