Luis Atencio, profile picture
Uploaded byLuis Atencio
PPT, PDF11,769 views

Delta v advanced control overview_en

This document provides an overview of DeltaV Embedded Advanced Control. It discusses how DeltaV makes advanced control easy to implement and sustain through three main products: 1. DeltaV InSight provides performance monitoring, loop diagnostics, adaptive tuning and adaptive control using embedded learning algorithms. 2. DeltaV Predict uses model predictive control to improve quality, increase throughput and reduce costs. 3. DeltaV Fuzzy Logic control blocks can replace PID blocks and improve response to disturbances through intuitive graphical configuration similar to PID blocks. The document emphasizes how DeltaV's embedded advanced control solutions are easier for control engineers to implement and sustain long-term compared to traditional advanced control systems.

Embed presentation

Downloaded 1,152 times
1 / 108
2 / 108
3 / 108
4 / 108
5 / 108
6 / 108
7 / 108
8 / 108
9 / 108
10 / 108
11 / 108
12 / 108
13 / 108
14 / 108
15 / 108
16 / 108
17 / 108
18 / 108
19 / 108
20 / 108
21 / 108
22 / 108
23 / 108
24 / 108
25 / 108
26 / 108
27 / 108
28 / 108
29 / 108
30 / 108
31 / 108
32 / 108
33 / 108
34 / 108
35 / 108
36 / 108
37 / 108
38 / 108
39 / 108
40 / 108
41 / 108
42 / 108
43 / 108
44 / 108
45 / 108
46 / 108
47 / 108
48 / 108
49 / 108
50 / 108
Most read
51 / 108
52 / 108
53 / 108
54 / 108
55 / 108
56 / 108
57 / 108
58 / 108
59 / 108
60 / 108
61 / 108
62 / 108
63 / 108
64 / 108
Most read
65 / 108
Most read
66 / 108
67 / 108
68 / 108
69 / 108
70 / 108
71 / 108
72 / 108
73 / 108
74 / 108
75 / 108
76 / 108
77 / 108
78 / 108
79 / 108
80 / 108
81 / 108
82 / 108
83 / 108
84 / 108
85 / 108
86 / 108
87 / 108
88 / 108
89 / 108
90 / 108
91 / 108
92 / 108
93 / 108
94 / 108
95 / 108
96 / 108
97 / 108
98 / 108
99 / 108
100 / 108
101 / 108
102 / 108
103 / 108
104 / 108
105 / 108
106 / 108
107 / 108
108 / 108
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 Emerson Confidential
Advanced Control for Operational Excellence  Improve Quality PlantWeb Benefits – Reduce Variability – Predict Lab Measurements  Increase Throughput – Continuously Push Limits – Protect Multiple Constraints  Reduce Costs – Maximize Efficiency and Reduce APC Energy Costs Impact – Accurate Quality Control to Reduce Inventory and Product Rework – Stabilize Control to Reduce Equipment Wear and Incident Risk Emerson Confidential
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! Emerson Confidential
Embedded APC Tools – What’s new? • NO extra Traditional Advanced databases Control • NO database synchronization Embedded APC: issues • Can run in DCS controllers • NO watchdog timers • Redundant and fast (1/sec) • NO fail/shed logic • Integrated operator user design interface • Configuration through • NO custom DCS standard Control Studio programming • Automated step testing and • NO interface Model ID programming • Off-line simulation and • NO operator training interface development Emerson Confidential
New Approach to APC Configuration DeltaV APC blocks are “Drag-n-Drop” Graphical Configuration using Control Studio Emerson Confidential
New Approach to APC Configuration System-wide tag browsing … all in the DCS database Emerson Confidential
Typical APC Project Timeline Months 1 2 3 4 5 6 7 8 9 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 Performed on-site Commissioning Embedded APC Technology Emerson Confidential
Traditional Advanced Control Over Time Start Project Start Commissioning End Commissioning Traditional APC 100% % On-line Time More than 50% of APC applications are turned off within the first 2 years after installation. time Yr 1 Yr 2 Emerson Confidential
Why Don’t 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 don’t understand what the APC is doing  Too expensive to bring in APC consultants How to Sustain Control Performance? Emerson Confidential
Must Build Solid Foundations You Can’t Have This… Advanced Control Control Foundation Without This… Emerson Confidential
Foundation Built on Health of Field Devices Fieldbus Status Is Consistently Used by DeltaV Advanced Control Emerson Confidential
DeltaV Embedded Advanced Control A Systematic Approach for Sustained Performance Analyze and Diagnose Identify Problems Re-Tune And Prioritize Or Fix Cause Monitor Advanced Performance Control Emerson Confidential
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” Advanced Control Process Model Calculations Predict / Neural / Fuzzy Emerson Confidential
DeltaV Embedded APC for Sustained Performance DeltaV APC Traditional APC 100% % On-line Time Faster to Commission + Sustained Performance = Greater $$’s Saved time Emerson Confidential
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 Emerson Confidential
Topics  DeltaV Advantage - Embedded Advanced Control  Advanced Control Product Suite  Experience / Examples Emerson Confidential
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! Emerson Confidential
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! Emerson Confidential
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 Emerson Confidential
Predictive Intelligence = Intelligent Control Adaptive Learning Algorithms for Intelligent Control Learn Evaluate • Observe • Validate • Identify • Compare • Remember • Diagnose Improve • Advise • Tune • Adapt Emerson Confidential
DeltaV InSight for Intelligent Control With InSight’s 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. Emerson Confidential
DeltaV InSight Bringing it all together:  Performance Monitoring • On-demandTuning  Loop Diagnostics • Adaptive Tuning  Embedded Learning • Simulation  Adaptive Tuning  Adaptive Control • Adaptive Control • Performance Monitoring • Operating Regions • Loop Diagnostics • Non-linear Control • Reporting • Model Identification • Control Diagnostics • Performance Indices Emerson Confidential
DeltaV InSight – Integrated User Interface Old DeltaV Inspect New DeltaV InSight Old DeltaV Tune New interface provides seamless transition between loop diagnostics and tuning. Emerson Confidential
Easily Launched in Context From the Control Studio DeltaV Explorer Operator Interface From the DeltaV Explorer Context sensitive from Control Studio Emerson Confidential
