Advanced Control, Optimization, and Monitoring

Transcription

1 Honeywell.com 2014 Honeywell Users Group Americas Advanced Control, Optimization, and Monitoring Perry Nordh P.Eng. 1 Document control number Honeywell Proprietary

2 2 Operations Excellence

3 Optimization BusinessDictionary.com: Finding an alternative with the most cost effective or highest achievable performance under the given constraints, by maximizing desired factors and minimizing undesired ones. 3

4 Benefit Delivery by APC: Push to Optimal Constraints Designed to hold plant at constraints Operator s Preferred/comfort Operating Region Plant economics determine the optimum constraints Valve Positions 4

5 Process Variability Reduction Regulatory control Regulatory control APC installed APC installed Shift operating point APC and RTO or operator interaction Specification or Limit or Specification or Limit Average Average Average Average Current Operation Wide spec limits specification limits Variations Reduction Variations Reduced with in Advanced Reduced Control Variation Move Average Closer to Specification or Limit Move closer to Specification Average closer to specification 5

6 Typical APC Benefits Tangible Benefits: Increased Throughput Improved Yields Decreased Operating Costs Improved Quality Consistency Increased Operating Flexibility Improved Process Stability Common payback period < 6 months Intangible Benefits: Improved Process Safety Process Watchdog Earlier Identification of Problems Improved Operator Effectiveness Focuses on key operating parameters Reduced Downstream Variability Fewer Process Upsets Better Process Information Increased Process Understanding 6 Field proven solutions with high ROI

7 Tangible APC Benefits Advanced Control and Optimization benefits are field proven and generate high rates of return on investment. Typical Benefits: Increased Throughput Improved Yields Decreased Operating Costs Improved Quality Consistency Increased Operating Flexibility Improved Process Stability Typical Payback: Oil and Gas Refining Chemicals Petrochem MMM Pulping/Paper Industrial Power 0 to 2 months 3 to 6 months 4 to 6 months 6 to 8 months 10 to 12 months 7 Advanced Process Control provides lucrative returns in any economy

8 Honeywell and Advanced Control World Leader in Advanced Control #1 Worldwide all Major Markets for 5+ Years Petrochemical & Chemical, Pulp & Paper, etc 150+ Higher Level Optimization Applications Multivariable Controller Applications 550+ Industrial Sites 300+ Customers Worldwide DCS-Independent Solution Source: ARC Report, APC and Optimization Outlook Estimated >$5 Billion in Benefits since 1996

9 What is Profit Suite? Embedded Regulatory Control Soft Sensing and Multivariate Statistical Analysis General case Process Specific Linear Multivariable Control Dynamic model-less Model-Based Predictive Control Nonlinear Model-based Control Rigorous Steady-State Rigorous Dynamic Empirical Dynamic Real-Time Optimization Dynamic Unit-based Optimization Dynamic Multi-Unit Optimization Benefit Sustainment Operator Engagement Monitoring Visualization Steady State, UniSim Steady State Non-linear Process Modeling Models CPM Application Profit Monitoring & Expert Diagnostics Multi-unit Coordination Profit & Global Optimizer Optimization Multivariable Profit Controller Control Profit & Unit Controller Optmization Express Advanced Profit SensorPro Regulatory Control Profit & Soft Toolkits Sensing Profit Loop, OperTune Base Level Regulatory Control Loopscout Process Design, UOPBest Practices, Measurement HPS Sales, Projects, & Control Services Devices Steady State and Dynamic Flow Sheet Simulation Operator Training and Simulation Dynamic, UniSim Optimize Non-linear w/ Process Rigorous Models Profit Design Studio Design & Simulation Profit Stepper 9 Unified Real-Time Process Optimization

10 Profit Suite Vision One Consistent technology platform MPC and Real Time Optimization Modeling environment Linear State Space Linear and Non-Linear control Profit Loop Profit Controller in C300 Profit Suite SDQP (Multi-Asset Optimization) Seconds Hours/Days 10

11 Customer Themes Infrastructure Irony Too many changes, slow down Yet we need to keep up, I need this update tomorrow Resources and Ease of Use Never enough skilled people, or simple enough software Optimization (energy, materials, people) Becoming an expectation How to expand effectiveness over time? Sustainment of benefits Year after year still comes to the top of the SUF/CAB priorities Benefits analysis and tracking status/benefits over time 11

