abb pa life cycle services serviceport access to ... · finding a needle in a hay stack few units...

ABB PA Life Cycle Services

ServicePort – Access to Efficiency Performance Services

© ABB Group

September 26, 2012 | Slide 2

Lifecycle Services Development Charter (agenda)

Identify

Value

Packaged Services

Sales

Productivity

Service

Tools

Optimize

Processes

Maximize

Systems

Responsive Efficient

Standard

Develop services and tools that address customer needs

Increase

Efficiency Increase Productivity

Leverage

Knowledge Built on

Expertise

Service

Development

Identify

Value Packaged Services

© ABB Group


Lifecycle Services Development Charter (agenda)

Identify

Value

Packaged Services

Sales

Productivity

Service

Tools

Optimize

Processes

Maximize

Systems

Responsive Efficient

Standard

Develop services and tools that address customer needs

Increase

Efficiency Increase Productivity

Leverage

Knowledge Built on

Expertise

Service

Development

Identify Value

Packaged Services

© ABB Group September 26, 2012 | Slide 4

Fingerprint Services follow a proven process

Diagnose (Fingerprints) Measure performance gap

Forecast Return on Investment

Deliver action plan

Implement (HandsOn) Fix performance gap

Define monitor plan

Sustain (Scan/Track) Manage performance gap

Schedule maintenance

Define condition triggers

Maintain to conditions

Proactive and collaborative

Increased

performance

1

Service

2

3

Diagnose

(Fingerprints)

Implement

(HandsOn)

Sustain

(Scan/Track)

Scalable Advanced Services delivery

Scalable Service Delivery

0 100

75

50

25

Best Option

Technical Tools

Troubleshooting/Implementation

Fingerprint

Stand alone

1. Service Solution – Loop Performance, Loop Tuning, Batch Performance

2. Service delivery – Fingerprint, Remote analysis, Continuous monitoring

3. Fingerprint is a light application with no hardware using technical tools

4. Technical Tool usage for Troubleshooting and implementation

5. ServicePort provides continuous monitoring, requires ServicePort Channels

ServicePort

Channels -

Continuous

monitoring





ABB Fingerprint Services: packaged deliverables for control systems and customer processes

Common Fingerprint:

Boiler, Paper Machine, OMC,

Alarm/Security

QCS (VPA, Shift Day, Standardize)

Loop Performance

Transition Analysis

Batch Analysis

Tuning

Loop Performance Services

Data Collection

DL300

Loop Performance Fingerprint

Loop Analyzer

Signal Analyzer

Loop Tuning

LoopTune

Plant Wide Disturbance Analysis

Loop Analyzer

Batch Analysis

Sequence Analyzer

High Speed data analysis

HSD500/AGP400

Loop Performance Monitoring

ServicePort Loop Performance Channel

© ABB Group


Continuous

Improvement at

Maximum efficiency

Diagnose

Implement

Solution Problem

Loop

Performance

Management

© ABB Group


LoopScan makes process troubleshooting efficient

Easy to identify issues

Hard to find THE

problem.

Impractical to find with

simple tools

Important to avoiding

false positives.

Finding a needle in a hay stack

Few units

Many units

Control loops will degrade in performance

PID Controllers are designed to:

Regulate the process

Reduce product instability

Improve operations

Manual Operation Output Out of range Increasing Variability Improving process

However, ABB is finding that:

PID loops are not being maintained

PID loops have degraded

PID loops are standing in the way of

production and performance.

35%

15% 30%

25%

Half life of process controllers Given: 100 PID loops all tuned at once.

Then: within 6 months, 50 of these loops will

degrade in performance.

Months

100

Loop p

erf

orm

ance

de

gra

da

tio

n

50

06

Simple PID utilization

© ABB Group


Diagnose Implement Sustain

Performance

potential

Application

Process

Time

Loop Performance Services manage performance gap

© ABB Group



Performance

potential

Application

Process

Time


1) Fingerprint

1

Gap

Goal Present

DiagnoseDiagnose

Gap

Goal Preset

© ABB Group



Performance

potential

Application

Process

Time


2) Implementation

2

Implement

1 2 3

Implement

1) Fingerprint

1

Gap

Goal Present

DiagnoseDiagnose

Gap

Goal Preset

© ABB Group



Performance

potential

Application

Process

Time

Loop Performance Services manage performance gap Sustain

Periodic Evaluation Periods

3) Scan

3 Manage

performance

gap

2) Implementation

2

Implement

1 2 3

Implement

1) Fingerprint

1

Gap

Goal Present

DiagnoseDiagnose

Gap

Goal Preset

© ABB Group



Performance

potential

Application

Process

Time

Loop Performance Services manage performance gap Sustain

Periodic Evaluation Periods

3) Scan

3 Manage

performance

gap

4

4) Track

Alert

2) Implementation

2

Implement

1 2 3

Implement

1) Fingerprint

1

Gap

Goal Present

DiagnoseDiagnose

Gap

Goal Preset

Fingerprint

On-Site

Performance Services reactive to proactive Event-driven action

Scheduling Collection Analysis Resolution

Collection Analysis Resolution

Collection Analysis


KPI

Trending

On Site

Remote On Site

On Site

Data Pool Remote

On Site

Data Pool

Resolution

On Site

On Site

On Site


Condition

Monitoring

On Site

Data Pool Remote

Event Trigger

On Site

Se

rvic

eP

ort

Reactive

Proactive

Short Lead time

No Lead time

Scan Services

Track Services

Periodic Remote

Enabled Service

Modules



ABB Fingerprint finds gaps, develops customer ROI

Data Collection/Testing

12 to 24 hours at 5-second data

Controller parameters

Customer interview: process area and

loop criticality definitions.

Performance Evaluation

Standard Methodology

Analysis Expertise

Performance Visualization

Report

Gap Analysis

ROI Forecast

Action Plan

Benchmark ROI Findings Plan

OPC

Collection

Tools

People

Process

Tools

Report

Action

Problem

Interpret

Analyze

View

Get

Goal: Continuous Improvement

Process Loops

Prioritize

and

Categorize

Tuning

Actuator

Signal

Logic

1 2

3

4

1 2

3

4

1 2

3

4

1 2

3

4

Action Plan

Implement

Stand Alone Tools Signal Analyzer

LoopTune

Loop Analyzer

Continuous Tools • ServicePort

© ABB Group


Optimization Services: Performance Migration

Maximum Off Specification

Diagnose: Current

Implementation: Corrective Action

Sustain: Improvement Projects

Optimal: Mechanical Constraints

Reduction in Variability = Less Raw Material Usage

Improved energy consumption

Wider Operating Window

Increases in production, quality, and product purity

Faster troubleshooting time

Advanced Automation Solutions

Goal

© ABB Group


QCS Performance Fingerprint

Production Capability Thruput

Reel Speed

Lost Time

Reel Variability Total

Distribution

Trends

Control Utilization Auto/Manual

Grade change

Fingerprint Inputs: Shift/Day Report

VPA reel Report

Standardize Report

Check Sample Reports

Tuning/Setup Parameters

ABB Analysis Tools VPA200

CU100

SA100

MD400

Excel

ReportPro

Non Invasive – One week of scope

Sensor Stability Standarize

Check Sample

Calibrate Sample

Settings

QCS Performance Fingerprint

© ABB Group


QCS Performance

Fingerprint

Packaged Service

Modules

Implementation

Solutions

Production Capability

Reel Statistics

Control Utilization

Sensor Stability

Tuning/Setup Cluster

Non Invasive

Well defined

decision tree for

optimal solution

definition

© ABB Group


QCS Performance Fingerprint Production: Variability and Lost Time

Range 100 t/d

Average 3 hr/day

If variability can be reduced,

Then the reduction translates

into a production increase.

