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10.1

Using DMCplus Controllers

 Copyright 1999 Aspen Technology, Inc.
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Use of Aspen Custom Modeler and Aspen Dynamics and This Manual
This manual is intended as a guide to using Aspen Custom Modeler and Aspen Dynamics software.
This documentation contains AspenTech proprietary and confidential information and may not be
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 Contents
Introduction
About This Manual.......................................................................................................... vii
For More Information..................................................................................................... viii
Online Help................................................................................................................. viii
Printed Manuals ........................................................................................................... ix
World Wide Web ........................................................................................................... ix
Technical Support ..............................................................................................................x
AspenTech Internet Technical Support Page ................................................................x
AspenTech Hotline .........................................................................................................x

1 Using DMCplus Controllers

Running Step Tests on a Dynamic Simulation .............................................................. 1-2
Defining a Step Test ................................................................................................... 1-2
Example Task ............................................................................................................. 1-3
Running the Step Test................................................................................................ 1-3
Exporting Step Test Results as Collect Files ............................................................. 1-4
Using a DMCplus Controller in a Dynamic Simulation ................................................ 1-5
System Requirements................................................................................................. 1-5
Configuring the Controller in DMCplus .................................................................... 1-5
Configuring the Controller in your Dynamic Simulation .......................................... 1-6
About the Configure Form.......................................................................................... 1-7
About the ConfigureUnits Form................................................................................. 1-9
Automatic Configuration of Units of Measurement..................................................1-12
Running the Simulation with a DMCplus Controller...............................................1-12

2 Example of Using a DMCplus Controller

Running the Simulation in Aspen Plus...................................................................... 2-2
Modifying the Regulatory Control Loops ................................................................... 2-2
Designing the Multivariable Control Scheme............................................................ 2-5
Importing the Data..................................................................................................... 2-8
Creating and Updating a Controller Configuration File ..........................................2-10
Configuring the DMCplus Controller in Aspen Dynamics .......................................2-11
Studying Disturbances ..............................................................................................2-14

Index

Using DMCPlus Controllers iii

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iv Using DMCPlus Controllers
Version 10.1
 Introduction
This chapter describes:
• The contents of this manual
• Where to find further information

About This Manual

This manual describes using a DMCplus controller with an Aspen Modeler
product, that is Aspen Dynamics or Aspen Custom Modeler.

Using DMCPlus Controllers vii

Version 10.1
For More Information
Aspen Modeler products have comprehensive online help systems. If you prefer to
read printed documentation, you can use the PDF files supplied on the
installation CD. If you need more detailed assistance than that provided in the
online Help and the PDF files, you can contact Technical Support.

Online Help
The Aspen Modeler online help includes:

Description To access this help

Step-by-step instructions for
completing common
procedures
Detailed reference
information
From the application's Help menu, click Contents, and then on the Contents tab, double-
click the required title beginning Using…
From the application's Help menu, click Contents, and then on the Contents tab, double-
click the required Reference title

Printing Online Help

For instructions on printing online help, open your Aspen Modeler product. Then:
1. From the Help menu, click Contents.
2. On the Contents tab, double-click Using Help, then double-click Print Help
Topics.

Improving Online Help

We value your comments, suggestions, and criticisms. If you did not find the
information you wanted, needed more assistance than the online help provided,
or have any suggestions for future improvements to our online information, we
want to know. Please email your comments to Docs@Aspentech.com

Note If you have a query about the Aspen Modeler product itself and want to
email the AspenTech Support team, please contact your local Technical Support
office.

viii Using DMCPlus Controllers

Version 10.1
Printed Manuals
These manuals are supplied with your product:
• Aspen Custom Modeler and Aspen Dynamics Installation Guide This
guide is supplied with your product and provides instructions on installing
these products under Windows 95 and Windows NT.
• One or both of:
− Aspen Dynamics Getting Started The hands on tutorials in this book
guide you through converting a steady-state Aspen Plus simulation to a
dynamic simulation.
− Aspen Custom Modeler Getting Started The basic hands on tutorials
in this book help you familiarize yourself with Aspen Custom Modeler.

