das deltav system -...
TRANSCRIPT
Das DeltaV System
Contents
1 IntroductionThe DeltaV system deliversprecision control for better plantperformance—easy.
2 Advanced Control Embedded, easy-to-use,sophisticated advanced control.
4 DeltaV InspectProvides key plantmetrics for at-a-glance performanceand abnormalconditionmonitoring.
6 DeltaV TuneMakes loop tuningeasy–whether it’s PIDor fuzzy logic control.
8 DeltaV FuzzyProvides improve-ment over classic PIDcontrol for thosetough applications.
10 DeltaV PredictGives you state-of-the-art constrainedmultivariable modelpredictive control totackle the mostdifficult controlproblems—easy.
12 DeltaV NeuralProvides accuratevirtual sensors basedon neural nettechnology.
14 DeltaVSimulation SuiteProvides a completeengineering andoperatingenvironment, plusvirtual controller todevelop and testcontrol strategies on a PC.
16 DeltaV SimulationSuite - ProfessionalAdd Simulate Pro for more powerand advanced functionality such asglobal enable/disable of simulationand faster/slower than real-timeexecution of control and logic.
17 DeltaV SimulationSuite - MultinodeFor multiple user offlinedevelopment or full scale operatortraining systems, use SimulateMultinode.
18 DeltaV SimulationSuite - mimicA complete process modelingpackage that interfaces with theDeltaV system or with DeltaVSimulate.
20 HYSYS.PlantState-of-the-art dynamicsimulation technology that helpsyou design, manage and operateprocesses efficiently andeffectively.
20 HYSYS OperatorTraining System(HYSYS OTS+)Enables you to effectively useHYSYS process simulation in theDeltaV system for operatortraining.
21 Real TimeOptimization (RTO+)Model-based performancemonitoring and optimizationapplication that helps you makeinformed, up-to-date decisions.
21 MultivariateStatistical ProcessControl (MSPC+)Provides online processperformance monitoring ofcontinuous, batch and semi-batchprocesses.
22 e-fficiencyMaximize efficiency and minimizeshutdowns. A web-basedequipment performancemonitoring solution.
24 Emerson Can HelpWe have the people and expertisehelp you achieve operationalefficiency with precision control.
The DeltaV system makes advanced control not only easy, but it’s also fun to use. Duncan, the DeltaVspokesperson, is shown here representing the comprehensive suite of DeltaV advanced control products.Look for Duncan throughout this brochure and in our software.
Precision Control—Easy
Better operational efficiencythrough precision control iskey to profitably meetingyour customers'expectations and stayingahead of your competitors.
Better plantperformance—made easyThe PlantWeb® architecture and itskey component, the DeltaV™ digitalautomation system, provide a solidfoundation for deliveringrevolutionary results by combiningthe intelligence of digital fielddevices, the DeltaV system, andintegrated asset management.
This foundation delivers preciseregulatory control and optimizesyour plant assets.
Improve your plant performance atall stages: from planning and design,to implementation and startup,through operations, optimization,and maintenance, to evolution ofcontrol strategies and systems.
Studies show that nearly 40% of allprocess loops are under-performing.Less than 1% of these loops are beingaddressed with traditional advancedcontrol technologies.This opportunity forimprovement iswhere DeltaVadvanced control fits.
DeltaV advanced control providesthe full array of applicationsincluding automatic variabilityinspection, tuning, fuzzy logiccontrol, model predictive control,simulation, and optimization. And itseasy enough for the typical processengineer, not highly skilled,expensive specialists to use.
The result:� quicker return on investment� reduced process variability� increased product quality� lower costs.
And, best of all, DeltaVadvanced control makes it easy.
1
Introduction
Advanced Control
2
Precision control is deliveredfrom an array of advancedcontrol solutions includingvariability inspection, tuning,fuzzy logic, model predictivecontrol, simulation, andoptimization.
Built on a solid foundationA profitable, efficient operationbegins with a solid foundation. ThePlantWeb architecture is afoundation to deliver predictiveinformation from intelligent fielddevices to avoid unexpectedshutdowns, excessive variability andpinpointing trouble areas for quickresolutions.
Only the DeltaV system is built toaccept this wealth of fieldintelligence and deliver it where it's
needed. That means more robust,precise control that can adapt to thechanging conditions of your process.Without this solid foundation, extratime and energy are required tomaintain operations.
Easy to useGiven today's smaller, more hurriedplant staffs, DeltaV advanced controlapplications are built as part of thesame, easy to learn and useenvironment as standard regulatorycontrol. Fuzzy logic control dragsand drops just like a standard PIDblock. Even for basic PIDfunctionality, the DeltaV system hasmore capability than distributedcontrol systems and many timesmore capability than a PLC.