Lost time contribution: Grade

Change, Sheet Break, start

up, quality problems.

Control Utilization tool – reading Shift/Day Info

© ABB Inc.

September 26, 2012 |

System Reel Report

?

Target Actual Efficiency RES MDL CD TOT

38.28 38.28 100.00 1.54 0.34 0.81 1.77

Target Actual Efficiency RES MDL CD TOT

3.70 3.70 100.00 1.08 0.30 0.59 1.26

Basis Wt 1 LBS

Moisture 1 PCT

Quality Analysis

2-Sigma’s

© ABB Group


QCS Performance Fingerprint: Variability Distribution

0

2

4

6

8

10

12

14

16

18

20

22

2 Sigma as % of Process [Umidita Pope]

Perc

ent

CD MDL MDS TOT

Master_85_90 Master_100_120 Master_140_180 Master_200 Master_230_240

Master_280 Master_300_320 Master_350_360 Master_400

Master_85_90 13.553 14.629 8.509 21.682

Master_100_120 10.292 11.733 7.589 17.355

Master_140_180 9.875 12.138 6.150 16.813

Master_200 8.376 7.117 4.372 11.800

Master_230_240 8.228 10.451 5.314 14.324

Master_280 8.058 10.040 4.929 13.785

Master_300_320 7.479 10.216 5.885 13.962

Master_350_360 8.957 9.473 5.206 14.038

Master_400 0.000 0.000 0.000 0.000

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

2 Sigma as % of Process [Grammatura]

Perc

ent

CD MDL MDS TOT

Master_85_90 Master_100_120 Master_140_180 Master_200 Master_230_240

Master_280 Master_300_320 Master_350_360 Master_400

Master_85_90 1.557 1.587 2.463 3.318

Master_100_120 1.711 1.365 2.426 3.268

Master_140_180 1.113 1.670 1.617 2.578

Master_200 1.398 1.233 1.364 2.310

Master_230_240 1.609 2.655 1.546 3.468

Master_280 1.617 2.342 1.599 3.264

Master_300_320 1.465 2.806 1.476 3.493

Master_350_360 0.877 2.575 2.074 3.421

Master_400 0.000 0.000 0.000 0.000

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

1.3

2 Sigma [Ceneri]

2 S

igm

a

C D MD L MD S TO T

Master_85_90 Master_100_120 Master_140_180 Master_200

Master_230_240 Master_280 Master_300_320 Master_350_360 Master_400

A ll data in participating groups

Master_85_90 0.177 1.075 0.682 1.285

Master_100_120 0.138 0.932 0.575 1.104

Master_140_180 0.145 0.983 0.456 1.094

Master_200 0.138 0.777 0.441 0.904

Master_230_240 0.105 0.740 0.421 0.858

Master_280 0.118 1.043 0.457 1.145

Master_300_320 0.109 1.023 0.451 1.123

Master_350_360 0.102 0.813 0.641 1.040

Master_400 0.000 0.000 0.000 0.000

A ll data in participating groups 0.135 0.941 0.515 1.081

Grammatura Umidità

Ceneri MDL represents the frequency band

between 1 minute and 45 minutes.

MDL is 3 to 5 times higher than

expected in all measurements

© ABB Group


QCS Performance Fingerprint: Control Utilization

0

10

20

30

40

50

60

70

80

90

100

Machine 0 Controller Utilization By Month

MonthOct 2010 Nov 2010 Dec 2010 Jan 2011 Feb 2011 Mar 2011

CassaAfflusso Ceneri Grammatura PastaalSecco Umidita1Umidita2 VelocitaCoordinata

Month

CassaAfflusso 82.03 93.17 74.21 86.24 88.11 91.76Ceneri 80.18 90.03 71.64 84.14 83.04 89.40

Grammatura 79.76 90.68 71.65 83.14 84.86 88.78PastaalSecco 0.00 0.00 0.00 9.37 14.79 16.60

Umidita1 74.89 86.86 70.92 78.76 78.61 86.62Umidita2 60.47 53.39 47.35 54.85 58.17 55.24

VelocitaCoordinata 34.75 35.84 25.32 37.92 30.81 35.73

Goal >95%

1

QCS Performance Fingerprint: Tuning Number KPI’s

© ABB Group


Value High Limit Low Limit Value High Limit Low Limit Value High Limit Low Limit Value High Limit Low Limit

Name DW01_Control MT01_Control MT02_Control AC01_Control

Description Reel Bone Dry Reel Moisture Size Moisture Reel Ash

MV and SP Units (cu) lbs/ream % % %

Output Units (cu) % % % %

Number of Decimals 2 2 2 2

Range Maximum (cu) 100 20 20 30

Range Minimum (cu) 0 0 0 0

Maximum Setpoint (cu) 100 20 20 30

Minimum Setpoint (cu) 0 0 0 0

Setpoint Ramp (customer/sec) 0.200 1.000 0.010 0.100 1.000 0.010 0.100 1.000 0.010 0.060 1.000 0.010

Deadband (fraction) 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Normal Control Error (fraction) 0.300 0.300 0.100 0.300 0.500 0.200 1.000 1.000 0.200 0.200 0.300 0.100

Control Error Sp Change (fraction) 0.300 0.400 0.100 0.400 0.500 0.200 1.000 1.000 0.200 0.300 0.400 0.100

Control Model Filter (sec) 40 80 20 40s 100 30 50s 100 30 1m40s 180 40

Filter for Control (1=MDMS, 2=Filt MDMS,

3=FWPM, 4=Advanced) 3 3 3 3 3 3 3 3 3 3 3 3

Filter for Display (1=MDMS, 2=Filt MDMS,

3=FWPM, 4=Advanced) 3 3 3 3 3 3 3 3 3 3 3 3

Extended Sheet Break Time (sec) 20s 180 0 20s 180 0 20s 180 0 20s 180 0

Minimum Control Speed (cu) 10 200 5 10 200 5 10 200 5 10 200 5

Extended Control Speed Time (sec) 20s 180 0 20s 180 0 20s 180 0 20s 180 0

Download Auto Mode Restore FALSE 0 0 FALSE 0 0 FALSE 0 0 FALSE 0 0

Modeling Value High Limit Low Limit Value High Limit Low Limit Value High Limit Low Limit Value High Limit Low Limit