You can also install and print yourself copies of all of the Reference Manuals,
both What's New guides, the Aspen Dynamics User Guide, both Getting
Started guides, and this Using DMCPlus Controllers manual. For brief
descriptions of the contents of these manuals, see the Online Help or Chapter 7 of
the Installation Guide.

If you chose not to install these manuals when you installed your product, you
can install them and the Adobe Acrobat Reader needed to read them now. To do
this, run the D:\Docs\setup.exe program on the installation CD, where D: is the
drive letter of your CD ROM.

Note Adobe and Acrobat are trademarks of Adobe Systems, Incorporated.

When installed, to view and print the manuals:

1. From the Start menu, point to Programs, AspenTech, AM Documentation.
2. Click the PDF file you want to open.

World Wide Web

For additional information about AspenTech products and services, check the
AspenTech World Wide Web home page on the Internet at:

http://www.aspentech.com/

Using DMCPlus Controllers ix

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Technical Support
You can get help from AspenTech's technical support resources on the World Wide
Web, or by contacting an AspenTech office.

AspenTech Internet Technical Support Page

To obtain in-depth technical support information on the Internet, register at:

http://www.aspentech.com/ts

Approximately three days after registering, you will receive a confirmation e-mail
and you will then be able to access the most current Hotline contact information
and also:
• Training course schedules
• Product updates
• Details of support services
• any updated PDFs for Aspen Custom Modeler and Aspen Dynamics from
http://www.aspentec.com/tspsd/acm/acm.htm and
http://www.aspentec.com/tspsd/ad/ad.htm respectively

AspenTech Hotline
If you need help from an AspenTech Customer Support engineer, contact the
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Location Telephone Number Fax Number E-mail Address

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m
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Korea office +82-2/761-5800 +82-2/761/5803

❖ ❖ ❖ ❖

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1 Using DMCplus
Controllers
There are two capabilities in Aspen Custom Modeler™ and Aspen Dynamics™
designed to help you develop and test DMCplus™ controllers. You can:
• Run step tests on the dynamic simulation and export the results to the
DMCplus Collect file format for use by the model identification tool DMCplus
Model
• Use a DMCplus controller in a dynamic simulation

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Running Step Tests on a Dynamic

Simulation
This section describes how to generate step response results from a simulation for
import into DMCplus Model, where they can be used for model identification.

This section assumes that you have already created the dynamic simulation.

Defining a Step Test

To define a step test:
1. Determine the variables that you wish to perturb in the step tests and
determine their variable names.

Tip In Aspen Custom Modeler or Aspen Dynamics, the best place to look for
these variables is on the Manipulate forms of the blocks. These forms include
variables whose values can be changed at runtime and which are therefore
potential step testing perturbation variables.

Note Only variables that are Fixed can be perturbed in step tests.
2. In the All Items pane of the Simulation Explorer, select Flowsheet and in the
Contents pane, double-click Add Task.
3. When prompted, enter an appropriate name for the task, for example,
StepTest1.
4. Use Task Language to define the steps.
5. Now you can create a History Table containing the variables for which you
require results. To do this, from the Tools menu click New History Table.
6. Open the tables containing the variables you require and drag and drop the
variables from these tables to the History Table.

You must define the History Table before the run to ensure that results are
recorded for your chosen variable throughout the dynamic simulation.

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Example Task
An example task is shown here:
Task StepTest1 runs when time == 0.1

TC101.SPRemote : CC101.SPRemote * 1.05;

wait for time == 1.1;

TC101.SPRemote : CC101.SPRemote / 1.05;

wait for time == 2.1;

TC101.SPRemote : CC101.SPRemote * 0.95;

wait for time == 3.1;

TC101.SPRemote : CC101.SPRemote / 0.95;

wait for time == 4.1;

Pause;

End

This task increases the set point of a temperature controller by 5%, waits an hour
for the simulation to level out, and then reduces the set point to the original
value, and again waits an hour for the simulation to stabilize.

