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Bill Burke
Site Control Strategist
Shell Chemical, Geismar, LA
November 12, 2020
Applying PACE
Features to Common
Control Problems
Definitions & cautionary note
The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate legal entities. In this presentation “Shell”, “Shell Group” and “Royal Dutch Shell” are sometimes used for convenience where
references are made to Royal Dutch Shell plc and its subsidiaries in general. Likewise, the words “we”, “us” and “our” are also used to refer to Royal Dutch Shell plc and its subsidiaries in general or to those who work for them. These
terms are also used where no useful purpose is served by identifying the particular entity or entities. ‘‘Subsidiaries’’, “Shell subsidiaries” and “Shell companies” as used in this presentation refer to entities over which Royal Dutch Shell
plc either directly or indirectly has control. Entities and unincorporated arrangements over which Shell has joint control are generally referred to as “joint ventures” and “joint operations”, respectively. Entities over which Shell has
significant influence but neither control nor joint control are referred to as “associates”. The term “Shell interest” is used for convenience to indicate the direct and/or indirect ownership interest held by Shell in an entity or unincorporated
joint arrangement, after exclusion of all third-party interest.
This presentation contains forward-looking statements (within the meaning of the U.S. Private Securities Litigation Reform Act of 1995) concerning the financial condition, results of operations and businesses of Royal Dutch Shell. All
statements other than statements of historical fact are, or may be deemed to be, forward-looking statements. Forward-looking statements are statements of future expectations that are based on management’s current expectations
and assumptions and involve known and unknown risks and uncertainties that could cause actual results, performance or events to differ materially from those expressed or implied in these statements. Forward-looking statements
include, among other things, statements concerning the potential exposure of Royal Dutch Shell to market risks and statements expressing management’s expectations, beliefs, estimates, forecasts, projections and assumptions.
These forward-looking statements are identified by their use of terms and phrases such as “aim”, “ambition”, ‘‘anticipate’’, ‘‘believe’’, ‘‘could’’, ‘‘estimate’’, ‘‘expect’’, ‘‘goals’’, ‘‘intend’’, ‘‘may’’, ‘‘objectives’’, ‘‘outlook’’, ‘‘plan’’, ‘‘probably’’,
‘‘project’’, ‘‘risks’’, “schedule”, ‘‘seek’’, ‘‘should’’, ‘‘target’’, ‘‘will’’ and similar terms and phrases. There are a number of factors that could affect the future operations of Royal Dutch Shell and could cause those results to differ materially
from those expressed in the forward-looking statements included in this presentation, including (without limitation): (a) price fluctuations in crude oil and natural gas; (b) changes in demand for Shell’s products; (c) currency fluctuations;
(d) drilling and production results; (e) reserves estimates; (f) loss of market share and industry competition; (g) environmental and physical risks; (h) risks associated with the identification of suitable potential acquisition properties and
targets, and successful negotiation and completion of such transactions; (i) the risk of doing business in developing countries and countries subject to international sanctions; (j) legislative, fiscal and regulatory developments including
regulatory measures addressing climate change; (k) economic and financial market conditions in various countries and regions; (l) political risks, including the risks of expropriation and renegotiation of the terms of contracts with
governmental entities, delays or advancements in the approval of projects and delays in the reimbursement for shared costs; (m) risks associated with the impact of pandemics, such as the COVID-19 (coronavirus) outbreak; and (n)
changes in trading conditions. No assurance is provided that future dividend payments will match or exceed previous dividend payments. All forward-looking statements contained in this presentation are expressly qualified in their
entirety by the cautionary statements contained or referred to in this section. Readers should not place undue reliance on forward-looking statements. Additional risk factors that may affect future results are contained in Royal Dutch
Shell’s Form 20-F for the year ended December 31, 2019 (available at www.shell.com/investor and www.sec.gov). These risk factors also expressly qualify all forward-looking statements contained in this presentation and should be
considered by the reader. Each forward-looking statement speaks only as of the date of this presentation, [insert date]. Neither Royal Dutch Shell plc nor any of its subsidiaries undertake any obligation to publicly update or revise any
forward-looking statement as a result of new information, future events or other information. In light of these risks, results could differ materially from those stated, implied or inferred from the forward-looking statements contained in this
presentation.
We may have used certain terms, such as resources, in this presentation that the United States Securities and Exchange Commission (SEC) strictly prohibits us from including in our filings with the SEC. Investors are urged to
consider closely the disclosure in our Form 20-F, File No 1-32575, available on the SEC website www.sec.gov.
