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DeltaV Embedded Advanced Control

A New Approach to Advanced Control Overview Presentation

Topics

DeltaV Embedded Advanced Control Advantage DeltaV Advanced Control Product Suite

Experience / Examples

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Advanced Control for Operational Excellence

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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Advanced Control - The DeltaV Way

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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Embedded APC Tools Whats new?


NO extra databases NO database synchronization issues NO watchdog timers NO fail/shed logic design

Traditional Advanced Control


Embedded APC: Can run in DCS controllers Redundant and fast (1/sec) Integrated operator user interface Configuration through standard Control Studio Automated step testing and Model ID Off-line simulation and training

NO custom DCS programming


NO interface programming NO operator interface development
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New Approach to APC Configuration

DeltaV APC blocks are Drag-n-Drop

Graphical Configuration using Control Studio

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New Approach to APC Configuration

System-wide tag browsing all in the DCS database


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Typical APC Project Timeline


Months
1

10

11

12

Functional Design Det. Design, Config & Staging Step Tests & Model ID Traditional APC Technology Commissioning

Functional Design Det. Design & Config

Step Tests & Model ID


Commissioning Embedded APC Technology

Performed on-site

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Traditional Advanced Control Over Time


Start Project

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

Why Dont APC Applications Stay On-Line?

Regulatory control problems


Instrument failures Valve problems Poor loop tuning

Process changes
New constraints or limits Different control objectives Different process dynamics

Applications not maintained


Maintenance not budgeted

Lack of operator training


Operators dont understand what the APC is doing

Too expensive to bring in APC consultants

How to Sustain Control Performance?


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Must Build Solid Foundations


You Cant Have This
Advanced Control

Control Foundation

Without This
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Foundation Built on Health of Field Devices

Fieldbus Status Is Consistently Used by DeltaV Advanced Control


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DeltaV Embedded Advanced Control


A Systematic Approach for Sustained Performance Analyze and Diagnose Identify Problems And Prioritize

Re-Tune Or Fix Cause

Monitor Performance

Advanced Control

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DeltaV InSight A Control Performance Suite


Intelligent Controller Tuning Tune with InSight

Adaptive Control (Adapt) Control with InSight DeltaV InSight

Intelligent
Performance Monitoring Inspect with InSight Process Model Calculations Advanced Control Predict / Neural / Fuzzy

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DeltaV Embedded APC for Sustained Performance


DeltaV APC Traditional APC
100%

% On-line Time

Faster to Commission + Sustained Performance = Greater $$s Saved

time
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The DeltaV Embedded APC Advantage

Ease of Use
Intended for process control engineers Minimum APC consulting required

Integrated DeltaV Architecture


Common graphical configuration, operator displays, historian Advanced control technology embedded in system

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

DeltaV Advantage - Embedded Advanced Control Advanced Control Product Suite

Experience / Examples

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DeltaV Advanced Control Products

DeltaV InSight performance monitoring and loop tuning


Inspect: Monitors performance and identifies abnormal conditions. Automatically configured. Tune: On-demand and Adaptive tuning for any PID loop. Adapt: Closed loop adaptive control for any PID block.

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 Advanced Control Products

DeltaV Insight performance monitoring and loop tuning


Inspect: Monitors performance and identifies abnormal conditions. Automatically configured. Tune: On-demand and Adaptive tuning for any PID loop. Adapt: Closed loop adaptive control for any PID block.

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:

Easily identify control problems


Loop service and variability monitoring Device diagnostics

Quickly tune loops for improved control


On-demand and Adaptive Tuning Test tuning with simulation

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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Predictive Intelligence = Intelligent Control


Adaptive Learning Algorithms for Intelligent Control Learn
Observe Identify Remember

Evaluate
Validate Compare Diagnose

Improve
Advise Tune Adapt

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DeltaV InSight for Intelligent Control


With InSights Adaptive Learning you can:
Automatically calculate process models for every control loop in the system Benchmark Control Performance Diagnose and predict control problems Learn Evaluate Tune controllers (with no testing) Reduce start-up time for new control systems Reduce engineering time for simulations Identify APC Opportunities Improve Apply MPC (Predict) with no testing Implement closed loop adaptive control