It then repeats this for a 5% decrease in the temperature controller set point and
pauses the simulation.

This task only manipulates one variable, but you could go on to repeat this
perturbation sequence for other variables.

When creating the task you may need to use trial and error to ensure you allow
sufficient time between steps for the simulation to level out to a new steady state.

Running the Step Test

To run the step test:
1. Ensure that the simulation is at steady state before the step tests begin. A
convenient way to do this is to display the History Table as a Plot, and check
that the values of the variables do not vary with time prior to the start of the
step tests.

2. Activate the step test Task to be used.

3. Run the dynamic simulation.

Now you can export the results as a Collect file.

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Exporting Step Test Results as Collect Files

To export the step test results as a collect file:
1. In the History Table that you created, click with the right mouse button and
from the menu that appears, click Refresh.
The table is updated with the results from the simulation.
2. Click the right mouse button again and click Export Table.
The Export File Properties dialog box opens:

3. The TagName column contains the TagName property for each variable. Edit
this to enter the tag name that you wish to use to refer to the variable within
DMCplus.

To do this either double-click the TagName, or click the TagName and select
Edit TagName from the context menu. Every variable must have a tag name.

The maximum length of a DMCplus tag name is 12 characters. If the tag

name is longer than 12 characters, it will be truncated when exported to the
Collect file.

The Variable and Description columns contain the name and description for
each variable in the History Table. You cannot edit these.
4. When you are satisfied with the tag names click the Export button.
5. In the Export dialog box, select DMCplus Collect (*.clc) in the Save As Type
box, and enter the name for the file, then click Export.

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Using a DMCplus Controller in a Dynamic

Simulation
This section describes how to use a DMCplus™ controller in a simulation of the
process being controlled including:
• System requirements
• Configuring the controller in DMCplus
• Configuring the controller in your dynamic simulation
• Running the simulation with a DMCplus controller

System Requirements
To use a DMCplus controller in a simulation, you must have the following
software installed on an Intel PC running Windows NT 4.0:
• Aspen Custom Modeler or Aspen Dynamics 10.1 server
• DMCplus Online version 1.11
The Aspen Custom Modeler or Aspen Dynamics client user interface can run on
the same PC or another Windows NT or Windows 95/98 PC.

Note Use of Aspen Custom Modeler or Aspen Dynamics servers or DMCplus

Online running on other hardware platforms is not supported.

Configuring the Controller in DMCplus

You configure a DMCplus controller for use in a dynamic simulation in exactly
the same way as a controller for use on-line on a real plant. For details on how to
do this, see the DMCplus documentation.

Because the simulation schedules execution of the controller you must ensure
that the WTMODE entry for the controller is set to a value of 2.

You should place the .mdl and .ccf files for the controller in a folder with the same
name as the controller below the DMCplusOnline\app folder in your DMCplus
on-line installation. That is, these files should exist:
DMCplusOnline\app\controllername\controllername.mdl
DMCplusOnline\app\controllername\controllername.ccf

Where controllername is the name of your controller.

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Configuring the Controller in your Dynamic Simulation

The Aspen Custom Modeler and Aspen Dynamics libraries include a model called
DMCplus. In Aspen Dynamics you can find it in the Dynamics, ControlModels
folder. In Aspen Custom Modeler, this is in the Modeler, Models folder. This
model represents the DMCplus controller within your simulation, and will
automatically exchange measured and controlled variable values with the
controller, and schedule its execution.

To use this model:

1. Create a block on your flowsheet that uses this model.
2. Open the Configure form for the block and enter values for the number of
MVs (NMV), feed forwards (NFF) and CVs (NCV).
These values should be the same as in your DMCplus controller definition.
3. Graphically connect the controller inputs and outputs. Use the ControlSignal
stream type to connect each of the CVs and FFs from their source block to the
InputSignal port of the controller block. You are prompted to select which CV
or FF to connect the signal to.