Process Response (proc/actr) 0.026 0.2 0.005 -0.100 -0.05 -0.5 -0.100 -0.05 -0.5 0.021 0.1 0.01

Process Response Gain (unitless) 1.200 1.3 0.7 1.000 1.3 0.7 1.000 1.3 0.7 1.000 1.3 0.7

Process Response Final Calculated 0.031 0.2 0.005 -0.100 -0.05 -0.5 -0.100 -0.05 -0.5 0.021 0.1 0.01

Process Time Constant (sec) 52s 80 25 1m00s 120 40 1m10s 120 40 2m00s 180 60

Transport Distance (distance) 1100 2000 300 350 1000 100 450 1000 100 1100 2000 300

Actuator DeadTime (sec) 1m00s 120 20 1m00s 90 10 1m10s 90 10 1m30s 180 60

Closed-loop Time Constant (TAU) 1.5 3 1.2 1.5 3 1.2 1.5 3 1.2 1.5 4 1.5

Max Actuator Change (actr/sec)) 300 500 100 50 100 20 50 100 20 1.5 200 20

Max Actuator Change in AGC mode (actr/sec) 500 500 100 50 100 20 50 100 20 1.5 200 20

Feed Forward (stock flow) Value High Limit Low Limit Value High Limit Low Limit Value High Limit Low Limit Value High Limit Low Limit

Enable TRUE 1 0 TRUE 1 1 FALSE 0 0

Process Response 0.015 0.05 0.005 0.018 0.000 0.5 0

Process Resp Gain 1 1 1 1 1 1 1 1 1

Process Time Constant 50s 80 25 20s 80 25 52s 80 25

Transport Distance (Feet) 1100 2000 300 700 2000 300 500 2000 300

Actuator Deadtime (Sec) 1m00s 120 20 1m00s 120 20 1m00s 120 20

Filter Time 0s 20 0 0d0h0s 20 0 0s 20 0

Error Check (frac of SP) 1 1 0.2 1 1 0.2 1 1 0.2

Additional ChecksControl Model Filter Matches Process Time

Constant

Stock Feed Forward Time Constant matches

Stock to Weight Time Constant

Ratio of Feedforward time constant to primary

process time constant is not greater than 2.5

Feed forward filter is only used when feed

forward is tuned as a lead action

Weight Reel Moisture Size Moisture AshConfiguration

Tuning Check

Advanced Controls

Speed

Auto grade

MD Tuning Numbers

Scan Level

Modeling

Feed forward

Level 1

CD Tuning Numbers

Tuning

Modeling

Setup/Tuning Validation

Limit Check

Cross Check

QCS Performance Fingerprint: Sensor Stability

© ABB Group


Standardize Reports

Ensure reliable measurements

Check Sample Reports

Ensures repeatable measurements

Calibrate Sample

Ensures exact process measurements

0

1

Standardize Problems

Sta

ndari

ze P

roble

m S

en

sors

Air Column StdzAsh Stdz

Brightness StdzCaliper Stdz

Color StdzFormation Stdz

Moisture StdzOpacity Stdz

Weight Stdz

5

6

7

8

9

10

-1.0

-0.5

0.0

0.5

1.0

0

2

4

6

8

10

10

20

30

40

50

0

20

40

60

80

100

10

20

30

40

50

8 Thu

Jan 2009

15 Thu22 Thu 1 Sun 8 Sun 15 Sun22 Sun 1 Sun 8 Sun 15 Sun22 Sun

Frame 1:Caliper - Caliper Standardize

Sen

sor

Max

Sen

sor

Nois

e

Sen

sor

Zero

Bot

Pre

ssu

re

Sta

tus

Top

Pre

ssu

re

Sensor Max Sensor Noise Sensor Zero

Bot Pressure Status Top Pressure

1

© ABB Group



Harmony Fingerprint uses Harmony Analyzer

Firmware

Loading •GMI Suppression of Exception Reports

•Process Control Unit Overload

•Control way Problem Evidence

•TMax Exception Period Collision

•Error Counters

Jumpers

1

Control System Performance Fingerprint:

• Proprietary analysis tools

• Defined Scope

• Trained Engineers

System Issues

Harmony Diagnostic Tools Overview

© ABB

Aug 13, 2012 | Slide 29

Harmony Diagnostic Tools: semAPI

Harmony Direct (OPC Server)

DL300 (Datalogger)

HPA200 (Analyzer)

Prerequisites: CIU (ICT03/13) on central loop

Local bridges consist of IIT03 w/ B.4

firmware

1 Fingerprint can contain up to 3 loop,

50 PCUs per loop

Analyzing Diagnostic Data Harmony Performance Analyzer (HPA200)

© ABB

Aug 13, 2012 | Slide 30

The Harmony Performance Analyzer is used to analyze the collected data from the DL300 and provide valuable information using graphs and

tables that could help improve system performance.

Harmony Analyzer (HPA200) System Layout

© ABB

Aug 13, 2012 | Slide 31

The Harmony Analyzer provides a system topology layout. Each scanned loop becomes available for viewing. All PCUs, CIUs, and Bridge

nodes become visible in proper node order.

Harmony Analyzer (HPA200) Firmware Audit

© ABB

Aug 13, 2012 | Slide 32

A firmware audit can be conducted using the HPA200. Each module’s firmware revision is compared to the latest released revision. The HPA200

highlights modules with outdated firmware. Major revision changes are shown in red and minor changes are highlighted in yellow.

Harmony Control System Fingerprint Report

© ABB

Aug 13, 2012 | Slide 33

The report summarizes the system and any issues found. Each issue is given a recommended plan of action for an engineer

to tackle. Auto-generated reporting will eventually become an added feature to the Harmony Analyzer.

ServicePort – Scan solution

© ABB Group


OS -35

Return On Investment

Steady State -Variability Reduction

Target Shift

Quality Improvement

Less Broke as related to variability

Improved Lab test

Sheet Break reduction

Disturbance Rejection

Transient

Grade/Shade Change

Sheet Break recovery time – MD

Sheet Break recovery time – CD

Reduced Start Up time

© ABB Inc.


Machine

Response

Product

Variability

Stock

Approach

Stability Poor regulation

Offset from setpoint

Good regulation

Fingerprint: Weight and Moisture

0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17

COV Moisture = 36.45

Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 10 15 20 25 30 35 40 45 50 55 60 65

Actual vs. Calc. Profiles for 1 inch Zones

Profi

le

Zones

Actual Calculated

Profiling

Capability S

igm

a

Current Potential

Evaluates: Cyclic content of Weight and

Moisture in: Cross Direction and Machine

Direction from High Frequency up 500Hz

down to Low Frequency of 5 hours.

Evaluates: Automatic and

Manual mode operation of:

Weight, Moisture, and Total

Head.

