delta v advanced control overview_en

DeltaV Embedded DeltaV Embedded Advanced ControlAdvanced ControlA New Approach to Advanced ControlOverview Presentation

Emerson Confidential

TopicsTopics DeltaV Embedded Advanced Control Advantage DeltaV Advanced Control Product Suite Experience / Examples


Advanced Control for Operational ExcellenceAdvanced Control for Operational Excellence Improve Quality

– Reduce Variability– Predict Lab Measurements

Increase Throughput– Continuously Push Limits – Protect Multiple Constraints

Reduce Costs– Maximize Efficiency and Reduce

Energy Costs– Accurate Quality Control to Reduce

Inventory and Product Rework– Stabilize Control to Reduce

Equipment Wear and Incident Risk

PlantWeb Benefits

APCImpact


Advanced Control - The DeltaV WayAdvanced Control - The DeltaV Way

Enable the average process engineer to quickly

deploy state-of-the-art Advanced Control to

improve plant performance.

DeltaV Makes Advanced Control Easy!


• NO extra databases

• NO database synchronization issues

• NO watchdog timers

• NO fail/shed logic design

• NO custom DCS programming

• NO interface programming

• NO operator interface development

Embedded APC Tools – What’s new?Embedded APC Tools – What’s new?

Traditional Advanced Control

Embedded APC:• Can run in DCS controllers• Redundant and fast (1/sec)• Integrated operator user

interface• Configuration through

standard Control Studio• Automated step testing and

Model ID• Off-line simulation and

training


New Approach to APC ConfigurationNew Approach to APC Configuration

Graphical Configuration using Control

Studio

DeltaV APC blocks are “Drag-n-Drop”


New Approach to APC ConfigurationNew Approach to APC Configuration

System-wide tag browsing

… all in the DCS database


Typical APC Project TimelineTypical APC Project Timeline

1 2 3 4 5 6 7 8 9 10 11Months

12

Functional Design

Det. Design, Config & Staging

Step Tests & Model IDCommissioningTraditional APC Technology

Functional Design

Det. Design & Config

Step Tests & Model IDCommissioning

Performed on-site

Embedded APC Technology


% O

n-lin

e Ti

me

time

Traditional Advanced Control Over TimeTraditional Advanced Control Over Time

Traditional APC

More than 50% of APC applications are turned

off within the first 2 years after installation.

Start ProjectStart Commissioning

End Commissioning

Yr 1 Yr 2

100%


Why Don’t APC Applications Stay On-Line?Why Don’t APC Applications Stay On-Line? Regulatory control problems

– Instrument failures– Valve problems– Poor loop tuning

Process changes– New constraints or limits– Different control objectives– Different process dynamics

Applications not maintained– Maintenance not budgeted

Lack of operator training– Operators don’t understand what the APC is doing

Too expensive to bring in APC consultants

How to Sustain Control Performance?How to Sustain Control Performance?


Must Build Solid FoundationsMust Build Solid Foundations

AdvancedControl

Control Foundation

You Can’t Have This…

Without This…


Foundation Built on Health of Field DevicesFoundation Built on Health of Field Devices

Fieldbus Status Is Consistently Used by DeltaV Advanced Control


DeltaV Embedded Advanced ControlDeltaV Embedded Advanced ControlA Systematic Approach for Sustained PerformanceA Systematic Approach for Sustained Performance

Monitor Performance

Identify ProblemsAnd Prioritize

Analyze andDiagnose

Re-TuneOr Fix Cause

AdvancedControl


DeltaV InSight – A Control Performance SuiteDeltaV InSight – A Control Performance Suite

IntelligentPerformance Monitoring

“Inspect with InSight”

Intelligent Controller Tuning

“Tune with InSight”

Advanced ControlPredict / Neural / Fuzzy

Adaptive Control (Adapt)“Control with InSight”

DeltaVInSight

Process Model Calculations


time

DeltaV Embedded APC for DeltaV Embedded APC for Sustained PerformanceSustained Performance

Faster to Commission +Sustained Performance

= Greater $$’s Saved

DeltaV APCTraditional APC

% O

n-lin

e Ti

me

100%


The DeltaV Embedded APC AdvantageThe DeltaV Embedded APC Advantage Ease of Use

– Intended for process control engineers– Minimum APC consulting required

Integrated DeltaV Architecture– Common graphical configuration, operator displays, historian– Advanced control technology embedded in system