Tip You must connect all variables so that they are in the same order as in
your controller definition, for example use CV (1) for the first CV in your
controller.
4. Use the ControlSignal stream type to connect the MVs from the OutputSignal
port to their destination blocks. Typically the destination will be a remote
setpoint for a PID controller block.
Again, connect the MVs in the same order as the MVs in your controller
definition.
5. In the Configure form, enter values for each of the parameters.

For details on this form, see the next section.

6. Go to the ConfigureUnits form and define the unit of measurement
conversions. For details of this form, see About the ConfigureUnits Form on
page 1-9.

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About the Configure Form

This table describes the parameters on the Configure form.:
Parameter Description Valid values Default value

ControllerName DMCplus controller name Any string -

ControllerActive Controller active Yes Yes
No
NMV Number of MVs Any integer 2
NFF Number of FFs Any integer 2
NCV Number of CVs Any integer 2
MVTag MV DMCplus tag name Any string -
FFTag FF DMCplus tag name Any string -
CVTag CV DMCplus tag name Any string -
MVMan Manual MV value Any real 1.0

ControllerName for DMCplus

ControllerName specifies the name of the DMCplus controller to be used.
Capitalization is unimportant, in other words the name COL5X3 is equivalent to
col5x3.

ControllerActive for DMCplus

When ControllerActive=Yes, and the run mode is dynamic, the DMCplus
controller is loaded and used during the simulation.

When ControllerActive=No, or the run mode is not dynamic, the controller is not
run, and the MVs are set to MVMan – the manual MVs.

Set ControllerActive=No if you wish to disable the controller for an entire run, for
example if you are performing step tests. To switch the controller on and off
during a run use ONREQ.

NMV for DMCplus

Specifies the number of MVs. This should be equal to the number of MVs in the
DMCplus controller.

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NFF for DMCplus

Specifies the number of FFs. This should be equal to the number of FFs in the
DMCplus controller.

NCV for DMCplus

Specifies the number of CVs. This should be equal to the number of CVs in the
DMCplus controller.

MVTag for DMCplus

Specifies the DMCplus controller tag names (MDLDEP entry) for each MV. You
must enter a valid tag name for each MV, and this must match the name of an
MV in the DMCplus controller. The MVTag for each MV must be unique. The
capitalization of the MVTag is not important.

FFTag for DMCplus

Specifies the DMCplus controller tag names (MDLDEP entry) for each FF. You
must enter a valid tag name for each FF, and this must match the name of an FF
in the DMCplus controller. The FFTag for each FF must be unique. The
capitalization of the FFTag is not important.

CVTag for DMCplus

Specifies the DMCplus controller tag names (MDLIND entry) for each CV. You
must enter a valid tag name for each CV, and this must match the name of a CV
variable in the DMCplus controller. The CVTag for each CV must be unique. The
capitalization of CVTag is not important.

MVMan for DMCplus

Specifies the manual output values of the MVs. The MVs are set to these values
for all non-dynamic run modes. These values are also used as the initial values of
the controller MVs at the start of a dynamic simulation. MVMan can also be used
to change the MV values during a dynamic simulation when the controller is in
manual mode.

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About the ConfigureUnits Form

Internally, all Aspen Custom Modeler or Aspen Dynamics models work in the
Metric unit of measurement set. This is true regardless of the units of
measurement selected for input and display of results. To see values in this unit
of measurement set:
➤ From the Tools menu, point to Units of Measurement and click Metric.

By default, all CV and FF values passed to the DMCplus controller will be in

Metric units and all MV values returned from the controller will be assumed to be
in Metric units. If the units of measurement for any of the controller variables are
different, these units must be converted to achieve correct operation of the
controller.

