The document presents a framework for transforming continuous chemical process control from loop-based to state-based control, emphasizing automation and the integration of operator knowledge. It highlights the benefits of structured implementation, improved reliability, and reduced human error through the PUMA system, which has already shown promising results in a recent plant trial. Key technical aspects and networking strategies are discussed, along with references for further information.

1. 2019 Process Industry Conference
4-7 November | Houston, TX USA | Westin Houston Memorial City
Copyright 2019, ISA. All rights reserved. www.isa.org
No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.
State Based Control
for
Continuous Chemical
Processes
Process Unit Module Automation (PUMA)™
Abdul Susnerwala
Air Liquide
Bruce Eng
Air Liquide
Travis DeBenedetto
Puffer Sweiven
Win Worrall
Software Toolbox

2. PRESENTERS
● Bruce Eng, Air Liquide, APC Engineer CTE
● Abdul Susnerwala, Air Liquide, Engineer CTE
● Win Worrall, Account Manager, Software Toolbox
● Travis DeBenedetto Account Manager, Puffer Sweiven

3. COMPANY INFORMATION
A world leader in gases, technologies and
services for Industry and Health, Air
Liquide is present in 80 countries with
approximately 66,000 employees and
serves more than 3.6 million customers
and patients. Oxygen, nitrogen and
hydrogen are essential small molecules
for life, matter and energy. They embody
Air Liquide’s scientific territory and have
been at the core of the company’s
activities since its creation in 1902.

4. AGENDA
❖ Unit Operation
Continuous Process Control Requirement
Loop Based Control
Automate the Procedure
Transformation to State Based Control
❖ Networking of OPC Data
❖ Conditional Bridging
❖ PK Controller
❖ Results
Summary
References & Additional Information

5. UNIT OPERATION - Continuous Process Control Req
1. Repeatable optimized startup, run and shutdown.
2. Abnormal situation management using additional control strategies.
3. Intelligent alarming based on mode of operation.
4. Automatic enabling of equipment, devices and controllers based on the
mode of operation.
5. Automatic swapping to redundant equipment (pump swapping).
6. Enabling the Operator to run a process unit instead of individual devices.
7. Automatic sequencing of plant (unit to unit) startup and shutdown.

6. UNIT OPERATION - Loop Based Control LBC
There exists a Procedure on “How to Start, Run and Shutdown” a Unit in a
pre-specified order (or Sequence)
Loop Based Control (LBC)
1- Operator identifies the state
2- Operator executes commands
3- Operator waits for the next state
A B
C
D
E F
A
B1 C
D
E F
B2
A B1
C
D
E1 F
B2
Operator Billy’s procedure
Operator Chris’s procedure
Operator Andy’s procedure
time
time
time
E2
CtrlDesginer.Com © 2017
Start-Up RunABS SDRun

7. UNIT OPERATION - Automate the Procedure
There exists a Procedure on “How to Start, Run and Shutdown” a Unit in a
pre-specified order (or Sequence)
Loop Based Control (LBC)
1- Operator identifies the state
2- Operator executes commands
3- Operator waits for the next state
CtrlDesginer.Com © 2017
Start-Up RunABS SDRun

8. UNIT OPERATION - Automate the Procedure
There exists a Procedure on “How to Start, Run and Shutdown” a Unit in a
pre-specified order (or Sequence)
Loop Based Control (LBC)
1- Operator identifies the state
2- Operator executes commands
3- Operator waits for the next state
CtrlDesginer.Com © 2017
Start-Up RunABS SDRun
State Based Control (SBC)
1- SBC identifies the state
2- SBC Executes Commands
3- Operator permits predefined transitions
4- SBC observes for the next state

9. UNIT OPERATION - Transformation to State Based Control
A B
C
D
E F
A
B1 C
D
E F
B2
A B1
C
D
E1 F
B2
Operator Billy’s procedure
Operator Chris’s procedure
Operator Andy’s procedure
time
time
time
E2
A
B1 C
D
F
B2
Operator Billy’s procedure
time
E1
E2
• Capture the best
procedure from all
operators
• Improve and combine into
one
• Convert to SBC