Evaluates: On control

Performance and model for:

Weight, Moisture, and Caliper

Evaluates: On control

Performance of: Total Head,

Thick Stock Flow, Thick Stock

Consistency, Machine Chest

Level

Provides information on:

• Start up time

• Grade Change recovery

• Disturbance reduction

• Sheet break recovery

• Responsiveness


• Controllable Energy

• Mechanical Pulsations of vibrations

• Benchmark of machine stability


• Controllable Energy

• Stock Approach performance

• Tuning Quality

• Oscillation sources


• Will CD control improve the profile?

• Is current CD control optimized?

Fingerprint: Paper Machine

History (VPA)

OS

-3

7

Spectral Overlay

0.000

0.005

0.010

0.015

0.020

0.000

0.025

0.050

0.075

0.100

10-3 10-2 10-1 100 101

Sensor m100 Power Spectrum Comparison

BW11 m1

00MW

11 m100

Frequency (Cycle/Time)

0.000

0.005

0.010

0.015

0.020

0.025

0.000

0.025

0.050

10-2 10-1 100 101 102

Sensor M1k Power Spectrum Comparison

BW11 m1

kMO1

1 m1k


0.0000

0.0005

0.0010

0.0015

0.0020

0.0000

0.0025

0.0050

0.0075

0.0100

10-4 10-3 10-2 10-1

Overnight Power Spectrum Comparison

/AI C

hann

el/1M

E1.C

W11M

V:VA

LUE

1MT1

CTRL

:MV


Weight

Moisture

Weight

Moisture

Weight

Moisture

Single Point

1000Hz sample

3.4 min duration

Single Point

100Hz sample

34 min duration

Scanning

0.5Hz sample

5.7 Hrs duration

9.8 Min 17 Min

0.36 Hz

60 Hz

12 Hz

OS

-3

8

PM Fingerprint: Product Variability

0

10

20

30

40

50

60

70

80

Fingerprint Comparison - % Total COV

Co

mp

ariso

n

CD Decade 1 Decade 2 Decade 3 Decade 4 Decade 5 Decade 6

Weight Moisture

Weight 25.3743210 50.5483932 6.1163764 1.8690249 6.7068100 3.6419485 5.7431183 Moisture 2.2876263 84.7719421 3.6153731 0.5106572 0.8314567 2.8962073 5.0867424

QCS DCS Mechanical

Provides a summary of

the cyclic energy in the

sheet over a

corresponding frequency

band.

Includes Cross direction,

Weight and moisture up to

100 hertz.

OS

-3

9

PM Fingerprint: Machine Response

0

5

10

15

20

25

30

Machine Response IndexTotal = 38.476

Comp

ariso

n

1 2 3

Total Head Weight Moisture

Total Head 32.733Weight 3.040

Moisture 2.703

Acceptable

Performance

Provides an index for the

regulatory capability of

the control application. Machine

Response

Product

Variability

Fiber

Line

StabilityPoor regulation


Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5

A c tu a l v s . C a lc . P r o file s fo r 1 in c h Z o n e s

Pro

file

Z o n e s

A c tu a l C a l c u l a te d

Profiling

Capability

Sig

ma

Current Potential

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

OS

-4

0

PM Fingerprint: Machine Response

0

5

10

15

20

25

30

Machine Response IndexTotal = 38.476

Comp

ariso

n

1 2 3

Total Head Weight Moisture

Total Head 32.733Weight 3.040

Moisture 2.703

Acceptable

Performance

Provides an index for the

regulatory capability of

the control application. Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

1 2 8 .0

1 2 8 .5

1 2 9 .0

1 2 9 .5

1 3 0 .0

8 5 .0 0

8 5 .2 5

8 5 .5 0

0 5 0 1 0 0 1 5 0 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0 4 5 0 5 0 0 5 5 0 6 0 0

T o ta l H e a d : B o t to mT D H 3 0 - 4 6 0

SP

an

d M

VO

utp

ut

D a ta P o in ts , T s = 5 s e c

Automatic Mode

Closed Loop Test

SP Change

Manual Mode

Open Loop Test

Output Change

Also, visible signal

conditioning problems present

OS

-4

1

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

PM Fingerprint: Stock Approach Stability

0

1

2

3

4

5

6

7

Fiber Stability IndexTotal = 7.8261

Comp

ariso

n

1 2 3 4

Total Head Chest Level Stock Flow Consistency

Total Head 0.1115000Chest Level 7.4440999Stock Flow 1.9641000

Consistency 1.4011000

Acceptable

Performance

Index points to Machine chest level

as the primary problem

Indicates the stability of the

fiber line. A high index

suggests problems related to:

process, control, mixing, etc.

OS

-4

2

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

PM Fingerprint: Stock Approach Stability

0

1

2

3

4

5

6

7

Fiber Stability IndexTotal = 7.8261

Comp

ariso

n

1 2 3 4

Total Head Chest Level Stock Flow Consistency

Total Head 0.1115000Chest Level 7.4440999Stock Flow 1.9641000

Consistency 1.4011000

Acceptable

Performance

Index points to Machine chest level

as the primary problem

Indicates the stability of the

fiber line. A high index

suggests problems related to:

process, control, mixing, etc.

130

135

60

70

80

1800

1850

1900

4.1

4.2

0 250 500 750 1000 1250 1500 1750

Fiber Stability TrendsP oints = 1681

Total

Hea

dCh

est L

evel

Stoc

k Flow

Cons

isten

cy

raw data

Raw Data Trend (~5 hours) shows

that chest level impacts consistency

and stock flow.

OS

-4

3

PM Fingerprint: Profile Capability

-3.5

-3.0

-2.5

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

0 10 20 30 40 50 60 70 80 90

Actual vs. Calc. Profiles for 7.14 inch Zones

Profi

le

Zones

Actual Calculated

2 Sigma

• Original 0.54

• Capability 0. 38

• 30% Potential

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07

Calc. Power SpectrumPoint Width = 7.14

Powe

r (va

rianc

e)

Frequency (Cycle/Distance)

Actual Calculated

Power Spectrum

Current and

Forecast

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

Machine

Response

Product

Variability

Fiber

Line



Good regulation


0

20

40

60

80

100

CD

Deca

de 1

Deca

de 2

Deca

de 3

Deca

de 4

Deca

de 5

Deca

de 6C

OV

as a

perc

en

t o

f to

tal

weight

moisture

COV Weight = 5.17


Slow response

Fast response

Cyclic response

-7

-6

-5

-4

-3

-2

-1

0

1

2

3

0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5


Pro

file

Z o n e s


Profiling

Capability

Sig

ma

Current Potential

Using process data, setup information,

controller type, ABB can predict what

the capability of a current or new set of

actuators can do.

OS

-4

4

Fingerprint Block Diagram - Schedule

Paper Machine

Production

Data

Process

Data

VPA MR SS PC PV

RO

I

Exit Meeting: Benchmark, Initial findings and recommendations

Final Reports: Executive, Technical, and

Implementation Plan

Analysis

Final Analysis

Daily Activity List

Power Point per area

Week 1

Week 2

© ABB Inc.