12 Infrastructure Challenges Runtimes by industry are variable 3 or 4 weeks to 3 or 4 years IT standards are variable Updates tightly controlled by IT or by Process Control Integration and infrastructure variability Mixed vendors and multiple generations of OS Global versus local Support on site versus corporate support 12

13 Infrastructure innovations Virtual platforms Click-once, single install updates an entire console Incremental and flexibility of releases Centralized information/updates 13

14 Infrastructure: Platform Virtualization Customer-deployed Virtualized Platforms Reduce hardware costs (fewer servers) Increase availability (may require additional capability) Simplify disaster recovery Support deployment and execution of Profit Suite applications in virtualized environment Qualification, testing, and benchmarking 14

15 Infrastructure: Goals of Web Services Establish web server for use at L3/L3.5 Server would be primary gateway for L4 L3 access to Profit Suite Security Fully comply with Honeywell Network Security specifications Certificate-based security for Read or Read/Write access Use Click-Once technology Automated delivery of PSOS client to L4 desktop via web server Simplify delivery to L3 desktop Enable automated delivery of themes Enable easy updates of software Common Visualization for Manager, Engineer, and Operator 15

16 Infrastructure: Visualization Options # PSOS Solution Network Level Profit Suite Release User Why use this solution? 1 Thick Client Level 2/3 R300 or above Operators APC Engineers TCP/OPC is used for Data communication with locally installed themes 2 Smart Client Level 2/3 R412 or above Operators APC Engineers TCP/OPC is used for Data communication and IIS for patch + theme central management (when updated, themes are automatically copied to local station in case of network outage) 3 Web Client Level 3.5/4 R400 or above Process/APC or Maintenance Engineers, and Managers https/iis is utilized between PSOS client and PSOS server, TCP/OPC between PSOS server and APC Server 4 Terminal Server Level 3.5/4 R300 or above Process/APC or Maintenance Engineers Remote desktop connection from L4 to PSOS thick client installed at L3.5 with a Tunneller connection from L3.5 to L3 (TCP/IP communications). Only OPC DA and OPCHDA supported. 18

17 Infrastructure: Incremental releases Ease of install Installs like a patch Easier migration to new functionality Flexibility and Management of change Optional installation Install only what you need to Major releases will include new features and all functionality released in previous incremental releases 19

18 Infrastructure: Keeping up to date Support tab Profit Suite update matrix CPM Update matrix Virus images Compatibility Java policy 20

19 Customer Themes Infrastructure Irony Too many changes, slow down Yet we need to keep up, I need this update tomorrow Resources and Ease of Use Never enough skilled people, or simple enough software Optimization (energy, materials, people) Becoming an expectation How to expand effectiveness over time? Sustainment of benefits Year after year still comes to the top of the SUF/CAB priorities Benefits analysis and tracking status/benefits over time 21

20 Resources and Ease of Use Building in knowledge Templates and standard calculations (benefit study + calcs) Making it easier to use Operator guidance Extracting knowledge Auto documentation Enabling easier management of knowledge 22

21 Resources and Ease of Use Vector calculations Variable combination Offline to online limited to single step equations Limited to generate read value of a variable (CV/DV) Profit XL Not supported in offline and dependency on excel Custom toolkits / URT SDK Very powerful to write complex logic Cannot be used for offline vector generation for modeling 23

22 Building in Knowledge: Logic Blocks What is a Logic block? Custom logic to be executed before or after controller Define Logic block Define multistep equation using alias Assign URT/OPC connections for each variable Simulate calculation Deploy online 24

23 Building in Knowledge: Calcs Path forward Provide additional standard functions Provide means to use standard toolkits as functions in custom calculations Provide means of creating templates of functions Provide graphical capability to organize calculations 25

24 Building in Knowledge: Operator Guidance Provide the operator feedback on the performance of the controller and ways to improve it Specific to actions that operator has control over moving limits, placing variables back on control, dropping variables, etc. New visual components New algorithms for operator concern areas Increased messaging and advice 26

25 Building in Knowledge: Operator Guidance Horizontal Bar Charts Shows gain relationship Tips Messaging Displays notifications and advice for CV/MV Ideal Limits Shows relationship between current and ideal operating limits 27

