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DeltaV Embedded
Advanced Control
A New Approach to Advanced Control
Overview Presentation
Topics
       DeltaV Embedded Advanced Control Advantage
       DeltaV Advanced Control Product Suite
       Experience / Examples




Emerson Confidential
Advanced Control for Operational Excellence
   Improve Quality                         PlantWeb Benefits
     – Reduce Variability
     – Predict Lab Measurements
   Increase Throughput
     – Continuously Push Limits
     – Protect Multiple Constraints
   Reduce Costs
     – Maximize Efficiency and Reduce               APC
       Energy Costs                                Impact
     – Accurate Quality Control to Reduce
       Inventory and Product Rework
     – Stabilize Control to Reduce
       Equipment Wear and Incident Risk




Emerson Confidential
Advanced 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!




Emerson Confidential
Embedded APC Tools – What’s new?
• NO extra              Traditional Advanced
  databases                     Control
• NO database
  synchronization        Embedded APC:
  issues
                         • Can run in DCS controllers
• NO watchdog
  timers                 • Redundant and fast (1/sec)
• NO fail/shed logic     • Integrated operator user
  design                   interface
                         • Configuration through
• NO custom DCS            standard Control Studio
  programming
                         • Automated step testing and
• NO interface             Model ID
  programming
                         • Off-line simulation and
• NO operator              training
  interface
  development

 Emerson Confidential
New Approach to APC Configuration



                   DeltaV APC blocks are “Drag-n-Drop”




      Graphical
    Configuration
    using Control
       Studio


Emerson Confidential
New Approach to APC Configuration




    System-wide
    tag browsing

                       … all in the DCS database
Emerson Confidential
Typical APC Project Timeline
                                              Months
        1          2        3      4      5      6        7     8      9     10     11     12

     Functional Design
                            Det. Design, Config & Staging
                                                     Step Tests & Model ID
 Traditional APC Technology
                                                                       Commissioning


Functional Design
                       Det. Design & Config
                                Step Tests & Model ID
                                                                             Performed on-site
                                          Commissioning


Embedded APC Technology



Emerson Confidential
Traditional Advanced Control Over Time
                      Start Project
                              Start Commissioning
                                                    End Commissioning



                                                                        Traditional APC
 100%
     % On-line Time




                                         More than 50% of APC
                                         applications are turned
                                           off within the first 2
                                         years after installation.

                                           time        Yr 1                 Yr 2

Emerson Confidential
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?
Emerson Confidential
Must Build Solid Foundations
        You Can’t Have This…


                                       Advanced
                                        Control



                                Control Foundation




                       Without This…

Emerson Confidential
Foundation Built on Health of Field Devices




          Fieldbus Status Is Consistently Used
               by DeltaV Advanced Control

Emerson Confidential
DeltaV Embedded Advanced Control
A Systematic Approach for Sustained Performance
                          Analyze and
                           Diagnose
     Identify Problems                  Re-Tune
         And Prioritize                 Or Fix Cause



          Monitor                           Advanced
     Performance                            Control




Emerson Confidential
DeltaV InSight – A Control Performance Suite
              Intelligent
        Controller Tuning
      “Tune with InSight”




                                                   Adaptive Control (Adapt)
                                                     “Control with InSight”
                                     DeltaV
                                     InSight


             Intelligent
  Performance Monitoring
    “Inspect with InSight”                                   Advanced Control
                             Process Model Calculations    Predict / Neural / Fuzzy




Emerson Confidential
DeltaV Embedded APC for
Sustained Performance

                                          DeltaV APC
                                          Traditional APC

 100%
     % On-line Time




                        Faster to Commission +
                        Sustained Performance
                         = Greater $$’s Saved



                       time
Emerson Confidential
The 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




Emerson Confidential
Topics
       DeltaV Advantage - Embedded Advanced Control
       Advanced Control Product Suite
       Experience / Examples




Emerson Confidential
DeltaV 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!




Emerson Confidential
DeltaV 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!




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




Emerson Confidential
Predictive Intelligence = Intelligent Control
     Adaptive Learning Algorithms for Intelligent Control

                       Learn                   Evaluate
                       • Observe               • Validate
                       • Identify              • Compare
                       • Remember              • Diagnose




                                    Improve
                                    • Advise
                                    • Tune
                                    • Adapt




Emerson Confidential
DeltaV InSight for Intelligent Control
     With 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
                                                  Learn       Evaluate
     • Tune controllers (with no testing)
     • Reduce start-up time for new control systems
     • Reduce engineering time for simulations
     • Identify APC Opportunities                       Improve
     • 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.