High Frequency Results

0.0

0.1

0.2

0.3

0.00

0.25

0.50

0.75

0.0

0.2

0.4

10-5 10-4 10-3 10-2 10-1

Amplitude Spectrum ComparisonP oints = 131072

Basis W

eight

Moisture

1Mois

ture2

Cycles/PointX1000 Hz

Frequency Period BW MT1 MT2 diameter length Potential Source0.061 16.38 0.27 0.8 0.44 265 832 Machine Chest Level?

0.36 2.78 0.048 0.33 0.358 45.1 141.7 Top Felt

0.71 1.39 0.046 0.29 0.25 22.6 70.8 Wire?

1.84 0.54 0 0.298 0 8.76 27.5 ?

3.15 0.317 0.07 0.38 0 5.13 16.1 After Section Dryer

6.3 0.159 0.09 0.55 0 2.56 8.06 After Section Dryer

10.3 0.1 0.07 0.26 0.12 4.9 1.56 fan pump?

(Yankee speed = 3049fpm)

Amplitude

A

B

C

D

E

F

G

A E D C B G F

Single Point Frame data

collected at 100 Hz and

1000 Hz for complete high

frequency picture.

Provides insight into

pulsation and vibration in

both weight and moisture

OS

-4

6

Machine Chest Level Control Logic

65.0

67.5

70.0

72.5

75.0

55

60

65

70

75

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Raw Data

PM1_

AC45

0B_U

DMISC

_LI20

-331_

I_abb

svr_A

ccuR

ay_O

bjePM

1_AC

450B

_UDM

ISC_L

T20-3

10_I_

abbs

vr_Ac

cuRa

y_Ob

je

Sample Number, Ts = 5 , Total Samples = 7304

Manual

Operation

New

Control

Manual

Operation

New

Control

Control Logic Added,

Improvement > 90%

To

p C

he

st

Le

ve

l

B

ott

om

Ch

est

Le

ve

l

Diagnose: Fiber Stability Index High due to poor Machine chest regulation.

Implementation: Found that the poor Machine chest regulation was a control logic

problem. The logic was corrected, the loops were re-tuned, and the variability dropped by

over 90%

Sustain: Teach operators how to use new control logic, changed the SOP to make sure

control stayed in range.

OS

-4

7

Weight Before vs. After Tuning Changes

42.0

42.5

43.0

6

7

8

8300

8400

8500

4000 4500 5000 5500 6000 6500 7000 7500 Sample Number, Ts = 5 , Total Samples = 8653

Before After

Conditioned Weight

Moisture

Stock Flow

Improvement

45%

45%

50%

Additional 20 to 30% potential with improved stock flow regulation

OS

-4

8

Headbox 2 Before Vs After Tuning

07PIC2201 G: 6 to 2.2, Ti 11 to 13

07LIC2202 G: 1.4 to 0.6

Before After

OS

-4

9

Base Stock AI Setup Change

2300

2310

2320

2330

54.75

55.00

55.25

55.50

55.75

850 900 950 1000 1050 1100 1150 1200

Raw Data

Sample Number, Ts = 5 , Total Samples = 3242

07FIC101:MV 07FIC101:WSP

07FIC101:POUT 07ZI100.AI:VALUE

MV Deadband changed from 0.4% to 0.0%

Loop Performance Fingerprint

Evaluates: Overnight data - along

with the current DCS current loop tuning

parameters are used to benchmark DCS control

performance .

Evaluates: Bump

Tests - Performance of the

DCS control loops within two

categories including control,

process, and signal

conditioning issues.

Evaluates: Historical

Data - Process and control

loop interactions. Identifies

true source of process

disturbances.


• Over and under control

• Output Oscillation

• Offset and out of range loops

• Limit cycle and manual mode

• Control loop tuning validity


• Process and interactions

• Product Variability

• Raw material supply


• Process upset response

• Bad Valves

• Over filtering

• Quantized signals

• Noisy signals

Root Cause Analysis

Loop Tuning

Evaluation

Process Stability

Proportional

Inte

gra

l

Pressure Control Tuning

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Proportional

Inte

gra

l


0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Proportional

Inte

gra

l

0

1

2

3

4

5

6

7

8

9

10

11

Process Stabilit y Index

Occurr

ence

Oscillation Strange Bad Valve Process Out Of Range No Signal

27.10

27.12

27.14

27.16

27.18

27.20

27.22

27.24

27.26

27.28

27.30

27.32

42.0

42.1

42.2

42.3

42.4

42.5

42.6

42.7

42.8

42.9

43.0

43.1

93 421 749 1077 1405 1733 2061 2389

26-PIC-0334

MV

OU

T

26-PIC-0334.MV

26-PIC-0334.OUT

Operations interview to

define loop priority

Control Goals

Controller-

Set Point

Error Output

Controller Process Signal Conditioning

Controller Process FCE - Set Point Actual Process

Measured Process

Sensor

Disturbances

Error Output Input

Reduce error: SP-PV Insure Output impacts

Process

Minimize difference between actual

and measured process

Process FCE Actual Process

Disturbances

Output Input

Actual Process

Measured Process

Sensor

CONTROL PROCESS SIGNAL CONDITION

C1: Static Output P1: FCE Out of Range S1: Dead Signal

C2: Over tune P2: FCE Size S2: MV Out of Range

C3: Slow tune P3: FCE Broke S3: Quantization

C4: FCE travel P4: Calibration / FCE Leakage S4: Compression

C5: Offset P5: Intermittent Disturbance S5: Excessive Noise

C6: Error Deadband P6: Persistent oscillatory Dist. S6: Spikes

C7: Setpoint Oscillations P7: Questionable S7: Step Out

C8: Controller update rate slow S8: Over filter

C9: Questionable S9: Sampling rate

S10: Questionable

Signal

Conditioning

© ABB Group


Terms

Signal Conditioning: Getting the measurement to the controller with as “true” a signal as possible! (~15 items)

Sample time, Filtering, Quantization, deadbands, compression, compensation, calibration, saturation, decimal points, Dead Signals, Spikes, Outliers, non-Gaussian noise, Noise bursts, square root extraction.

Process: Ensuring that the FCE to Actual Process (Transfer Function) is repeatable and predictable. (~21 items)

Disturbances that are more powerful than the FCE, Process nature changes, process nonlinearity (sideways tank), FCE failure: Stiction, Backlash, hysteresis, resolution (on time, pulse width), valve size, valve type, DP drop across valve, cavitation, vena contracta, valve positioners, cams, electronic cams, VFD, process out of range.

Control: Deals with keeping the error near or at zero. Means is we want the MV to track the SP. (~25 items)

Tuning parameters, algorithm type, Setup parameters related to hi and low setpoint, output, and PV ranges, number of decimal points, Controller execution rate, Control deadbands, Additional degrees of freedom such as non linearity compensation options: gain scheduling, “beta” factor, adaptive control, out of range: wind up, loop is off(manual), offset from setpoint, rate of change of output, rate of change of setpoint, filtering.

