Optimization Services, Tools and Advanced Process Control · PDF file§October 29, 2013 | Slide 7 Control Performance Issues ... Process Economics - Quality Control and Production

§© ABB Service

Optimization Services, Tools andAdvanced Process Control

© ABB Service

Outline

§ Assuring Optimal Performance

§ Fingerprint Offerings and Examples

§ Control Loop Performance

§ Sustaining Performance§ ServicePort

§ Advanced Process Control§ ABB Predict & Control MPC

§ APC Services

§ ABB MPC in 800xA

© ABB Service

Optimization Service Methodology

Goal: Measure and Reduce Performance Gap, Extend system life,Operate at the mechanical system constraints

Proc

ess

Perf

orm

ance

Pote

ntia

l

Time (years)

100 %

ManualAuto

Ideal

Implement2.

Diagnose(Fingerprints)

Performance Gap

1.

Startup Continued Operation

Sustain(ProcessPRO)

3.

§© ABB Group§October 29, 2013 | Slide 4§© ABB Group§October 29, 2013 | Slide 4

ABB Fingerprint finds gaps, develops customer ROI

Data Collection/Testing§ 12 to 24 hours at 5-second data§Controller parameters§Customer interview: process areaand loop criticality definitions.

Performance Evaluation§Standard Methodology§Analysis Expertise§Performance Visualization

Report§Gap Analysis§ROI Forecast§Action Plan

BenchmarkROI Findings Plan

OPCCollectionTools

People

Process

Tools

Report

Action

Problem

Interpret

Analyze

View

Get

§© ABB Group

§October 29, 2013 | Slide 5

© ABB GroupOctober 29, 2013 | Slide 5© ABB GroupOctober 29, 2013 | Slide 5© ABB GroupOctober 29, 2013 | Slide 5

ABB Advanced Services: Fingerprints are packageddiagnostic services

§Common Industrial Services :§ Boiler§ Alarm§ Loop Performance§ Control System§ Transition Analysis§ Batch Analysis§ Tuning

© ABB Service

ABB Automation & Power World - May 18-20, 2010

CCH-101-1 11:00 Tuesday, room 351C

Doug Reeder, Ted MatskoLoop Performance Fingerprint for aDuPont Monomers Plant

§© ABB Group§October 29, 2013 | Slide 7

Control Performance Issues

PID Controllers are designed to:

• Regulate the process

• Reduce product instability

• Improve operations

Manual OperationOutput Out of rangeIncreasing VariabilityImproving process

However, ABB is finding that PID Automation:

• PID loops are not being maintained

• PID loops have degraded

• PID loops are standing in the way ofproduction and performance.

35%

15% 30%

25%

Half life of Process ControllersGiven: a 100 PID loops all tuned at once.

Then: it is estimated that with in 6 months,50 of these loops will have a degradation inperformance.

Months

100

Loop

perfo

rman

ce

degr

adat

ion

50

06

Simple PID Utilization

1

© ABB Service

© ABB Service

LoopAnalyzer Tool: Control Loop Diagnoses

CONTROL PROCESS SIGNAL CONDITIONING

C1: Manual P1: FCE Out of Range S1: Quantized

C2: Oscillating Setpoint P2: FCE Size S2: Excessive Noise

C3: Error Deadband P3: FCE Problem S3: Spikes

C4: Offset P4: FCE Leakage S4: Step Out

C5: Over Control P5: Intermittent Disturbance S5: Data Compression

C6: Slow Control P6: Persistent Disturbance S6: Over Filtered

C7: FCE Travel P7: Questionable S7: Sampling Rate

C8: Slow Update Rate S8: No Signal

C9: Questionable Control S9: MV Out of Range

S10: Questionable

FCE = Final Control Element

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Loop FingerprintOscillating Loops

§ When a loop oscillates inautomatic mode and there isnot evidence of an externaldisturbance, over tuning is apossible cause.

§ Power spectrum shows twofrequencies of interest

§ This loop is in the TFESynthesis area

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Loop FingerprintFinal Control Element Problem

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

§ Exhibits classic stiction

§ Controller output ramps up and down in triangular pattern

§ Process variable moves in square wave

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Loop FingerprintReport

§ The report highlights some loops, as shown in the previousslides and summarizes the results in tables. This table isfor the TFE Synthesis section of the plant.