Emerson Confidential
DeltaV InSight
                                                      Bringing it all together:
                                                              Performance
                                                               Monitoring
•   On-demandTuning
                                                              Loop Diagnostics
•   Adaptive Tuning                                           Embedded Learning
•   Simulation                                                Adaptive Tuning
                                                              Adaptive Control



                                                           •   Adaptive Control
•   Performance
    Monitoring                                             •   Operating Regions
•   Loop Diagnostics                                       •   Non-linear Control
•   Reporting
                           •   Model Identification
                           •   Control Diagnostics
                           •   Performance Indices
    Emerson Confidential
DeltaV InSight – Integrated User Interface
       Old DeltaV Inspect          New DeltaV InSight




       Old DeltaV Tune




                             New interface provides seamless
                            transition between loop diagnostics
                                         and tuning.


Emerson Confidential
Easily Launched in Context
                 From the
              Control Studio      DeltaV Explorer
             Operator Interface
                                        From the DeltaV
                                           Explorer




      Context sensitive from
         Control Studio

Emerson Confidential
DeltaV Insight – Architecture



Data Analysis
and Reporting                                                      UI from any
Runs in Server                                                     workstation




                        Embedded Learning Runs in the Controller
                        • Fast Data Capture

                        • Small Communications Load

                        • Runs in Background
 Emerson Confidential
DeltaV 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.



Emerson Confidential
DeltaV 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



Emerson Confidential
Control Performance Monitoring
“Inspect with InSight”
      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

Emerson Confidential
Control Block Performance Indices
    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
    Tuning Index is the % change in
    control variability between current
    tuning and recommended adaptive
    tuning.

Emerson Confidential
DeltaV 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




Emerson Confidential
DeltaV InSight - Asset Monitoring
      Device Alerts are reported
       through InSight Asset
       Displays
      Overview provides graphical
       display for Asset Alerts of
       System, Area, and Modules     Right-Click


      Asset Display identifies
       Asset Alerts including:
        – Asset Failed
        – Maintenance Soon
        – Advisory
        – Communications Failed
      Easily Launch AMS Device
       Manager in Context to
       access detailed diagnostics

Emerson Confidential
DeltaV InSight – Loop Tuning
   Two methods of loop tuning are supported
     On-demand Tuning
        – Steps control output
          to identify tuning
        – Same as old TUNE
     Adaptive Tuning
        – No Testing
        – Uses Process
          Learning during
          normal operations




Emerson Confidential
DeltaV 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




Emerson Confidential
On-Demand Tuning - Options for the Expert


                                   Power for the
                                  Advanced User !




Emerson Confidential
DeltaV InSight - Adaptive Tuning
Provides Tuning Based on Normal Operator Changes

                                             InSight automatically
                                              calculates dynamic
                       Before vs. After       models from
                                              operator changes
                                             Model Quality and
                                              Learning Status
                                             Tuning criteria and
                                              desired speed of
                                              response
                                             Tuning
                                              Recommendation
                                             No Testing Required




Emerson Confidential
DeltaV InSight - Model Analysis
  Gain Process Insight with 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




Emerson Confidential
DeltaV InSight - Control Simulation
   Test your tuning with Dynamic Simulation

                                          Closed loop
                                           simulation of
                                           setpoint and
                        View Dynamic       disturbance
                          Response         changes for
                                           recommended
                                           tuning
                        Select New Tuning Simulation for both
                                       
                       Speed vs RobustnessAdaptive and On-
                                           demand Tuning



Emerson Confidential
DeltaV InSight – Adaptive Control
    Non-linear Process Example
         Process gain and dynamics may change as a function of
          operating conditions such as valve position or feed rate.




Emerson Confidential
Non-linear Process Models




Emerson Confidential
DeltaV InSight – Adaptive Control
 InSight identifies tuning in
up to 5 regions of operation




Emerson Confidential
DeltaV InSight – Adaptive Control




Emerson Confidential
DeltaV InSight – Adaptive Control
                       Adaptive control adjusts
                         tuning to improve
                        control performance




Emerson Confidential
InSight 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




Emerson Confidential
Area Control Performance Report




Emerson Confidential
Area Control Performance Report




Emerson Confidential
DeltaV 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




Emerson Confidential
Easy As PID…

                       DeltaV Explorer




                        Replace PID with
                       Fuzzy Logic Control


Emerson Confidential
DeltaV Fuzzy Function Block

                       Pre-defined Fuzzy
                         Logic Control




Emerson Confidential
Use DeltaV InSight to Tune Fuzzy Logic




                        Transfer recommended
                       constants to fuzzy control




Emerson Confidential
Simulated Response




Emerson Confidential
Fuzzy Logic Control vs PID
Setpoint Change        Load Disturbance



                         FLC
                                                          FLC



                               PID
                                                                    PID

                         FLC
                                                 FLC



                                                           PID
                         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.