Sustained Performance– Built-in tools to optimize regulatory control performance– Accounts for health of field devices

Reduced Cost– Faster project implementation– Easier to maintain


TopicsTopics DeltaV Advantage - Embedded Advanced Control Advanced Control Product Suite Experience / Examples


DeltaV Advanced Control ProductsDeltaV Advanced Control Products DeltaV InSight – performance monitoring and loop tuning

– Inspect: Monitors performance and identifies abnormal conditions. Automatically configured.

– Tune: On-demand and Adaptive tuning for any PID loop.– Adapt: Closed loop adaptive control for any PID block.

DeltaV Predict/Pro – Model Predictive Control (MPC) with embedded optimization for small and large applications.

DeltaV Neural – On-line property estimation for process measurements normally only available from lab analysis.

DeltaV Simulate/Pro – Off-line training and engineering environment. Run DeltaV on your laptop!


DeltaV Advanced Control ProductsDeltaV Advanced Control Products DeltaV Insight – performance monitoring and loop tuning

– Inspect: Monitors performance and identifies abnormal conditions. Automatically configured.

– Tune: On-demand and Adaptive tuning for any PID loop.– Adapt: Closed loop adaptive control for any PID block.

DeltaV Predict/Pro – Model Predictive Control (MPC) with embedded optimization for small and large applications.

DeltaV Neural – On-line property estimation for process measurements normally only available from lab analysis.

DeltaV Simulate/Pro – Off-line training and engineering environment. Run DeltaV on your laptop!


DeltaV InSightDeltaV InSight

Easily identify control problems– Loop service and variability monitoring– Device diagnostics

Quickly tune loops for improved control– On-demand and Adaptive Tuning– Test tuning with simulation

Gain process insight with embedded learning

Easy to Use – Out of the Box– No Configuration Required– Adapts to system configuration

changes

Poor control costs your company money. DeltaV InSight provides a cost effective way to improve control performance:


Predictive Intelligence = Intelligent ControlPredictive Intelligence = Intelligent Control

Adaptive Learning Algorithms for Intelligent Control

Evaluate• Validate• Compare• Diagnose

Learn• Observe• Identify• Remember

Improve• Advise• Tune• Adapt


DeltaV InSight for Intelligent ControlDeltaV InSight for Intelligent ControlWith InSight’s Adaptive Learning you can:• Automatically calculate process models for every

control loop in the system• Benchmark Control Performance • Diagnose and predict control problems • Tune controllers (with no testing)• Reduce start-up time for new control systems• Reduce engineering time for simulations• Identify APC Opportunities • Apply MPC (Predict) with no testing• Implement closed loop adaptive control

Never before has a Control System provided embedded learning algorithms for every control loop; enabling intelligent monitoring,

diagnostics, and advanced tuning.

Learn Evaluate

Improve


DeltaV InSight DeltaV InSight

Performance Monitoring

Loop Diagnostics Embedded Learning Adaptive Tuning Adaptive Control

•On-demandTuning•Adaptive Tuning•Simulation

• Performance Monitoring

• Loop Diagnostics• Reporting

• Model Identification• Control Diagnostics• Performance Indices

Bringing it all together:

• Adaptive Control• Operating Regions• Non-linear Control


DeltaV InSight – Integrated User InterfaceDeltaV InSight – Integrated User InterfaceOld DeltaV Inspect

Old DeltaV Tune

New DeltaV InSight

New interface provides seamless transition between loop diagnostics

and tuning.


Control Studio DeltaV Explorer

Easily Launched in Context Easily Launched in Context

Context sensitive from Control Studio

From the DeltaV Explorer

From the Operator Interface


DeltaV Insight – ArchitectureDeltaV Insight – Architecture

Embedded Learning Runs in the Controller • Fast Data Capture • Small Communications Load • Runs in Background

Data Analysis and Reporting Runs in Server

UI from any workstation


DeltaV InSight – Process LearningDeltaV InSight – Process Learning InSight monitors each control

block to detect changes to SP (or OUT in manual), called a Trigger Event.