ProcessFCE Actual ProcessSensor

Disturbances

Output Input

Process Actual Process

Measured Process

Sensor

Signal Conditioning Process

Controller-

Set Point

Error Output

Control

KPI Determination

Data

Mathematical Formulations

KPI

Rules

Diagnoses

Solution Surface

Loop Performance

Setpoint

Measured Value

Output

Mode (Optional)

Setup

Tuning Parameters

KPI Navigation

Trend Visualization

KPI sorted by severity

KPI sorted by number of problems

Overall rating for KPI Categories

Loop Analyzer

Loop Performance KPI’s

• Control

• Process

• Signal Conditioning

Sorting on KPI severity

Oscillating

Output Manual

Over

Control

Output

Out Of

Range

Slow

Control

Oscillating

Setpoint Offset Deadband Noisy Spikes Quantized

Over

Filtered Oscillation Strange

Bad

Valve

Process

Out Of

Range

1 LIC21-1115

PIC21-

1112

LIC21-

1132

LIC21-

1081

1MT1.CT

RL FIC101ST

LIC21-

1095 FIC21-1110 FIC20-311

LIC21-

1146 TDH30-460 LIC21-1101

PDIC11-

1006

LIC21-

1132

FIC30-

1403

2 PIC21-1140

LIC21-

1146 PIC20-301

LIC21-

1115 FIC20-335 1PL1.CTRL FIC30-425

FIC21-

1112 LIC21-1147 LIC11-030

LIC21-

1095

LIC21-

1125

FIC30-

1402

3 LIC21-1101

PIC21-

1103B

FIC21-

1114

LIC21-

1101

FIC21-

1108 FIC20-311 FIC20-335 1MT1.CTRL

FIC21-

1154 FIC30-425

4 LIC21-1125

FIC21-

1156

CIC21-

1129

PIC21-

1140

FIC21-

1109

NIC30-

772:MV FIC21-1114

FIC21-

1092

PIC21-

1140

5 LIC21-1132

FIC21-

1154

PIC21-

1150

LIC11-

1001

RIC21-

130

FIC21-

1113 LIC21-1115

FIC21-

1155 BP_SIZE

6 PIC21-1145

FIC21-

1092 LIC20-310

LIC21-

1132 FIC101ST

PIC21-

1103B LIC21-2005

FIC21-

1107

7 LIC21-2005

LIC21-

1147

FIC21-

1110

1PL1.CTR

L

PIC21-

1145 PIC20-301

8 PIC20-301

PIC21-

1112A

FIC21-

1107

FIC21-

1114

FIC21-

1003 PIC21-1140

9 FIC21-1114 LIC11-030 LIC30-462 BP_SIZE 1PL1.CTRL

10 PIC21-1150

FIC21-

1112

CIC21-

1129 RIC21-130

11 LIC20-310

FIC21-

1003 PIC20-301 LIC21-1132

12 RIC21-130

PDIC11-

1006 LIC30-462

1SP.CTRL:

MV

13 BP_SIZE

FIC21-

1113

LIC21-

1132 LIC30-462

14 FIC30-425 LIC20-310 LIC20-310

15 LIC30-462

FIC21-

1113

16

1DW1.CT

RL

17

1MT1.CT

RL

18

FIC21-

1110

19 FIC20-335

20

FIC21-

1155

21

FIC21-

1107

22

LIC11-

1001

Control Signal Conditioning Process

Classification

KPI Reporting

Supports Loop Performance

Fingerprint

© ABB Inc.


Loop Performance Fingerprint Loop Analyzer – Performance Calculations

Navigation

options

Diagnosis

results

in tree

Loops Ranked

for selected

Diagnosis

Diagnosis results in frame for selected loop

Navigate by

clicking on

bars

© ABB Inc.


Loop Performance Fingerprint Loop Analyzer – More Plots

Plot types

Quick comparison plots, any plot

type, one tag frozen on top half

Power Spectrum

Histogram

Group Trend

© ABB Inc.


Loop Performance Fingerprint Final Control Element Problem

This is a flow controller that is the inner loop of a cascade.

Exhibits classic stiction

Controller output ramps up and down in triangular pattern

Process variable moves in square wave

Loop Analyzer on Compressed Data

Compressed Data resulting in wrong classification

© ABB Inc.


Loop Performance Fingerprint Report

The report highlights some loops, as shown in the previous

slides and summarizes the results in tables. This table is

for the TFE Synthesis section of the plant.

© ABB Inc.


Loop Performance Fingerprint Plant wide Disturbance Analysis

Disturbances in chemical plants act on many process variables

LC1

TI1

TI7

DP1

TI6

TI2

TI3

DP2

TI4

LI2 TI5

TC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1TI2

TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

Disturbances can propagate counter flow because of recycle and

thermal integration

© ABB Inc.




LC1

TI1

TI7

DP1

TI6

TI2

TI3

DP2

TI4

LI2 TI5

TC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1TI2

TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1

TI2 TI1

DP2

LI2

DP1

LC1


thermal integration

© ABB Inc.


Loop Performance Fingerprint PCA Cluster Example

Find signals with

similar patterns,

probably due to

disturbances

Not looking for

oscillating signals

Here all signals are

in two columns that

are adjacent

© ABB Inc.


Implementation Example PID Loop Parameter Example

Improved tuning after

implementation phase

The tuning documented

during Fingerprint

Questionable

Range

Sweet Spot

Signal Analysis

LoopTune: Implementation improvements


Analysis

Identification

Tuning and Simulation

LoopTune Standard Reporting

Visualization

and Setup

Collection

LoopTune

Results stored as a LoopTune channel in ServicePort

Provides long term process model tracking.

Supports

Self Regulating

Non-Self Regulating

Auto Model Identification

LoopTune: Tuning/Simulation

Supports

800xA Controllers

Harmony/Infi90 Controllers

Mod300 Controllers

Generic industry standard controllers

Plug in modules for custom controllers

LoopTune: Loop Tuning Report

Automatically generates

Loop Tuning Reports



Example of improved control loop performance

Original Tuning

(Unstable)

New Tuning

Manual Operation

Much

Better

AGP400: High Speed Data Collection

© ABB Group


Portable

or

Continuous

P/V Kit



Sequence Analysis

Multiple Changes

Custom Trend Visualization

Detailed Analysis

Standard KPI

Transition

Time Deviation Error

Prediction

Accuracy

KPIs

Batch Analysis Overview of Methodology Define Event Marking

Perform Aggregate Statistics and KPI’s Data View

Batch Process

Sequence 3

Segment Definitions

Sequence Definition options: leading edge, falling edge, time

trigger, user defined, external triggers, logical conditions

Sequence 1

Sequence 2

© ABB Group



Introducing Performance Channels

Goal: Maintain improved

performance level

Adjust service operating

procedures

Improve standard operating

procedures

Remote Capable monitoring

Specifics are a function of the

Implement phase

Periodic monitoring of key

process indicators utilizing

local or remote expertise

© ABB Group


Scan/Track: Remote Enabled Delivery Options

Root Cause

Analysis

Loop Tuning

Evaluation

ProcessStability

Proportional

Inte

gra

l


0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Proportional

Inte

gra

l


0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Proportional

Inte

gra

l

Proportional

Inte

gra

l


0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Proportional

Inte

gra

l


0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Proportional

Inte

gra

l

0

1

2

3

4

5

6

7

8

9

10

11

Process Stabilit y Index

Occurr

ence

Oscillation Strange Bad Valve Process Out Of Range No Signal

27.10

27.12

27.14

27.16

27.18

27.20

27.22

27.24

27.26

27.28

27.30

27.32

42.0

42.1

42.2

42.3

42.4

42.5

42.6

42.7

42.8

42.9

43.0

43.1

93 421 749 1077 1405 1733 2061 2389

26-PIC-0334

MV

OU

T

26-PIC-0334.MV

26-PIC-0334.OUT

Packaged Services

(Fingerprint)Periodic

(LoopScan)