Emerson Confidential
Fuzzy 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                                         After
                       (using DeltaV PID)                          (using DeltaV Fuzzy)




                                 Source: Emerson Exchange, October 2004
                                         Shell Deer Park Paper
Emerson Confidential
DeltaV 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



Emerson Confidential
Model Predictive Control
                                                Learns From The Past
                                                To Predict The Future
                        Modeled
                       Relationship




                   Past               Present            Future


Emerson Confidential
Multivariable Dynamic Process Models




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




Emerson Confidential
Graphical Configuration



                   DeltaV APC blocks are “Drag-n-Drop”




      Graphical
    Configuration
    using Control
       Studio


Emerson Confidential
Automated Step Testing


                         Process Steps




Emerson Confidential
Process Model Displays




Emerson Confidential
Individual Step Response View




Emerson Confidential
Modifying Step Responses




                       Enter Step Response Constants




Emerson Confidential
Model Validation




Emerson Confidential
MPC Control Simulation




Emerson Confidential
Automatic Operator Display



                                                    Trend Window

                                                      Past             Future




                        Control    Manipulated   Constraint   Disturbance
                       Variables    Variables    Variables     Variables




Emerson Confidential
APC Optimization

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

                                                    Production
          Throughput         APC                    Increase $$
                                                    Throughput
                                                    at limit
                                                    Operator
                                                    Setpoint
                                   Time

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

Emerson Confidential
Built-in LP Optimization


                                                  100% position




                                                                  100% position
                                     Maximized
                                      Minimized
                                     Maximized
                       0% position




                                        Profit
                                       Energy
                                     Throughput



                                                    0% position




Emerson Confidential
Objective Function Configuration


                                           Define multiple
                                          operating modes




        Select from list of
                                               Set Max/Min
       controller variables
                                                and Price




                  Easy to set up and configure the
                        built-in LP Optimizer
Emerson Confidential
Easily Select Optimization Mode




                Select from list of
               Optimization Modes




Emerson Confidential
Optimizer Detail Display



                   Current
                   Values




                             Optimal
                             Values




Emerson Confidential
DeltaV 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




Emerson Confidential
Inferential Sensor Configuration



                          Lab Entry Block




                       Select Inputs




Emerson Confidential
Select Neural Training Data

                              ● Select training
                                set from historian

                              ● Exclude bad data
                                segments

                              ● Train the network




Emerson Confidential
Training the Neural Network




                         Auto detection of
                         over-training




Emerson Confidential
Sensitivity Plot, Input Selection




Emerson Confidential
Validating Neural Models




                       Naphtha 95% Point Prediction
Emerson Confidential
Neural Results – Naphtha 95% Point

                                   SR Naphtha EP

           380
           375            Crude Switch
           370
           365                                               Lab
           360                                               NN Prediction
           355                                               Filtered
           350
           345
           340
           07-Aug-03   09-Aug-03     11-Aug-03   13-Aug-03
            00:00:00    00:00:00      00:00:00    00:00:00




Emerson Confidential
DeltaV 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


Emerson Confidential
DeltaV Architecture
                       Control Design and Configuration
                         are Independent of Hardware




                                              Distributed
                                               Control
                                             Functionality




Emerson Confidential
DeltaV Control System Simulation
                           DeltaV Simulate Standalone
                       ●   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




Emerson Confidential
DeltaV “Multi-Node” Control Simulation
                  Multi-Node Environment
     Operator Station   Professional Plus   Application Station
                                                                  ●   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




Emerson Confidential
DeltaV “Multi-Node” Control Simulation
                                                Process Simulator
                                                    via OPC
                                                                      ●   Supports mimic Process
   Multi-Node Environment                                                 Simulator running in DeltaV
                                                                          Workstation
                                           Application Station with
   Operator Station    Professional Plus      mimic Simulator
                                                  App Station
                                                                      ●   Supports Third Party
                                                                          Process Simulators via
                                                                          standard OPC




Emerson Confidential
DeltaV “Multi-Node” Control Simulation

                Multi-Node Environment
                                                                       ●   Supports mimic Process
                                                                           Simulator running in DeltaV
      Operator Station       Professional Plus   Application Station       Workstation
                                                                       ●   Supports Third Party
                                                                           Process Simulators via
                                                                           standard OPC
                                                                       ●   Supports I/O simulation and
                                                                           Fieldbus emulation with
                                                                           virtual I/O module and mimic
                                                                           simulation

                         Process Simulator
                         With Virtual I/O
                         Module




Emerson Confidential
Simulate Parameter for I/O Blocks
                        Using Simulated Process 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




Field
Inputs



 Emerson Confidential
Process Simulation via OPC

                                               Process Simulation
                                               Packages are easily
                                              integrated with DeltaV
                                                Simulate via OPC.

