mon 14.25measuring and maintaining advanced control performance r saliss honeywell

8/10/2019 Mon 14.25measuring and Maintaining Advanced Control Performance R Saliss Honeywell

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Measuring and MaintainingAdvanced Control Performance


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Agenda

What is the problem?Why does Advanced Process Control performance

decay?

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How to measure APC benefits

Requirements for a successful maintenanceprogram


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The Good News?

APC is now widely accepted in the

process industries

APC technology is well-provenand understood

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Well-performing APC can delivermulti-million $$ benefits

..so, whats theproblem?


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Is there a problem?

APC is an asset and needs to be maintained

Poorly performing APC can deliver zero benefits

Poorly performing APC may even cost money!

Its not so easy to measure performance and detect a drop-off

Its very difficult to track economic performance of APC

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wrong

Skilled resources are scarce in order to understand the problemand fix the applications

You bet theres a problem!


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So, why does APC performance decline?

Design

Poorly conceived missing variables or improper

objectives Incomplete applications designed around poorly

functioning instruments, etc.

Maintenance

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Plant modifications Process changes

Instrumentation malfunctions

Changes to regulatory tuning & structure, instruments &

analysers Lack of modern tools (effort prioritization and efficiency)

Operator acceptance and understanding


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Operator acceptance and understanding

Change in personnel

Lack of training

Lack of involvement and acceptance at original project

Leads to

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PID loops in manual

Turned off because not understood

Adversarial attitude vs. First line of defense


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Poor Performance!

Poor Performance!

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Process

DesignController

Design

Process

Changes

Control

Hierarchy

NMP zeros Nonlinearity

Interactions

ControllerStructure

Constraints

Uncertainty in

process model,

disturbances

Sensor failure

layer PID layer

Various

subsystems

Process

DesignController

Design

Process

Changes

Control

Hierarchy


Interactions

ControllerStructure

Constraints

Uncertainty in

process model,

disturbances

Sensor failure

layer PID layer

Various

subsystems


Interactions

ControllerStructure

Constraints

Uncertainty in

process model,

disturbances

Sensor failure

layer PID layer

Various

subsystems


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So what do we need to do? Define

What are the problems?

What are meaningful metrics for success?

Measure

True economic performance of APC to justify investment and demonstrate dollarvalue to all stakeholders

Relative and absolute performance to indicate when need controllers need

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attention Analyse

Root cause analysis tools to help diagnosis

Consider the APC and PID monitoring performance together

Implement

Need the APC HMI and basic performance measurement to be designed withoperators in mind

Control

Consider monitoring and maintenance tools and procedures as part of

continuous improvement process


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Monitoring Requirement checklist

Make use of modern system and network capabilities.

Remote monitoring is increasingly possible with IT

technology, especially

suited to remote operations eg offshore assets and difficultlocations

10

,

monitoring APC

Regulatory controls and instruments

Alarm systems

Use visualisation and reporting methods that are simpleand easy to understand, appropriate to the user role

Provide diagnosis and root cause analysis tools


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APC Maintenance Program Goals

Safety & Reliability APC must be safe, reliable and predictable

Operations and operators must be comfortable and confident Measure value in terms of economic returns

Metrics that measure real-time economic value are required

Value improvement program needs to be in place

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Variables outside the scope of the APC box need to be tracked Maintenance requirements on assets need to be quantified

Collaboration & decision support Reduce decisions made in isolation

Work with other parts of organization to determine highest priority

maintenance tasks Communication & visibility

Communicate value to executive management

Create the visibility necessary to justify investment


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Uptime Most basic goal used to measure performance Provides lowest long term ROI Organizational visibility is typically within APC department

Value degrades over time back to pre-APC levels Operators call the shots, objective function relatively constant Support level is reactive

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Time (Months)

6 12 18

50

100

Ben

efits(%ofOriginal)

24


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Incentivized Operators Operators goaled to use controller

ROI better than uptime, but not sustained very well

Organizational visibility typically broadens to unit supervision

Operators determine ultimate value but benefits fall off Operators call shots but somewhat aware of consequences of moves

Support level is reactive with some proactive aspects

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Time (Months)

6 12 18

50

100

Benefits(%ofOriginal)

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Push Constraints Unit operations goaled to push constraints (typically process engineer)

ROI sustained better than previous methods

Organizational visibility broadens to operations management

Engineered objective function determines value

Objective function specified to push variables in predefined directions

Support level reactive and proactive

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Time (Months)

6 12 18

50

100


24


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Operating Value Production planning tracks operating value

ROI sustained and in terms of current economics

Organizational visibility extends up to production planning

Unit economics determines value Objective function based on product values and operating costs

Support level reactive, proactive and opportunity assessment

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Time (Months)

6 12 1

8

50

100


24


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Production Planning Tool Production planning incorporates APC into planning process

Best sustained ROI and helps drive RT operating decisions

Organizational visibility extends to executive management

Economic value maximized Economic objectives determined at site wide level

Support level reactive, proactive, opportunity assessment and incorporatesvariables outside of APC scope

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Time (Months)

6 12 18

50

100


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Measuring APC PerformanceUtilization: If the controlleris not being used, there islikely a fundamental problem.