DeltaV Insight – Architecture Data Analysis and Reporting UI from any Runs in Server workstation Embedded Learning Runs in the Controller • Fast Data Capture • Small Communications Load • Runs in Background Emerson Confidential
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. Emerson Confidential
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 ON- LINE using DeltaV InSight  Learning is available on DeltaV and Fieldbus PID blocks Emerson Confidential
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 Emerson Confidential
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. Emerson Confidential
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 Emerson Confidential
DeltaV InSight - Asset Monitoring  Device Alerts are reported through InSight Asset Displays  Overview provides graphical display for Asset Alerts of System, Area, and Modules Right-Click  Asset Display identifies Asset Alerts including: – Asset Failed – Maintenance Soon – Advisory – Communications Failed  Easily Launch AMS Device Manager in Context to access detailed diagnostics Emerson Confidential
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 Emerson Confidential
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 Emerson Confidential
On-Demand Tuning - Options for the Expert Power for the Advanced User ! Emerson Confidential
DeltaV InSight - Adaptive Tuning Provides Tuning Based on Normal Operator Changes  InSight automatically calculates dynamic Before vs. After models from operator changes  Model Quality and Learning Status  Tuning criteria and desired speed of response  Tuning Recommendation  No Testing Required Emerson Confidential
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 Emerson Confidential
DeltaV InSight - Control Simulation Test your tuning with Dynamic Simulation  Closed loop simulation of setpoint and View Dynamic disturbance Response changes for recommended tuning Select New Tuning Simulation for both  Speed vs RobustnessAdaptive and On- demand Tuning Emerson Confidential
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. Emerson Confidential
Non-linear Process Models Emerson Confidential
DeltaV InSight – Adaptive Control InSight identifies tuning in up to 5 regions of operation Emerson Confidential
DeltaV InSight – Adaptive Control Emerson Confidential
DeltaV InSight – Adaptive Control Adaptive control adjusts tuning to improve control performance Emerson Confidential
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 KPI’s in customized reports via Excel and DeltaV Reporter Emerson Confidential
Area Control Performance Report Emerson Confidential
Area Control Performance Report Emerson Confidential
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 Emerson Confidential
Easy As PID… DeltaV Explorer Replace PID with Fuzzy Logic Control Emerson Confidential
DeltaV Fuzzy Function Block Pre-defined Fuzzy Logic Control Emerson Confidential
Use DeltaV InSight to Tune Fuzzy Logic Transfer recommended constants to fuzzy control Emerson Confidential
Simulated Response Emerson Confidential
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. Emerson Confidential
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 After (using DeltaV PID) (using DeltaV Fuzzy) Source: Emerson Exchange, October 2004 Shell Deer Park Paper Emerson Confidential
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 Emerson Confidential
Model Predictive Control Learns From The Past To Predict The Future Modeled Relationship Past Present Future Emerson Confidential
Multivariable Dynamic Process Models The Model Consists Of Step Responses That Show The Relationship Between Every Process Input And Output Emerson Confidential
Graphical Configuration DeltaV APC blocks are “Drag-n-Drop” Graphical Configuration using Control Studio Emerson Confidential
Automated Step Testing Process Steps Emerson Confidential
Process Model Displays Emerson Confidential
Individual Step Response View Emerson Confidential
Modifying Step Responses Enter Step Response Constants Emerson Confidential
Model Validation Emerson Confidential
MPC Control Simulation Emerson Confidential
Automatic Operator Display Trend Window Past Future Control Manipulated Constraint Disturbance Variables Variables Variables Variables Emerson Confidential
APC Optimization Often as simple as maximizing one variable to its most limiting constraints… Production Throughput APC Increase $$ Throughput at limit Operator Setpoint Time … but modern APC tools can do much more if needed. Emerson Confidential
Built-in LP Optimization 100% position 100% position Maximized Minimized Maximized 0% position Profit Energy Throughput 0% position Emerson Confidential
Objective Function Configuration Define multiple operating modes Select from list of Set Max/Min controller variables and Price Easy to set up and configure the built-in LP Optimizer Emerson Confidential
Easily Select Optimization Mode Select from list of Optimization Modes Emerson Confidential
Optimizer Detail Display Current Values Optimal Values Emerson Confidential
DeltaV Neural – Property Estimation ● Create virtual sensors for on- line measurements normally only available through lab analysis ● Easy to understand and use, cost effective ● General nonlinear modeling tool Emerson Confidential
Inferential Sensor Configuration Lab Entry Block Select Inputs Emerson Confidential
Select Neural Training Data ● Select training set from historian ● Exclude bad data segments ● Train the network Emerson Confidential
Training the Neural Network Auto detection of over-training Emerson Confidential
Sensitivity Plot, Input Selection Emerson Confidential
Validating Neural Models Naphtha 95% Point Prediction Emerson Confidential
Neural Results – Naphtha 95% Point SR Naphtha EP 380 375 Crude Switch 370 365 Lab 360 NN Prediction 355 Filtered 350 345 340 07-Aug-03 09-Aug-03 11-Aug-03 13-Aug-03 00:00:00 00:00:00 00:00:00 00:00:00 Emerson Confidential
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 Emerson Confidential
DeltaV Architecture Control Design and Configuration are Independent of Hardware Distributed Control Functionality Emerson Confidential