26 Building in Knowledge: Operator Guidance Context Sensitive Trends Trends based on the CV/MV Selection 28

27 Building in Knowledge: Operator Guidance What are the controller objectives? The main objectives of the controller are feed maximization and minimization of energy usage. Also, the controller would bring down the variations in the plant especially the product qualities. What are critical CVs? Critical CVs are those which are key variables to achieve the controller objective. They have to be kept in line always. FAQs Gives additional information about the controller 29

28 Building in Knowledge: Operator Heuristics CV Status Status and limits Stable CV steady state violating hard limits Stable CV Read Value violating hard limits CV Steady State is moving a lot CV Read value is moving a lot Stable CV steady state violating hard limits All MVs in Oper mode MVs in Oper mode and other MVs at limits (at SS) Controller is Handling Constraints Tuning and Design Call the Engineer Stable CV Read Value violating hard limits CV Steady State violating limits Short term dynamic error Longer term dynamic error, i.e. very slow Tuning and Design Call the Engineer 30

29 Building in Knowledge: Operator Heuristics CV Steady State is moving a lot DV is noisy MV(s) in control is/are oscillatory Tuning and Design. Call the Engineer MV is not moving enough No reason to move Against a limit Decoupling or in constraint conflict Tuning and design Call the engineer CV Read Value is moving a lot Uncontrollable Noise Unmeasured disturbances Noisy DV Oscillatory MV Tuning and design Call the engineer MV is moving too much Non-oscillatory MV moves MV moves caused by a noisy DV MV moves caused by another MV Tuning and design Call the engineer 31

30 Extracting Knowledge: PSES/PDS Auto-document Information Contained in the As Built Doc : Project Information Customer Information Controller Objectives Optimization Objectives Controller Variables Controller Model Images Calculations Annotations Tuning Parameters BLC Information Connections 32

31 Extracting Knowledge: Auto-documentation APC engineer uses PSES auto documentation feature to create As built document (.docx) during Profit Controller Design phase Based on the information APC engineer enters in PSES auto documentation workflow and Controller Design process, the As built document will be populated with the key information about the Controller Project. Runtime tuning changes can be reflected in the document by importing the URT platform. User can add additional information to the.docx file to get the complete document. For non-pses users who use PDS/PSRS for Controller Design, similar feature is provided in PDS/PSRS. 33

32 Extracting Knowledge: Auto-documentation Document Format: Use Office 2007 Open XML Format.docx File Office is not required for Auto Doc feature to generate.docx file.docx file can be opened and edited by Office 2007 Older versions of Office users can download a free update that enables them to open and edit.docx files Availability: Will be Available in Profit Suite R412 This feature will be extended for PSP and PO in future releases 34

33 Customer Themes Infrastructure Irony Too many changes, slow down Yet we need to keep up, I need this update tomorrow Resources and Ease of Use Never enough skilled people, or simple enough software Optimization (energy, materials, people) Becoming an expectation How to expand effectiveness over time? Sustainment of benefits Year after year still comes to the top of the SUF/CAB priorities Benefits analysis and tracking status/benefits over time 35

34 Optimization (energy, materials, people) Optimize over time (Energy / Materials) Use less energy to produce the same thing Use less raw material to produce the same thing Variability of success Support and training and required skills Operator interactions and trust Troubleshooting and the ability to understand directionality People Points back to resources and ease of use Still need to develop the ease of use at the optimization level 36

35 Profit Suite Vision Integration with Honeywell DCS Profit Suite in C300 Integration with Operations Excellence Portfolio and other applications Operations Management (OM Pro) / Limits Management optimizing within a safe operating window Regulatory controls / Performance Monitoring with Profit Loop / CPM Data integration/reporting PHD Solving larger optimization problems Supply chain / network optimization Multi-asset optimization 37

36 Issues: People Technology Business Regulatory to APC gap Skills gap APC to RTO gap Skills gap Limits / achievability Different objectives (scope gap) Plant-wide model to APC/RTO gap Skills gap Different objectives (KPIs), different management structures in customer base (site-dependent, industry dependent) Plant limitations not commonly understood, different methods of compensation in each area Only common ground is the economic contribution 38

37 Optimization: Technology Relationships Planning and Scheduling Model Re-use First Principles Model(s) Unit Optimizer Advanced Process Control Economic Optimizer Model Re-use Regulatory Control Monitoring 40

