maximizing the return on your control investment meet the experts sessions part2

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Maximizing the Return on Your Control Investment Part 2 of 2 Meet the Experts Sessions

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The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.

TRANSCRIPT

Page 1: Maximizing the return on your control investment meet the experts sessions part2

Maximizing the Return on Your

Control InvestmentPart 2 of 2

Maximizing the Return on Your

Control InvestmentPart 2 of 2

Meet the Experts Sessions

Page 2: Maximizing the return on your control investment meet the experts sessions part2

PresentersPresenters

James Beall

Terry Blevins

Page 3: Maximizing the return on your control investment meet the experts sessions part2

AgendaAgenda

Justifying the installation of multi-loop control techniques

Recognizing when advanced control techniques are needed to achieve best control performance.

Page 4: Maximizing the return on your control investment meet the experts sessions part2

When is Reduced Variability ImportantWhen is Reduced Variability Important

The objectives of a process control system generally fall into one of three categories:

Economic IncentiveSafety and Environmental ComplianceEquipment Protection

The degree to which a control loop must reduce variability depends in many cases on the objective of the control loop.

Page 5: Maximizing the return on your control investment meet the experts sessions part2

Economic IncentiveEconomic Incentive

The economics of plant operation may be impacted by process variation when maximum production and operating efficiency are achieved at a specific operating condition.

In such cases, any variation from these operating conditions will reduce production.

Page 6: Maximizing the return on your control investment meet the experts sessions part2

Impact of Operating Target Impact of Operating Target

When a process is characterized by having a global maximum, then performance may be worse if the setpoint is incorrect for the current operating conditions.

A key point in control system installation and maintenance is that decreasing variability is desirable, but it is also important to specify the operating setpoints needed to achieve best process performance.

Page 7: Maximizing the return on your control investment meet the experts sessions part2

Operating at a LimitOperating at a Limit

If plant production is not limited by the market, that is, an increase in production can always be sold, then maximum profit may often be achieved by running the plant at maximum throughput.

If production cannot be increased because of a physical limit in equipment operation, by reducing variation in the process operation, it is often possible to shift the production target to increase plant production without exceeding the physical limit in equipment operation.

Page 8: Maximizing the return on your control investment meet the experts sessions part2

Impact of Reduced VariabilityImpact of Reduced Variability

By reducing the variation in an economic control loop, plant production may be increased without exceeding the limits associated with the process area that is the plant bottleneck.

This simple concept is often the basis used to justify the cost of upgrading or installing a better control system in a plant.

Page 9: Maximizing the return on your control investment meet the experts sessions part2

Example – Ammonia Plant Example – Ammonia Plant

Page 10: Maximizing the return on your control investment meet the experts sessions part2

Example – Impact of Synthesis Bed TemperatureExample – Impact of Synthesis Bed Temperature

Page 11: Maximizing the return on your control investment meet the experts sessions part2

Impact of Synthesis Bed TemperatureImpact of Synthesis Bed Temperature

There is a strong incentive to install control capability that will automatically regulate the synthesis converter quench valve to maintain the bed temperature at setpoint.

Since an ammonia plant may produce over 1000 tons of ammonia per day, even a small increase in production for a given feed rate can significantly increase the profit generated by the plant.

Page 12: Maximizing the return on your control investment meet the experts sessions part2

Example – Impact of Loop PressureExample – Impact of Loop Pressure

Page 13: Maximizing the return on your control investment meet the experts sessions part2

Example – Impact of Loop PressureExample – Impact of Loop Pressure

The synthesis loop pressure control is an example of an economic control loop in which production is maximized by running as close as possible to a pressure limit.

An average increase in synthesis loop pressure would provide a 0.05%/Atm increase in production.

Page 14: Maximizing the return on your control investment meet the experts sessions part2

Utilize Process Capacity to Absorb VariabilityUtilize Process Capacity to Absorb Variability

“Capacity” in the process can be used to attenuate or absorb variability

Primary source of process capacity is level control

To utilize level control as a capacity tune the controller only “fast” enough to hold the PV within the allowable level deviation (ALD) for a maximum load change

Page 15: Maximizing the return on your control investment meet the experts sessions part2

Utilize Process Capacity to Absorb VariabilityUtilize Process Capacity to Absorb Variability

Lambda

PV Back to SP in 6 x Lambda

Step change in load (inflow)

Controller Output changing outflowsmoothly!