Continuous

(LoopTRACK)

Root Cause Analysis

Cluster Analysis

Loop Stability

KPI

KPI

KPI

TroubleshootingLocal DeliveryAutomated

Reporting

Event

Reporting

Notify

Alarm

Phone

email

Message

Trigger

Diagnose Sustain

Corr

ective A

ction

Implement

Local Remote Enabled Delivery

3


ABB’s Advanced Process Control Methodology

Stabilize

Process -

Loop

Performance

Fingerprint

Process

Interaction

Matrix

Identification -

APC

Fingerprint

APC

System

Solution

(MIMO)

Process

Interaction

Matrix

Identification -

APC SCAN

Monitor

Performance

LoopSCAN

Pre Study + Implementation

Quick Customer Value

Project delivery improved

Installation and

commissioning Periodic Service

No results erosion

Continuous Improvement

Proven Approach

Service Service

3

© ABB Group


Technical Tool Architecture

System

Hardware

Software

Control

Process

Sort Notify

Driver

Event History: KPI + Data

Optimization Tools

KPIs

Structured

Data Alarm

Phone

email

Message

Trigger

Fingerprint

Report

Scan Report

Track

Report Get

View Analyze Interpret Report

Unique Solutions

Common Infrastructure

DataPro

Data Segments

Service Applications

LCS Service

Data file

KPI

File User

ABB Applications

Key:

Technical Tools

Analyzer

Engine

Application

User Interface Fingerprint

Report

OPC

DL300

Data

Logger

Diagnostic Service Tools

Stand alone

User Driven

File based

Implementation

Corrective Action:

Tuning, Software,

Hardware, etc.

Stand alone – Technical Tools

Establish Value

Proof Statement

Standard Apps: Boiler Fingerprint

Alarm/Event Fingerprint

System Performance

Loop Analysis

Transition Analysis

Batch Analysis

Tuning

APC Fingerprint

LCS Service

Data file

KPI

File User

ABB Applications

Key:

Technical Tools

Analyzer

Engine

Application

User Interface Fingerprint

Report

OPC

DL300

Data

Logger

Diagnostic Service Tools

Stand alone

User Driven

File based

Implementation

Corrective Action:

Tuning, Software,

Hardware, etc.

Stand alone – Technical Tools

Scan Services

Regular

Track Services

Monitoring

ServicePort

Establish Value

Proof Statement

Standard Apps: Boiler Fingerprint

Alarm/Event Fingerprint

System Performance

Loop Analysis

Transition Analysis

Batch Analysis

Tuning

APC Fingerprint

© ABB Group



ABB ServicePort – Access to Efficiency!

The ABB ServicePort is the secure

portal through which customers access

configuration tools, diagnostic

applications, improvement activities,

performance-sustaining troubleshooting,

and scanning software that deploys

agreed actions. ABB can connect to any

system through ServicePort, which

resides at the customer site, and

implement fixes to diagnosed problems.

Regular delivery of Scan and Track services can

be done safely and securely with ABB’s

ServicePort.

© ABB Group


ServicePort topology

Drives OCS Operator Stations Historian Instruments/

Actuators

Customer-Defined Access

Service Capabilities

APC Scan/Track

Services

Control Tuning Optimization

Services

Event

Notification

Support

Services

Software

Support

Remote

Troubleshooting

System

Health Check

DriveScan/Track LoopScan/Track HoistScan/Track ServicePro

Troubleshooting

Services

System Scan/Track

Engineering Stations

Local

Remote

Secure Access

Customer-Defined Access

Secure Tunnel

Firewall

ServicePort: Data Flows

800xA

Loop

Analyzer

Loop

Tune

Loop

Channel

Loop

Tune

ServicePort Explorer

Standard OPC

Batch

Analyzer

Batch

Channel

OCS OPC Direct

PDA

Analyzer

PDA

Channel

Alarm

Analyzer

Alarm

Channel

ABB

OPC

Data

Logger

(DL300)

800xA Standard OPC Raw

Data HSD500 OPC

© ABB Group


ServicePort Explorer

Define/Search

for Triggers

ServicePort

Explorer

Channels

KPI1 Engine KPI2 Engine KPIn Engine

Event 1 Event 2 Event n

Explorer: View/Scan/Track Service Channels

• Process

• Platform

• System

• Drives

. . .

Service Channel Components

SCAN

TRACK

View

Goal Present

Math

Function

KPI(s)

Rules

Gap> rule= Alarm

Trend for Experts

• Expert level.

• Visual validation.

• No automatic triggers.

• Data arranged by asset requirements.

• Determination of a KPI that is

proportional to expert evaluation.

• Defines good and bad

performance.

Seve

rity

• Continuous evaluations of KPI

calculations and reporting.

• Tailored to customer requirements

of asset criticality.

ServicePort Explorer – Dave View

1. Select ServicePort – Displays navigation Menu 2. Expand Performance Analysis menu item

3. Expand Channel 10.1 – View

4. Select DataView. This will cause the display that is shown to appear 5. Next Select a loop name and a time event. The SP, MV, and Out along with loop

KPI’s will be displayed

ServicePort Explorer – Scan: Event and Time Views

1. Select ServicePort – Displays navigation Menu 2. Expand Performance Analysis menu item

3. Expand Channel 10.2 – Scan

4. Select EventView. This will cause the display that is shown to appear 5. Next Select a time event. The number of loops with problems related to control,

signal conditioning, or Process for this time event will be shown.

6. KPI Level 1 and Level 2 Pareto charts can be drilled into from the top drop down menu.

7. Historical Trends of KPI’s per event can be evaluated by selecting Time Based View

In this case, the

Signal Conditioning

KPI’s indicate a

large number of

violations.

ServicePort Explorer – Scan: Level 1 Event view

In this case, data compression is the cause of the signal KPI violations. This causes analysis results to be less accurate

ServicePort – Data View

ServicePort Explorer – Improved Navigation

Much Faster presentation of information.

ServicePort Explorer – Track (Near Future Release)

User builds Notification Rules.

Rules are logical expressions comparing KPI’s to thresholds of interest.