Implementing traditional advancedcontrol solutions on DCSor PLC systems requiredlarge up-front softwareand services investments.Maintaining the solutionrequired expensiveexpertise every time plantconditions changed.
Given the high cost, these traditionalsolutions could be used only in a few,high-return applications.
The embedded DeltaV advancecontrol applications are designed forthe typical process engineer to useon a much broader array of controlchallenges.
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ddaattaa aanndd ssttaattuuss ttoopprreevveenntt ccoonnttrroolllliinngg oonn
bbaadd ddaattaa..
Uncertain, device needs maintenance soon!
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PID functionblock capability
DeltaV DCS PLC
Embedded, easy-to-use,sophisticated advanced control.
“For the first time in my32-year career, all theelements of advanced
control have come togethereasily in one place–DeltaV. Automatic loop tuning and
performance analysis,model predictive control,
intelligent sensors, dynamicsimulation, operator and
engineer training, and realtime optimization—all from my laptop.”
— Greg McMillan
Solutia Inc.
USA
3
Digital.
Smart.
Here to stay.
Reliable, validated dataData received from intelligent fielddevices, like Emerson'sFOUNDATIONTM fieldbus and HART®
devices, provide the quality of thedata to the DeltaV system. Thisassures that the regulatory andadvanced control algorithms areworking with good data and cantake corrective action in the case ofquestionable or bad data.
The result is more precise controland efficient operations.
In the following pages, see the valuethe entire array of advanced controlsolutions can apply to youroperation.
Get embedded, easy-to-use,sophisticated advanced control.
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DeltaVInspect
Optimize your plant—easy.4
Eliminate time spent chasingproblems by having them find you.
Automatic loopperformance monitoringDeltaV Inspect is an advanced
process monitoring application that
instantly identifies
high process
variability and
under-performing
control loops.
Inspect quickly and
easily keeps you
informed of the health of your
process and control strategies
without any need for configuration
or setup. This functionality,
combined with an easy-to-use
operator interface, ensures a finely
tuned process that produces
quality, on-time products.
Easy to useWith DeltaV Inspect, there is no
setup or configuration required. It's
ready to start inspecting when
you are.
Inspect also automatically
recognizes control blocks as they
are added to or deleted as control
requirements change.
Using the filter and sorting capability
of Inspect, you can easily focus on
the control modules that may be
causing variability and affecting
plant performance. By quickly
identifying under-performing loops
and taking corrective action, you can
reduce process variability and
increase the efficiency of your
operation.
Broad range of inspectionDeltaV Inspect continuously
monitors for incorrect modes,
limited control conditions and bad
or uncertain inputs. It automatically
identifies these abnormal conditions
and graphically displays them on a
DeltaV workstation. The percentage
of time that these conditions exist
over an hour, shift, or day is
computed for every block and then
compared to a configured global
limit for each condition.
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5
Focuses on main
causes of
lowered control
performance.
“The objective of 95% ofcontrol applications is
high quality and uniformproducts. One of the key
factors is theperformance of control
loops, which is known todecay with time.”
—Bill Bialkowski,
Entech
USA
When one of these limits is
exceeded, the associated module
will be included in the Abnormal
Conditions summary.
DeltaV Inspect:� Identifies abnormal conditions in
the field�Requires no configuration�Allows plant-wide and remote
access�Monitors control modules as they
are added, automatically.
In addition to monitoring for
incorrect modes, limited control
conditions, and bad or uncertain
inputs, Inspect continuously
monitors process variability and
control loop performance. The
DeltaV input/output and control
function blocks automatically
calculate both total standard
deviation and capability standard
deviation with no configuration
required. The total standard
deviation provides a continuous
measurement of process variability.
Inspect uses a Variability Index to
monitor control loop performance in
addition to process variability. The
Variability Index, calculated from
total standard deviation and
capability standard deviation,
provides a quantitative measure of
how much variability could be
reduced with optimum control loop
performance.
Inspect provides plant-wide control
performance and control utilization
indices. The performance index
provides a measure of overall loop
performance. The control utilization
index provides a measure of how
frequently control loops are
operating in the correct mode.
Why let process problems hide when
DeltaV Inspect can automatically
seek them out for you?
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Poorly tuned loops meanlower quality, lost production,reduced profits, andpotentially costlyenvironmental and safetyissues. DeltaV Tune delivers aneasy-to-use, yet powerfultuning solution.
Loop tuning made easyUsing DeltaV Tune, no specialcontrol knowledge is required totune a control loop for optimumoperation. No longer must you relyon tuning experts to keep yourfacility running at peak efficiency.Operators, engineers, and maintenance technicians will all findDeltaV Tune easy to learn and use.