Use the ConfigureUnits form to define the units of measurement used and any
conversion factors required:

Name Description Valid values Default value

MVUOM MV unit of measurement Any string -

MVFactor MV UOM conversion factor Any real 1.0
MVOffset MV UOM conversion offset Any real 0.0
FFUOM FF unit of measurement Any string -
FFFactor FF UOM conversion factor Any real 1.0
FFOffset FF UOM conversion offset Any real 0.0
CVUOM CV unit of measurement Any string -
CVFactor CV UOM conversion factor Any real 1.0
CVOffset CV UOM conversion offset Any real 0.0

MVUOM for DMCplus

Specifies the units of measurement for each MV. The DMCplus model will check
the units of measurement against those in the DMCplus controller definition
(ENGIND entry). When the simulation is run the model will warn if there are
any differences.

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MVFactor for DMCplus

Specifies the unit of measurement conversion factor for each MV. The MV values
in metric units and the value returned from the DMCplus controller are related
as follows:

MV = MVdmcp * MVFactor + MVOffset

Where:

MV = MV value in metric units

MVdmcp = MV value returned from the DMCplus controller

MVOffset for DMCplus

Specifies the unit of measurement conversion offset for each MV. The MV values
in metric units and the value returned from the DMCplus controller are related
as follows:

MV = MVdmcp * MVFactor + MVOffset

Where:

MV = MV value in metric units

MVdmcp = MV value returned from the DMCplus controller

FFUOM for DMCplus

Specifies the units of measurement for each FF. The DMCplus model will check
the units of measurement against those in the DMCplus controller definition
(ENGIND entry). When the simulation is run the model will warn if there are
any differences.

FFFactor for DMCplus

Specifies the unit of measurement conversion factor for each FF. The FF values
in metric units and the value returned from the DMCplus controller are related
as follows:

FF = FFdmcp * FFFactor + FFOffset

Where:

FF = FF value in metric units

FFdmcp = FF value returned from the DMCplus controller

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FFOffset for DMCplus

Specifies the unit of measurement conversion offset for each FF. The FF values in
metric units and the value returned from the DMCplus controller are related as
follows:

FF = FFdmcp * FFFactor + FFOffset

Where:

FF = FF value in metric units

FFdmcp = FF value returned from the DMCplus controller

CVUOM for DMCplus

Specifies the units of measurement for each CV. The DMCplus model will check
the units of measurement against those in the DMCplus controller definition
(ENGDEP entry). When the simulation is run the model will warn if there are
any differences.

CVFactor for DMCplus

Specifies the unit of measurement conversion factor for each CV. The CV values
in metric units and the value actually passed to the DMCplus controller are
related as follows:

CV = CVdmcp x CVFactor + CVOffset

Where:

CV = CV value in metric units

CVdmcp = CV value passed to the DMCplus controller

CVOffset for DMCplus

Specifies the unit of measurement conversion offset for each CV. The CV values
in metric units and the value actually passed to the DMCplus controller are
related as follows:

CV = CVdmcp x CVFactor + CVOffset

Where:

CV = CV value in metric units

CVdmcp = CV value passed to the DMCplus controller

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Automatic Configuration of Units of Measurement

For convenience, you can automatically complete the ConfigureUnits table by
running the UOMFactors script for the block. This script assumes that the units
you are currently using to display results in your simulation are the same as
those used in the DMCplus controller.

To complete the ConfigureUnits table automatically using the UOMFactors

script:
1. Select the units for all of the MVs, FFs, and CVs.

Do this by going to the block containing the variable, opening the appropriate
table, and changing the units of measurement to those used in the DMCplus
controller.
2. In the Simulation Explorer, go to the controller block and run the
UOMFactors script.
The ConfigureUnits table will be completed automatically.

Note If the DMCplus units of measurement for a variable are not in the list of
available units, you must enter the units, conversion factor and conversion offset
manually.

Running the Simulation with a DMCplus Controller

When you run a dynamic simulation with the controller active, if you have not
already loaded or started the controller using DMCplus Manage, the controller is
automatically loaded and started.

Open the Results form to see the current values of the MVs, CVs and Feed
Forward variables.

