On-line Process Control Lab Access and Use Deminar

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Recorded demo/seminar of Greg McMillan presenting On-line Process Control Lab with Access and Use Instructions on May 27, 2010.

Screencast of presentation available at: http://www.screencast.com/t/Y2Q4NjM0Y

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On-line Process Control Lab Access and Use Deminar

  1. 1. Interactive Opportunity Assessment Demo and Seminar (Deminar) Series for Web Labs – Online Process Control Lab Access and Use May 27, 2010 Sponsored by Emerson, Experitec, and Mynah Created by Greg McMillan and Jack Ahlers Website - Charlie Schliesser (csdesignco.com)
  2. 2. Welcome <ul><li>Gregory K. McMillan </li></ul><ul><ul><li>Greg is a retired Senior Fellow from Solutia/Monsanto and an ISA Fellow. Presently, Greg contracts as a consultant in DeltaV R&D via CDI Process & Industrial. Greg received the ISA “Kermit Fischer Environmental” Award for pH control in 1991, the Control Magazine “Engineer of the Year” Award for the Process Industry in 1994, was inducted into the Control “Process Automation Hall of Fame” in 2001, and was honored by InTech Magazine in 2003 as one of the most influential innovators in automation. Greg is the author of numerous books on process control, his most recent being Essentials of Modern Measurements and Final Elements for the Process Industry. Greg has been the monthly “Control Talk” columnist for Control magazine since 2002. Greg’s expertise is available on the web site: http://www.modelingandcontrol.com/ </li></ul></ul>
  3. 3. Top Ten Reasons Why an Automation Engineer Makes a Great Spouse or at Least a Wedding Gift <ul><li>(10) Reliable from day one </li></ul><ul><li>(9) Always on the job </li></ul><ul><li>(8) Low maintenance - minimal grooming, clothing, and entertainment costs </li></ul><ul><li>(7) Many programmable features </li></ul><ul><li>(6) Stable </li></ul><ul><li>(5) Short settling time </li></ul><ul><li>(4) No frills or extraneous features </li></ul><ul><li>(3) Relies on feedback </li></ul><ul><li>(2) Good response to commands and amenable to real time optimization </li></ul><ul><li>And the Number 1 Reason : </li></ul>
  4. 4. Top Ten Reasons Why an Automation Engineer Makes a Great Spouse or at Least a Wedding Gift <ul><li>(1) Readily tuned </li></ul>
  5. 5. Today we are on Location of Virtual Plants
  6. 6. Free Access to Virtual Plants
  7. 7. My Planned Uses of Virtual Plants <ul><li>ISA 2010 Automation Week Presentation Tuning and Control Loop Performance </li></ul><ul><li>Emerson Exchange 2010 Short Course: Interactive Exploration of Process Control Improvement </li></ul><ul><li>Chapter on Industrial PID Applications in new book PID Beyond 2000: Lessons Learned and New Approaches, Springer, 2010 </li></ul><ul><li>KU Continuing Education Course - Process Control Improvement </li></ul><ul><li>Tuning and Control Loop Performance, 4 th Edition Momentum Press, 2011 </li></ul><ul><li>Interactive Opportunity Assessment – Online Exploration and Quantification of Process Control Improvements , ISA, 2011 </li></ul><ul><li>Advanced pH Measurement and Control , 4 th Edition, ISA, 2012 </li></ul><ul><li>What are Your Uses? </li></ul><ul><ul><li>To share your opportunities, ideas, and scores, send an Email to me at [email_address] </li></ul></ul>
  8. 8. <ul><li>Not an Emulation but a Virtual “State of the Art” DCS </li></ul><ul><li>Operator Screens to Create a Control Room Experience </li></ul><ul><li>All the Power of Basic and Advanced Process Control </li></ul><ul><li>No DCS Configuration or Parameter Access Needed </li></ul><ul><li>Structural Changes “On the Fly” (no download required) </li></ul><ul><li>Enough Interesting Scenarios for a Year of Exploration and Quantification of Process Control Improvements </li></ul><ul><li>Enough Variety of Process, Measurement, and Valve Dynamics to study 99% of the process industry’s control applications </li></ul><ul><ul><li>For very slow processes, proportionally scale down the process time constants and dead times to keep the ratio constant of Process Lag 2 to the sum of small process and measurement time constants and delays </li></ul></ul>Features of Online Process Control Labs “ Hands-On Learning” Provides the Best Educational Experience”
  9. 9. click button for each desired lab (concurrent labs are possible) click on arrow to return to this main lab menu DeltaV Operate Main Screen Click to restore PID setpoint, PID mode, PID limits, PID tuning, PID options, process dynamics, measurement dynamics, disturbance dynamics, and control valve dynamics