Wide variety ofapplicationsDeltaV Tune uses patented relayoscillation principles to measure theprocess dynamics. This techniqueminimizes the process disturbanceand reduces tuning time. Onceprocess dynamic characteristics havebeen established, you can choosefrom a list of process types such asflow, temperature, etc. that DeltaVTune will use to calculate tuningconstants.
DeltaV Tune works equally well withfast or slow processes, self-regulating or integrating processes,and loops with dead time or a noisyinput signal. PID and fuzzy logiccontrol loops with process dynamics
ranging from fast tomoderately slowcan be quicklytuned in seconds.
This can result in fasterstartups and swifterresponse to changing looprequirements. And becauseDeltaV Tune is immune to asignificant level of noiseand process loaddisturbances, you can tune the mostdifficult loops with confidence.
Power for advanced usersYou can take advantage of theExpert tuning option and usealternative tuning rules such as: �Modified Ziegler Nichols� Lambda� Lambda-Averaging Level� Lambda-Smith Predictor� Internal Model Control.
In addition, experienced users cananalyze loop stability and examinesimulated loop responses to setpoint changes and loaddisturbances.
DeltaV Tune also providessophisticated but easy to use loopsimulation and analysis views thatallow control loop performance tobe predicted before the new tuningis used.
Tune your most difficult loops with confidence and ease.6
DeltaVTune
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“The CAC Monsantoplant in Muscatine, Iowa
was successful inimproving loop
performance withsignificantly reduced
effort compared to anyalternative tuning
methods.”—Ken Meyer,
Monsanto
USA
7
You can view a simulated loopresponse based on therecommended tuning parameters,and can even compare the responsewith the current tuning parameters.You can also assess loop stabilitywith a robustness plot and easily seethe impact of different loop tuning parameters.
The tuning results, including thecalculated process dynamics and thetuning method, can be saved to afile for future reference. This alsoprovides a way for you to store andrecall different tuning constants fordifferent process conditions or products.
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Optimize your
process and
increase quality,
production, and
profits.
DeltaVFuzzy
DeltaV Fuzzy is easy to use, easy to tune.8
Fuzzy Logic control sosmart, it’s simplePID has traditionally been the
workhorse of the process industries.
It ‘s easy to implement and it’s
robust. Now, DeltaV Fuzzy allows
faster response to set
point changes or load
disturbances without
overshoot. On many
loops, the patented
algorithm provides
superior performance
versus traditional PID control. Tests
have shown loop performance
improvement of 30-40% over
traditional PID.
Process loops that exhibit non-linear
control are excellent candidates for
fuzzy logic control. Since fuzzy logic
provides fast response times with
virtually no overshoot, it's excellent
for loops that experience frequent
set point changes or load
disturbances. For example, in
temperature and composition loops
where overshoot can ruin the
product, fuzzy logic's response curve
provides better control.
In addition, loops with noisy process
signals have better stability and
tighter control when fuzzy logic
control is applied.
DeltaV Fuzzy is:�As easy to use and configure as PID� Superior to PID control for set
point and load changes�Highly tolerant of noisy signals and
non-linear processes� Included in every DeltaV system.
But not all fuzzy logic is created
equal. The big difference between
DeltaV Fuzzy and traditional fuzzy
loops is that you don't have to learn
the fundamentals of fuzzy
mathematics to do control.
The DeltaV fuzzy logic control
function block uses easy-to-
understand scaling factors for
tuning. Plus, the algorithm manages
all the rules implementation for you.
In addition, unlike traditional fuzzy
controllers, DeltaV Fuzzy can be
commissioned and tuned using the
DeltaV Tune product.
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Secure, smart,intuitive—Easy.
9
DeltaV Fuzzy offers a practical, field-
proven substitute for PID control. It's
robust, easy to implement, and
provides superior performance over
PID in many cases. DeltaV Fuzzy is
even capable of handling loops
where manual control was once the
only option.
All this makes implementing and
maintaining fuzzy logic control loops
very easy, even for first-time users.
“We are now able toprocess different
products sequentiallybecause we know the
dryer will respond fastenough to the new
settings using DeltaVFuzzy. We have
increased throughput,eliminated off-quality
and damaged products,and reduced
reprocessing.”—Francisco Campa
The Dixie Group
USA
Better than PID
for many
applications.
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Model predictive controlthat's easy and accessibleDeltaV Predict offers you an entirelynew approach to theimplementation ofconstrainedmultivariable modelpredictive control.DeltaV Predict'scapabilities easilyaddress processinteractions anddifficult dynamics. Since thesemodel predictive control algorithmsrun in the DeltaV controller, yourcritical strategies run in a high-speed, rugged, optionally redundantenvironment.
And best of all, DeltaV Predict is easyfor a typical control engineer toimplement—without the aid of costly
outside experts. Custom operatordisplays are automatically createdwith a single mouse click.