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:

On-demandTuning Adaptive Tuning Simulation

Performance Monitoring Loop Diagnostics Embedded Learning Adaptive Tuning Adaptive Control

Performance Monitoring Loop Diagnostics Reporting


Adaptive Control Operating Regions Non-linear Control

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Model Identification Control Diagnostics Performance Indices

DeltaV InSight Integrated User Interface


Old DeltaV Inspect

New DeltaV InSight

Old DeltaV Tune

New interface provides seamless transition between loop diagnostics and tuning.

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Easily Launched in Context


From the Control Studio Operator Interface DeltaV Explorer
From the DeltaV Explorer

Context sensitive from Control Studio


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DeltaV Insight Architecture

Data Analysis and Reporting Runs in Server

UI from any workstation

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Embedded Learning Runs in the Controller Fast Data Capture Small Communications Load Runs in Background

DeltaV InSight Process Learning

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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DeltaV InSight Enable Process Learning

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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Control Performance Monitoring


Inspect with InSight

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

Device and Valve Diagnostics


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Control Block Performance Indices


Block Summary Display provides trends, current values, and limits for:
Control Service Statistics Incorrect Mode Limited Control Output Uncertain Input Control Performance Indices Standard Deviation Variability Index Oscillation Index Tuning Index
Tuning Index is the % change in control variability between current tuning and recommended adaptive tuning.
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DeltaV InSight 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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DeltaV InSight - Asset Monitoring

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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DeltaV InSight Loop Tuning


Two methods of loop tuning are supported

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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DeltaV InSight - On-demand Tuning

Used to tune PID and fuzzy logic control blocks

Guides user through tuning


-

Set Step Size Test

Simulate

Same features as old DeltaV Tune

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On-Demand Tuning - Options for the Expert

Power for the Advanced User !

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DeltaV InSight - Adaptive Tuning


Provides Tuning Based on Normal Operator Changes

Before vs. After

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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DeltaV InSight - Model Analysis


Gain Process Insight with Model Analysis

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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DeltaV InSight - Control Simulation


Test your tuning with Dynamic Simulation

View Dynamic Response

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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DeltaV InSight Adaptive Control


Non-linear Process Example

Process gain and dynamics may change as a function of operating conditions such as valve position or feed rate.

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Non-linear Process Models

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DeltaV InSight Adaptive Control


InSight identifies tuning in up to 5 regions of operation

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DeltaV InSight Adaptive Control

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DeltaV InSight Adaptive Control


Adaptive control adjusts tuning to improve control performance

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InSight Performance Reports

Standard Out-of-Box Reports


Quickly identify control problems Track performance, communicate results Schedule for automatic generation Easy, Easy, Easy
No Configuration or Maintenance

Customized Reports
Add production KPIs in customized reports via Excel and DeltaV Reporter

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Area Control Performance Report

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Area Control Performance Report

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DeltaV Fuzzy - As Easy to Use as PID


Pre-configured Fuzzy Logic Controller May replace PID for most applications

Improved response to process disturbances


Quick tuning with DeltaV InSIght

Configuration is Easy exactly like PID

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Easy As PID
DeltaV Explorer

Replace PID with Fuzzy Logic Control

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DeltaV Fuzzy Function Block


Pre-defined Fuzzy Logic Control

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Use DeltaV InSight to Tune Fuzzy Logic

Transfer recommended constants to fuzzy control

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Simulated Response

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Fuzzy Logic Control vs PID


Setpoint Change Load Disturbance

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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Fuzzy Control Results

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)

Source: Emerson Exchange, October 2004 Shell Deer Park Paper


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DeltaV Predict - Model Predictive Control


Handles difficult process dynamics, reduces variability and protects constraints Easy and fast implementation Fully embedded, no integration required - Configuration - Operator Displays - Historian Scaleable, Practical Model Predictive Control Optimizes process within constraints

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Model Predictive Control


Learns From The Past To Predict The Future Modeled Relationship

Past

Present

Future

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Multivariable Dynamic Process Models

The Model Consists Of Step Responses That Show The Relationship Between Every Process Input And Output

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Graphical Configuration

DeltaV APC blocks are Drag-n-Drop

Graphical Configuration using Control Studio

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Automated Step Testing

Process Steps

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Process Model Displays

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Individual Step Response View

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Modifying Step Responses

Enter Step Response Constants

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Model Validation

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MPC Control Simulation

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Automatic Operator Display

Trend Window Past Future

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

Time but modern APC tools can do much more if needed.