                                            OPC Read
                                             of OUT

OPC Write to
Simulate_In


 OPC
 Client
 Driver
                       Process Simulation
Emerson Confidential
DeltaV Simulate Pro – Added Features
                                  All inputs blocks assigned to a node
                                  may be changed to Simulate Enable
                                  or Disable, Setup or Normal mode
                                  with a single request.
                                  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
    Select the node(s) that you   execution of all modules assigned to
    want to access (ProPlus and   a node.
    App Stations only)


          Simulate Pro is designed to coordinate
             simulation and support replay.
Emerson Confidential
DeltaV Simulate Pro – Entry Playback

                                        Restore saved simulation
                                        scenario

                                       Playback operator entries
                                       with simulation to re-enact
                                       training session

                                        View operator entries in
                                        Event Journal

                                       Make changes or skip
                                       operator entries during
                                       replay


          Improve Training Effectiveness with
             Playback of Operator Entries
Emerson Confidential
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


Emerson Confidential
DeltaV Simulate -
 Simulation Download Web Service
     ●   Automatically synchronize DeltaV and MiMiC
     ●   Reduce Engineering Costs
     ●   Improve Simulation Accuracy




Emerson Confidential
DeltaV APC on Legacy Platforms
 Universal                 GUS
                                                                DeltaV
Station (US)                       APP Node
                                   (Or PHD)                 ProPlus Station

                                                 OPC I/F

                                                                          Option 1: Run APC
                                                                          in Work Station
                             TDC3000
                               LCN
                                              PLC Gateway
                                                                                 DeltaV
                                                                                 Controller
                 APM
                 HPM

                                                                          Option 2: Run APC
                                 IOPs
                                                                          in controller
                                                  Serial I/F Options
              Serial I/O
                FTA




Emerson Confidential
Topics
       DeltaV Advantage - Embedded Advanced Control
       Advanced Control Product Suite
       Experience / Examples




Emerson Confidential
Example Predict Licensees
                                Total
End User Company                MVs     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


Emerson Confidential
Refinery APC Example



                       Ergon, West Virginia




Emerson Confidential
Ergon 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




Emerson Confidential
Main MPC
                       Control Icon




                       MPC Temp
                        Targets




Emerson Confidential
Atm Controller Performance
              Controller              Crude
                ON                   Change

                                                    CV
                                                    SP
                                                    MV
                                                    Lab
                                                    Spec
                           Naphtha       Hvy Kero




                             Kero             AGO

Emerson Confidential
Atmospheric Column
Neural Network Predictions
             Column Temps & Yields

                                                TC
                       Predicted NA        FC
                                                      FC

                           95%
Column Temps                                         FC
                                                                  Naphtha
   & Yields                                                Kero
                                           FC
                                                     FC
Predicted AGO
     95%                                                   Hvy Kero
                                                     FC
                              FC      TC


         Crude                                             AGO
                         FC
                                                           Resid to VAC
   Fuel Gas                                                Column



Emerson Confidential
Neural Results – Naphtha 95% Point

                                   SR Naphtha EP

           380
           375            Crude Switch
           370
           365                                               Lab
           360                                               NN Prediction
           355                                               Filtered
           350
           345
           340
           07-Aug-03   09-Aug-03     11-Aug-03   13-Aug-03
            00:00:00    00:00:00      00:00:00    00:00:00




Emerson Confidential
Variability Reduction
                                  Before                After
                                                                        Reduction in
                              Average   St. Dev.   Average   St. Dev.    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%




Emerson Confidential
Crude/Vac Unit APC Project Timeline
                       Activity                     Timeframe

      Functional Design Specification                3 weeks

         DeltaV APC Projects
      Application Configuration are                  < 1 day
         25-50% Faster and Less
      Step Costly than traditional
           Tests                                     10 days
                 APC Projects
      Commissioning                                  1 week



    Scope: Two 4x4 MPC controllers, 3 Neural Nets


Emerson Confidential
Lime Kiln Project ~Canfor -
Northwood Pulpmill




Emerson Confidential
Kiln Process MPC Application

                                                                 TT   AT                     DT
                                                                                                  Lime Mud
                                 PT
                                                                  Cold
                                                                                             FT     Feed
                                                    TT
                                                                  End
                       TT
                                Hot
   Fuel Flow                    End
                                                                                Mud Filter
     FT



                                                Main Drive
                                                                  ID Fan
                            Lime Product
                                           Lime Kiln Process

                                                                 Hot-end Temperature
                                                                      (controlled)


                        Energy Flow                             Cold-end Temperature
                       (manipulated)                                 (controlled)


                       ID Fan Speed                                 Excess Oxygen
                       (manipulated)                           (controlled and constraint)


                       Lime Mud Flow                             Hood Draft Pressure
                       (optimized and                               (constraint)
                        disturbance)

                                                                 Kiln Stack Emissions
                                                                      (constraint)

Emerson Confidential
Northwood Lime Kiln
 DeltaV MPC Control Performance - Benefits



                                                                       Average       Specific
                                               Average                    Lime       Energy
                                               Specific     Average Product         Standard      % Time on
                                                Energy      Mud Flow      Flow      Deviation    DeltaV MPC
                                               (filtered)   (filtered) (filtered)   (filtered)     Control
             Period                               (GJ/t)        (t/d)      (t/d)       (GJ/t)     (Average)
             Sept.3,2000 to Oct.15,2001            9.15       584.77     270.14         1.18
             Sept.3,2000 to Apr.8,2001             9.62       571.70     264.10         1.34
             Dec.17,2000 to Apr.8,2001             8.78       593.64     274.24         1.20
DeltaV       Sept.3,2000 to Jan.7,2001            10.20       560.49     258.92         1.43
             Oct.15,2001 to Jan.8,2002             8.22       688.13     317.89         0.14       97.60%
 MPC
                                                                                                Operator
                                              Reduced                 Increased Reduced
                                                                                              Confidence -
                                              Specific                   Lime    Variability
                                                                                             97.6% UPTIME!
                                               Energy                 Production   89.5%
                                               7-20%                    16-20%
                                          (0.56 - 1.98 GJ/t)