  10. 10. performance metrics are generated in Run mode click to select mode click to get PID faceplate click to get trend chart click to enter time for Test and Run modes (load upsets occur in Test and Run modes) click any block in block diagram to get access to data entry screen for PID options and run conditions (process, measurement, upset, and valve details)
  11. 11. Secondary (inner loop) PID’s setpoint is primary (outer loop) PID’s output AC1- 1 is primary PID and AC1- 2 is secondary PID
  12. 12. Feedforward signal added to PID output use a measurement of the disturbance AC1- 1 is primary PID and AC1- 2 is secondary PID
  13. 13. University of Texas Unit Operations Lab Reactor Click for Dynamics
  14. 14. See article “Virtual Plant Provides Real Insights” in Chemical Processing, http://www.chemicalprocessing.com/articles/2008/255.html Click for Dynamics
  15. 15. click on open folder to select your lab trend chart if your lab trend chart is not already open
  16. 16. configured upsets occur in Run and Test modes performance metrics are computed in Run mode click on value to get data entry screen with pull down menu for mode
  17. 17. click on value to get data entry screen to enter new value (pull down menu for PID structure has 8 choices)
  18. 18. click on value to get data entry screen to enter new value (process dynamics can only be changed in Explore mode) primary process and secondary process Lag2 has values for PV increasing and PV decreasing (the minimum Lag2 for process simulator stability is 1 sec) for an integrating process type, the integrating process gain is the process gain multiplied by factor divided by Lag2 (units of 1/sec) create nonlinear gain by clicking on factor values and entering multiplier of primary process gain Lag2 must be largest time constant in primary process Lag2 must be largest time constant in secondary process
  19. 19. click on value to get data entry screen to enter new value refresh time is time between communications to PID (periodic reporting) sensitivity is minimum change in measurement for communication (exception reporting) Feedforward Gain and “Dynamic Compensation” (Lead-Lag) are accessible in Feedforward Loop Lab 03
  20. 20. click on value to get data entry screen to enter new value configured upsets do not occur in Explore mode
  21. 21. click on value to get data entry screen to enter new value create nonlinear valve by clicking on %Flow values and entering % of max flow “ Valve Step %” is step size of stair-case response (valve’s resolution limit) “ Valve L/L Lag” is Lag time of Lead/Lag & “ Valve L/L Lead” is Lead time of Lead/Lag applied to valve signal to kick actuator thru deadband (backlash) and stick-slip (stiction) permissible value range is 0 – 100 negative number
  22. 22. Click on magnifying glass to get detail view of limits and tuning Click on Duncan to get DeltaV Insight for “On-Demand” and “Adaptive” tuning
  23. 23. “ On-Demand Tuning” automatically identifies dynamics from relay oscillation introduced click on PID tag and then Tune
  24. 24. “ Adaptive Tuning” automatically identifies dynamics from setpoint or manual output change or injected pulse (For More Info See Emerson Exchange 2009 Presentation on DeltaV Insight for Loop Monitoring and Tuning) click on PID tag and then Tune
  25. 25. Online Process Control Lab Access <ul><li>Objective – Show access to web site and virtual plant </li></ul><ul><li>Activities: </li></ul><ul><ul><li>Go to http://www.processcontrollab.com/ </li></ul></ul><ul><ul><li>Show How to Connect screen </li></ul></ul><ul><ul><li>Show Request Access to a Virtual Plant </li></ul></ul><ul><ul><li>Make a Remote Desktop connection to the assigned Virtual Plant </li></ul></ul><ul><ul><li>Click on DeltaV Operate </li></ul></ul><ul><ul><li>Put all of the Process Control Labs in the Run mode </li></ul></ul><ul><ul><li>Click on Trend Chart icon and open up charts for all of the Labs </li></ul></ul><ul><ul><li>On Main DeltaV Operate screen discuss the Restore button </li></ul></ul><ul><ul><li>In the Process Control Lab website show Help screen </li></ul></ul><ul><ul><li>In the Process Control Lab website show Instructions screen </li></ul></ul><ul><ul><li>Go back to Remote Desktop Connection for Virtual Plant </li></ul></ul><ul><ul><li>Minimize screens and in FlexLock select Logoff Windows </li></ul></ul>
  26. 26. Help Us Improve These Deminars! WouldYouRecommend.Us/105679s21/
  27. 27. Join Us June 9, Wednesday 10:00 am CDT <ul><li>PID Tuning for Self-Regulating Processes (How to Compensate for Nonlinearities in Flow, Liquid Pressure, and Heat Exchanger Loops) </li></ul><ul><li>Look for a recording of Today’s Deminar later this week at: </li></ul><ul><li>www.ModelingAndControl.com </li></ul><ul><li>www.EmersonProcessXperts.com </li></ul>
  28. 28. QUESTIONS?

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