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Built-in LP Optimization

100% position

0% position

Maximized Minimized Maximized Profit Energy Throughput

0% position

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100% position

Objective Function Configuration

Define multiple operating modes

Select from list of controller variables

Set Max/Min and Price

Easy to set up and configure the built-in LP Optimizer


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Easily Select Optimization Mode

Select from list of Optimization Modes

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Optimizer Detail Display

Current Values

Optimal Values

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DeltaV Neural Property Estimation

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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Inferential Sensor Configuration

Lab Entry Block

Select Inputs

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Select Neural Training Data


Select training set from historian Exclude bad data segments Train the network

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Training the Neural Network

Auto detection of over-training

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Sensitivity Plot, Input Selection

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Validating Neural Models

Naphtha 95% Point Prediction


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Neural Results Naphtha 95% Point


SR Naphtha EP
380 375 370 365 360 355 350 345 340 07-Aug-03 00:00:00

Crude Switch

Lab NN Prediction Filtered

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

Distributed Control Functionality

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DeltaV Control System Simulation


DeltaV Simulate Standalone

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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DeltaV Multi-Node Control Simulation


Multi-Node Environment
Operator Station Professional Plus Application Station

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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DeltaV Multi-Node Control Simulation


Process Simulator via OPC

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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DeltaV Multi-Node Control Simulation


Multi-Node Environment
Operator Station Professional Plus Application Station

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

Process Simulator With Virtual I/O Module

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Simulate Parameter for I/O Blocks


Using Simulated Process Inputs:
All DeltaV I/O Blocks have a Simulate Parameter When Simulate is Enabled, AI blocks use the SIMULATE_IN value for measured value SIMULATE_IN may be entered manually or from process simulator

Field Inputs

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Process Simulation via OPC


Process Simulation Packages are easily integrated with DeltaV Simulate via OPC.
OPC Read of OUT OPC Write to Simulate_In

OPC Client Driver

Process Simulation
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DeltaV Simulate Pro Added Features


All inputs blocks assigned to a node may be changed to Simulate Enable or Disable, Setup or Normal mode with a single request. Save and Restore allows a snapshot of control module parameters to be created or restored. Initialization of all dynamic blocks to steady state with a single request.

Select the node(s) that you want to access (ProPlus and App Stations only)

Faster or Slower than real-time execution of all modules assigned to a node.

Simulate Pro is designed to coordinate simulation and support replay.


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DeltaV Simulate Pro Entry Playback


Restore saved simulation scenario Playback operator entries with simulation to re-enact training session View operator entries in Event Journal Make changes or skip operator entries during replay

Improve Training Effectiveness with Playback of Operator Entries


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DeltaV Simulate for SIS

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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DeltaV Simulate Simulation Download Web Service


Automatically synchronize DeltaV and MiMiC Reduce Engineering Costs

Improve Simulation Accuracy

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DeltaV APC on Legacy Platforms


Universal Station (US) GUS APP Node (Or PHD) DeltaV ProPlus Station

OPC I/F
Option 1: Run APC in Work Station

TDC3000 LCN
PLC Gateway APM HPM IOPs DeltaV Controller

Option 2: Run APC in controller

Serial I/F Options


Serial I/O FTA

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Topics

DeltaV Advantage - Embedded Advanced Control

Advanced Control Product Suite Experience / Examples

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Example Predict Licensees


End User Company Petrovietnam Total MVs 60 Purchase Date Aug-03

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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Refinery APC Example