Using DeltaV Predict, processvariability may be reduced and theprocess throughput automaticallyadjusted to maintain the process atits operating constraints. As processconditions change, DeltaV Predictautomatically adapts to allowmaximum throughput withoutviolating any operating constraints.
With model predictive control,managing units involving processinteraction and multiple operatingconstraints, control is easier thanwith the traditional, complex PIDcontrol strategies. DeltaV Predictfully automates testing of theprocess used to establish the processmodel. And on fast-responding
processes, controllergeneration may bedone in a matter ofseconds, versus thehours or daysrequired withtraditionaltechniques formultivariablecontrol.
Using a built-in simulationenvironment, you can examine thecontrol response before installingDeltaV Predict on your process. Youcan also observe the controlresponse to set point changes andprocess load disturbances. And, youcan use DeltaV Predict to train youroperators before commissioning.DeltaV Predict provides:�Reduced process variability�Greater throughput� Easier implementation� Fully automated model
development� Standard constraint handling�An embedded simulation
environment.
Improved, sustained performance means real savings.
DeltaVPredict
10
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MMooddeell PPrreeddiiccttiivvee CCoonnttrrooll iiss iimmpplleemmeenntteedd aass aa ffuunnccttiioonnbblloocckk;; mmaakkiinngg ddeeppllooyymmeenntt ffaasstt aanndd eeaassyy..
DeltaV PredictTraditional MPC
Time
SustainedPerformance
Retu
rn
SustainedPerformanceFaster
CommissioningFasterCommissioning
“The robustness of thecontrol exceeds all
expectations. The systemeven seems to perform
optimally when burningfour different fuels
concurrently. To date weare achieving near 100%
control program uptime.”— Dave Sordi
Canfor Corp.
Canada
11
Maximum
throughput
without violating
operating
constraints.
Unlike many traditional MPCproducts, DeltaV Predict is designedto allow control to continue, evenwhen the process gain anddynamics change.
By providing this robustness in thecontrol design, the need toperiodically re-commission control isminimized or entirely eliminated.
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DeltaV Neural, gives you apractical way to create virtualsensors formeasurementspreviously avail-able onlythrough labanalysis. It canalso be used toaugmentonstream analytical devices orreplace them where they arenot practical.
Easy to useDeltaV Neural automatically uses thehistorical data provided from theDeltaV system's embeddedhistorian. You can quickly and easilytrain the neural network and verifythe accuracy of the resulting model.
Like the rest of the DeltaV system'sintuitive, easy-to-use environment,DeltaV Neural blocks are available todrag and drop from the ControlStudio palette.
Rock solid, controller-based executionOnce the neural network is trainedand tested, it's executed in afunction block in the DeltaV
controller to give continuousindication of the predicted quality asfast as once every second.
The DeltaV controller provides yourvirtual sensor a high-speed, rugged,and optionally redundant controlenvironment, ideally suited for yourmost demanding applications.
Accurately estimatesquality parametersOne of the greatest challenges inprocess control is getting timely dataon hard-to-measure variables.Generally, this includes variablesrelated to quality or environmentalaspects of production. Thesevariables are often obtained byperiodically gathering productsamples and analyzing them offlinein a laboratory.
DeltaVNeural
12
Estimate quality parameters on-line withvirtual sensors—accurately and easily.
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13
Quickly train
and execute
your neural
network.
“Using DeltaV Neural, we estimate acid
specific gravity in sixevaporators once per
second with an averageerror of less than 0.25%.”
—Vince Artingstall
A Major South African
Chemical Company
But by the time you get the results,it might be too late to make controladjustments.
Neural network technology hasbeen used to predict key qualityvariables such as octane numbers,NOX emissions, melt index andother quality parameters. Throughneural network models based onhistorical process measurements,you can predict future processperformance quickly. In addition,the non-linear nature of neuralnetwork models can sometimes beuseful in applications where firstprincipal models give poor results. DeltaV Neural:� Easily creates neural networks� Executes neural network as a
function block� Provides automatic pre-
processing, design, training, andverification�Allows expert mode interaction in
the neural network development.
Now you can replace and crosscheck physical sensors andanalyzers, and have an inexpensiveonline predictor of lab test results.
Reduce your process variability andincrease product quality, whileeliminating much of the need formanual sampling with DeltaVNeural—easy.
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DeltaV SimulateImagine starting automation systemdesign, configuration and logiccheckout, andoperator traininglong before yoursystem hardwarearrives. Now youcan, withEmerson's easyDeltaV Simulate.
Notebook PC-basedsimulationThis industry-first innovation lets youconfigure an entire DeltaV system onyour desktop or notebook PCwithout any connected hardware.DeltaV Simulate gives you thefreedom to begin critical pathproject tasks such as configurationcheckout and display building whenyou're ready.