InSight captures response data and calculates a dynamic process model for each Trigger Event. Models are stored in a database for use in loop diagnostics and adaptive tuning.

Users may modify default values for SP or OUT move size required for a Trigger Event in the Learning Set-up Display.


DeltaV InSight – Enable Process LearningDeltaV InSight – Enable Process Learning

Learning may be enabled in Control Studio during configuration, or

Learning may be enabled in DeltaV Explorer

Learning may also be enabled and disabled ON-LINE using DeltaV InSight

Learning is available on DeltaV and Fieldbus PID blocks


Control Performance MonitoringControl Performance Monitoring

Explorer tree allows easy navigation of control hierarchy

Overview display summarizes performance for System, Area, Units and Modules

Abnormal Control Conditions indicated for Problem Loops:– Control Service Status:

• Incorrect mode• Limited control output• Bad/Uncertain input

– Control Performance Status:• Standard Deviation• Variability Index• Oscillation Index• Tuning Index

– Device and Valve Diagnostics

“Inspect with InSight”


Block Summary Display provides trends, current values, and limits for: Control Service Statistics– Incorrect Mode– Limited Control Output– Uncertain Input

Control Performance Indices– Standard Deviation– Variability Index– Oscillation Index– Tuning Index

Control Block Performance IndicesControl Block Performance Indices

Tuning Index is the % change in control variability between current tuning and recommended adaptive tuning.


DeltaV InSight – Tuning IndexDeltaV InSight – Tuning Index Quickly identifies loops

that have recommended tuning

Tuning display filter will only indicates loops with:– Significant improvement in

variability (e.g., >20%)– High model confidence– Currently have high

variability


DeltaV InSight - Asset MonitoringDeltaV InSight - Asset Monitoring Device Alerts are reported

through InSight Asset Displays

Overview provides graphical display for Asset Alerts of System, Area, and Modules

Asset Display identifies Asset Alerts including:– Asset Failed– Maintenance Soon– Advisory– Communications Failed

Easily Launch AMS Device Manager in Context to access detailed diagnostics

Right-Click


DeltaV InSight – Loop TuningDeltaV InSight – Loop Tuning

On-demand Tuning – Steps control output

to identify tuning– Same as old TUNE

Adaptive Tuning– No Testing– Uses Process

Learning during normal operations

Two methods of loop tuning are supported


DeltaV InSight - On-demand TuningDeltaV InSight - On-demand Tuning

● Used to tune PID and fuzzy logic control blocks

● Guides user through tuning

- Set Step Size- Test- Simulate

● Same features as old DeltaV Tune


On-Demand Tuning - Options for the Expert On-Demand Tuning - Options for the Expert

Power for the Advanced User !


DeltaV InSight - Adaptive TuningDeltaV InSight - Adaptive Tuning

InSight automatically calculates dynamic models from operator changes

Model Quality and Learning Status

Tuning criteria and desired speed of response

Tuning Recommendation

No Testing Required

Provides Tuning Based on Normal Operator Changes


DeltaV InSight - Model AnalysisDeltaV InSight - Model Analysis

Models automatically stored in a model database

Various plot options to analyze impact of operating conditions on process models

Average of selected models may be utilized to establish the recommended tuning

Gain Process Insight with Model Analysis


DeltaV InSight - Control SimulationDeltaV InSight - Control Simulation

Closed loop simulation of setpoint and disturbance changes for recommended tuning

Simulation for both Adaptive and On-demand Tuning

Test your tuning with Dynamic Simulation

Select New TuningSpeed vs Robustness

View Dynamic Response


DeltaV InSight – Adaptive ControlDeltaV InSight – Adaptive ControlNon-linear Process Example Process gain and dynamics may change as a function of

operating conditions such as valve position or feed rate.