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 Emerson Confidential
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 Emerson Confidential
DeltaV “Multi-Node” Control Simulation Process Simulator via OPC ● Supports mimic Process Multi-Node Environment Simulator running in DeltaV Workstation Application Station with Operator Station Professional Plus mimic Simulator App Station ● Supports Third Party Process Simulators via standard OPC Emerson Confidential
DeltaV “Multi-Node” Control Simulation Multi-Node Environment ● Supports mimic Process Simulator running in DeltaV Operator Station Professional Plus Application Station 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 Emerson Confidential
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 Emerson Confidential
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 Emerson Confidential
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. Faster or Slower than real-time Select the node(s) that you execution of all modules assigned to want to access (ProPlus and a node. App Stations only) Simulate Pro is designed to coordinate simulation and support replay. Emerson Confidential
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 Emerson Confidential
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 Emerson Confidential
DeltaV Simulate - Simulation Download Web Service ● Automatically synchronize DeltaV and MiMiC ● Reduce Engineering Costs ● Improve Simulation Accuracy Emerson Confidential
DeltaV APC on Legacy Platforms Universal GUS DeltaV Station (US) APP Node (Or PHD) ProPlus Station OPC I/F Option 1: Run APC in Work Station TDC3000 LCN PLC Gateway DeltaV Controller APM HPM Option 2: Run APC IOPs in controller Serial I/F Options Serial I/O FTA Emerson Confidential
Topics  DeltaV Advantage - Embedded Advanced Control  Advanced Control Product Suite  Experience / Examples Emerson Confidential
Example Predict Licensees Total End User Company MVs Purchase Date Petrovietnam 60 Aug-03 Lucite International 40 Jan-02 Solutia, Inc. 60 Jun-98 Canadian Forest Products Ltd. 38 Apr-01 Baxter 32 Apr-01 Petrotel-Lukoil 30 Jan-04 Petrogal 30 Feb-05 BASF Corporation 25 May-04 Norske-Skog Canada 25 Jun-03 Flint Hills Resources, LP 20 Jun-04 Huntsman ICI 20 Oct-00 Husky Energy 20 Nov-04 Monsanto Company 20 Jul-03 Emerson Confidential
Refinery APC Example Ergon, West Virginia Emerson Confidential
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 Emerson Confidential
Main MPC Control Icon MPC Temp Targets Emerson Confidential
Atm Controller Performance Controller Crude ON Change CV SP MV Lab Spec Naphtha Hvy Kero Kero AGO Emerson Confidential
Atmospheric Column Neural Network Predictions Column Temps & Yields TC Predicted NA FC FC 95% Column Temps FC Naphtha & Yields Kero FC FC Predicted AGO 95% Hvy Kero FC FC TC Crude AGO FC Resid to VAC Fuel Gas Column Emerson Confidential
Neural Results – Naphtha 95% Point SR Naphtha EP 380 375 Crude Switch 370 365 Lab 360 NN Prediction 355 Filtered 350 345 340 07-Aug-03 09-Aug-03 11-Aug-03 13-Aug-03 00:00:00 00:00:00 00:00:00 00:00:00 Emerson Confidential
Variability Reduction Before After Reduction in Average St. Dev. Average St. Dev. Std. Dev. Atm Column SR NAPHTHA EP 349.55 14.89 347.10 4.30 71.1% AGO EP 636.32 10.54 634.41 6.22 41.0% OVERHEAD TEMP 253.18 5.01 260.91 1.80 64.1% KERO DRAW TEMP 362.59 4.60 366.60 1.86 59.5% HVY KERO TEMP 459.37 5.65 462.72 2.60 54.0% AGO DRAW TEMP 528.14 5.60 530.77 2.55 54.5% Vacuum Column WAX DIST 95% POINT 934.36 12.28 933.78 8.56 30.3% VGO CHIMNEY TEMP 358.58 7.32 365.74 3.23 55.8% WAX VAP TEMP 542.47 5.99 599.50 2.29 61.8% H WAX VAP TEMP 651.77 5.39 671.75 3.74 30.7% Emerson Confidential
Crude/Vac Unit APC Project Timeline Activity Timeframe Functional Design Specification 3 weeks DeltaV APC Projects Application Configuration are < 1 day 25-50% Faster and Less Step Costly than traditional Tests 10 days APC Projects Commissioning 1 week Scope: Two 4x4 MPC controllers, 3 Neural Nets Emerson Confidential
Lime Kiln Project ~Canfor - Northwood Pulpmill Emerson Confidential
Kiln Process MPC Application TT AT DT Lime Mud PT Cold FT Feed TT End TT Hot Fuel Flow End Mud Filter FT Main Drive ID Fan Lime Product Lime Kiln Process Hot-end Temperature (controlled) Energy Flow Cold-end Temperature (manipulated) (controlled) ID Fan Speed Excess Oxygen (manipulated) (controlled and constraint) Lime Mud Flow Hood Draft Pressure (optimized and (constraint) disturbance) Kiln Stack Emissions (constraint) Emerson Confidential
Northwood Lime Kiln DeltaV MPC Control Performance - Benefits Average Specific Average Lime Energy Specific Average Product Standard % Time on Energy Mud Flow Flow Deviation DeltaV MPC (filtered) (filtered) (filtered) (filtered) Control Period (GJ/t) (t/d) (t/d) (GJ/t) (Average) Sept.3,2000 to Oct.15,2001 9.15 584.77 270.14 1.18 Sept.3,2000 to Apr.8,2001 9.62 571.70 264.10 1.34 Dec.17,2000 to Apr.8,2001 8.78 593.64 274.24 1.20 DeltaV Sept.3,2000 to Jan.7,2001 10.20 560.49 258.92 1.43 Oct.15,2001 to Jan.8,2002 8.22 688.13 317.89 0.14 97.60% MPC Operator Reduced Increased Reduced Confidence - Specific Lime Variability 97.6% UPTIME! Energy Production 89.5% 7-20% 16-20% (0.56 - 1.98 GJ/t) Emerson Confidential
Northwood Lime Kiln DeltaV MPC Control Performance- Benefits DeltaV MPC %Reduction Before Control Control in Variability Hot-end Temperature variations (2-sigma) Deg C 134.86 18.46 -86.3% Cold-end Temperature variations (2-sigma) Deg C 43.9 8.12 -81.5% Excess Oxygen variations (2-sigma) % 1.9 0.18 -90.5% Specific Energy Variations (2 sigma) GJ/t 2.96 0.28 -90.5% Tight Control on DeltaV MPC! Emerson Confidential
Baxter MPC Distillation Column Control Condensers Vent Pressure and Temperature PT TT Reflux (Return) Flow PI TI FT FI FIC RSP FT + Takeoff (Distillate) Flow TT TI Mid Column Temperature Column CV 1 MV 1 RTO CV 2 (OPTIM) MV 2 AV 1 AV 2 MPC EU/ TT TI DV SEC Bottom Column Temperature RSP XIC Boilup Steam Reactor Emerson Confidential
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 Emerson Confidential
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. Emerson Confidential
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 Emerson Confidential
Emerson Confidential