With DeltaV Simulate, you canconfigure all supported features,including continuous, batch, and
advanced control—along withthe associated workstationdisplays, alarms and historiandata, and OPC connectivity.
What's more, you can fullysimulate all operator interfaceand selected control moduleexecution in your PC to helpwith control logic checkout.
And, using the control and I/Oblock simulation capability ofthe DeltaV system, you cansupply field measurementvalues and status to thesimulation manually or byblocks used to simulate theprocess.With DeltaV Simulate, you can:�Configure an entire DeltaV
system and fieldbus devicesfrom a single PC�Check out control logic and
operator interface usingsimulation�Configure and fully verify OPC
interfaces to the DeltaV system�Run with no additional DeltaV
hardware, I/O, or system licenses.
DeltaVSimulation Suite
14
Process simulation and operator training—the easy way.
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“Solutia Inc. isdramatically reducing
the overall life-cycle costof their control systems
through the ability toexecute dynamic process
simulations with allfeatures of the control
system on a single PC.”— Greg McMillan
Solutia Inc.
USA
15
Effective trainerUsing function blocks to simulatethe process, you can create dynamicprocess simulations to supportoperator and engineering training.This can turn your DeltaV Simulateinto an effective training solution.
No need for costly additionalhardware training systems like priorautomation systems required.
DeltaV Simulate provides a platformthat third-party developers can useto develop and test OPC interfacesto the DeltaV system that areneeded for advanced control.For more sophisticated applications,you can use OPC-compliant processsimulation packages like HYSYS ormimic™ with DeltaV Simulate. Thisprovides process and control systemcheckout and operator trainingbefore DeltaV hardware is installed.
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Recurring
benefits that
really payoff.
16
DeltaV Simulation Suite
Simulate ProfessionalGet the most out of your high-fidelity process simulation bycontrolling it with the modules thatwill run in your DeltaV system.DeltaV Simulate Professional is acomplete environment for off-lineprocess and control systemsimulation.
DeltaV Simulate Professional allowsthe simulated modules to beexecuted more quickly or slowlythan real time—or stoppedcompletely. When your processsimulation can execute faster thanreal time, being able to match thecontrol system execution to thesimulation will cut hours off thesimulation of a slow process.
The execution rate of all modulesassigned to a node may be changedat any time with a single request.
Through the DeltaV SimulateProfessional application, you caneasily enable or disable simulation onall I/O blocks assigned to the node.Simulate status for modules within avirtual controller is indicated by thesummary list shown in the upperright portion of the user interface.
DeltaV Simulate Professional alsoallows dynamic blocks in themodules assigned to the node to beinitialized with a single request.
Parameters are included in theApplication Station and the stand-alone Simulate PC to allow asimulation application toprogrammably enable/disablesimulation, initialize dynamic blocks,and set the execution faster/slowerthan real time.
Simulate Professional:� Executes DeltaV control more
slower or faster than real time� Enables with a single request I/O
simulation on all blocks on a node� Initializes with a single request all
dynamic blocks on a node� Expands virtual controller
capability�Allows process simulation
applications to coordinate controlsimulation.
These parameters may be written bythe simulation package using OPC.
Extending the capabilities ofDeltaV Simulate.
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“The system is userfriendly, there is a real
integration and the rest works by itself.”
— Matias Morales
PDVSA
Venezuela
17
Offline, faster
than realtime
simulation.
DeltaV Simulate Professional canextend capabilities of a DeltaVSimulate workstation, or in the caseof a Simulate Multinode system aDeltaV ProfessionalPLUS Station orApplication Station. Of course,DeltaV Simulate Professional cannotbe installed as part of any systemconnected to a live process.
Simulate MultinodeWith DeltaV Simulate Multinode,Application Stations may be addedto allow control execution to bedistributed between it and theProfessionalPLUS Station. Also,DeltaV Operator Stations andcontrollers may be added to supportyour training ordevelopmentsystemrequirements.
Building trainingsystems has neverbeen so easy.Since you can usethe sameconfiguration asthe real onlinesystem does, younever have toconvert, compile,or redo anyconfiguration. Allengineeringconfiguration from the on-line system may becompletely reused in the trainingsystem with zero extra effort.
It works with everything fromcontrol, to operator graphics, to OPCinterface applications.Simulate Multinode:� Trains operators in a secure
environment with the exactconfiguration as the online system�Develops control strategies and
tests your system in a cost-effective off-line system thatmirrors your plant�Deploys tested applications faster
than ever before� Promotes faster, safer system
startups with trained staff andproven control strategies.