 Emerson Confidential
Northwood Lime Kiln
DeltaV MPC Control Performance- Benefits

                                                  DeltaV MPC       %Reduction
                                   Before Control Control          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!




Emerson Confidential
Baxter MPC Distillation Column Control
                                                             Condensers                           Vent Pressure and
                                                                                                    Temperature

                                                                                                      PT         TT


                                   Reflux (Return) Flow
                                                                                                      PI         TI
                                        FT        FI                                FIC

                                                                                       RSP
                                                                           FT


                                                             +             Takeoff (Distillate)
                                                                                 Flow



                                   TT        TI

                                   Mid Column
                                   Temperature


                          Column                                          CV 1                MV 1         RTO
                                                                          CV 2 (OPTIM)        MV 2
                                                                          AV 1
                                                                          AV 2
                                                                                 MPC
                                                       EU/
                                   TT        TI                           DV
                                                       SEC

                                   Bottom Column
                                    Temperature



                                                                                        RSP
                                                                                 XIC
                                                                      Boilup



                                                                                                             Steam

                       Reactor


Emerson Confidential
Quantified Business Results
Noel 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




Emerson Confidential
Learning More About DeltaV
Advanced 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.




Emerson Confidential
Summary
   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




Emerson Confidential
Emerson Confidential

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Delta v advanced control overview_en