More Related Content

PDF
Delta V Control System Overview
bySumeet Goel
 
PPTX
New DeltaV Module Templates to Easily Configure, View, and Trend Advanced Pre...
byEmerson Exchange
 
PDF
Delta v emerson_getting_started
byJoseLuisPallyZegarra
 
PDF
DeltaV Virtualization
byEmerson Exchange
 
PDF
Dcs functional block diagrams
byJesusLopez715693
 
PPTX
Boot camp advanced tools and techniques
byEmerson Exchange
 
PDF
Fieldbus Tutorial Part 2 - Justifying Fieldbus
byEmerson Exchange
 
PPT
Dcs operator training
bySaudi International Petrochemical Company
 
Delta V Control System Overview
bySumeet Goel
 
New DeltaV Module Templates to Easily Configure, View, and Trend Advanced Pre...
byEmerson Exchange
 
Delta v emerson_getting_started
byJoseLuisPallyZegarra
 
DeltaV Virtualization
byEmerson Exchange
 
Dcs functional block diagrams
byJesusLopez715693
 
Boot camp advanced tools and techniques
byEmerson Exchange
 
Fieldbus Tutorial Part 2 - Justifying Fieldbus
byEmerson Exchange
 
Dcs operator training
bySaudi International Petrochemical Company
 

What's hot

PDF
DeltaV Safety Instrumented System Overview
bySumeet Goel
 
PPTX
DeltaV Operator Training
byKoch Modular Process Systems, LLC.
 
PPT
CENTUM CS300 R3
byAhmedAmri23
 
PPT
DeltaV Development Systems in a Virtualized Environment
byEmerson Exchange
 
PDF
Fieldbus Tutorial Part 7 - Fieldbus Communication
byEmerson Exchange
 
PDF
Utilizing DeltaV Advanced Control Innovations to Improve Control Performance
byEmerson Exchange
 
PPTX
YOKOGAWA CENTUM CS 3000 R3
byRehan Fazal
 
PDF
Dcs course
byMohamed A Hakim
 
PDF
Alarm management at DeltaV
byRobert-Emmanuel Mayssat
 
PPTX
Smooooth Operations - Configuration Tips for Analog Blocks
byEmerson Exchange
 
PDF
Distributed Control System (Presentation)
byThunder Bolt
 
PPT
Foundation fieldbus
bysharadonlinemails
 
PDF
DeltaV Electronic Marshalling
bySumeet Goel
 
PPTX
Interesting and Useful Features of the DeltaV PID, Ratio and Bias/Gain Contro...
byEmerson Exchange
 
PDF
Fieldbus Tutorial Part 8 - Fieldbus Function Blocks
byEmerson Exchange
 
PPTX
All about scada
byStella Hermias
 
PPTX
DCS an overview
byDeepan Babu
 
PPSX
Honeywell Experion HS
byShivam Singh
 
PDF
Supervisory Contro and Data Acquisition - SCADA
byAhmed Elsayed
 
PDF
Fieldbus Tutorial Part 1 - Fieldbus Overview
byEmerson Exchange
 
DeltaV Safety Instrumented System Overview
bySumeet Goel
 
DeltaV Operator Training
byKoch Modular Process Systems, LLC.
 
CENTUM CS300 R3
byAhmedAmri23
 
DeltaV Development Systems in a Virtualized Environment
byEmerson Exchange
 
Fieldbus Tutorial Part 7 - Fieldbus Communication
byEmerson Exchange
 
Utilizing DeltaV Advanced Control Innovations to Improve Control Performance
byEmerson Exchange
 
YOKOGAWA CENTUM CS 3000 R3
byRehan Fazal
 
Dcs course
byMohamed A Hakim
 
Alarm management at DeltaV
byRobert-Emmanuel Mayssat
 
Smooooth Operations - Configuration Tips for Analog Blocks
byEmerson Exchange
 
Distributed Control System (Presentation)
byThunder Bolt
 
Foundation fieldbus
bysharadonlinemails
 
DeltaV Electronic Marshalling
bySumeet Goel
 
Interesting and Useful Features of the DeltaV PID, Ratio and Bias/Gain Contro...
byEmerson Exchange
 
Fieldbus Tutorial Part 8 - Fieldbus Function Blocks
byEmerson Exchange
 
All about scada
byStella Hermias
 
DCS an overview
byDeepan Babu
 
Honeywell Experion HS
byShivam Singh
 
Supervisory Contro and Data Acquisition - SCADA
byAhmed Elsayed
 
Fieldbus Tutorial Part 1 - Fieldbus Overview
byEmerson Exchange
 

Similar to Delta v advanced control overview_en

PPTX
Capstone Technology Canada - Advanced Process Control Project Lifecycle
bymorinsteve_capstone
 
PPTX
Why rthplc v2
bytanima123
 
PPTX
Ai show rxi the platform
byjtmcall
 
PDF
ICS Industrial Controls Brochure
byjdeanEE
 
PDF
Embedded Controls Development (1).pdf
byservotechinc78
 
PPT
Viewpoint_PnP.ppt
byAmit yadav
 
PPTX
Technical presentation on
byPriya_Srivastava
 
PPT
Practical Embedded Controllers: Troubleshooting and Design
byLiving Online
 
PDF
Sgcp12 parry-amantys
byJustin Hayward
 
PDF
Delta Electronics Dop-ae57Gstd Human Machine Interface.pdf
bybharataeliyamarine
 
PPTX
automation,vfd,plc,scada overview
bypratikguptateddy
 
PPTX
automation,vfd,plc,scada overview
byPratik Gupta
 
PPTX
Vfd
byPratik Gupta
 
PDF
The Future of Machine Building is NOW!
bySchneider Electric
 
PDF
PID Advances in Industrial Control
byEmerson Exchange
 
PPTX
Acs880 All-compatible ABB industrial drives​
byJalal Benhiba
 
PDF
InSource 2017 IIoT Roadshow: Collecting and Moving Data
byInSource Solutions
 
PPTX
Basic understanding of PLC RTU DCS SCADA
byssuser10fbca
 
PPTX
Modernization Lessons Learned -Part 2
byEmerson Exchange
 
PDF
brochure-deltav-version-15-interactive-flyer-deltav-en-8618114.pdf
bySilviaDelRo2
 
Capstone Technology Canada - Advanced Process Control Project Lifecycle
bymorinsteve_capstone
 