PV

Setpoint

Inflow

Outflow

LIC

Outflow = inflow

Change in PV stopped

Page 16: Maximizing the return on your control investment meet the experts sessions part2

Utilize Process Capacity to Absorb VariabilityUtilize Process Capacity to Absorb Variability

Choose the arrest time “slow” enough to provide a variability sink yet maintain level within the allowable variation

Lambda = __2 * ALV___ Kp * MLD

– ALV = Allowable Level Variation

– Kp = Integrating process gain

– MLD = Maximum Load Disturbance (converted to % of level controller output scale)

Page 17: Maximizing the return on your control investment meet the experts sessions part2

Utilize Process Capacity to Absorb VariabilityUtilize Process Capacity to Absorb Variability

Level

Manipulated

Variable

Before

Level

Manipulated

Variable

After

Page 18: Maximizing the return on your control investment meet the experts sessions part2

Reducing Control VariationReducing Control Variation

When tuning is not sufficient to achieved the desired level of variation in critical control parameter or to maintain it at an operating limit, then multi-loop techniques may sometimes be applied to improve control. Three common multi-loop techniques are:

Feedforward ControlCascade ControlOverride Control

Page 19: Maximizing the return on your control investment meet the experts sessions part2

Going Beyond Single Loop ControlGoing Beyond Single Loop Control

The more advanced control techniques should only be considered if the control objectives cannot be achieved using basic single loop feedback control.

Complex control strategies are more difficult to engineer, commission and maintain at optimal performance.

Page 20: Maximizing the return on your control investment meet the experts sessions part2

Multi-loop Control – Feedforward ControlMulti-loop Control – Feedforward Control

If a measurement of the disturbance is available to the control system, then through the application of feedforward control, it is possible to anticipate the impact of the disturbance.

Action can automatically be taken to correct for the measured disturbance before it impacts the controlled parameter.

Feedforward control is always done in conjunction with feedback control

Page 21: Maximizing the return on your control investment meet the experts sessions part2

Example – Steam HeaterExample – Steam Heater

Page 22: Maximizing the return on your control investment meet the experts sessions part2

Feedforward ControlFeedforward Control

If the process response to changes in the manipulated and disturbance inputs can be characterized as first-order plus deadtime, then the difference in the process response may be compensated for by using a deadtime block and a lead-lag block in the feedforward path.

Page 23: Maximizing the return on your control investment meet the experts sessions part2

Cascade ControlCascade Control

Cascade control may be applied when a process is composed of two or more (sub)processes in series.

Any change in the manipulated input to the first process in the series will impact the output of the other processes.

The output of each process in the series is the controlled parameter of the PID associated with that process.

Page 24: Maximizing the return on your control investment meet the experts sessions part2

Cascade Control – BenefitsCascade Control – Benefits

The primary benefits of cascade control are:

The PID at each point in the cascade can react quickly to disturbance inputs to its associated process. If the PID responds quickly enough, changes introduced by disturbance inputs will have little or no impact on the downstream processes.Cascade control may be implemented to compensate for the non-linear installed characteristic of a regulating valve. The slave loop could be tuned to quickly adjust the valve to achieve its setpoint requested by the master loop. Thus, the non-linear installed characteristic of the valve would have no impact on the tuning or response of the master loop.

Page 25: Maximizing the return on your control investment meet the experts sessions part2

Example – Boiler Steam TemperatureExample – Boiler Steam Temperature

The temperature of steam supplied by utility boilers can have a large impact on process operation.

In an attemperator, steam is mixed with water to regulate the temperature of steam exiting the boiler.

The spray valve is used to adjust the flow rate of water introduced into the

attemperator.

Page 26: Maximizing the return on your control investment meet the experts sessions part2

Cascade Control ImplementationCascade Control Implementation

Cascade control may be implemented when a process is made up of a series of processes.

One PID block is required for each process in the series. For normal operations, the master loop is maintained in Automatic

mode and the slave loop is operated in Cascade mode.

Page 27: Maximizing the return on your control investment meet the experts sessions part2

Cascade Control – Use of External ResetCascade Control – Use of External Reset

The PID block in DeltaV is designed to support dynamic reset limiting, also commonly know as external reset feedback.

– External Reset Feedback – Calculation of the PID integral contribution based on a measurement of the manipulated process input

The performance of cascade control loop may be improved

by enabling this option.

Page 28: Maximizing the return on your control investment meet the experts sessions part2

Override ControlOverride Control

The implementation of override control is often the most effective way to maintain the process within its operating constraint limits.

In general, override control may be implemented using two or more PID blocks and a control selector block.

Under normal operating conditions, the controlled parameter is maintained at setpoint by the selected PID. The override PID takes an active role if the value of the constraint variable approaches its setpoint.

Page 29: Maximizing the return on your control investment meet the experts sessions part2

Override Example – CompressorOverride Example – Compressor

In this example of override control, a large natural gas compressor is powered by an electric motor. Under normal operating conditions, the gas flow to the compressor is regulated to maintain a constant discharge pressure.

However, the load on the electric motor changes as the gas flow rate changes.

