Optimizing your

Process Operations

Ric Snyder
Insert Photo Here Rockwell Automation

Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Automation for Process Industries

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 2

 PlantPAx Advanced Process Control Portfolio

Real-time Optimization
Increasing Effort & Increasing Value

Model Predictive
Control
Pavilion8
Nonlinear Multivariable Dynamic MPC
Control

Linear Multivariable Control

Inferential Sensors PlantPAx Model Builder

PlantPAx Fuzzy Designer
Advanced Regulatory
Control Logix IMC, CC, MMC

Regulatory Control Logix PID, PIDE, AOI

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

 Why Advanced Process Control?

• Advanced Regulatory Control

– Focus is on PROCESS variables – levels, flows, temperatures, pressures,
etc.
– Improve poorly performing loops and/or automate manual loops
– Compensate for dead-time and simple process interactions

• Model Predictive Control

– Focus is on PRODUCT variables – purity/impurity, production rate, product
quality, product specifications (e.g. moisture content, color, density, fineness,
etc.)
– Sends setpoints to process control loops
• Requires good regulatory control to achieve potential benefits
– Improve product quality
– Increase throughput and/or yield
– Reduce energy usage
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 4
Starch Dryer Application Overview

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 5

 Starch Dryer Example

PID Temperature Control

• Neither moisture laboratory samples nor
Output limit
moisture soft sensor are available
• Disturbances not seen in the outlet PID
SP
Dried starch out
temperature are not corrected or slowly
Tout
corrected Tout Ctrl

• Ambient Humidity
• Starch consistency

Hot air & starch mixture

• Inlet air flow temperature Feeder Speed

Time Delay
Tin Setpoint Valve
SP
Position
PID VFD Motor

Inlet Temp Ctrl Starch

feeder

12 bar
Hot
Steam heat flow
Inlet temp

2 bar
Hot Heat exchangers
Heat recovery CTRL-valve(s)
Water
T_Z1 T_Z2 Tin
Inlet air flow
inlet

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 6

Exhaust Air Temp. PID Control

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“Do Nothing” Control

Moisture SP

Moisture PV

Feed Rate

Exhaust Temperature PV
Exhaust Temperature SP

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 8

 PID Control Performance

Moisture SP

Moisture PV

Feed Rate

Exhaust Temperature PV

Exhaust Temperature SP

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 9

Advanced Process Control Using
Soft Sensor and IMC

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 10

 You can’t control what you can’t measure

• What if in-line sensors are

unavailable, unreliable, too expensive

Process
Samples

Analysis
One hour
Process
to one day
Adjustments
delay !

143.0
Lab Results

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 11

 Solution: Soft Sensor

• Software model that predicts

process values based on
real-time process data
Process
Samples
Analysis

Process Real-time
Adjustments measurement! 143.0

Soft Sensor
Prediction %LabrateResults
temp thick
0.34 0.34 12.01 5.10
∂u ∂ 2u
0.45 0.45 = c12.34
2 5.34
∂t ∂ t2
0.12 0.12 12.67 5.23
( x - υ6.02
+1
Uo 2
0.14
⌠0.14exp 13.03 )
dυ
Real-time 2c √π t ⌡0.46
0.46 4c2 t 6.70
13.67
-1

Process Data 0.67 0.67 13.69 4.98

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 12

 PlantPAx ModelBuilder

• PlantPAx ModelBuilder for off-line data

analysis and modeling
• SoftSensor Designer converts models to AOI’s
Process
Samples
Analysis

Process
Adjustments
143.0

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 13

 Model Based Control in Logix
IMC_01
• Regulatory control functions based on Internal IMC ...

Model Control (IMC) algorithm 0.0

Internal Model Control
0.0
PV CVEU
– Handles first order plus dead-time (FOPDT) models 0.0
SPProg SP
0.0
0.0 0
• Gain, time constant, and delay parameters 00
SPCascade ProgOper
0
CC_01

– Good for processes with dead-time or processes with CC ...

simple coupling 0.0

Coordinated Control
0.0
PV CV1EU

• Different Function Blocks for Specific Problems

0.0 0.0
SPProg CV2EU
0.0 0.0
CV1Prog CV3EU
0.0 0.0

– IMC (Internal Model Control) 0

CV2Prog

CV3Prog
SP

ProgOper
0
0 0

• Replace single PID loop to address dead-time MMC_01

MMC ...

– CC (Coordinated Control) 0.0

Modular Multivariable Control
0.0

• Additional control outputs (2 or 3) for coordinating

PV1 CV1EU
0.0 0.0
PV2 CV2EU
0.0 0.0

multiple actuators for a single process variable 0.0

SP1Prog

SP2Prog
CV3EU

SP1
0.0
0.0 0.0

– MMC (Modular Multivariable Control) 0.0

CV1Prog
CV2Prog
SP2
ProgOper
0

• Coordinates 2 loops that interact with each other

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 14

 Starch Dryer Example
PV
IMC Moisture Control Moisture Moisture
• Moisture Soft Sensor is used for outlet SoftSens Lab Sensor

moisture control Moisture Ctrl

Amb Air Sample
SP Humidity
IMC Dried starch out
Exhaust T Ctrl
Tout
SP
PV
PID
CV Starch density

Hot air & starch mixture

Feeder Speed

Time Delay
Tin Setpoint Valve
SP
Position
PID VFD Motor

Inlet Temp Ctrl Starch

feeder

12 bar
Hot
Steam heat flow
Inlet temp

2 bar
Hot Heat exchangers
Heat recovery CTRL-valve(s)
Water
T_Z1 T_Z2 Tin
Inlet air flow
inlet