Ergon, West Virginia

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Ergon Project Scope

Atmospheric Crude and Vacuum Units


2 Model Predictive Controllers 4 x 4, 3 x 3 3 Neural Networks
SR Naphtha 95% point AGO 95% point Wax distillate 95% point

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Main MPC Control Icon

MPC Temp Targets

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Atm Controller Performance


Controller ON Crude Change

Naphtha

Hvy Kero

CV SP MV Lab Spec

Kero
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AGO

Atmospheric Column Neural Network Predictions


Column Temps & Yields Predicted NA 95% Column Temps & Yields
FC TC FC FC

FC

Naphtha Kero

Predicted AGO 95%


FC TC

FC

Hvy Kero
FC

Crude
FC

AGO
Resid to VAC Column

Fuel Gas

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Neural Results Naphtha 95% Point


SR Naphtha EP
380 375 370 365 360 355 350 345 340 07-Aug-03 00:00:00

Crude Switch

Lab NN Prediction Filtered

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%

934.36 358.58 542.47 651.77

12.28 7.32 5.99 5.39

933.78 365.74 599.50 671.75

8.56 3.23 2.29 3.74

30.3% 55.8% 61.8% 30.7%

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Crude/Vac Unit APC Project Timeline


Activity Functional Design Specification Timeframe 3 weeks < 1 day 10 days 1 week

DeltaV APC Projects Application Configuration

are 25-50% Faster and Less Step Costly Tests than traditional APC Projects
Commissioning

Scope: Two 4x4 MPC controllers, 3 Neural Nets

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Lime Kiln Project ~Canfor Northwood Pulpmill

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Kiln Process MPC Application


TT PT TT TT AT DT FT

Fuel Flow
FT

Hot End

Cold End Mud Filter

Lime Mud Feed

Main Drive ID Fan Lime Product

Lime Kiln Process


Hot-end Temperature (controlled)

Energy Flow (manipulated) ID Fan Speed (manipulated)

Cold-end Temperature (controlled)

Excess Oxygen (controlled and constraint) Hood Draft Pressure (constraint) Kiln Stack Emissions (constraint)

Lime Mud Flow (optimized and disturbance)

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Northwood Lime Kiln DeltaV MPC Control Performance - Benefits

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

% Time on DeltaV MPC Control (Average)

97.60%

Reduced Specific Energy 7-20% (0.56 - 1.98 GJ/t)

Operator Increased Reduced Confidence Lime Variability 97.6% UPTIME! Production 89.5% 16-20%

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Northwood Lime Kiln DeltaV MPC Control Performance- Benefits


DeltaV MPC Before Control Control Hot-end Temperature variations (2-sigma) Deg C Cold-end Temperature variations (2-sigma) Deg C Excess Oxygen variations (2-sigma) % Specific Energy Variations (2 sigma) GJ/t %Reduction in Variability

134.86

18.46

-86.3% -81.5% -90.5% -90.5%

43.9 1.9

8.12 0.18

2.96

0.28

Tight Control on DeltaV MPC!

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Baxter MPC Distillation Column Control


Condensers Vent Pressure and Temperature
PT TT

Reflux (Return) Flow PI


FT

TI

FI

FIC RSP

FT

+
TT

Takeoff (Distillate) Flow

TI

Mid Column Temperature

Column

CV 1 CV 2 (OPTIM) AV 1 AV 2
TT

MV 1 MV 2

RTO

MPC

TI

EU/ SEC

DV

Bottom Column Temperature

RSP XIC Boilup

Steam

Reactor

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Quantified Business Results Noel Perez Baxter de Puerto Rico

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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Learning More About DeltaV Advanced Control

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

Advanced Control Improves Operational Excellence


Improved Product Quality Increased Process Throughput Reduced Operating Costs

DeltaV Integration Improves Efficiency and Reliability


Uses common database, operator interface, configuration tools, and simulation environment Access to Field Device Health improves reliability

DeltaV Embedded APC is Cost Effective


Faster implementation Sustained Performance Fewer Consultants Needed

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