  • 1. DeltaV Embedded Advanced Control A New Approach to Advanced Control Overview Presentation
  • 2. Topics  DeltaV Embedded Advanced Control Advantage  DeltaV Advanced Control Product Suite  Experience / Examples Emerson Confidential
  • 3. Advanced Control for Operational Excellence  Improve Quality PlantWeb Benefits – Reduce Variability – Predict Lab Measurements  Increase Throughput – Continuously Push Limits – Protect Multiple Constraints  Reduce Costs – Maximize Efficiency and Reduce APC Energy Costs Impact – Accurate Quality Control to Reduce Inventory and Product Rework – Stabilize Control to Reduce Equipment Wear and Incident Risk Emerson Confidential
  • 4. Advanced 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! Emerson Confidential
  • 5. Embedded APC Tools – What’s new? • NO extra Traditional Advanced databases Control • NO database synchronization Embedded APC: issues • Can run in DCS controllers • NO watchdog timers • Redundant and fast (1/sec) • NO fail/shed logic • Integrated operator user design interface • Configuration through • NO custom DCS standard Control Studio programming • Automated step testing and • NO interface Model ID programming • Off-line simulation and • NO operator training interface development Emerson Confidential
  • 6. New Approach to APC Configuration DeltaV APC blocks are “Drag-n-Drop” Graphical Configuration using Control Studio Emerson Confidential
  • 7. New Approach to APC Configuration System-wide tag browsing … all in the DCS database Emerson Confidential
  • 8. Typical APC Project Timeline Months 1 2 3 4 5 6 7 8 9 10 11 12 Functional Design Det. Design, Config & Staging Step Tests & Model ID Traditional APC Technology Commissioning Functional Design Det. Design & Config Step Tests & Model ID Performed on-site Commissioning Embedded APC Technology Emerson Confidential
  • 9. Traditional Advanced Control Over Time Start Project Start Commissioning End Commissioning Traditional APC 100% % On-line Time More than 50% of APC applications are turned off within the first 2 years after installation. time Yr 1 Yr 2 Emerson Confidential
  • 10. 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? Emerson Confidential
  • 11. Must Build Solid Foundations You Can’t Have This… Advanced Control Control Foundation Without This… Emerson Confidential
  • 12. Foundation Built on Health of Field Devices Fieldbus Status Is Consistently Used by DeltaV Advanced Control Emerson Confidential
  • 13. DeltaV Embedded Advanced Control A Systematic Approach for Sustained Performance Analyze and Diagnose Identify Problems Re-Tune And Prioritize Or Fix Cause Monitor Advanced Performance Control Emerson Confidential
  • 14. DeltaV InSight – A Control Performance Suite Intelligent Controller Tuning “Tune with InSight” Adaptive Control (Adapt) “Control with InSight” DeltaV InSight Intelligent Performance Monitoring “Inspect with InSight” Advanced Control Process Model Calculations Predict / Neural / Fuzzy Emerson Confidential
  • 15. DeltaV Embedded APC for Sustained Performance DeltaV APC Traditional APC 100% % On-line Time Faster to Commission + Sustained Performance = Greater $$’s Saved time Emerson Confidential
  • 16. The 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 Emerson Confidential
  • 17. Topics  DeltaV Advantage - Embedded Advanced Control  Advanced Control Product Suite  Experience / Examples Emerson Confidential
  • 18. DeltaV 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! Emerson Confidential
  • 19. DeltaV 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! Emerson Confidential
  • 20. DeltaV InSight Poor control costs your company money. DeltaV InSight provides a cost effective way to improve control performance:  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 Emerson Confidential
  • 21. Predictive Intelligence = Intelligent Control Adaptive Learning Algorithms for Intelligent Control Learn Evaluate • Observe • Validate • Identify • Compare • Remember • Diagnose Improve • Advise • Tune • Adapt Emerson Confidential
  • 22. DeltaV InSight for Intelligent Control With 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 Learn Evaluate • Tune controllers (with no testing) • Reduce start-up time for new control systems • Reduce engineering time for simulations • Identify APC Opportunities Improve • 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. Emerson Confidential
  • 23. DeltaV InSight Bringing it all together:  Performance Monitoring • On-demandTuning  Loop Diagnostics • Adaptive Tuning  Embedded Learning • Simulation  Adaptive Tuning  Adaptive Control • Adaptive Control • Performance Monitoring • Operating Regions • Loop Diagnostics • Non-linear Control • Reporting • Model Identification • Control Diagnostics • Performance Indices Emerson Confidential
  • 24. DeltaV InSight – Integrated User Interface Old DeltaV Inspect New DeltaV InSight Old DeltaV Tune New interface provides seamless transition between loop diagnostics and tuning. Emerson Confidential
  • 25. Easily Launched in Context From the Control Studio DeltaV Explorer Operator Interface From the DeltaV Explorer Context sensitive from Control Studio Emerson Confidential
  • 26. DeltaV Insight – Architecture Data Analysis and Reporting UI from any Runs in Server workstation Embedded Learning Runs in the Controller • Fast Data Capture • Small Communications Load • Runs in Background Emerson Confidential
  • 27. DeltaV 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. Emerson Confidential
  • 28. DeltaV 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 Emerson Confidential
  • 29. Control Performance Monitoring “Inspect with InSight”  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 Emerson Confidential
  • 30. Control Block Performance Indices 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 Tuning Index is the % change in control variability between current tuning and recommended adaptive tuning. Emerson Confidential
  • 31. DeltaV 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 Emerson Confidential