Why rthplc v2
bytanima123
 
Ai show rxi the platform
byjtmcall
 
ICS Industrial Controls Brochure
byjdeanEE
 
Embedded Controls Development (1).pdf
byservotechinc78
 
Viewpoint_PnP.ppt
byAmit yadav
 
Technical presentation on
byPriya_Srivastava
 
Practical Embedded Controllers: Troubleshooting and Design
byLiving Online
 
Sgcp12 parry-amantys
byJustin Hayward
 
Delta Electronics Dop-ae57Gstd Human Machine Interface.pdf
bybharataeliyamarine
 
automation,vfd,plc,scada overview
bypratikguptateddy
 
automation,vfd,plc,scada overview
byPratik Gupta
 
Vfd
byPratik Gupta
 
The Future of Machine Building is NOW!
bySchneider Electric
 
PID Advances in Industrial Control
byEmerson Exchange
 
Acs880 All-compatible ABB industrial drives​
byJalal Benhiba
 
InSource 2017 IIoT Roadshow: Collecting and Moving Data
byInSource Solutions
 
Basic understanding of PLC RTU DCS SCADA
byssuser10fbca
 
Modernization Lessons Learned -Part 2
byEmerson Exchange
 
brochure-deltav-version-15-interactive-flyer-deltav-en-8618114.pdf
bySilviaDelRo2
 

More from Luis Atencio

PPTX
Safety life cycle seminar IEC61511
byLuis Atencio
 
PDF
HUman centred design applied to Graphics (Emerson, DeltaV)
byLuis Atencio
 
PPT
Blendingwith DeltaV
byLuis Atencio
 
PDF
Unified industrial wireless networks (cisco)
byLuis Atencio
 
PPT
Emerson Wireless Presentacion a Clientes
byLuis Atencio
 
PPT
Wireless hart conceptos basicos
byLuis Atencio
 
PPTX
Electronic marshalling vs remote io
byLuis Atencio
 
PPT
Blending with deltav
byLuis Atencio
 
PPT
DeltaV overview v11
byLuis Atencio
 
Safety life cycle seminar IEC61511
byLuis Atencio
 
HUman centred design applied to Graphics (Emerson, DeltaV)
byLuis Atencio
 
Blendingwith DeltaV
byLuis Atencio
 
Unified industrial wireless networks (cisco)
byLuis Atencio
 
Emerson Wireless Presentacion a Clientes
byLuis Atencio
 
Wireless hart conceptos basicos
byLuis Atencio
 
Electronic marshalling vs remote io
byLuis Atencio
 
Blending with deltav
byLuis Atencio
 
DeltaV overview v11
byLuis Atencio
 

Recently uploaded

PPTX
Data Privacy and Protection: Safeguarding Information in a Connected World
byYasir Naveed Riaz
 
PPTX
Software Analysis &Design ethiopia chap-2.pptx
byAbbas484771
 
PDF
Internet_of_Things_IoT_for_Next_Generation_Smart_Systems_Utilizing.pdf
byRoshanSyed12
 
PDF
The major tech developments for 2026 by Pluralsight, a research and training ...
byChris Skinner
 
PDF
Energy Storage Landscape Clean Energy Ministerial
bySurajitBanerjee38
 
PDF
Is It Possible to Have Wi-Fi Without an Internet Provider
bySidra Jefferi
 
PDF
Eredità digitale sugli smartphone: cosa resta di noi nei dispositivi mobili
bySpeck&Tech
 
PPTX
cybercrime in Information security .pptx
byismaeelsahib032
 
PPTX
From Backup to Resilience: How MSPs Are Preparing for 2026
byMSP360
 
PPTX
Chapter 3 Introduction to number system.pptx
byGetachewAbera9
 
PDF
ElyriaSoftware — Powering the Future with Blockchain Innovation
byElyria Software
 
PPTX
Cloud-and-AI-Platform-FY26-Partner-Playbook.pptx
byiuiuiuiu1
 
PDF
DevFest El Jadida 2025 - Product Thinking
byElmehdi AMLOU
 
PDF
Six Shifts For 2026 (And The Next Six Years)
byDavid Armano
 
PDF
Unser Jahresrückblick – MarvelClient in 2025
bypanagenda
 
PDF
Digit Expo 2025 - EICC Edinburgh 27th November
byRay Bugg
 
PPTX
Unit-4-ARTIFICIAL NEURAL NETWORKS.pptx ANN ppt Artificial neural network
byssuserd4481a
 
PDF
Dev Dives: AI that builds with you - UiPath Autopilot for effortless RPA & AP...
byUiPathCommunity
 
PPT
software-security-intro in information security.ppt
byismaeelsahib032
 
PDF
Day 5 - Red Team + Blue Team in the Cloud - 2nd Sight Lab Cloud Security Class
by2nd Sight Lab
 
Data Privacy and Protection: Safeguarding Information in a Connected World
byYasir Naveed Riaz
 
Software Analysis &Design ethiopia chap-2.pptx
byAbbas484771
 
Internet_of_Things_IoT_for_Next_Generation_Smart_Systems_Utilizing.pdf
byRoshanSyed12
 
The major tech developments for 2026 by Pluralsight, a research and training ...
byChris Skinner
 
Energy Storage Landscape Clean Energy Ministerial
bySurajitBanerjee38
 
Is It Possible to Have Wi-Fi Without an Internet Provider
bySidra Jefferi
 
Eredità digitale sugli smartphone: cosa resta di noi nei dispositivi mobili
bySpeck&Tech
 
cybercrime in Information security .pptx
byismaeelsahib032
 
From Backup to Resilience: How MSPs Are Preparing for 2026
byMSP360
 
Chapter 3 Introduction to number system.pptx
byGetachewAbera9
 
ElyriaSoftware — Powering the Future with Blockchain Innovation
byElyria Software
 
Cloud-and-AI-Platform-FY26-Partner-Playbook.pptx
byiuiuiuiu1
 
DevFest El Jadida 2025 - Product Thinking
byElmehdi AMLOU
 
Six Shifts For 2026 (And The Next Six Years)
byDavid Armano
 
Unser Jahresrückblick – MarvelClient in 2025
bypanagenda
 
Digit Expo 2025 - EICC Edinburgh 27th November
byRay Bugg
 
Unit-4-ARTIFICIAL NEURAL NETWORKS.pptx ANN ppt Artificial neural network
byssuserd4481a
 