As well as using the Aspen Custom Modeler or Aspen Dynamics user interface,
you can use DMCplus OPCON to interact with the controller during the
simulation.

Use the Manipulate table to change controller settings during the simulation.

Tip It is easier to pause the simulation before changing values in this table.

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The Manipulate table enables you to change:

Name Description Valid Values Default Value

ONREQ Master on/off request 0 (Off) 1

switch 1 (On)
MVMan Manual MV value Any real 1.0

ONREQ for DMCplus

Corresponds to the ONREQ flag in the DMCplus controller. Set ONREQ to 1 to
have the controller update the values of the MVs, or 0 to switch this off.

If you change from on to off, the MVs will be frozen at their current values. You
can manually change their values. To do this:
➤ Enter your required value in the MVMan row.
The corresponding MV will then change to this value.

MVMan for DMCplus

Specifies the manual output values of the MVs. The MVs are set to these values
for all non-dynamic run modes. These values are also used as the initial values of
the MVs at the start of a dynamic simulation.

MVMan can also be used to change the MVs during a dynamic simulation when
the controller is inactive or switched off.

❖ ❖ ❖ ❖

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1-14 Using DMCplus Controllers

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2 Example of Using a
DMCplus Controller
This example describes a simulation in which 98% pure methylcyclohexane
(MCH) is recovered from a mixture of MCH and toluene. Because these
components form a close boiling system that is difficult to separate by simple
binary distillation, phenol is used as an extractant to enhance the relative
volatility of MCH over toluene. This example describes the steps required to set
up a DMCplus controller to control the process.

To follow this example, you need a licensed copy of DMCplus® Online.

All of the files for this example are supplied in the MchDMC example folder.

If you have installed Aspen Dynamics ™ in the default location, this folder is in
C:\Program Files\Aspentech\Dynamics\10.1\Examples.

For more information about using DMCplus with Aspen Dynamics, see the Using
DMCplus Controllers Help.

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Example

Running the Simulation in Aspen Plus

Firstly, the simulation was run and exported from Aspen Plus using the file
MchDMC.bkp. If you do this yourself:
• Ensure the Dynamic button is pressed in.
• Because the required dynamic information has already been entered, the
simulation just needs to be run.
• Export the file as a flow driven dynamic simulation (.dynf file).

Modifying the Regulatory Control Loops

In Aspen Dynamics, when you open the file that was exported from Aspen Plus,
the simulation is automatically updated to insert some default pressure and level
regulatory controls.

These regulatory control loops were then modified to reflect the actual control
configuration in the plant. The following figure shows the modified configuration:

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 Chapter 2

The regulatory loops were then tuned. This is the configuration prior to the
installation of the DMCplus controller. Notice that in addition to the default PID
loops created after the Aspen Plus simulation, two other PID loops were added:
• A PHENOLPID loop increases the flow of phenol to increase the purity of
MCH in the product stream.
• The REB_PID loop regulates reboiler duty to control the temperature on
stage 19 of T-1. Stage 19 was chosen because it is sensitive to composition
changes at the bottom of the column.

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Example

The following plot was generated using Aspen Plus and varying the distillate
rate:

This version of the file is available as MchRegCtrl.dynf. You can run the
simulation, introduce disturbances and view the responses. When simulating a
real plant, compare the performance of the simulation with real data, and make
modifications as necessary.

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Designing the Multivariable Control Scheme

Next, the multivariable control scheme was designed and the flowsheet modified
to reflect the desired configuration.

For example, the level loop associated with the feed drum V-1 will be controlled
manually by DMCplus. This is because DMCplus controller will not use the
LC_FEED PID loop to control the level. Similarly, the PHENOLPID loop will be
set to manual because DMCplus will rely on multiple manipulated variables to
decide the most economical way to control MCH purity in the product stream.

The Aspen Dynamics simulation was prepared to collect data during the
DMCplus step test. During a step test, manipulated variables in the DMCplus
controller are stepped and data is collected in order to generate DMCplus models
for the controlled variables.