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Loop FingerprintPlantwide Disturbance Analysis

§ Disturbances in chemical plants act on many process variables

LC1

TI1

TI7

DP1

TI6

TI2TI3

DP2

TI4

LI2TI5

TC1

§ Disturbances can propagate counter flow because of recycle andthermal integration

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Loop FingerprintPCA Cluster Example

§ Find signals withsimilar patterns,probably due todisturbances

§ Not looking foroscillating signals

§ Here all signals arein two columns thatare adjacent

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Increasedperformance

1

Service

2

3


Implement(HandsOn)

Sustain(Scan/Track)

© ABB GroupOctober 29, 2013 | Slide 14

Loop Optimization implements improvements

Goal: Improve current performance level§ Scope based on Diagnose phase

§ Focused, scheduled activities

§ Proven practices

§ ABB-managed improvement program

§ Solution categories:§ Hardware§ Operations§ Tuning§ Application§ Process

2

Proactive and collaborative

Workbench: Implementation improvements

§© ABB Group§October 29, 2013 | Slide 15

Analysis

Identification

Tuning and Simulation

Tool WorkbenchStandard Reporting

Visualization

and Setup

Collection

2

© ABB Service

© ABB Service

C549I11:15 Wednesday, April 25, 2012 (room 371D)

Batch Process OptimizationBASF Polymerization Reactor

ABB Automation & Power World: April 23-26, 2012

© ABB Inc.October 29, 2013 | Slide 17

BASF Batch Reactor OptimizationProcess Economics - Quality Control and Production Rate

Process Economics is tied to two things

§ Quality Control§ Decrease cost, i.e. lower energy

§ Increase yield at same quality

§ Reduce offspec losses

§ Value increases with quality

§ Production Rate§ Hold fixed costs constant

§ Increase production rate, revenue

§ For a batch process, production rate means cycle time

§ For this polyester product, Step 4 dominates

© ABB Service


BASF Batch Reactor OptimizationProcess Economics - Quality Control and Production Rate

§ Quality variance is very low for this product

§ Batch held until all specs metèincrease time

§ Lab tests repeated, manual adjustments

§ This plant is Production Ratelimited on this product

§ Long cycle time

§ 5 day x 24 hr work week

§ 120 hrs working time

§ 60 hrs = 2; 40 hrs = 3 batches

§ Opportunity

§ Reduce varianceof step times

© ABB Service


BASF Batch Reactor OptimizationReducing Batch Cycle Times

§ This plot confirms conclusion about vacuum and batchcycle time

§ Real data is not always pretty (scatter)§ Due to lab measurement, operator manual

operations, unknown contaminants

Step4 Elapsed Time(Vacuum)

Conclusion:Investigate cost toimprove vacuum.

Achieved cycle timeimprovements.

© ABB Service

© ABB Service

Increasedperformance

1

Service

2

3


Implement(HandsOn)

Sustain(Scan/Track)


Loop Optimization helps sustain customer results

Goal: Maintain improved performance level

§ Adjust maintenance operating procedures

§ Adjust standard operating procedures

§ Remote process monitoring

§ Specifics are a function of theImplement phase

§ Periodic monitoring of keyprocess indices utilizing localor remote expertise

3

Proactive and collaborative

© ABB Service© ABB GroupOctober 29, 2013 | Slide 21© ABB GroupOctober 29, 2013 | Slide 21

ABB ServicePortTM

Secure, remote delivery for Scan and Track

§ Secure portal residing at customer sitethrough which plant personnel andABB experts can access:

§ Configuration tools

§ Diagnostic applications

§ Improvement activities

§ Performance-sustainingtroubleshooting

§ Scanning software that deploysagreed actions.

§ ABB can connect to any systemthrough ServicePort and implementfixes to diagnosed problems.

Desk top

Full Size

Workbench Tools – Improve efficiency and quality ofservice results

Data Collection

§ DL400

§ AGP400

Loop Performance Fingerprint

§ Loop Analyzer

§ Signal Analyzer

Loop Tuning

§ LoopTune

Batch and Grade Change Analysis

§ Sequence Analyzer

§ Loop Performance Monitoring

§ ServicePort Loop Performance Channel


ContinuousImprovement at

Maximum efficiency

Diagnose

Implement

Solution Problem§Performance

§Management

ServicePort + Channels


§ ServicePort Base Unit

§ Process Channels

§ Control Loop

§ Quality Control System

§ Mine Hoist

§ Equipment Channels

§ Harmony

§ 800xA

§ Cyber Security

§ Remote Access Platform


ABB ServicePort: Access to experts, reduces costs

SCAN Performance Service Reports

§ Statistical Evaluation of Historical KPI’s performed twice a year

§ Ensures stability of KPI’s

§ Reduces the risk of false positives

§ Keep up to date with process

§ Crucial to ensure continuous improvement

© ABB Service


Sustain: track KPIs to ensure improvement

1

KPI

Trac

king

§ Total

§ CD

§ RES

§ MDL

§ Q1 § Q2 § Q3 § Q4

§ Delivery Schedule

Productionincrease!

Variabilitydecrease!

§ContinuousImprovement

What’s APC?

