Gregory Rogers, PE June HCP-0101 Fundamental of Advanced Controls

Transcription

1 Gregory Rogers, PE June 2018 HCP-0101 Fundamental of Advanced Controls

2 HCP (Advanced Controls) Journey Training Lineup 1 09:15 10:00am HCP-0101 Fundamentals of APC Greg Rogers Enterprise Products 10:00 10:30am Break 10:35 11:15am HCP-0201 Developing Your APC Project Kerry Sartain - GP 11:25 12:10am HCP-0301 APC solutions, Tools and Maintenance Perry Nordh - Honeywell 12:10 1:10pmLunch 1:10 1:55pm HCP-0401 Roundtable Discussion [P Salon] 2:10 2:50pm HCP-0501 Implementing APC in your Facility Keith Yeager WestRock Company 2:50 3:20pm Break 3:20 5:20pm HCP-0601 Workshop Perry Nordh - Honeywell

3 Benefits of Advanced Control $ Typical Benefits: - Of course, Money! Increased Production and/or Profit Margin Energy savings Improved Product Quality Reduced Process Variability - Improved control for manpower optimization $ Typical payback periods, very fast for some but majority < 1 year

4 General Summary What is Advanced Control? Advanced Control is broken down into two basic categories: - Advanced Process Control (APC) - Advanced Regulatory Control (ARC)

5 Advanced Regulatory Control ARC (Advanced Regulatory Control) is typically control that goes beyond Basic PID control but typically done within the confines of the control system. - This would be like inferred composition - Ratio Control - analyzer control where we build in limits boil up calculations duty control on a reboiler - Boiler Master control - Complex feed forward installations We also consider some inferential models built in the DCS as ARC.

6 Advanced Process Control APC (Advanced Process Control) is more aptly considered as model based control. - This is either a series of 1st order interrelated models (most common) - In some cases, though highly less often, first principles models that control the process. - Typically reside on a separate server and drives set point changes only to the closed loops on the control system. Honeywell RMPCT (Robust Multivariable Predictive Control Technology). Honeywell Profit Suite Aspen DMC

7 Decision Metrics Vendor Capability In House Support Software Capability Remote Support Cost Vendor Capability Vendor background in gas processing and fractionation Vendor support capability In-House Control Engineering Support The long term support and ease of integration are of concern. Ease of linking to Process Data Historian or similar and create base models from that data prior to going to site. Software Capability Statistical information on loop closure Ability to optimize or just operate at constraints Ease of execution and ability to run offline as well as online and produce results Ability to use non linear results as a constraint such as a parabolic curve and not just a 1st order curve. Ability to link data to Static or Dynamic Process Model. May just need to dump data to excel and import to capture gains

8 Decision Metrics Vendor Capability In House Support Software Capability Remote Support Cost Software Capability, continued Ability to create linear models without step test. Not necessary but nice. Ability to run statistical analysis on data and develop curves and equations from the data that can be used in the model or linked equations. Ease of integration and easy operator interface into DCS Screens and user friendly GUI. - Into Honeywell System - Into other system Remote Support Ability to remote support by Vendor Ability to remote support by In House Control Engineer Cost Initial Cost Annual Cost / Support Perpetual License

9 Honeywell Profit Suite Software Profit Controller Profit Controller Express Profit Optimizer - Simulation that sits atop Profit Controller for wide area optimization Links to historical data easily. Integrates well into Experion. Profit Stepper - Helps in the step test process Profit Sensor pro - Analyzer modeling - Add your calculations and go. Many other capabilities we have not used yet

10 Project Lifecycle More detail in later presentations Phase 1 - Cost Benefit Analysis Advanced Control Cost Existing control and instrumentation upgrade cost (if applicable) - Review with Operations and Engineering - Submit AFE Phase 2 - Develop the Multi Variable Model off-line and check against Process Model - Develop the Key Performance Index Honeywell provides project proposal - Pre-step testing - Order software/hardware - Preliminary Design - Prepare the Basic Process Control System (including field instrumentation) for the Advanced Control System. - Training (Operations and Support Teams) - Develop Step Test plan / Step Testing - Install hardware (EAS node) - Model Identification / Review Meeting - Install Inferential analyzer tags - Commissioning - Acceptance Period (Warranty) - As-Built documentation Phase 3 - Continuous Work Flow Process (next slide)

11 Continuous Work Process Operations / Field Engineering: 1. Keep the system on-line. 2. Notify Control Engineering when there is a problem 3. Enter economic data. 4. Tracking KPI 5. Support mechanical upgrades Operations / Field Engineering Control Engineering Control Engineering: 1. Continuous Basic Control Improvements 2. Monitor health of System. 3. Ensure the system is in AUTO and investigate when system is down. 4. Track system benefits OPTIMIZATION Commercial: 1. Support KPI Development on a continuous basis 2. Provide regular plant economics 3. Provide production availability guidance Commercial Optimization Engineering Optimization Engineering: 1. Define Constraints. Model Based Equation based 2. Support benefit Analysis. 3. Use data from the Advanced Control System to define limits in the process.