Non-linear Process ModelsNon-linear Process Models


DeltaV InSight – Adaptive ControlDeltaV InSight – Adaptive ControlInSight identifies tuning in

up to 5 regions of operation


DeltaV InSight – Adaptive ControlDeltaV InSight – Adaptive Control


DeltaV InSight – AdaptiveDeltaV InSight – Adaptive ControlControlAdaptive control adjusts tuning to improve control

performance


InSight Performance ReportsInSight Performance Reports Standard Out-of-Box Reports

– Quickly identify control problems– Track performance, communicate results– Schedule for automatic generation– Easy, Easy, Easy

• No Configuration or Maintenance

Customized Reports– Add production KPI’s in customized

reports via Excel and DeltaV Reporter


Area Control Performance ReportArea Control Performance Report


DeltaV Fuzzy - As Easy to Use as PIDDeltaV Fuzzy - As Easy to Use as PID

• Pre-configured Fuzzy Logic Controller

• May replace PID for most applications

• Improved response to process disturbances

• Quick tuning with DeltaV InSIght

• Configuration is Easy - exactly like PID


DeltaV Explorer

Easy As PID…Easy As PID…

Replace PID withFuzzy Logic Control


DeltaV Fuzzy Function BlockDeltaV Fuzzy Function Block

Pre-defined FuzzyLogic Control


Transfer recommended constants to fuzzy control

Use DeltaV InSight to Tune Fuzzy LogicUse DeltaV InSight to Tune Fuzzy Logic


Simulated ResponseSimulated Response


Setpoint Change Load Disturbance

FLC

PID

FLC

PID

FLC

PID

FLC

PID

Notice at both SP change and at load disturbance the FLC output change is more dramatic than PID. Resulting in faster return to SP. Also notice as PV approaches SP, the FLC exhibits less overshoot.

Fuzzy Logic Control vs PID Fuzzy Logic Control vs PID


Fuzzy Control ResultsFuzzy Control Results DeltaV “Fuzzy” pH Control: Tighter control of effluent pH results in 8% decrease in

amount of caustic used. Value = 720 GPD caustic; eliminated nuisance alarms

Before(using DeltaV PID)

After(using DeltaV Fuzzy)

Source: Emerson Exchange, October 2004Shell Deer Park Paper


DeltaV Predict - Model Predictive ControlDeltaV Predict - Model Predictive Control

● Handles difficult process dynamics, reduces variability and protects constraints

● Easy and fast implementation ● Fully embedded, no

integration required- Configuration- Operator Displays- Historian

● Scaleable, Practical Model Predictive Control

● Optimizes process within constraints


Model Predictive ControlModel Predictive ControlLearns From The PastTo Predict The Future

Past Present Future

ModeledRelationship


Multivariable Dynamic Process ModelsMultivariable Dynamic Process Models

The Model Consists Of Step Responses That Show The Relationship Between Every Process Input And Output


Graphical ConfigurationGraphical Configuration

Graphical Configuration using Control

Studio

DeltaV APC blocks are “Drag-n-Drop”


Automated Step TestingAutomated Step Testing

Process Steps


Process Model DisplaysProcess Model Displays


Individual Step Response ViewIndividual Step Response View


Enter Step Response Constants

Modifying Step ResponsesModifying Step Responses


Model ValidationModel Validation


MPC Control SimulationMPC Control Simulation


Trend Window

Past Future

Automatic Operator DisplayAutomatic Operator Display

Constraint Variables

Control Variables

Manipulated Variables

Disturbance Variables


APC OptimizationAPC Optimization

Time

Throughput Production Increase $$

Throughput at limit

Operator Setpoint

APC

Often as simple as maximizing one variable to its most limiting constraints…

… but modern APC tools can do much more if needed.


Built-in LP OptimizationBuilt-in LP Optimization

100% position

0% position

0% p

ositi

on

100%

pos

ition

80 deg F

120 deg F

50 psi

100 psi

Maximized ThroughputMaximized

ProfitMinimized

Energy


Objective Function ConfigurationObjective Function Configuration

Select from list of controller variables Set Max/Min

and Price

Define multiple operating modes

Easy to set up and configure the built-in LP Optimizer


Easily Select Optimization ModeEasily Select Optimization Mode

Select from list of Optimization Modes


Optimizer Detail DisplayOptimizer Detail Display

Current Values

Optimal Values


DeltaV Neural – Property EstimationDeltaV Neural – Property Estimation

● Create virtual sensors for on-line measurements normally only available through lab analysis