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 15

IMC Control with Soft Sensor – SP Change

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 16

IMC Control with Soft Sensor –
Disturbance

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 17

Advanced Process Control Using
Model Predictive Control

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 18

 Model Predictive Control
A Systematic Approach for Control of Processes with Constrained Nonlinear Dynamics

Model Predictive Controller

Trial
actions
Optimizer Control
actions

Process
Model
Trial
outcomes

Process

Measurements Disturbances

The key to effective control is good modeling

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 19

Spray Dryer Challenges

From To Cyclones
• Control powder moisture to
Mixers
target
Tower Pressure Tower Top
Deaerator Controller OP Temperature
PIC TT
• Maintain Tower Temperature
and Tower Under-Pressure
301-304
319 Avg
Hold Tank

below limits
• Minimize Tower Temperature
Slurry Slurry Slurry when possible to reduce energy
Flow Temperature Density
FIC
305
TT
310
DT
304
usage
Drop Tank

CV
Slurry
347 Recirculation
FIC Inlet Air Flow
314
Valve

VSD
TIC
315
Natural Gas FT
Flow
804 Inlet Air
Temperature

• Multiple interacting
control loops • No inline
Powder
Moisture moisture sensor

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 20

 Spray Dryer Solution from Rockwell

From To Cyclones
Mixers

Manipulate air flow, slurry flow,

Tower Pressure Tower Top
Deaerator Controller OP Temperature

and air temperature setpoints

TT
PIC 301-304
319 Avg
Hold Tank

to control powder moisture to

Pavilion8
target and maintain tower
temperature & pressure
Dynamic MPC within Slurry Slurry Slurry

constraints while compensating

Flow Temperature Density
FIC TT DT
305 310 304

for slurry temperature and Drop Tank

density variations CV
Slurry
347 Recirculation
FIC Inlet Air Flow
314
Valve

PlantPAx
Powder Moisture
Model Prediction
Builder VSD
TIC
315
Natural Gas FT
Flow
804 Inlet Air
Temperature

Powder
Moisture

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 21

Spray Dryer Model Predictive Control

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 22

Spray Dryer MPC Performance Metrics

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 23

 Benefits of Model Predictive Control

SPECIFICATION OR LIMIT
KEY TARGET

BEFORE MPC WITH MPC WITH OPTIMIZATION

TIME

• Faster moisture measurement and tighter control allows

average moisture target to be increased
– Sell more water/less expensive ingredients
– Reduce energy used for drying
– Increase throughput through dryer
Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 24
 Thank you!

Insert Photo Here

Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

 APC Town Hall Voting
Session

Insert Photo Here

Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL – McCormick Place West

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Automation for Process Industries

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 27

 PlantPAx Advanced Process Control Portfolio

Real-time Optimization
Increasing Effort & Increasing Value

Model Predictive
Control
Pavilion8
Nonlinear Multivariable Dynamic MPC
Control

Linear Multivariable Control

Inferential Sensors PlantPAx Model Builder

PlantPAx Fuzzy Designer
Advanced Regulatory
Control Logix IMC, CC, MMC

Regulatory Control Logix PID, PIDE, AOI

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

 Why Advanced Process Control?

• Advanced Regulatory Control

– Focus is on PROCESS variables – levels, flows, temperatures, pressures,
etc.
– Improve poorly performing loops and/or automate manual loops
– Compensate for dead-time and simple process interactions

• Model Predictive Control

– Focus is on PRODUCT variables – purity/impurity, production rate, product
quality, product specifications (e.g. moisture content, color, density, fineness,
etc.)
– Sends setpoints to process control loops
• Requires good regulatory control to achieve potential benefits
– Improve product quality
– Increase throughput and/or yield
– Reduce energy usage
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 29
 Question #1

1: What is your experience with implementing Advanced Process

Control?
a. A lot with PlantPAx
b. Some with PlantPAx
c. A lot with other DCS
d. Some with other DCS
e. None
 Question #2

2: What types of APC have you implemented in your facility? (Select

all that apply)
a. Cascaded/feed forward regulatory control loops
b. Model based (IMC or other) regulatory control
c. Fuzzy logic
d. Inferential sensors
e. Linear Model Predictive Control (MPC)
f. Nonlinear MPC
g. Steady-state optimization, online or off-line
 Question #3

3: What is your experience with automatic step testing for dynamic

model identification?
a. I have used a 3rd party tool and the results were useful
b. I have used a 3rd party tool and the results were not useful
and/or it caused unacceptable process disturbances
c. I have not used it but am in general agreement with the
concept and would like to try it
d. I have not used it and don't know if it would be useful or not
e. I have not used it and I don't believe our operators would
accept using it
 Question #4

4: What is your preferred approach for implementing MPC

applications in your plant?
a. Purchase a fixed price solution from RA with predefined
benefits, implemented by RA
b. Purchase an MPC software license and application
engineering services from RA but participate in the implementation
c. Purchase an MPC software license only and implement myself
or with preferred SI
 Question #5

5: What is your preferred technology platform for MPC?

a. Unrestricted linear and nonlinear MPC in a separate server
b. Scalable but limited (e.g. max per 10 input 10 output per MPC,
max 3 MPC) linear MPC on a separate board in the controller
c. Limited (max. 5 input, 5 output) linear MPC as Logix function
block
 Question #6

6: What are your plans for implementing Soft Sensors in your

facility?
a. No immediate needs and/or plans to implement
b. Not sure if we have any potential applications
c. We have potential applications but the ROI is too low to justify
d. We have potential applications and would like to have RA
implement
e. We have potential applications and would like to get training on
PlantPAx Model Builder to implement ourselves
 Submitted Ideas

1. Item 2
 Question #7

7: Of all the items discussed during the session, please rank the top
three priorities that you would like to see RA focus on for future
releases

1.

2.

3.