© ABB Service

§ APC – Advanced Process Control

§ ARC - Advanced Regulatory Control

§ MPC – Model Predictive Control

§ MIMO – Multiple Inputs, Multiple Outputs

§ Constraints – Process or Physical Limits

§ Linear Programming – Cost Minimization

§ IMP – Inferential Modeling Platform

§ Scheduling and Batch optimization

ABB’s Predict and Control APC Solution

§© ABB Service

Features

§ True Multivariable Control

§ State Space, Model Predictive Control (MPC) Structure

§ Subspace and Prediction Error model identificationmethods

§ Constraints (MVs and CVs): prioritize up to 30 classes

§ OPC connectivity to process data

§ Inferential Modeling Platform (IMP) to infer variables orproperties that are difficult to measure

APC - Predict and Control

§© ABB Service

§ Allows safe operation closer to constraints

§ Smooths operation by predicting effects of control movesand compensating

§ Works best when base level controls are optimized

APC Fingerprint

§© ABB Service

Features

§ Uses Predict and Control EngineeringTools

§ Quantifies critical process interactions

§ Determines $ benefits from APC

§ Suggests best structure

§ Suggests required MV’s, CV’s, DV’s

§ Determines additional measurementrequirements and value

§ Allows customer to get the best APCproduct for their plant

Optimize IT Predict & Control Performance§ 3 simulation runs of the HOF problem

§Comparingtypical DMCtreatment of

disturbances tostate feedback,using the Shell

Heavy OilFractionatorproblem withunmeasured

disturbances andmodeling error

§1st exampleDMC like tuning,

compositions(blue and red)

have largedeviationscaused by

unmeasuredcooling duty

disturbances,(magenta line,

lower grid)

§2nd example,P&C with

Kalman Filterestimate for

disturbances.

§Large reductionin PV deviation.

§

§3rd example,P&C with KalmanFilter estimate for

disturbances.

§Using additionalPVs

§Furtherreduction in PV

deviation.

§

§© ABB Service

Predict & Control PerformanceAmmonia Stripping Operation APC

§Minimizes operating cost (steam, caustic, &acid)

§Regulates pH and NH3

§Enforces environmental limits on wastestream

§9% reduction in unit operating cost

ROI: 6 months

Predict & Control PerformanceButadiene Purification Process APC

ROI: 11 months

§ Reduction of steam consumption

§ Reduction of solvent use

§ Lower product quality variability

§ Key process variables closer tosetpoint targets

§ Less work load for operators at alllevels

§© ABB Service

APC Recommissioning Services

§ For APC controllers that are not in serviceor not performing as expected

§ Reevaluate APC design

§ Retest and rebuild MPC models

§ Simulate and retune controller

§ Monitor performance

§ Recommissioning services available forvarious APC software

§© ABB Service

DMCplus 800xA Interface

o ABB Interface tags defined in 800xA to linkDMCplus tags to control loop and analog tags

o 800xA library created and can be reused fordifferent DMCplus applications

Optimizer

Controller

SubControl

DMCContTypeMV

DMCSubType

FForCV

DpaPidCC

ReadMMSWrite MMS

RealIOor Real

MV DpaAnalogOutCC

(Future)

MMS

ReadMMS

InOut

RealIOMMSRead orRealMMSRead

§© ABB Service


MV Faceplate

§© ABB Service


CV Faceplate

MPC in 800xA Project Workflow

§ Controller design off line§ Perform plant testing§ Use Model Builder to create model§ Use closed loop simulation module to calculate initial

set of tuning parameters§ Export model and parameters

§ Controller implementation in 800xA§ Create application in Control Builder§ Import model and tuning parameters in 800xA service

using Plant Explorer§ On-line tuning using 800xA faceplates

Model and Control Design Tool

§ Environment for handlingdata import and data setmanipulation

§ Subspace identificationand graphical methods formodelling

§ Initial controller design§ Controller export for

subsequent import in runtimeenvironment

Controller Configuration in 800xA

§ Control Module for MPC§ Configured from CB or FD§ Control connections

between CM and level 1controllers

§ Faceplates for interaction§ Mode logic§ Constraint definitions

§ Options to connect signals§ Graphical connections§ Textual connections

PV and MV Faceplates

Overall Benefits of the ABB approach

§ Highest controller performance§ Choice of right technology for your process§ Comprehensive performance service packages§ ABB experience in over 500 APC implementations

§ Lower overall cost of ownership§ modular and scalable software packages§ user friendly modeling environment to lower

implementation effort and model maintenance§ Low project risk§ Process know how and experience§ Strict project management procedures

Results: High ROI at low risk

© ABB Service

Optimization Services, Tools and Advanced Process Control · PDF file§October 29, 2013 | Slide 7 Control Performance Issues ... Process Economics - Quality Control and Production

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