10. NETWORK - OPC Architecture

11. NETWORK - OPC Bridging

12. NETWORK - OPC Application Software

13. Deliberate Communication
● Safeguard against accidental writes to critical tags
○ Potential Consequences: loss of product quality, plant shutdown, etc
○ Writing the wrong value or right value at wrong time
● Problems most likely to occur during the following times
○ Startup of PUMA
○ Maintenance of PUMA
○ Shutdown or startup of bridge (data hub)
● Philosophy
○ Communication tags divided into “critical” and non-critical tags
○ Before writing to critical parameters, correct communication must be proven using
non-critical tags
○ DCS (and operator) should have the ability to disable all writes to critical parameters
○ PUMA should have the ability to disable writes to critical parameters when they aren’t
required (prevent writes at wrong time)

14. NETWORK - OPC Conditional Bridging

15. SYSTEM - Hardware
PK Controller - Powerful Stand Alone, Easily Integrated
• No Proplus required
• Multiple Sizes Available
• 2 or 8 GB 250 pt Continuous Historian
• Powerful Controller
• On-Board Configuration Saving
• Repeatable Solution
• Compact
• Competitively Priced
• Reliable OPC UA Communication
• Familiar Engineering Tools, Graphics and Hardware

16. SYSTEM - Cabinet

17. SYSTEM - Familiar Engineering Software
• Used for Engineering Standalone PK Controllers
• Available as Virtual Machine or regular Media Installation
- Virtual Machine can be installed on any PC running Windows 10
• VMWare
• Virtualbox
• Same engineering tools as DeltaV
- DeltaV Explorer
- Control Studio
- DeltaV Operate
• Additional Functionality
- Project Management Tools
- Authenticate PK Controllers
- Compare two configurations to identify changes
- Backup configurations to SD-Card on PK Controller
• Configuration Database limited to 1 PK Controller

18. RESULTS - Flow Diagram of Pure Argon Column
AIRSEPARATION
UNIT
PUREARGON
COLUMN

19. RESULTS - Operation Trend for Pure Argon ColumnBEFORE

20. RESULTS - Operation Trend for Pure Argon ColumnAFTER

21. RESULTS - Plant Procedure of Pure Argon Column

22. RESULTS - PUMATM Implementation

23. SUMMARY
• Using Work Process defined gives a structured approach to converting a
legacy code into a code utilizing State Based Control Strategy
• PUMA is designed to be an agnostic solution to minimize impact to the DCS,
Process and Operators.
• It is vehicle to capture tribal knowledge of operators for a specific plant
• Improves overall reliability of the plant by reducing potential Human error
• Implementation Cost for PUMA using DeltaV PK Controller and Cogent
Datahub is expected to be offsetted in a period of six months.
• Ingleside TX ASU implemented PUMA in August 2019 on Pure Argon
Column. Based on the data for past year we are expecting to make 530 tons
of additional LOX
• PUMA on argon provides an additional handle to OCC (Operational Control
Center) to cope with dynamic demand of Gulf Coast Pipeline

24. REFERENCES & ADDITIONAL INFORMATION
Special Thanks to Dr. Yahya Nazer who led me through the process of
converting our first plant (Ingleside TX - ASU) to State Based Control
Following are informative videos on subject by him:
http://ctrldesigner.com/
https://www.youtube.com/watch?v=eNEKOlV_JXM
https://www.youtube.com/watch?v=T26m4dEepoA
https://www.youtube.com/watch?v=-aUPobpSFCE
Additional References:
https://web-material3.yokogawa.com/Modular_Procedural_Automation.us.pdf
http://isawwsymposium.com/wp-content/uploads/2013/08/WWAC2013_Tennant-Myers_procedural-automation-ISA106_slides_1up
.pdf
http://www.novatechweb.com/wp-content/uploads/2012/09/Batch-Manufacturing-Article.pdf
https://www.honeywellprocess.com/library/news-and-events/presentations/HUG12-ISA-106-Automated-Procedures.pdf
https://web-material3.yokogawa.com/BU36J06B10-01E.pdf
https://web-material3.yokogawa.com/ISA_106_TR1_Infographic.us.pdf
https://search-ext.abb.com/library/Download.aspx?DocumentID=3BSE092101&LanguageCode=en&DocumentPartId=&Action=Lau
nch

25. NETWORK - OPC Application Software
A Single Application Limits Your
- Integration Points
- Risk
- Cyber Security Attack Surface
- Number of Applications to Upgrade/Migrate
Add New Functionality without adding Applications