To avoid the current exceeding some limit, the motor current is the constraint variable and the discharge pressure is the controlled parameter in the override control strategy.

Page 30: Maximizing the return on your control investment meet the experts sessions part2

Override Control ImplementationOverride Control Implementation

The control selector block supports upstream and downstream back calculation connections.

Numbered pairs of input and back calculation outputs of the control selector should be connected to the same PID.

Dynamic reset should be enabled.

The control selector may be configured as a high or low selection.

Page 31: Maximizing the return on your control investment meet the experts sessions part2

Addressing Difficult DynamicsAddressing Difficult Dynamics

The control performance achieved may not be satisfactory when PID feedback control is applied to a deadtime-dominant process. In such cases, control performance may be improved by replacing PID feedback control with Model Predictive Control.

Page 32: Maximizing the return on your control investment meet the experts sessions part2

Testing to Determine Process ModelTesting to Determine Process Model

The DeltaV Predict application is used to automatically identify the process step response model.

The user may specify the amount the manipulated parameter is to be changed during testing and a guess of how long it takes the process to fully respond to a change in the manipulated parameter.

Page 33: Maximizing the return on your control investment meet the experts sessions part2

Model and Controller GenerationModel and Controller Generation

After testing is complete and Autogenerate is selected, the step response model and MPC controller are generated.

In general, MPC may also be used to control processes having multiple inputs and multiple outputs.

For each manipulated or disturbance input, the step response model shows the impact of a 1% change in this input (with all other inputs constant).

Page 34: Maximizing the return on your control investment meet the experts sessions part2

Validation of Step ResponseValidation of Step Response

To validate the identified step response model, the changes in the manipulated and disturbance input that occurred during testing can be passed through the model.

The response calculated using the model can then be plotted against the actual process output response as shown.

Page 35: Maximizing the return on your control investment meet the experts sessions part2

Simulate EnvironmentSimulate Environment

Simulate may be selected to view how the process will respond to a change in setpoint or disturbance input.

Since MPC internally uses the model to predict process outputs, this prediction may be shown in the operator interface and the simulation environment.

Page 36: Maximizing the return on your control investment meet the experts sessions part2

Using MPC to Address Process InteractionsUsing MPC to Address Process Interactions

When a process is characterized by multiple manipulated process inputs and multiple controlled process outputs, there is a potential for process interaction.

The interaction of the manipulated inputs and controlled outputs is automatically accounted for by MPC.

Page 37: Maximizing the return on your control investment meet the experts sessions part2

MPC Replacement for PID OverrideMPC Replacement for PID Override

When a process output is a constraint parameter in PID feedback control, this constraint parameter measurement is simply added as an input to the MPC block.

The design and implementation is thus much simpler than override control using two PID blocks and a control selector block.

Page 38: Maximizing the return on your control investment meet the experts sessions part2

Example - Batch Chemical ReactorExample - Batch Chemical Reactor

Page 39: Maximizing the return on your control investment meet the experts sessions part2

Batch Reactor – ProcessingBatch Reactor – Processing Using Model Predictive Control (MPC), it is possible

to operate at the temperature and pressure operating constraints to achieve the maximum possible feed rate and reduce the batch cycle time.

Page 40: Maximizing the return on your control investment meet the experts sessions part2

MPC Control of a Batch ReactorMPC Control of a Batch Reactor

Page 41: Maximizing the return on your control investment meet the experts sessions part2

Example - Spray Dryer ControlExample - Spray Dryer Control A slurry feed is sprayed into the dryer and the liquid component is removed by

a hot gas stream to create a powdered product. The slurry feed rate is normally set by the operator but may be reduced by pressure override control.

If the product residual moisture content is measured on-line, then moisture control may be cascaded to the air heater temperature loop.

Page 42: Maximizing the return on your control investment meet the experts sessions part2

Spray Dryer Control Using MPCSpray Dryer Control Using MPC Through the use of MPC, it is possible to maximize dryer throughput by maintaining

the feed rate at a value that maintains the dryer at its spray pressure constraint.

Page 43: Maximizing the return on your control investment meet the experts sessions part2

SummarySummary

An on-line measurement of control utilization and variability is provided by DeltaV Insight.

Exploring the causes of poor utilization is the first step in resolving measurement, actuator or control issues.

When single loop control is not sufficient to achieve the desired level of control the multi-loops solutions should be explored.

MPC may be used to address difficult dynamic or process interactions that are difficult address using PID.

Page 44: Maximizing the return on your control investment meet the experts sessions part2

Where To Get More InformationWhere To Get More Information

Many of the ideas discussed in this session are addressed “Control Loop Foundation – Batch and Continuous Processes”. Information on this book may be found at the book’s web site:

– http://controlloopfoundation.com/

Also, by going to this web site you can use your web browser to perform the 19 workshops that go with this book.