Performance: controllermay be ON, yet performing

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.

analyze the performanceof the various CVs,constraint variables, etc.

Diagnostics: identify &pinpoint the areas ofdeficiency (e.g. model plantmismatch, improper tuning,instrumentation issues, etc.)


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Metric Goal

Service Factor Weekly > 90%, Quarterly > 95%

CV/MV

Example of APC performance metrics

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EffectiveService Factor

Weekly> 90%, Quarterly > 80%

Model Index %

This is an example of simple and effective metricsimplemented by a Honeywell customer across multiple

controllers and sites


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&

&

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Original benefits were estimated to be $300K per year Primary controller objective is to Maximize Feed

Maximizing feed is indicated by operating very close to two keyconstraints

Assume that each constraint is equally important to indicate that feedis maximized

Define Custom Performance Metrics as follows:


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PM1 = 10*(% of time close to constraint A + % of time close to constraintB)/200 Best value of PM is 10.

Benefits Metric: PM2 defined as 30* PM1 which is the annual benefit derived by the

controller over the time period,

LossMetric: PM3 : (300- PM2)

Flag a controller based on lost benefits Compare applications on a common basis


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Controller June

1-5

June

5-10

June

10-15

June

15-20

June

20-25

June

25-30

Overall

Preflash1.90 2.90 8.09 9.44 8.95 8.13 6.32

Crude1.68 3.11 8.07 8.15 6.86 8.71 6.02

Vacuum2.33 1.91 8.26 7.85 8.28 7.24 5.98

DIH2.89 3.33 6.57 8.17 7.26 9.93 6.34

Debut6.00 8.14 7.94 5.25 5.37 4.59 6.62

GasCon 5.59 4.51 6.63 6.03 6.34 5.98 5.43


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x egen8.98 8.80 8.26 8.03 8.47 8.59 8.76

Syn Tower 5.79 4.60 4.78 4.31 4.61 4.64 4.81

VRU 6.25 7.67 7.15 6.11 7.25 4.51 6.55

Poly Splitter 7.71 6.13 7.45 8.65 5.32 4.73 6.58

Isomax Rx 1.95 3.38 6.00 2.10 5.66 5.87 4.62

Isomax Debut 0.96 5.04 5.34 7.26 8.15 5.42 5.07

Isomax Frac 0.86 3.92 5.89 2.95 6.36 5.28 3.91

B-4401 2.57 6.51 9.75 7.48 4.00 8.92 6.95

H2Grid 2.88 6.72 5.24 5.28 3.56 8.33 6.02

E-4021 5.03 0.95 3.26 4.04 0.38 0.00 2.63

E-4106 6.83 3.15 4.05 7.56 5.87 7.42 5.73

E-4161 7.36 2.90 0.66 0.01 3.53 4.51 3.04


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APC Performance Visualisation

22 MV Effective Utilization


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APC Performance Visualisation

23 Constraint Monitoring


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On line benefits assessment Best Operator Method*Assumptions:

Validated model

Operator can make limited amount of moves

Operator will always make just the right move

Calculation:

=

25

= measured output MINUS controller contribution PLUSoperator contribution (MVs moved at lower frequency)

Controller moves

)Y(F(Y)F(

))Y(FY((Y)F(

YY(Y)F(

,

HPhHP

unc

LPhHPunc

operhHP

unc

)

)

)

48

48

48

=

=

+=

)(un

*As presented by E Tolsma & R Fourie, Sasol, Honeywell User Group 2010


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Calculate delta:

Use the 5% New Limit Rule

Thus, make use of actual limit and not controllers hard limit. Benefit delta between and :(Y)F

hHP48)(Yunc

On line benefits assessment Best Operator Method

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0

5%

)(uncY

)(48hHP

Y


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Sustaining Benefits: Industrial Adaptive Workflow

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RuntimeMetrics

Diagnosticsand Analysis

Real-time CLiD Runtime Infrastructure

Automate tasks where sensible

Result:

Improve Overall Sustainability

Enable Remote Serviceability

Enable Remote Collaboration

Real-Time Update


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APC Monitoring Technology: A Merger of Strengths

Profit Expert

ControlPerformance Monitor

CV model and phase index& residual analysis

Estimator/Analyzer KPIs

PID controller KPIsNext Generation

Monitoring Platform

MES Standards-based

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MV/DV specific model qualityTuning Recommendations and

Confidence

Constraint set analytics

Detailed Printed Reporting

Loop ScoutBenchmarking

Remote Data Support

Expert Guidance

Sort & Filter

presented via

Web-centric reportingNotification services

Aggregate results

Business-Level Workflowintegration


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Summary APC is an asset that needs monitoring and maintenance

to sustain benefits

Tool and techniques are available to measureperformance

Information must be relevant and appropriate

Use same visualisation and re ortin methods as for

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other automation assets Measuring and tracking economic performance is key

Consider APC monitoring & maintenance as part ofcontinuous improvement workflow


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Thankyou!

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mon 14.25measuring and maintaining advanced control performance r saliss honeywell

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