Dev Dives: AI that builds with you - UiPath Autopilot for effortless RPA & AP...
byUiPathCommunity
 
software-security-intro in information security.ppt
byismaeelsahib032
 
Day 5 - Red Team + Blue Team in the Cloud - 2nd Sight Lab Cloud Security Class
by2nd Sight Lab
 

Delta v advanced control overview_en

  • 1.
    DeltaV Embedded Advanced Control ANew Approach to Advanced Control Overview Presentation
  • 2.
    Topics  DeltaV Embedded Advanced Control Advantage  DeltaV Advanced Control Product Suite  Experience / Examples Emerson Confidential
  • 3.
    Advanced Control forOperational Excellence  Improve Quality PlantWeb Benefits – Reduce Variability – Predict Lab Measurements  Increase Throughput – Continuously Push Limits – Protect Multiple Constraints  Reduce Costs – Maximize Efficiency and Reduce APC Energy Costs Impact – Accurate Quality Control to Reduce Inventory and Product Rework – Stabilize Control to Reduce Equipment Wear and Incident Risk Emerson Confidential
  • 4.
    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! Emerson Confidential
  • 5.
    Embedded APC Tools– What’s new? • NO extra Traditional Advanced databases Control • NO database synchronization Embedded APC: issues • Can run in DCS controllers • NO watchdog timers • Redundant and fast (1/sec) • NO fail/shed logic • Integrated operator user design interface • Configuration through • NO custom DCS standard Control Studio programming • Automated step testing and • NO interface Model ID programming • Off-line simulation and • NO operator training interface development Emerson Confidential
  • 6.
    New Approach toAPC Configuration DeltaV APC blocks are “Drag-n-Drop” Graphical Configuration using Control Studio Emerson Confidential
  • 7.
    New Approach toAPC Configuration System-wide tag browsing … all in the DCS database Emerson Confidential
  • 8.
    Typical APC ProjectTimeline Months 1 2 3 4 5 6 7 8 9 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 Performed on-site Commissioning Embedded APC Technology Emerson Confidential
  • 9.
    Traditional Advanced ControlOver Time Start Project Start Commissioning End Commissioning Traditional APC 100% % On-line Time More than 50% of APC applications are turned off within the first 2 years after installation. time Yr 1 Yr 2 Emerson Confidential
  • 10.
    Why Don’t APCApplications 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 don’t understand what the APC is doing  Too expensive to bring in APC consultants How to Sustain Control Performance? Emerson Confidential
  • 11.
    Must Build SolidFoundations You Can’t Have This… Advanced Control Control Foundation Without This… Emerson Confidential
  • 12.
    Foundation Built onHealth of Field Devices Fieldbus Status Is Consistently Used by DeltaV Advanced Control Emerson Confidential
  • 13.
    DeltaV Embedded AdvancedControl A Systematic Approach for Sustained Performance Analyze and Diagnose Identify Problems Re-Tune And Prioritize Or Fix Cause Monitor Advanced Performance Control Emerson Confidential
  • 14.
    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” Advanced Control Process Model Calculations Predict / Neural / Fuzzy Emerson Confidential
  • 15.
    DeltaV Embedded APCfor Sustained Performance DeltaV APC Traditional APC 100% % On-line Time Faster to Commission + Sustained Performance = Greater $$’s Saved time Emerson Confidential
  • 16.
    The DeltaV EmbeddedAPC 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 Emerson Confidential
  • 17.
    Topics  DeltaV Advantage - Embedded Advanced Control  Advanced Control Product Suite  Experience / Examples Emerson Confidential
  • 18.
    DeltaV Advanced ControlProducts  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! Emerson Confidential
  • 19.
    DeltaV Advanced ControlProducts  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! Emerson Confidential
  • 20.
    DeltaV InSight Poor controlcosts 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 Emerson Confidential
  • 21.
    Predictive Intelligence =Intelligent Control Adaptive Learning Algorithms for Intelligent Control Learn Evaluate • Observe • Validate • Identify • Compare • Remember • Diagnose Improve • Advise • Tune • Adapt Emerson Confidential
  • 22.
    DeltaV InSight forIntelligent Control With InSight’s 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. Emerson Confidential
  • 23.
    DeltaV InSight Bringing it all together:  Performance Monitoring • On-demandTuning  Loop Diagnostics • Adaptive Tuning  Embedded Learning • Simulation  Adaptive Tuning  Adaptive Control • Adaptive Control • Performance Monitoring • Operating Regions • Loop Diagnostics • Non-linear Control • Reporting • Model Identification • Control Diagnostics • Performance Indices Emerson Confidential
  • 24.
    DeltaV InSight –Integrated User Interface Old DeltaV Inspect New DeltaV InSight Old DeltaV Tune New interface provides seamless transition between loop diagnostics and tuning. Emerson Confidential
  • 25.
    Easily Launched inContext From the Control Studio DeltaV Explorer Operator Interface From the DeltaV Explorer Context sensitive from Control Studio Emerson Confidential
  • 26.
    DeltaV Insight –Architecture Data Analysis and Reporting UI from any Runs in Server workstation Embedded Learning Runs in the Controller • Fast Data Capture • Small Communications Load • Runs in Background Emerson Confidential
  • 27.
    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. Emerson Confidential
  • 28.
    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 ON- LINE using DeltaV InSight  Learning is available on DeltaV and Fieldbus PID blocks Emerson Confidential
  • 29.
    Control Performance Monitoring “Inspectwith 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 Emerson Confidential
  • 30.
    Control Block PerformanceIndices 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. Emerson Confidential
  • 31.
    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 Emerson Confidential
  • 32.