Problem Setup
Control Objective
• Maximize feed flow (FS546)
• Sending feed to FS546 is more valuable
Design Considerations
• Potential to saturate FS546
• Concern about robbing too much flow leading to loss
of level control (LS501)
Design Considerations
• Based on a piece of a real controller
• Other constraints exist not relevant to this discussion
• LS501/FS546/FS527 are PID controllers (“S” is a unit
designation)
Other
ConstraintsMaximize
Handling MV Saturation
Previous Solutions (SMOC & Others)
• Make MV.OP a CV with high priority
• Hard MV limits
PACE Solution
• Use BLC model construct (closed-loop
formulation shown)
• Automatically detects saturation and updates
the model to compensate
• No extra CVs or MV limits needed
• FC is simple to model based on OP/PV trend
and assumed dynamics
• Can transform OP if necessary
SP🡪PV is always
unity gain
MV
SP🡪OP Model
Predicts Saturation
OP vs. PV slope
yields gain for
SP🡪OP Model
Maintaining Level Control
Other
Constraints
Maintain Min
% Tot Flow
Risk of saturating the upstream level
controller if FS546 pulls too much feed
Intuitive Solution
• Calculated CV is non-linear
Potential Issues
• Linearize around operating point
• Can lead to model mismatch as rates change
• Redesign CV limit to be linear
Previous Solution
PACE NL Block Solution
Wild Flow
MV
DV: Wild Flow
MV
NL CV
PACE Solution
= Native Non-Linear Model
• Simple implementation via NL block interface
• Negligible additional design effort
• Enter the model, and it “just works”
• Calculation performed by the model
• Inputs go through POV Calibration
• Full dynamics of model are available (unlike
DCS calculation)
• Reduce DCS load & complexity
Used “None” type variable in
PACE, so POV calibration
unneeded
PACE NL Block Performance
MV
CV
Wild Flow
Simulated with noise on the
wild flow (DV) and stepped the
CV low limit
• MV SS value correct despite large move
in MV (nonlinear model in action)
• Eliminated “self-inflicted” model mismatch,
because the CV is a calculated metric, not
a process measurement
Green = Steady-State Value
Blue = Current Value
Incorporating Level Controller BLC Model
Opportunity to introduce prediction
of the wild flow, since the wild flow is
set by a base-layer level controller
• Level SP & PV become DVs
• “Wild flow” predicted based on SP changes and
PV disturbances
• BLC construct understands the closed-loop
behavior of the level controller tuning
• BLCs can be applied wherever appropriate, not
just on MVs
• Set Input Disturbance Fraction (IDF) = 0.1
This relationship can be modelled in
PACE using a second BLC representation
LS501.SP
LS501.PV
LS501.OP
New BLC Models Wild Flow Pred.
Advantages of BLCs & Intermediate Variables (IVs)
Retuning LC requires only a partial model
update (not all the way to CVs)
• Closed-loop SP move
• Update of PID tuning parameters entered directly
into the model
Depending on BLC representation, BLC model
update involves either:
LS501.SP
LS501.PV
LS501.OP
New BLC Models Wild Flow Pred.
Either can be done online if desired
IVs also provide checkpoints in the model where
predictions are validated against plant
measurements
IVs break the modelling problem down into
bite-size chunks
Level Disturbance Performance
without LC BLC Models Green = Steady-State Value
Blue = Current Value
MV CV
DV
Controller responds exclusively
in feedback. SS value (green)
follows wild flow measurement
Level Response
Level Disturbance Performance
with LC BLC Models Green = Steady-State Value
Blue = Current Value
MV
CV
IV
Level Response
Model quickly identifies accurate
SS values for MV and IV
Bonus: Wild flow prediction allows for better
rejection of noise via POV Calibration
Level Disturbance Performance
with LC BLC Models Blue = Without LC BLC
Red = With LC BLC
30% Reduction in CV violation,
even with a very fast feedback
component
Summary – Features Employed
BLC model on MV to handle saturation
• Use of OP vs. PV for modelling flow controller BLC
Nonlinear Block to natively implement
calculated ratio
Maximize
Other
Constraints
None-type variable to move calculation
entirely into PACE model (out of DCS)
Adding LS501 BLC construct to predict
wild flow (FS527)
• Demonstrated 30% reduction in CV violation with
added predictive capabilities
Some general benefits of IVs and BLCs
The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Questions?