● Easy to understand and use, cost effective

● General nonlinear modeling tool


Inferential Sensor ConfigurationInferential Sensor Configuration

Lab Entry Block

Select Inputs


Select Neural Training DataSelect Neural Training Data

● Select training set from historian

● Exclude bad data segments

● Train the network


Training the Neural NetworkTraining the Neural Network

Auto detection of over-training


Sensitivity Plot, Input SelectionSensitivity Plot, Input Selection


Validating Neural ModelsValidating Neural Models

Naphtha 95% Point Prediction


Neural Results – Naphtha 95% PointNeural Results – Naphtha 95% Point

SR Naphtha EP

340345350355360365370375380

07-Aug-0300:00:00

09-Aug-0300:00:00

11-Aug-0300:00:00

13-Aug-0300:00:00

LabNN PredictionFiltered

Crude Switch


DeltaV SimulateDeltaV Simulate

● Configure your DeltaV system off-line on a single PC

● Check out control logic and operator interface using PC simulation

● Provides multi-user, global engineering and training environments

● Easy integration with dynamic process simulation packages such as mimic


DistributedControl

Functionality

DeltaV ArchitectureDeltaV Architecture

Control Design and Configuration are Independent of Hardware


DeltaV Control System SimulationDeltaV Control System Simulation

● All features of the control system may be combined for execution on a single PC or multi-node network.

● Plant configuration may be utilized in this simulation environment with no change in configuration.

Benefit: Reduce Costs in

● Engineering● Maintenance● Equipment

DeltaV Simulate Standalone


DeltaV “Multi-Node” Control SimulationDeltaV “Multi-Node” Control Simulation

Multi-Node Environment

OPTIO

NAL

● Simulation capability with both virtual and real controllers (controllers optional)

● Provides global engineering environment – Multiple engineers on the same development system

● Provides multi-user training environment – Multiple operators on the same or parallel sessions

Professional PlusOperator Station Application Station


Professional PlusOperator Station App Station

Process Simulator via OPC

DeltaV “Multi-Node” Control SimulationDeltaV “Multi-Node” Control Simulation● Supports mimic Process

Simulator running in DeltaV Workstation

● Supports Third Party Process Simulators via standard OPC


Application Station with mimic Simulator


DeltaV “Multi-Node” Control SimulationDeltaV “Multi-Node” Control Simulation


Professional PlusOperator Station

Process Simulator With Virtual I/O Module

Application Station

● Supports mimic Process Simulator running in DeltaV Workstation

● Supports Third Party Process Simulators via standard OPC

● Supports I/O simulation and Fieldbus emulation with virtual I/O module and mimic simulation


Simulate Parameter for I/O Blocks

Field Inputs

● All DeltaV I/O Blocks have a Simulate Parameter● When Simulate is Enabled, AI blocks use the

SIMULATE_IN value for measured value● SIMULATE_IN may be entered manually or from

process simulator

Using Simulated Process Inputs:


Process Simulation Packages are easily

integrated with DeltaV Simulate via OPC.

Process Simulation via OPCProcess Simulation via OPC

Process Simulation

OPC Client Driver

OPC Read of OUT

OPC Write to Simulate_In


DeltaV Simulate Pro – Added FeaturesDeltaV Simulate Pro – Added Features

Save and Restore allows a snapshot of control module parameters to be created or restored.

Initialization of all dynamic blocks to steady state with a single request.

Faster or Slower than real-time execution of all modules assigned to a node.

All inputs blocks assigned to a node may be changed to Simulate Enable or Disable, Setup or Normal mode with a single request.

Select the node(s) that you want to access (ProPlus and App Stations only)

Simulate Pro is designed to coordinate simulation and support replay.


DeltaV Simulate Pro – Entry PlaybackDeltaV Simulate Pro – Entry Playback

Playback operator entries with simulation to re-enact training session

View operator entries in Event Journal

Restore saved simulation scenario

Improve Training Effectiveness with Playback of Operator Entries

Make changes or skip operator entries during replay


DeltaV Simulate for SIS DeltaV Simulate for SIS Simulate an entire

plant with both BPCS and SIS simulation together

Simulate the same SIS logic that is implemented in the plant

Great for Operator Training Systems (OTS)

Easier Factory Acceptance Testing (FAT) for projects


DeltaV Simulate -DeltaV Simulate -Simulation Download Web ServiceSimulation Download Web Service