    DeltaV InSight -Asset Monitoring  Device Alerts are reported through InSight Asset Displays  Overview provides graphical display for Asset Alerts of System, Area, and Modules Right-Click  Asset Display identifies Asset Alerts including: – Asset Failed – Maintenance Soon – Advisory – Communications Failed  Easily Launch AMS Device Manager in Context to access detailed diagnostics Emerson Confidential
  • 33.
    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 Emerson Confidential
  • 34.
    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 Emerson Confidential
  • 35.
    On-Demand Tuning -Options for the Expert Power for the Advanced User ! Emerson Confidential
  • 36.
    DeltaV InSight -Adaptive Tuning Provides Tuning Based on Normal Operator Changes  InSight automatically calculates dynamic Before vs. After models from operator changes  Model Quality and Learning Status  Tuning criteria and desired speed of response  Tuning Recommendation  No Testing Required Emerson Confidential
  • 37.
    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 Emerson Confidential
  • 38.
    DeltaV InSight -Control Simulation Test your tuning with Dynamic Simulation  Closed loop simulation of setpoint and View Dynamic disturbance Response changes for recommended tuning Select New Tuning Simulation for both  Speed vs RobustnessAdaptive and On- demand Tuning Emerson Confidential
  • 39.
    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. Emerson Confidential
  • 40.
  • 41.
    DeltaV InSight –Adaptive Control InSight identifies tuning in up to 5 regions of operation Emerson Confidential
  • 42.
    DeltaV InSight –Adaptive Control Emerson Confidential
  • 43.
    DeltaV InSight –Adaptive Control Adaptive control adjusts tuning to improve control performance Emerson Confidential
  • 44.
    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 KPI’s in customized reports via Excel and DeltaV Reporter Emerson Confidential
  • 45.
    Area Control PerformanceReport Emerson Confidential
  • 46.
    Area Control PerformanceReport Emerson Confidential
  • 47.
    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 Emerson Confidential
  • 48.
    Easy As PID… DeltaV Explorer Replace PID with Fuzzy Logic Control Emerson Confidential
  • 49.
    DeltaV Fuzzy FunctionBlock Pre-defined Fuzzy Logic Control Emerson Confidential
  • 50.
    Use DeltaV InSightto Tune Fuzzy Logic Transfer recommended constants to fuzzy control Emerson Confidential
  • 51.
  • 52.
    Fuzzy Logic Controlvs 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. Emerson Confidential
  • 53.
    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 After (using DeltaV PID) (using DeltaV Fuzzy) Source: Emerson Exchange, October 2004 Shell Deer Park Paper Emerson Confidential
  • 54.
    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 Emerson Confidential
  • 55.
    Model Predictive Control Learns From The Past To Predict The Future Modeled Relationship Past Present Future Emerson Confidential
  • 56.
    Multivariable Dynamic ProcessModels The Model Consists Of Step Responses That Show The Relationship Between Every Process Input And Output Emerson Confidential
  • 57.
    Graphical Configuration DeltaV APC blocks are “Drag-n-Drop” Graphical Configuration using Control Studio Emerson Confidential
  • 58.
    Automated Step Testing Process Steps Emerson Confidential
  • 59.
  • 60.
    Individual Step ResponseView Emerson Confidential
  • 61.
    Modifying Step Responses Enter Step Response Constants Emerson Confidential
  • 62.
  • 63.
  • 64.
    Automatic Operator Display Trend Window Past Future Control Manipulated Constraint Disturbance Variables Variables Variables Variables Emerson Confidential
  • 65.
    APC Optimization Often as simple as maximizing one variable to its most limiting constraints… Production Throughput APC Increase $$ Throughput at limit Operator Setpoint Time … but modern APC tools can do much more if needed. Emerson Confidential
  • 66.
    Built-in LP Optimization 100% position 100% position Maximized Minimized Maximized 0% position Profit Energy Throughput 0% position Emerson Confidential
  • 67.
    Objective Function Configuration Define multiple operating modes Select from list of Set Max/Min controller variables and Price Easy to set up and configure the built-in LP Optimizer Emerson Confidential
  • 68.
    Easily Select OptimizationMode Select from list of Optimization Modes Emerson Confidential
  • 69.
    Optimizer Detail Display Current Values Optimal Values Emerson Confidential
  • 70.
    DeltaV Neural –Property Estimation ● Create virtual sensors for on- line measurements normally only available through lab analysis ● Easy to understand and use, cost effective ● General nonlinear modeling tool Emerson Confidential
  • 71.
    Inferential Sensor Configuration Lab Entry Block Select Inputs Emerson Confidential
  • 72.
    Select Neural TrainingData ● Select training set from historian ● Exclude bad data segments ● Train the network Emerson Confidential
  • 73.
    Training the NeuralNetwork Auto detection of over-training Emerson Confidential
  • 74.
    Sensitivity Plot, InputSelection Emerson Confidential
  • 75.
    Validating Neural Models Naphtha 95% Point Prediction Emerson Confidential
  • 76.
    Neural Results –Naphtha 95% Point SR Naphtha EP 380 375 Crude Switch 370 365 Lab 360 NN Prediction 355 Filtered 350 345 340 07-Aug-03 09-Aug-03 11-Aug-03 13-Aug-03 00:00:00 00:00:00 00:00:00 00:00:00 Emerson Confidential
  • 77.
    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 Emerson Confidential
  • 78.
    DeltaV Architecture Control Design and Configuration are Independent of Hardware Distributed Control Functionality Emerson Confidential
  • 79.
    DeltaV Control SystemSimulation 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 Emerson Confidential
  • 80.
    DeltaV “Multi-Node” ControlSimulation 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 Emerson Confidential
  • 81.
    DeltaV “Multi-Node” ControlSimulation Process Simulator via OPC ● Supports mimic Process Multi-Node Environment Simulator running in DeltaV Workstation Application Station with Operator Station Professional Plus mimic Simulator App Station ● Supports Third Party Process Simulators via standard OPC Emerson Confidential