Violations will be stored in an event list or sent via email for support

User can pick the KPI of interest

© ABB Group


Sustain: Scan KPIs to ensure improvement

1

KP

I T

rac

kin

g

Kpi1

Kpi3

Kpi2

Kpi4

Q1 Q2 Q3 Q4

Delivery Schedule

Production

increase!

Variability

decrease!

Continuous

Improvement

LoopScan Performance Service Report

Statistical Evaluation of Historical KPI’s performed twice a year

Ensures stability of KPI’s

Reduces the risk of false positives

Keep up to date with process

Crucial to ensure continuous improvement

Service Delivery – Single Channel Delivery model

January December

SCAN Service Report: SCAN Analysis /report/Implementation planning/ Notification Validation

On Demand Service: Remote troubleshooting assistance/Track Triggered

Calibration Fingerprint/Training

Regular Performance Calculations/evaluations/Daily Usage

Pharma Oil and Gas

Chemical Channel Offerings

Industrial Automation

Loop Performance

Batch Performance

Transition Performance

Plant wide disturbance analysis

LoopTuning

OEE

APC Interactions

Platform Diagnostic Services

Harmony Performance

800xA Performance

Alarm and Event

Security

Drives

GMD

Low Voltage

Minerals

Hoist Performance

Dragline

Pulp and Paper

VPA

Control Utilization

Standardize

Check Sample

Calibrate Sample

Machine Direction Grade

Change Transition

Batch

Sheetbreak recovery

Startup efficiency

Profile performance

Profile transition

profile recovery

Profile tuning

Machine Direction QCS

Tuning

Product Variability

Machine Response

Profile Capability View Options: View – Scan - Track

Pharma Oil and Gas

Chemical Channel Offerings

Industrial Automation

Loop Performance

Batch Performance

Transition Performance

Plant wide disturbance analysis

LoopTuning

OEE

APC Interactions

Platform Diagnostic Services

Harmony Performance

800xA Performance

Alarm and Event

Security

Drives

GMD

Low Voltage

Minerals

Hoist Performance

Dragline

Pulp and Paper

VPA

Control Utilization

Standardize

Check Sample

Calibrate Sample

Machine Direction Grade

Change Transition

Batch

Sheetbreak recovery

Startup efficiency

Profile performance

Profile transition

profile recovery

Profile tuning

Machine Direction QCS

Tuning

Product Variability

Machine Response

Profile Capability View Options: View – Scan - Track

Customized Service

from

Proven Solutions

Service Delivery – Multi Channel Delivery model

January December

Scheduled SCANService: SCAN Analysis /report/Implementation planning/ Notification Validation

On Demand Service: Remote troubleshooting assistance

Calibration Fingerprint/Training

Periodic Performance Calculations/evaluations: Time based, Event based

Time

Event

Channel – Process/Equipment

ServicePort Pilot sites

© ABB Group


SCA Eerbeek, NL

Gasco Habshan, AE

Glatfelter Chillicothe, OH, US

ABB Finland (development system)

IP Augusta, GA, US

ISAB Powerplant, IT

Kinross Mining, BR

Lion Copolymer Geismar, LA, US

Sappi Nijmegen, NL

UPM Changshu, Jiangsu, CN

GP Big Island, VA, US

APP Tjiwi Kima, Sidoarjo, ID

Boise International Falls, MN, US

Domtar Ashdown, AR, US

NOVA Chemical Painesville, OH, US

ServicePort - Benefit to Customer

Maintenance Expense

Production

Platform Stability

Tre

nd

s

ServicePort provides:

Proven Solutions, Immediate access to experts, Customizable Applications

Directly impacts: Production

ABB Apps

1 2 3 4 5 . . .

Advanced services: increasing customer loyalty and expanding service scope

Example: Chillicothe paper, Ohio, USA

Customer challenge: poor maintenance practices, poor

system performance and low quality after market parts

used by a third party negatively effecting the customers

own product quality.

ABB solution: A QCS performance Fingerprint,

ServicePro contract management tool were utilized to

identify the issues and to show best practices and tools.

Optimization services like continuous performance

tracking with ServicePort were included to create

customer value beyond traditional maintenance contracts.

Customer benefits: Value-add analysis which provided

the customer with increased automation efficiency beyond

the original scope of the audit.

Advanced services: increasing customer loyalty and expanding service scope

Example: Lion Copolymer, Louisiana, USA

Customer challenge: A three-line chemical polymers

plant makes multiple grade changes. Automation

performance has declined as product line expanded into

specialty chemicals.

ABB solution: LoopPerformance and Transition

Fingerprints packaged with Implementation Services for

Tuning and Corrective Action. ServicePort for sustaining

production enhancements.

Customer benefits: Estimates of over $1Million per year

in increased production and reduced off-spec waste

byproducts.

ABB benefit: 1st Chemicals Industry contract in the USA

with Transition Fingerprint and ServicePort. 1st Fingerprint

plus Implementation service contract for Chemicals

Industry growth initiative. Enhanced competitive position

against 3rd party with black box APC claims.

© ABB Group

Customer need

Replacement of knowledge that left the company

Expert support for legacy control system

Fast responses to production issues

ABB’s response

ServicePort for onsite control system support

Delivers ABB expert resources remotely

Provides tech support

Performs non-invasive checks on the operating

system

Temporary resident field service engineer

Customer Benefit

Replaces lost expertise

Solves tech support issues immediately

Identifies problems before they occur

Provides diagnostics to troubleshoot disturbances

Delivers ABB Optimization Solutions

Reduces costs

Need-identification-to-resolution within 45 days

Site: Pulp Mill, AR, USA

Unit: Pulp Mill

Issues:

Customer lost an important engineer

INFI 90 system required upgrade

Self-maintenance no longer possible

Agreement:

1-yr agreement + resident engineer

Customer Case Study Pulp mill, Arkansas, USA

ServicePort: Partnering for Success

Customer Benefit

Use of same technical tools that ABB experts use.

Regular updating of software.

Training/support/access to world class subject matter

experts.

Continuous Monitoring of customer defined assets.

Optimize time to solution as well as resource planning.

Periodic Performance Scan reports to ensure continuous

process improvement, reduced false positives, improved

key performance indicators, adaptation to conditions or

process changes.

ServicePort + Channels

© ABB Group


ServicePort Base Unit

Calibration Fingerprint

Start-up Services

Process Channels

2 scan reports per year

On Demand Process Support

Equipment Channels

2 scan reports per year

On Demand Process Support

Workbench Troubleshooting/Implementation Tools:

DataLogger, Signal Analyzer, LoopTune, Loop Analyzer,

Sequence Analyzer

Remote Access Platform

Loop Performance Services Portfolio

Saleable Service Selection

Fingerprint

Implementation

WorkBench Tools

Data Logger

Signal Analyzer

Loop Tune

Loop Analyzer

ServicePort Base Unit

Process Channel

Remote Access Platform

Secure Data Tunnel

Training

© ABB Group


abb pa life cycle services serviceport access to ... · finding a needle in a hay stack few units...

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