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VViirrttuuaall ccoonnttrroolllleerrRReeaall ccoonnttrroolllleerr
DeltaVSimulation Suite
mimicTM
Use mimic to simulate the processyou are controlling with the DeltaVsystem. mimic is a completeprocess-modeling application thatconnects with the DeltaV system orwith DeltaV Simulate.
mimic lets you easily create low—andmedium fidelity models of yourprocess in realtime and test yourcontrol strategies without affectingyour actual process.
Using your DeltaV configurationdatabase as input data, mimic willautomatically create simple loop anddiscrete control tiebacks. mimicincludes all tools to import processinformation directly from a DeltaVsystem configuration. These toolsreduce the time it takes to develop asimulation and increase the ability todefine simple behaviors for fielddevices including FOUNDATION
fieldbus devices.
Using your DeltaV moduleconfiguration, mimic willautomatically create simple loop anddiscrete control tiebacks. Dependingon your simulation needs, yoursimulation configuration could be complete.
If you have more sophisticatedsimulation requirements, mimicoffers you complete processmodeling capability. You can modelyour process conditions to betterunderstand the behavior of theprocess.
mimic hardwareconnectionmimic emulates the actual DeltaVI/O to simulate field device behaviorand response. The I/O signals arechanneled through mimic, not thereal I/O.
No special controllerconfiguration isrequired to usemimic because itconnects directlyonto the DeltaV I/O bus and looksjust like DeltaV I/O to the controller.
A workstation with one or moreDeltaV controller I/O cards interfaceswith each controller I/O bus. OneDeltaV controller I/O card is requiredfor each controller to be simulatedsimultaneously.
18
Model your process in realtime andtest control strategies—easy.
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mimic softwareconnectionIn the OPC version of mimic, theprocess simulation communicatesdirectly with the control modulerunning in a DeltaV Simulateenvironment.
mimic can be running in the samePC as DeltaV Simulate or in aseparate PC connected to theSimulate PC via TCP/IP.
mimic includes configuration toolsthat allow process information to be
imported directlyfrom a DeltaVsystemconfiguration. Thesetools reduce thetime it takes todevelop a simulationand increase theability to definesimple behaviors forfield devices.
Training and testing The mimic Training Manageraddresses many aspects of controlsystem operation including:�Keyboard use�Display access� Process/emergency procedures� Process upsets�Control system dynamics.
These items play a crucial role in howwell control room operatorsperform. Simulation with mimicallows you to use the actual controlsystem hardware and software totrain operators. This builds operatorconfidence, resulting in fasterstartup and lower downtime.
The mimic Training Manageraddresses process-specificsimulation and a series of eventscenarios tested during the trainingsession. While the trainee uses theactual operator console as thewindow into the process, the traineruses the Training Manager and athird-party graphics package tomonitor the session. From thisinterface, the trainer can controlhow the process reacts, introducefailures, direct the trainee towardspecific areas of the process, andmonitor trainee performance inrecovering from failures and processupset conditions.
For more information visit the mimicwebsite at wwwwww..MMuunnggeerrPPDD..ccoomm .
“The standard OPCcommunications protocol
built into the DeltaVsystem will make
interfaces between thevarious network
applications seamless.”—David Greer,
Shell Philippines Exploration B.V.
Automatically
create simple
loop and
discrete
control tiebacks.
19
High-fidelitySimulation
20
Simulation-based operator training.
HYSYS.PlantHYSYS.Plant is the most state-of-the-art dynamic simulation technologyavailable today. Use the high fidelityHYSYS.Plant simulation with DeltaVSimulate to easily address criticalbusiness objectives such asproduction levels, time to market,design quality, safety, and efficiencyfor even your most complex processunits.
In addition, you can simulateproduction changes and feedchanges and anticipateddisturbances to determine therobustness of your process designand DeltaV control strategy.
HYSYS.Plant and the DeltaV systemare connected via the standard OPCcapabilities of both products.HYSYS.Plant enables you tounderstand the source ofbottlenecks, process upsets, and
quality problems, and it helps youidentify opportunities for eliminatingthem. You can devise improvedcontrol strategies and assess theirbenefits before modifying the actualprocess.
A comprehensive set of models forunit operations such as distillationand reaction is available.HYSYS.Plant can give you increasinglevels of detail regarding equipmentgeometry and configuration,depending on the desired fidelityand point in the lifecycle.
Hysys.Plant:� Screens process designs�Validates control strategies�Reveals the source of the process
problems� Improves process operations.
HYSYS.OTS+High fidelity simulation-basedoperator training systems provide anenvironment inwhich to improveyour plant's safety,operability, andprofitability.
Using the HYSYS.OTS+ real-timedynamic simulation capabilities inthe DeltaV Simulate environment,your operators can practiceresponding to abnormal andemergency operations. HYSYS.OTS+enables operators to design andevaluate process control strategiesprior to plant commissioning.