  • 82.
    DeltaV “Multi-Node” ControlSimulation Multi-Node Environment ● Supports mimic Process Simulator running in DeltaV Operator Station Professional Plus Application Station 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 Emerson Confidential
  • 83.
    Simulate Parameter forI/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 Emerson Confidential
  • 84.
    Process Simulation viaOPC 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 Emerson Confidential
  • 85.
    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. Faster or Slower than real-time Select the node(s) that you execution of all modules assigned to want to access (ProPlus and a node. App Stations only) Simulate Pro is designed to coordinate simulation and support replay. Emerson Confidential
  • 86.
    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 Emerson Confidential
  • 87.
    DeltaV Simulate forSIS  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 Emerson Confidential
  • 88.
    DeltaV Simulate - Simulation Download Web Service ● Automatically synchronize DeltaV and MiMiC ● Reduce Engineering Costs ● Improve Simulation Accuracy Emerson Confidential
  • 89.
    DeltaV APC onLegacy Platforms Universal GUS DeltaV Station (US) APP Node (Or PHD) ProPlus Station OPC I/F Option 1: Run APC in Work Station TDC3000 LCN PLC Gateway DeltaV Controller APM HPM Option 2: Run APC IOPs in controller Serial I/F Options Serial I/O FTA Emerson Confidential
  • 90.
    Topics  DeltaV Advantage - Embedded Advanced Control  Advanced Control Product Suite  Experience / Examples Emerson Confidential
  • 91.
    Example Predict Licensees Total End User Company MVs Purchase Date Petrovietnam 60 Aug-03 Lucite International 40 Jan-02 Solutia, Inc. 60 Jun-98 Canadian Forest Products Ltd. 38 Apr-01 Baxter 32 Apr-01 Petrotel-Lukoil 30 Jan-04 Petrogal 30 Feb-05 BASF Corporation 25 May-04 Norske-Skog Canada 25 Jun-03 Flint Hills Resources, LP 20 Jun-04 Huntsman ICI 20 Oct-00 Husky Energy 20 Nov-04 Monsanto Company 20 Jul-03 Emerson Confidential
  • 92.
    Refinery APC Example Ergon, West Virginia Emerson Confidential
  • 93.
    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 Emerson Confidential
  • 94.
    Main MPC Control Icon MPC Temp Targets Emerson Confidential
  • 95.
    Atm Controller Performance Controller Crude ON Change CV SP MV Lab Spec Naphtha Hvy Kero Kero AGO Emerson Confidential
  • 96.
    Atmospheric Column Neural NetworkPredictions Column Temps & Yields TC Predicted NA FC FC 95% Column Temps FC Naphtha & Yields Kero FC FC Predicted AGO 95% Hvy Kero FC FC TC Crude AGO FC Resid to VAC Fuel Gas Column Emerson Confidential
  • 97.
    Neural Results –Naphtha 95% Point SR Naphtha EP 380 375 Crude Switch 370 365 Lab 360 NN Prediction 355 Filtered 350 345 340 07-Aug-03 09-Aug-03 11-Aug-03 13-Aug-03 00:00:00 00:00:00 00:00:00 00:00:00 Emerson Confidential
  • 98.
    Variability Reduction Before After Reduction in Average St. Dev. Average St. Dev. Std. Dev. Atm Column SR NAPHTHA EP 349.55 14.89 347.10 4.30 71.1% AGO EP 636.32 10.54 634.41 6.22 41.0% OVERHEAD TEMP 253.18 5.01 260.91 1.80 64.1% KERO DRAW TEMP 362.59 4.60 366.60 1.86 59.5% HVY KERO TEMP 459.37 5.65 462.72 2.60 54.0% AGO DRAW TEMP 528.14 5.60 530.77 2.55 54.5% Vacuum Column WAX DIST 95% POINT 934.36 12.28 933.78 8.56 30.3% VGO CHIMNEY TEMP 358.58 7.32 365.74 3.23 55.8% WAX VAP TEMP 542.47 5.99 599.50 2.29 61.8% H WAX VAP TEMP 651.77 5.39 671.75 3.74 30.7% Emerson Confidential
  • 99.
    Crude/Vac Unit APCProject Timeline Activity Timeframe Functional Design Specification 3 weeks DeltaV APC Projects Application Configuration are < 1 day 25-50% Faster and Less Step Costly than traditional Tests 10 days APC Projects Commissioning 1 week Scope: Two 4x4 MPC controllers, 3 Neural Nets Emerson Confidential
  • 100.
    Lime Kiln Project~Canfor - Northwood Pulpmill Emerson Confidential
  • 101.
    Kiln Process MPCApplication TT AT DT Lime Mud PT Cold FT Feed TT End TT Hot Fuel Flow End Mud Filter FT Main Drive ID Fan Lime Product Lime Kiln Process Hot-end Temperature (controlled) Energy Flow Cold-end Temperature (manipulated) (controlled) ID Fan Speed Excess Oxygen (manipulated) (controlled and constraint) Lime Mud Flow Hood Draft Pressure (optimized and (constraint) disturbance) Kiln Stack Emissions (constraint) Emerson Confidential
  • 102.
    Northwood Lime Kiln DeltaV MPC Control Performance - Benefits Average Specific Average Lime Energy Specific Average Product Standard % Time on Energy Mud Flow Flow Deviation DeltaV MPC (filtered) (filtered) (filtered) (filtered) Control Period (GJ/t) (t/d) (t/d) (GJ/t) (Average) Sept.3,2000 to Oct.15,2001 9.15 584.77 270.14 1.18 Sept.3,2000 to Apr.8,2001 9.62 571.70 264.10 1.34 Dec.17,2000 to Apr.8,2001 8.78 593.64 274.24 1.20 DeltaV Sept.3,2000 to Jan.7,2001 10.20 560.49 258.92 1.43 Oct.15,2001 to Jan.8,2002 8.22 688.13 317.89 0.14 97.60% MPC Operator Reduced Increased Reduced Confidence - Specific Lime Variability 97.6% UPTIME! Energy Production 89.5% 7-20% 16-20% (0.56 - 1.98 GJ/t) Emerson Confidential
  • 103.
    Northwood Lime Kiln DeltaVMPC Control Performance- Benefits DeltaV MPC %Reduction Before Control Control in Variability Hot-end Temperature variations (2-sigma) Deg C 134.86 18.46 -86.3% Cold-end Temperature variations (2-sigma) Deg C 43.9 8.12 -81.5% Excess Oxygen variations (2-sigma) % 1.9 0.18 -90.5% Specific Energy Variations (2 sigma) GJ/t 2.96 0.28 -90.5% Tight Control on DeltaV MPC! Emerson Confidential
  • 104.
    Baxter MPC DistillationColumn Control Condensers Vent Pressure and Temperature PT TT Reflux (Return) Flow PI TI FT FI FIC RSP FT + Takeoff (Distillate) Flow TT TI Mid Column Temperature Column CV 1 MV 1 RTO CV 2 (OPTIM) MV 2 AV 1 AV 2 MPC EU/ TT TI DV SEC Bottom Column Temperature RSP XIC Boilup Steam Reactor Emerson Confidential
  • 105.
    Quantified Business Results NoelPerez – 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 Emerson Confidential
  • 106.
    Learning More AboutDeltaV 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. Emerson Confidential
  • 107.
    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 Emerson Confidential
  • 108.