In this example, the model is used to generate the step test results. In practice,
this would normally be done using the real plant and not the model, although the
model can be used to help plan the step testing program.

Tip In order to collect data, create a history table(s) containing all the variables
required for DMCplus modeling.

The following figure shows a history table, with some selected tags.

The faceplates of the two controllers PHENOLPID and LC_FEED were used to
set the controllers to manual before beginning the step test.

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Automating the Step Test

To automate the step test, tasks were added to the Aspen Dynamics simulation.

The task Steptest1 in the example file calls subtasks FF_FEED, FF_CWTWMP,
FF_FEEDT, MVSTEPS and FINISHTEST to accomplish this. Step inputs are
made to the manipulated variables, followed by a wait to allow the variables to
come to steady state, so that the effect of the change can be identified by
DMCplus Model.

This version of the file is saved as MchStepTest.dynf.

Having activated the task Steptest1, the simulation was run. When it had
finished, the history table(s) were exported. The DMCplus tag names are
specified at this time.

About the Tagnames

Tagnames are identifiers (up to 12 characters) used by DMCplus to identify
variables. These should be specified when the history table is saved at the end of
the step test, in DMCplus readable format (clc file).

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The manipulated variables (MV) selected for this controller are:

Tagname Description

LC-FEED.OP Feed to T-1 from V-1

A-PHENPID.OP Phenol feed to T-1
Q-REBPID.SP Tray 19 temperature cascaded to reboiler duty
PC-TOP.SP Top pressure in T-1
F-REFLUX Reflux in T-1

Other independents that are modeled as feedforwards (FF) are:

Tagname Description

F-FEEDMCH MCH feed to V-1

T-WATERIN Cooling water temperature to condenser
F-FEEDTOL Toluene feed to V-1

The controlled variables (CV) are:

Tagname Description

L-DRUMV1 Level in V-1 (held within upper and lower limits)

DP-T2T21 Pressure drop in tower (held within dumping and flooding limits)
Q-REBPID.OPX Reboiler duty (constrained by maximum available duty)
F-WATER Cooling water flow to condenser (constrained by maximum flow)
A-PHENPID.PV MCH concentration in top product stream (product specification)
F-MCHPROD Top MCH product flow rate from T-1 (constrained by the amount downstream units can
accept)
PHENOLRATIO Phenol to feed ratio (minimum limit for relative volatility)
T-STAGE19PCT Pressure compensated temperature on stage 19 (maintain minimum temperature to prevent
loss of MCH in bottoms product). Temperature on stage 19 is compensated linearly for
variations in tower pressure. The expression for the PCT calculation is:
PCT = Tray19Temp(F) - 14.12 (TowerPressure(psi) - 16)
Note The numbers are converted to Metric units when implemented in Aspen Dynamics.
PC-TOP.PV Pressure in tower T-1 (prevent tower from running into vacuum or exceeding equipment
pressure specification)

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Importing the Data

DMCplus Model was opened and the collected data file(s) imported. The vectors
were plotted as shown in the following figure:.

Cases in the Model file listing independents and dependents, data ranges, times
to steady state were created:.

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The case(s) were run to identify DMCplus models and the models generated by
the case(s) were viewed. An example is shown in the following figure:

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A model matrix was assembled, selecting the most appropriate models from
different cases:

This model was exported as a file (mchcol.mdl) for use by the controller. All the
above operations in DMCplus Model are saved in the file mchcol.dpp.

Creating and Updating a Controller Configuration File

The model file (mchcol.mdl) was imported in DMCplus Build then exported as a
controller configuration file (ccf). This is available as mchcol.ccf.

The ccf file was imported in DMCplus Simulate and the controller was tuned and
Tuning parameters were changed to get the desired response from the controller.

The ccf file was updated from the Controller menu to save the tuning changes.