Engineers and operators can use therigorous dynamic model to illustrateand clarify any number of controlconcepts. You can run "what-if"sequences and change processcontrol strategies to test alternativeconcepts. When problem areas areidentified, engineering design teamscan use that same model as theirbasis for process redesign andcontrol strategy development.
For more on Hyprotech's HYSYSproducts, visit wwwwww..hhyypprrootteecchh..ccoomm//hhyyssyyss//..
HYSYS.Plant interfaces with the DeltaV system through OPC.
21
RTO+Real Time OptimizationOptimal plant performance ismaintained by continuouslyadjusting operating conditions inreaction to variables like changingfeed quality variations, product andutility prices, equipment outages,and changing ambient conditions.
Emerson's RTO+ is a model-based,performance monitoring andoptimization application designed tohelp you make these critical plantoperation and maintenancedecisions. It automaticallydetermines the optimum operatingconditions required to maximizeyour margins.
RTO+ is accurate and fast, butabove all, it is robust (typicalonline times over 95%).
You can build process models,using modeling packages likeHYSYS, with RTO+. You can alsoperform multi-time-period look-ahead optimization using variedconditions.RTO+:� Improves process control for
large applications�Reduces operating costs� Improves process stability�Reduces standard deviation� Improves set point control� Is running in over 400 applications
around the world.
For more on Emerson's RTO+, visit
MSPC+Multivariate StatisticalProcess ControlMajor technical challenges facing theprocess manufacturing industries arethe need to improve productionconsistency and the need to provideearly warning of processmalfunctions. Emerson's MSPC+ isthe first product specificallydeveloped for online processperformance monitoring of
continuous, batch, and semi-batchprocesses. It focuses on earlyidentification of potential productquality problems.
Multivariate statistical processcontrol (MSPC) addresses several ofthe fault detection limitations foundin traditional univariate SPC. You candevelop reference models using theDeltaV historian as data representinggood or desirable production.
MSPC+ Online tracks aprocess moving out ofcontrol and enables youto identify thevariables, orcombination ofvariables, that are the
probable cause of the drift. Then,you can adjust the process to avoidcontinued manufacture of non-conforming product.
You can easily identify the originalvariables whose contribution haschanged from that predicted fromthe nominal model with acontribution plot.MSPC+:� Improves process control for largeapplications�Reduces operating costs� Improves process stability�Reduces standard deviation� Improves set point control� Is running in over 400 applications
around the world.
For more on Emerson's MSPC+, visit
Optimization &Process Monitoring
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22
Access in secure web environment.
e-fficiency
Your window toperformance analysisEmerson's e-fficiency is a web-based
equipment performance monitoring
service, designed to maximize
utilization and minimize
unscheduled shutdowns within the
process manufacturing industries.
This service delivers real value to
your operation, by taking process
data and producing validated
information concerning the
operating performance of plant or
process equipment.
Based on rigorous model-based
technology using data reconciliation,
validation and parameter estimation
calculations, e-fficiency provides
easy and cost-effective access to
current equipment performance
data, customized reports, and
graphical representations, all via a
standard web browser.
The service can be accessed at any
time wherever you have access to
the Internet. Users can assess the
effect the performance of plant
equipment is having on the
efficiency of the plant in terms of
throughput, downtime, and stability.
Customers can troubleshoot
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23
Early
identification
of equipment
problems.
equipment problems early, remotely
and at low cost.
e-fficiency can be applied to andprovide accurate monitoring of;� Boilers�Compressors � Expansion� Turbines � Furnaces �Gas Turbines �Heat Exchangers �Hydraulic Turbines � Pumps � Steam Turbines
It also tracks the cost of the
degradation in equipment
performance in real-money terms.
e-fficiency enables users to make
essential decisions based on hard
facts. Maintenance schedules can be
optimized to extend run times and
plan activities accurately.
With e-fficiency you can:
�Compare unit performance across
multiple units
�Access performance data
remotely anywhere in the world
� Produce accurate reports against
performance targets
�React in a timely manner to
changes in equipment
performance
�Optimize cleaning and
maintenance cycles
� Increase operating performance of
the production facility.
For more on Emerson's e-fficiency,
visit: wwwwww..ee--ffffiicciieennccyy..ccoomm..
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means of gathering thepertinent information via
the worldwide web andworking with onsite
operators and engineers tomanage the equipment
performance.”—David Stewart
Wood Group Engineering
USA
Better operational efficiencythrough precision control issomething Emerson canhelp you achieve throughour global network ofindustry and applicationspecialists.
Our industry experts in chemical,food & beverage, oil & gas, lifesciences, pulp & paper, and manyother industries have the experienceto apply the full range of advancedcontrol solutions for your operations.