12 APC Implementation Topics APC, which do I choose? How to Justify APC? Problems encountered along the way and how to fix them Results Keys to successful implementation

13 APC/ARC: Which to choose? Versus typical PID controls with respect to Cost and Effort ARC Advanced Regulatory Control PCE Profit Controller Express PC Profit Controller Excellent Good N/A System with Low ROI Good Better N/A Small Process Better Not Suggested Excellent Large System with large Dead Time Better Excellent Excellent Large System with small Dead Time

14 How to Justify APC The following methods can be utilized when determining benefits Model based Advanced Control: - Statistical Data review plant historical data to uncover true operating limits Increased rate Reduction in energy - Understand the reduction in variability potential for your process. Some experts publish that you can run 40-80% closer to your spec limit once you reduce the variation of your control variable by changing from PID control to APC. A typical realistic reduction in variability is 20-50% Discuss plant capabilities and abnormal operating conditions with local operations. Talk to all the operators, but try to find out which ones are considered the most knowledgeable. The project goals were set with an 80% confidence factor to make sure they were justified if we came up a little short of the goal. After APC

15 APC Terms CV Control Variable - Equivalent of a PV in a PID loop. Analyzers, Tower DP, Pressure, Temperature, etc. MV Manipulated Variable - Equivalent of the setpoint in a PID loop. Feed rate, Hot Oil Flow, Reflux Flow, etc.

16 APC Model Advanced Control

17 Problems encountered and how to fix them Controller Adjustments - Expect to fine tune the models online after installed. - Model conflicts will appear as you approach optimum conditions. Set some models to prediction-only Use control priority to direct APC to which model it should use first - Don t be scared to modify set-points and limits as the process changes. Don t let APC stay at MV limits, instead try to reach CV limits - A good balance must be struck between the CV s across the different loops. - Sometimes limits get set too close together and the model isn t accurate enough to maintain the CV between the limits. This results in unsteady operation. - Usually one limit is more important than the other so widen them out enough to allow for stable control and increased degrees of freedom.

18 Problems encountered and how to fix them Operator personalities - Too hot or too cold! some run very passively some very aggressively some run it wherever it was when they came in. - Train operations!!! How to operate. How it works. How to get help. - If you change it, log it! Some MV limits were still being changed. Management then required operators to put the changes in the log with the time and a reason for the change. This pretty much ended limit changes to APC. - Prove it! Once the system has proven it s capability, you re home free. We don t run that way As improvements are made in one plant the operators are often asked to make adjustment in other like plants. Once running in the middle was proven OK to all operators, we gradually worked back towards the most aggressive operator until the unit was optimized.

19 Problems Encountered and how to fix them How plant controls improve with APC: Watch the operators change how they operate. Passive O O O O Aggressive

20 Results Baseline. - Know where you want to go. Continuous monitoring ensures sustained results - Follow-up: operations, commercial, engineering - Track your payback to use for future projects - Do spot check against historical data - Advertise the benefits to upper management. Only install what you need. Don t waste money. Some factors are out of your control. - Do the best you can. - Make everyone aware. Control to what makes the most money - Operating parameters and needs change. - Don t ignore energy savings

21 Results Build KPI tracking tools Encouraged operators and supervisors to use the tools, trends, plots, etc to see what their controllers are doing. Create notification metrics to Control Engineer and supervision. APC Monitoring CV s, MV s, Process Data, etc

22 Keys to successful implementation Age is a factor. - Preferably old enough that regulatory controls are well-tuned and young enough that valves and instrumentation aren t falling apart. Obtain operator input prior to designing the model. The process control engineer should work closely with Honeywell to be able to support the system after the project is completed. Provide on-the-job training to operations during step testing and commissioning. Clamp your MV s very tightly when first turning it on, gradually widening them out. Any configuration problems or model errors that occur won t upset the unit, and will be quickly forgotten by the operators. Don t go for broke on day one of commissioning. Try for stable control first, then work on feed and product maximization. Once APC is working well and operators are comfortable, economic optimization should be attempted.

23 Keys to successful implementation Have someone assigned to each APC or an overall APC engineer. If these systems aren t monitored regularly, over time they will get turned off and operations will lose confidence. Using a simulator model - Static models are good but Dynamic Model is much better. A model can: Validate perceived impacts to changes in the process Help test the system and graphics Be used for training Prove interactions between CV s and MV s Provide data for equations to be used in Profit Sensor Pro as a CV - Cautions when using a simulator The model must be accurate Even if you have a good model to predict initial gains, step test is still necessary. Many aspects of the controller will not be available in process simulators. Monitor the controls on a regular basis after implementation and keep in touch with the operators. APC You get out of it what you put into it!

24 Key Takeaway APC delivers documented and sustainable profits with improved plant operability You should utilizing proven technology. Consider the following in your analysis: - Vendor Capability - In House dedicated Support - Software Capability - Remote Support - Cost You need management support You need operator buy-in

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