●Automatically synchronize DeltaV and MiMiC●Reduce Engineering Costs●Improve Simulation Accuracy


DeltaV APC on Legacy PlatformsDeltaV APC on Legacy Platforms

APP Node(Or PHD)

DeltaVProPlus Station

UniversalStation (US)

OPC I/F

APM HPM

Serial I/O FTA

IOPs

PLC Gateway

GUS

Serial I/F Options

TDC3000 LCN

Option 1: Run APC in Work Station

DeltaVController

Option 2: Run APC in controller


TopicsTopics DeltaV Advantage - Embedded Advanced Control Advanced Control Product Suite Experience / Examples


Example Predict LicenseesExample Predict Licensees

End User CompanyTotalMVs Purchase Date

Petrovietnam 60 Aug-03

Lucite International 40 Jan-02

Solutia, Inc. 60 Jun-98

Canadian Forest Products Ltd. 38 Apr-01

Baxter 32 Apr-01

Petrotel-Lukoil 30 Jan-04

Petrogal 30 Feb-05

BASF Corporation 25 May-04

Norske-Skog Canada 25 Jun-03

Flint Hills Resources, LP 20 Jun-04

Huntsman ICI 20 Oct-00

Husky Energy 20 Nov-04

Monsanto Company 20 Jul-03


Refinery APC ExampleRefinery APC Example

Ergon, West VirginiaErgon, West Virginia


Ergon Project ScopeErgon Project Scope Atmospheric Crude and Vacuum Units 2 Model Predictive Controllers – 4 x 4, 3 x 3 3 Neural Networks

– SR Naphtha 95% point– AGO 95% point– Wax distillate 95% point


Main MPC Control Icon

MPC Temp Targets


Atm Controller PerformanceAtm Controller Performance

CVSPMVLabSpec

Controller ON

Naphtha

Kero AGO

Hvy Kero

Crude Change


Atmospheric ColumnAtmospheric ColumnNeural Network PredictionsNeural Network Predictions

Naphtha

Kero

Hvy Kero

AGO

Resid to VAC Column

FC

FC

FCFC

FC

FC

FC

FC

TC

Crude

Fuel Gas

TCPredicted NA 95%

Predicted AGO 95%

Column Temps & Yields

Column Temps & Yields


Neural Results – Naphtha 95% PointNeural Results – Naphtha 95% Point

SR Naphtha EP

340345350355360365370375380

07-Aug-0300:00:00

09-Aug-0300:00:00

11-Aug-0300:00:00

13-Aug-0300:00:00

LabNN PredictionFiltered

Crude Switch


Variability ReductionVariability Reduction Before After

Average St. Dev. Average St. Dev.Reduction in

Std. Dev.Atm Column SR NAPHTHA EP 349.55 14.89 347.10 4.30 71.1% AGO EP 636.32 10.54 634.41 6.22 41.0% OVERHEAD TEMP 253.18 5.01 260.91 1.80 64.1% KERO DRAW TEMP 362.59 4.60 366.60 1.86 59.5%

HVY KERO TEMP 459.37 5.65 462.72 2.60 54.0%

AGO DRAW TEMP 528.14 5.60 530.77 2.55 54.5% Vacuum Column WAX DIST 95% POINT 934.36 12.28 933.78 8.56 30.3% VGO CHIMNEY TEMP 358.58 7.32 365.74 3.23 55.8% WAX VAP TEMP 542.47 5.99 599.50 2.29 61.8% H WAX VAP TEMP 651.77 5.39 671.75 3.74 30.7%


Crude/Vac Unit APC Project TimelineCrude/Vac Unit APC Project TimelineActivity Timeframe

Functional Design Specification 3 weeks

Application Configuration < 1 day

Step Tests 10 days

Commissioning 1 week

Scope: Two 4x4 MPC controllers, 3 Neural Nets

DeltaV APC Projects are 25-50% Faster and Less Costly than traditional

APC Projects


Lime Kiln Project ~Canfor - Lime Kiln Project ~Canfor - Northwood PulpmillNorthwood Pulpmill