CChheemmiiccaallBecause no two chemical operationsare alike and your needs are unique,the last thing you need is a"standard" solution. From industrialchemicals to fibers, Emerson has thepeople who can make your goals areality.
Solutions are available to thefollowing chemical processes:
Industrial
� Inorganic acids
�Alcohols
� Liquified gases
� Paints
�Resins
�Adhesives
� Solvents
�Detergents
Specialty
�Catalysts
� Laboratory chemicals
�Dyes
� Inks
� Pigments
Fibers
�Nylon
� Polyester
�Rayon
and many more.
Food & BeverageFrom brewing to bottling and frommixing to baking, Emerson offersyou our best in class products,services, and personnel. From beerto butter, we can work with you tofind the perfect solution for yourneeds. Whether you requireengineering services or plantoptimization, Emerson can help youachieve your goals.Solutions are available to thefollowing food & beverageprocesses:
� Brewing process control
�Citrus process control
�Dairy products
� Beverage processing
� Sugar production
�Corn processing
� Solutions for batch and blending
� Evaporators
� Specialty equipment design
�Regulatory compliance
and many more.
Oil & GasOur Oil & Gas expertshave the ability to workwith you to assist indeveloping plans for newfacilities as well as inoptimizing theperformance of yourcurrent environment.From pipelines torefining, Emerson bringsthe experience that isnecessary to achieveoperational efficiency.
Solutions are available to thefollowing upstream anddownstream processes:
Upstream
� Platform automation
�Wellhead control
�Gas processing
�Gas liquefaction
�Utilities
Refining
� FCC units, CRR units
�Hydrocracker units
�Delayed coker units
� Blending
Petrochemical
�Olefins
�Nylon intermediate
� Polymers
�C4 hydrocarbons
�Aromatics
� Polyolefins
and many more.
Achieving operational efficiency.
EmersonCan Help
24
Life SciencesRegulatory compliance. Genome-based rapid drug discovery.Validated manufacturingautomation suites and seamlessintegration—from drug conceptionthrough packaging. For manypharmaceutical and biotechcompanies, the fast-changing worldsof compliance and technology havecreated the need for a partner whounderstands both their uniqueprocess requirements and thetechnology best suited to ensureconsistent quality.
Solutions are available to thefollowing pharmaceutical andbiotech processes:
� Batch reactors
� Blending
� Buffer / media preparation
�Centrifuging
�Crushing
�Crystallization
�Diffusing
�Distillation
� Evaporating
� Fermenting
� Filtration / ultrafiltration
�Hydrogenation
�Mixing
� Packaging
� Separating
� Sterilize in place
� Streamline regulatory compliance
� Temperature ramping
�Vacuum pan control
and many more.
Pulp & PaperFrom pulping to coating, includingrecovery and power systems,Emerson brings the experience thatis necessary to have a positive effecton your bottom line.
Solutions are available to thefollowing pulp & paper processes
� Pulping
�Digesters
� Brown stock washers
� Bleach plant
�Recovery
� Evaporation
�Recovery boiler
� Lime kiln
� Slaker and caustisizing
� Papermaking
� Stock preparation
� Paper machine
and many more.
Contact us today on our full breadthof solutions at:
Industry and
application
experts ready
to help.
25
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“We wanted to greatlyreduce the time required
to engineer, test andinstall the automationportion of this project.
We expect this project tobe completed in half the
time of prior projects andlook to time-saving
technologies like DeltaV tohelp us accomplish our
goals."—Per Kronovall
AstraZeneca
Europe
PlantWeb, DeltaV, the DeltaV design, Emerson Process Management and the Emerson Process Management designare marks of one of the Emerson Process Management group of companies. All other marks are the property of theirrespective owners.The contents of this publication are presented for informational purposes only, and while everyeffort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express orimplied, regarding the products or services described herein or their use or applicability. We reserve the right to modi-fy or improve the designs or specifications of such products at any time without notice.
© Fisher-Rosemount Systems, Inc. 2002 All rights reserved.
Form D350695X012 / Printed in USA / 15M AQ, 10M A4/ 01/02
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To locate an Emerson Process Management representative or sales office near you, or to receiveany of the aforementioned brochures, CDs andDVD, visit our website at: wwwwww..EEaassyyDDeellttaaVV..ccoomm, or call us at:Asia Pacific: 65.777.8211
Europe: 41.41.768.6111
Latin America: +1.512.832.3572
North America: +1.888.FOR.FRSI
(+1.888.367.3774)
Customers requesting this brochure have alsorequested the following:
Emerson Process Management
Fisher-Rosemount Systems, Inc.8301 Cameron RoadAustin, Texas 78754 USAT +1.512.418.7400F +1.512.418.7505
www.EasyDeltaV.com