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Both the model and the ccf files were copied into a newly created folder in the app
directory of DMCplus Online. For example, if the controller name was mchcol,
then you would copy mchcol.mdl (model file) and mchcol.ccf (ccf file) into the
DMCplusOnline\app\mchcol folder.

Configuring the DMCplus Controller in Aspen

Dynamics
In Aspen Dynamics, a DMCplus block was placed on the flowsheet.

The controller was configured by inserting tag names, as in the model file, and
connecting the dependents and independents to the appropriate variables in the
dynamic simulation using control signals.

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The flow diagram now looks like:

The units were configured using the ConfigureUnits form on the DMCplus block
and the controller turned on using the Configure form.

In DMCplus Online, the Operator Console (DMCplus View) was used to change
operating limits and to further tune the controller. The configuration was saved
using the Manage program.

When the dynamic simulation was run, plots of manipulated and controlled
variables were viewed to monitor the performance of the controller.

Tip The example file, MchDMCplus.dynf contains predefined plots MVs, FFs,
CV1to5 and CV6to9.

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If you open the Operator Console, you can see how the controller drives towards
constraints:

The highlighted numbers indicate that the controlled variable is at a lower or

upper limit constraint. Notice how the controller tries to minimize pressure,
reboiler temperature, meet the low limit of MCH concentration in the product
stream and maximize the valuable product stream.

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The corresponding plots in Aspen Dynamics looks like this:

Studying Disturbances
To study the effect of disturbances, you can perturb the feedforward (FF)
variables in the DMCplus controller either manually by using the appropriate
forms, or by using tasks.

In the example, there are two tasks DIST_CW and DIST_FEED that disturb the
cooling water temperature and feed flow rate respectively. Activate these tasks
whenever desired to study the effect of disturbances.

The following figure shows the effect of lowering the feed rate to the drum V-1. As
the level L-DRUMV1 approaches the low limit, the controller reduces feed to the
column, in order to prevent V-1 from running dry. The following figure shows the
active constraints in this case.

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Notice how the controller tries to minimize steam, pressure and run close to the
low limit constraint of MCH product specification, while trying to balance the
level.

The corresponding Aspen Dynamics plots are shown in the following figure:

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Activate the task DIST_CW to study the effect of disturbances in cooling water
temperature. DIST_CW increases cooling water temperature to 104 °F. The
controller is driven to new constraints as shown in this figure:

Notice how the controller hits the upper limit on cooling water flow, maximizes
valuable product, minimizes pressure and reboiler temperature. It also increases
phenol to compensate the loss in MCH because of higher tower temperature. The
corresponding Aspen Dynamics plots are shown in the following figure:

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Notice also how the feed disturbances increase feed to the drum V-1 and allow the
controller to maximize product flow.

❖ ❖ ❖ ❖

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M
Manipulate table
about 2-12
MVFactor for DMCplus 2-9
MvMan 2-12

Index MVMan for DMCplus 2-7

MVs for DMCplus 2-7
MVTag for DMCplus 2-7
MVUnits for DMCplus 2-9

R
A Results
step test 2-2
AutoMan 2-12

S
C
Scripts
Collect files 2-4 UOMFactors 2-11
Configure form Simulations
description 2-7 with DMCplus 2-12
ConfigureUnits form Step tests
description 2-9 defining 2-2
ConfigureUnits table exporting 2-4
configuring automatically 2-11 results 2-4
Configuring running 2-2, 2-3
DMCplus controllers 2-6
ControllerOn 2-7
Controllers T
DMCplus 2-1, 2-7, 2-12
CVFactor for DMCplus 2-9 Tasks
CVOffset for DMCplus 2-9 step test 2-2
CVs for DMCplus 2-7 To export the step test results as 2-4
CVTag for DMCplus 2-7 To run the step test 2-3
CVUnits for DMCplus 2-9
U
D
Units of measurement
DMCplus automatic configuration 2-11
configuring controller 2-6 defining 2-9
overview 2-1 UOMFactors script 2-11
system requirements 2-6
DMCplus model 2-7

E
Exporting

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