Kiln Process MPC Application Kiln Process MPC Application

Fuel Flow

Lime MudFeed

TT AT

PT FT

DT

TT

TT

FT

HotEnd

ColdEnd

ID FanMain Drive

Mud Filter

Lime Product

Energy Flow(manipulated)

Lime Mud Flow(optimized anddisturbance)

ID Fan Speed(manipulated)

Hot-end Temperature(controlled)

Cold-end Temperature(controlled)

Excess Oxygen(controlled and constraint)

Hood Draft Pressure(constraint)

Kiln Stack Emissions(constraint)

Lime Kiln Process


Northwood Lime Kiln Northwood Lime Kiln DeltaV MPC Control Performance - BenefitsDeltaV MPC Control Performance - Benefits

Period

Average Specific Energy

(filtered) (GJ/t)

Average Mud Flow (filtered)

(t/d)

Average Lime

Product Flow

(filtered) (t/d)

Specific Energy

Standard Deviation (filtered)

(GJ/t)

% Time on DeltaV MPC

Control (Average)

Sept.3,2000 to Oct.15,2001 9.15 584.77 270.14 1.18Sept.3,2000 to Apr.8,2001 9.62 571.70 264.10 1.34Dec.17,2000 to Apr.8,2001 8.78 593.64 274.24 1.20Sept.3,2000 to Jan.7,2001 10.20 560.49 258.92 1.43Oct.15,2001 to Jan.8,2002 8.22 688.13 317.89 0.14 97.60%

ReducedSpecificEnergy7-20%

(0.56 - 1.98 GJ/t)

OperatorConfidence -

97.6% UPTIME!

DeltaVMPC

ReducedVariability

89.5%

IncreasedLime

Production16-20%


Northwood Lime Kiln Northwood Lime Kiln DeltaV MPC Control Performance- BenefitsDeltaV MPC Control Performance- Benefits

Before ControlDeltaV MPC Control

%Reduction in Variability

Hot-end Temperature variations (2-sigma) Deg C 134.86 18.46 -86.3%Cold-end Temperature variations (2-sigma) Deg C 43.9 8.12 -81.5%Excess Oxygen variations (2-sigma) % 1.9 0.18 -90.5%Specific Energy Variations (2 sigma) GJ/t 2.96 0.28 -90.5%

Tight Control on DeltaV MPC!


Baxter MPC Distillation Column ControlBaxter MPC Distillation Column Control

TT

XIC

TT

FT

FT

TI

TI

FICFI

PT TT

PI TI

+

Reactor

Column

Condensers Vent Pressure andTemperature

Reflux (Return) Flow

Takeoff (Distillate)Flow

Mid ColumnTemperature

Bottom ColumnTemperature

Boilup

MPC

CV 1 MV 1

MV 2

AV 1AV 2

DVEU/SEC

RTO

RSP

RSP

CV 2 (OPTIM)

MPC Distillation Control

Steam


Quantified Business ResultsQuantified Business ResultsNoel Perez – Baxter de Puerto RicoNoel Perez – Baxter de Puerto Rico For the batch distillation process, the time to complete a

cycle has now been reduced by an average of 3.35 hours.

This is a 20% decrease in batch time which resulted in a throughput increase of 5.4%.

This production increase equates to annual incremental revenue of just over US$2 million for this unit alone.

Incremental production at this rate could defer the requirement to add capacity through plant capacity expansion.

The capital expenditure that would have been required to provide this additional capacity is approx US$5MM

http://www.ariba.com/customers/cust_byindustry.cfm?typeid=13&customerid=121


Learning More About DeltaV Learning More About DeltaV Advanced ControlAdvanced Control

Book was inspired by DeltaV Advanced Control Products. This book is available from ISA or may be ordered at EasyDeltaV.com/Bookstore

The application sections include guided tours based on DeltaV Advanced Control Products

CD provides an overview video for each section and examples. Copies of the displays, modules, and Simulation Cases are included.


SummarySummary Advanced Control Improves Operational Excellence

– Improved Product Quality– Increased Process Throughput– Reduced Operating Costs

DeltaV Integration Improves Efficiency and Reliability– Uses common database, operator interface, configuration tools,

and simulation environment– Access to Field Device Health improves reliability

DeltaV Embedded APC is Cost Effective– Faster implementation– Sustained Performance– Fewer Consultants Needed