  • 32. DeltaV InSight - Asset Monitoring  Device Alerts are reported through InSight Asset Displays  Overview provides graphical display for Asset Alerts of System, Area, and Modules Right-Click  Asset Display identifies Asset Alerts including: – Asset Failed – Maintenance Soon – Advisory – Communications Failed  Easily Launch AMS Device Manager in Context to access detailed diagnostics Emerson Confidential
  • 33. DeltaV InSight – Loop Tuning Two methods of loop tuning are supported  On-demand Tuning – Steps control output to identify tuning – Same as old TUNE  Adaptive Tuning – No Testing – Uses Process Learning during normal operations Emerson Confidential
  • 34. DeltaV 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 Emerson Confidential
  • 35. On-Demand Tuning - Options for the Expert Power for the Advanced User ! Emerson Confidential
  • 36. DeltaV InSight - Adaptive Tuning Provides Tuning Based on Normal Operator Changes  InSight automatically calculates dynamic Before vs. After models from operator changes  Model Quality and Learning Status  Tuning criteria and desired speed of response  Tuning Recommendation  No Testing Required Emerson Confidential
  • 37. DeltaV InSight - Model Analysis Gain Process Insight with 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 Emerson Confidential
  • 38. DeltaV InSight - Control Simulation Test your tuning with Dynamic Simulation  Closed loop simulation of setpoint and View Dynamic disturbance Response changes for recommended tuning Select New Tuning Simulation for both  Speed vs RobustnessAdaptive and On- demand Tuning Emerson Confidential
  • 39. DeltaV InSight – Adaptive Control Non-linear Process Example  Process gain and dynamics may change as a function of operating conditions such as valve position or feed rate. Emerson Confidential
  • 41. DeltaV InSight – Adaptive Control InSight identifies tuning in up to 5 regions of operation Emerson Confidential
  • 42. DeltaV InSight – Adaptive Control Emerson Confidential
  • 43. DeltaV InSight – Adaptive Control Adaptive control adjusts tuning to improve control performance Emerson Confidential
  • 44. InSight 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 Emerson Confidential
  • 45. Area Control Performance Report Emerson Confidential
  • 46. Area Control Performance Report Emerson Confidential
  • 47. DeltaV 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 Emerson Confidential
  • 48. Easy As PID… DeltaV Explorer Replace PID with Fuzzy Logic Control Emerson Confidential
  • 49. DeltaV Fuzzy Function Block Pre-defined Fuzzy Logic Control Emerson Confidential
  • 50. Use DeltaV InSight to Tune Fuzzy Logic Transfer recommended constants to fuzzy control Emerson Confidential
  • 52. Fuzzy Logic Control vs PID Setpoint Change Load Disturbance FLC FLC PID PID FLC FLC PID 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. Emerson Confidential
  • 53. Fuzzy 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 After (using DeltaV PID) (using DeltaV Fuzzy) Source: Emerson Exchange, October 2004 Shell Deer Park Paper Emerson Confidential
  • 54. DeltaV 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 Emerson Confidential
  • 55. Model Predictive Control Learns From The Past To Predict The Future Modeled Relationship Past Present Future Emerson Confidential
  • 56. Multivariable Dynamic Process Models The Model Consists Of Step Responses That Show The Relationship Between Every Process Input And Output Emerson Confidential
  • 57. Graphical Configuration DeltaV APC blocks are “Drag-n-Drop” Graphical Configuration using Control Studio Emerson Confidential
  • 58. Automated Step Testing Process Steps Emerson Confidential
  • 60. Individual Step Response View Emerson Confidential
  • 61. Modifying Step Responses Enter Step Response Constants Emerson Confidential
  • 64. Automatic Operator Display Trend Window Past Future Control Manipulated Constraint Disturbance Variables Variables Variables Variables Emerson Confidential
  • 65. APC Optimization Often as simple as maximizing one variable to its most limiting constraints… Production Throughput APC Increase $$ Throughput at limit Operator Setpoint Time … but modern APC tools can do much more if needed. Emerson Confidential
  • 66. Built-in LP Optimization 100% position 100% position Maximized Minimized Maximized 0% position Profit Energy Throughput 0% position Emerson Confidential
  • 67. Objective Function Configuration Define multiple operating modes Select from list of Set Max/Min controller variables and Price Easy to set up and configure the built-in LP Optimizer Emerson Confidential
  • 68. Easily Select Optimization Mode Select from list of Optimization Modes Emerson Confidential
  • 69. Optimizer Detail Display Current Values Optimal Values Emerson Confidential
  • 70. DeltaV 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 Emerson Confidential
  • 71. Inferential Sensor Configuration Lab Entry Block Select Inputs Emerson Confidential
  • 72. Select Neural Training Data ● Select training set from historian ● Exclude bad data segments ● Train the network Emerson Confidential
  • 73. Training the Neural Network Auto detection of over-training Emerson Confidential
  • 74. Sensitivity Plot, Input Selection Emerson Confidential
  • 75. Validating Neural Models Naphtha 95% Point Prediction Emerson Confidential
  • 76. Neural Results – Naphtha 95% Point SR Naphtha EP 380 375 Crude Switch 370 365 Lab 360 NN Prediction 355 Filtered 350 345 340 07-Aug-03 09-Aug-03 11-Aug-03 13-Aug-03 00:00:00 00:00:00 00:00:00 00:00:00 Emerson Confidential
  • 77. DeltaV 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 Emerson Confidential
  • 78. DeltaV Architecture Control Design and Configuration are Independent of Hardware Distributed Control Functionality Emerson Confidential
  • 79. DeltaV Control System Simulation DeltaV Simulate Standalone ● 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 Emerson Confidential
  • 80. DeltaV “Multi-Node” Control Simulation Multi-Node Environment Operator Station Professional Plus Application Station ● 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 Emerson Confidential