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Using A Unique, Next Generation APC Solution To Address Common Problems In The Field

  • 1. Bill Burke Site Control Strategist Shell Chemical, Geismar, LA November 12, 2020 Applying PACE Features to Common Control Problems
  • 2. Definitions & cautionary note The companies in which Royal Dutch Shell plc directly and indirectly owns investments are separate legal entities. In this presentation “Shell”, “Shell Group” and “Royal Dutch Shell” are sometimes used for convenience where references are made to Royal Dutch Shell plc and its subsidiaries in general. Likewise, the words “we”, “us” and “our” are also used to refer to Royal Dutch Shell plc and its subsidiaries in general or to those who work for them. These terms are also used where no useful purpose is served by identifying the particular entity or entities. ‘‘Subsidiaries’’, “Shell subsidiaries” and “Shell companies” as used in this presentation refer to entities over which Royal Dutch Shell plc either directly or indirectly has control. Entities and unincorporated arrangements over which Shell has joint control are generally referred to as “joint ventures” and “joint operations”, respectively. Entities over which Shell has significant influence but neither control nor joint control are referred to as “associates”. The term “Shell interest” is used for convenience to indicate the direct and/or indirect ownership interest held by Shell in an entity or unincorporated joint arrangement, after exclusion of all third-party interest. This presentation contains forward-looking statements (within the meaning of the U.S. Private Securities Litigation Reform Act of 1995) concerning the financial condition, results of operations and businesses of Royal Dutch Shell. All statements other than statements of historical fact are, or may be deemed to be, forward-looking statements. Forward-looking statements are statements of future expectations that are based on management’s current expectations and assumptions and involve known and unknown risks and uncertainties that could cause actual results, performance or events to differ materially from those expressed or implied in these statements. Forward-looking statements include, among other things, statements concerning the potential exposure of Royal Dutch Shell to market risks and statements expressing management’s expectations, beliefs, estimates, forecasts, projections and assumptions. These forward-looking statements are identified by their use of terms and phrases such as “aim”, “ambition”, ‘‘anticipate’’, ‘‘believe’’, ‘‘could’’, ‘‘estimate’’, ‘‘expect’’, ‘‘goals’’, ‘‘intend’’, ‘‘may’’, ‘‘objectives’’, ‘‘outlook’’, ‘‘plan’’, ‘‘probably’’, ‘‘project’’, ‘‘risks’’, “schedule”, ‘‘seek’’, ‘‘should’’, ‘‘target’’, ‘‘will’’ and similar terms and phrases. There are a number of factors that could affect the future operations of Royal Dutch Shell and could cause those results to differ materially from those expressed in the forward-looking statements included in this presentation, including (without limitation): (a) price fluctuations in crude oil and natural gas; (b) changes in demand for Shell’s products; (c) currency fluctuations; (d) drilling and production results; (e) reserves estimates; (f) loss of market share and industry competition; (g) environmental and physical risks; (h) risks associated with the identification of suitable potential acquisition properties and targets, and successful negotiation and completion of such transactions; (i) the risk of doing business in developing countries and countries subject to international sanctions; (j) legislative, fiscal and regulatory developments including regulatory measures addressing climate change; (k) economic and financial market conditions in various countries and regions; (l) political risks, including the risks of expropriation and renegotiation of the terms of contracts with governmental entities, delays or advancements in the approval of projects and delays in the reimbursement for shared costs; (m) risks associated with the impact of pandemics, such as the COVID-19 (coronavirus) outbreak; and (n) changes in trading conditions. No assurance is provided that future dividend payments will match or exceed previous dividend payments. All forward-looking statements contained in this presentation are expressly qualified in their entirety by the cautionary statements contained or referred to in this section. Readers should not place undue reliance on forward-looking statements. Additional risk factors that may affect future results are contained in Royal Dutch Shell’s Form 20-F for the year ended December 31, 2019 (available at www.shell.com/investor and www.sec.gov). These risk factors also expressly qualify all forward-looking statements contained in this presentation and should be considered by the reader. Each forward-looking statement speaks only as of the date of this presentation, [insert date]. Neither Royal Dutch Shell plc nor any of its subsidiaries undertake any obligation to publicly update or revise any forward-looking statement as a result of new information, future events or other information. In light of these risks, results could differ materially from those stated, implied or inferred from the forward-looking statements contained in this presentation. We may have used certain terms, such as resources, in this presentation that the United States Securities and Exchange Commission (SEC) strictly prohibits us from including in our filings with the SEC. Investors are urged to consider closely the disclosure in our Form 20-F, File No 1-32575, available on the SEC website www.sec.gov.