  • 81. DeltaV “Multi-Node” Control Simulation Process Simulator via OPC ● Supports mimic Process Multi-Node Environment Simulator running in DeltaV Workstation Application Station with Operator Station Professional Plus mimic Simulator App Station ● Supports Third Party Process Simulators via standard OPC Emerson Confidential
  • 82. DeltaV “Multi-Node” Control Simulation Multi-Node Environment ● Supports mimic Process Simulator running in DeltaV Operator Station Professional Plus Application Station Workstation ● Supports Third Party Process Simulators via standard OPC ● Supports I/O simulation and Fieldbus emulation with virtual I/O module and mimic simulation Process Simulator With Virtual I/O Module Emerson Confidential
  • 83. Simulate Parameter for I/O Blocks Using Simulated Process 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 Field Inputs Emerson Confidential
  • 84. Process Simulation via OPC Process Simulation Packages are easily integrated with DeltaV Simulate via OPC. OPC Read of OUT OPC Write to Simulate_In OPC Client Driver Process Simulation Emerson Confidential
  • 85. DeltaV Simulate Pro – Added Features All inputs blocks assigned to a node may be changed to Simulate Enable or Disable, Setup or Normal mode with a single request. 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 Select the node(s) that you execution of all modules assigned to want to access (ProPlus and a node. App Stations only) Simulate Pro is designed to coordinate simulation and support replay. Emerson Confidential
  • 86. DeltaV Simulate Pro – Entry Playback Restore saved simulation scenario Playback operator entries with simulation to re-enact training session View operator entries in Event Journal Make changes or skip operator entries during replay Improve Training Effectiveness with Playback of Operator Entries Emerson Confidential
  • 87. 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 Emerson Confidential
  • 88. DeltaV Simulate - Simulation Download Web Service ● Automatically synchronize DeltaV and MiMiC ● Reduce Engineering Costs ● Improve Simulation Accuracy Emerson Confidential
  • 89. DeltaV APC on Legacy Platforms Universal GUS DeltaV Station (US) APP Node (Or PHD) ProPlus Station OPC I/F Option 1: Run APC in Work Station TDC3000 LCN PLC Gateway DeltaV Controller APM HPM Option 2: Run APC IOPs in controller Serial I/F Options Serial I/O FTA Emerson Confidential
  • 90. Topics  DeltaV Advantage - Embedded Advanced Control  Advanced Control Product Suite  Experience / Examples Emerson Confidential
  • 91. Example Predict Licensees Total End User Company MVs 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 Emerson Confidential
  • 92. Refinery APC Example Ergon, West Virginia Emerson Confidential
  • 93. Ergon 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 Emerson Confidential
  • 94. Main MPC Control Icon MPC Temp Targets Emerson Confidential
  • 95. Atm Controller Performance Controller Crude ON Change CV SP MV Lab Spec Naphtha Hvy Kero Kero AGO Emerson Confidential
  • 96. Atmospheric Column Neural Network Predictions Column Temps & Yields TC Predicted NA FC FC 95% Column Temps FC Naphtha & Yields Kero FC FC Predicted AGO 95% Hvy Kero FC FC TC Crude AGO FC Resid to VAC Fuel Gas Column Emerson Confidential
  • 97. Neural Results – Naphtha 95% Point SR Naphtha EP 380 375 Crude Switch 370 365 Lab 360 NN Prediction 355 Filtered 350 345 340 07-Aug-03 09-Aug-03 11-Aug-03 13-Aug-03 00:00:00 00:00:00 00:00:00 00:00:00 Emerson Confidential
  • 98. Variability Reduction Before After Reduction in Average St. Dev. Average St. Dev. 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% Emerson Confidential
  • 99. Crude/Vac Unit APC Project Timeline Activity Timeframe Functional Design Specification 3 weeks DeltaV APC Projects Application Configuration are < 1 day 25-50% Faster and Less Step Costly than traditional Tests 10 days APC Projects Commissioning 1 week Scope: Two 4x4 MPC controllers, 3 Neural Nets Emerson Confidential
  • 100. Lime Kiln Project ~Canfor - Northwood Pulpmill Emerson Confidential
  • 101. Kiln Process MPC Application TT AT DT Lime Mud PT Cold FT Feed TT End TT Hot Fuel Flow End Mud Filter FT Main Drive ID Fan Lime Product Lime Kiln Process Hot-end Temperature (controlled) Energy Flow Cold-end Temperature (manipulated) (controlled) ID Fan Speed Excess Oxygen (manipulated) (controlled and constraint) Lime Mud Flow Hood Draft Pressure (optimized and (constraint) disturbance) Kiln Stack Emissions (constraint) Emerson Confidential
  • 102. Northwood Lime Kiln DeltaV MPC Control Performance - Benefits Average Specific Average Lime Energy Specific Average Product Standard % Time on Energy Mud Flow Flow Deviation DeltaV MPC (filtered) (filtered) (filtered) (filtered) Control Period (GJ/t) (t/d) (t/d) (GJ/t) (Average) Sept.3,2000 to Oct.15,2001 9.15 584.77 270.14 1.18 Sept.3,2000 to Apr.8,2001 9.62 571.70 264.10 1.34 Dec.17,2000 to Apr.8,2001 8.78 593.64 274.24 1.20 DeltaV Sept.3,2000 to Jan.7,2001 10.20 560.49 258.92 1.43 Oct.15,2001 to Jan.8,2002 8.22 688.13 317.89 0.14 97.60% MPC Operator Reduced Increased Reduced Confidence - Specific Lime Variability 97.6% UPTIME! Energy Production 89.5% 7-20% 16-20% (0.56 - 1.98 GJ/t) Emerson Confidential
  • 103. Northwood Lime Kiln DeltaV MPC Control Performance- Benefits DeltaV MPC %Reduction Before Control Control 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! Emerson Confidential
  • 104. Baxter MPC Distillation Column Control Condensers Vent Pressure and Temperature PT TT Reflux (Return) Flow PI TI FT FI FIC RSP FT + Takeoff (Distillate) Flow TT TI Mid Column Temperature Column CV 1 MV 1 RTO CV 2 (OPTIM) MV 2 AV 1 AV 2 MPC EU/ TT TI DV SEC Bottom Column Temperature RSP XIC Boilup Steam Reactor Emerson Confidential
  • 105. Quantified Business Results Noel 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 Emerson Confidential
  • 106. Learning More About DeltaV Advanced 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. Emerson Confidential
  • 107. Summary  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 Emerson Confidential