  • 3. Problem Setup Control Objective • Maximize feed flow (FS546) • Sending feed to FS546 is more valuable Design Considerations • Potential to saturate FS546 • Concern about robbing too much flow leading to loss of level control (LS501) Design Considerations • Based on a piece of a real controller • Other constraints exist not relevant to this discussion • LS501/FS546/FS527 are PID controllers (“S” is a unit designation) Other ConstraintsMaximize
  • 4. Handling MV Saturation Previous Solutions (SMOC & Others) • Make MV.OP a CV with high priority • Hard MV limits PACE Solution • Use BLC model construct (closed-loop formulation shown) • Automatically detects saturation and updates the model to compensate • No extra CVs or MV limits needed • FC is simple to model based on OP/PV trend and assumed dynamics • Can transform OP if necessary SP🡪PV is always unity gain MV SP🡪OP Model Predicts Saturation OP vs. PV slope yields gain for SP🡪OP Model
  • 5. Maintaining Level Control Other Constraints Maintain Min % Tot Flow Risk of saturating the upstream level controller if FS546 pulls too much feed Intuitive Solution • Calculated CV is non-linear Potential Issues • Linearize around operating point • Can lead to model mismatch as rates change • Redesign CV limit to be linear Previous Solution
  • 6. PACE NL Block Solution Wild Flow MV DV: Wild Flow MV NL CV PACE Solution = Native Non-Linear Model • Simple implementation via NL block interface • Negligible additional design effort • Enter the model, and it “just works” • Calculation performed by the model • Inputs go through POV Calibration • Full dynamics of model are available (unlike DCS calculation) • Reduce DCS load & complexity Used “None” type variable in PACE, so POV calibration unneeded
  • 7. PACE NL Block Performance MV CV Wild Flow Simulated with noise on the wild flow (DV) and stepped the CV low limit • MV SS value correct despite large move in MV (nonlinear model in action) • Eliminated “self-inflicted” model mismatch, because the CV is a calculated metric, not a process measurement Green = Steady-State Value Blue = Current Value
  • 8. Incorporating Level Controller BLC Model Opportunity to introduce prediction of the wild flow, since the wild flow is set by a base-layer level controller • Level SP & PV become DVs • “Wild flow” predicted based on SP changes and PV disturbances • BLC construct understands the closed-loop behavior of the level controller tuning • BLCs can be applied wherever appropriate, not just on MVs • Set Input Disturbance Fraction (IDF) = 0.1 This relationship can be modelled in PACE using a second BLC representation LS501.SP LS501.PV LS501.OP New BLC Models Wild Flow Pred.
  • 9. Advantages of BLCs & Intermediate Variables (IVs) Retuning LC requires only a partial model update (not all the way to CVs) • Closed-loop SP move • Update of PID tuning parameters entered directly into the model Depending on BLC representation, BLC model update involves either: LS501.SP LS501.PV LS501.OP New BLC Models Wild Flow Pred. Either can be done online if desired IVs also provide checkpoints in the model where predictions are validated against plant measurements IVs break the modelling problem down into bite-size chunks
  • 10. Level Disturbance Performance without LC BLC Models Green = Steady-State Value Blue = Current Value MV CV DV Controller responds exclusively in feedback. SS value (green) follows wild flow measurement Level Response
  • 11. Level Disturbance Performance with LC BLC Models Green = Steady-State Value Blue = Current Value MV CV IV Level Response Model quickly identifies accurate SS values for MV and IV Bonus: Wild flow prediction allows for better rejection of noise via POV Calibration
  • 12. Level Disturbance Performance with LC BLC Models Blue = Without LC BLC Red = With LC BLC 30% Reduction in CV violation, even with a very fast feedback component
  • 13. Summary – Features Employed BLC model on MV to handle saturation • Use of OP vs. PV for modelling flow controller BLC Nonlinear Block to natively implement calculated ratio Maximize Other Constraints None-type variable to move calculation entirely into PACE model (out of DCS) Adding LS501 BLC construct to predict wild flow (FS527) • Demonstrated 30% reduction in CV violation with added predictive capabilities Some general benefits of IVs and BLCs
  • 14. The names of corporations, organizations, products and logos herein are either registered trademarks or trademarks of Yokogawa Electric Corporation and their respective holders. Questions?