38 Optimization: Optimization Envelope Blending Components Straight-run products Straight-Run or Blending From the optimality perspective: The full (pink) scope guarantees the plantwide optimality The smaller (blue) scope does not, unless all market prices for components are available. 41

39 Customer Themes Infrastructure Irony Too many changes, slow down Yet we need to keep up, I need this update tomorrow Resources and Ease of Use Never enough skilled people, or simple enough software Optimization (energy, materials, people) Becoming an expectation How to expand effectiveness over time? Sustainment of benefits Year after year still comes to the top of the SUF/CAB priorities Benefits analysis and tracking status/benefits over time 42

40 Sustainment of benefits It all comes down to $,,,,,, Estimation of benefits in Profit SensorPro Value optimization and value monitoring Better connections between monitoring and APC Things in CPM that could be in Profit Suite (& vice versa) Need to start from workflow CPM workflow is proven Needs accurate metrics to be believed (valve will happily do the wrong thing) Needs to be scalable 43

41 Reducing Total Cost of Ownership Lowering the cost of the APC lifecycle requires: Core MPC technology built for entire lifecycle Extensions to existing technology, not re-creation Standard, repeatable work process for supporting the lifecycle Tools to monitor and repair applications that don t require a Highly skilled individual Lower lifecycle costs are provided by: Reducing time spent on Sustain activities Reduce the skill level required to Sustain applications Reducing the benefits lost due to degraded controller performance Capturing additional benefits opportunistically as they become available 44

42 APC Lifecycle Basis C P M C P Deploy M C P M Sustain C P M Design Implement Operate Maintain Repair Deploy Sustain Design Evaluate process and operating objectives Implement Create and install controller Operate Gather operations input and train the operators, test Operate Use the controller to generate benefits Maintain Ensure ongoing and improved generation of benefits Repair Fix controller if no longer meeting operating objectives 45

43 CPM Versions and TaiJi PID CPM Standard PID monitoring MPC monitoring Signal validation Dispositions and workflow tracking Standard and custom KPIs Historical integration with TaiJi PID CPM Lite PID only Developed for simple install and setup TaiJi PID DCS independence Can use historical data, CSV input Can tune multiple loops at once Compare open and closed loop settling time to desired settling time Can cut out bad data before identification Enables feed forward identification 46

44 CPM Algorithm improvements: Oscillation period Oscillation Period or frequency - Duration of one complete cycle between peak to peak - Reported in minutes Common oscillation in loops - Interacting loops may oscillate at the same frequency Methods used in CPM - Spectral based period estimation Power spectrum - Time domain based method Zero cross over Auto-correlation function (ACF) 47

45 Combining oscillation methods Each oscillation method output is considered as a measurement point Kalman approach is applied to get more accurate measurement of oscillation period Spectral method time series cross-over method ACF cross-over method Oscillation periods Weights are determined based on individual algorithm accuracy against hand classified data Weighted average of oscillation periods 48

46 Combining Valve Stiction Algorithms Kalman filter approach Weights are determined based on individual algorithm accuracy against hand classified data Method 1 Shape-based Valve stiction probabilities Weighted average of valve stiction probabilities Method 2: Wavelet based Method 3: Non-Linear Index based Flow and Pressure loops: All three methods are combined to give one single stiction probability Level and Temperature loops Only Method 3 is used. 49

47 Do something with the answer If there is no action taken (fixing, tuning, etc.) There is no value to the process or operations Actions that create a performance improvement: 1. Tune: TaiJi PID (all systems), OperTune (Experion) TaiJi PID is an additional license and separate install OperTune is included with Experion systems 2. Fix: create a work order for I&E staff Note: investigating is an action, but doesn t have any net affect on the process or operations 50

48 Sustain Maintain: CPM Tune it Run tuning software to improve Fix it Something mechanical Investigate further Common oscillations Controllers not in normal mode Expert Guidance (CPM Lite) 51

49 Performance Improvement: TaiJi-PID PID Equation Selection Tuning preferences 52

50 Control Performance Monitor (Standard & Lite) Operational Benefits Better control Increased throughput (1-5%) Energy savings (1-10%) Improved stability Cut variability in half Remove control induced cycles Maintenance Benefits Reduce valve wear $815/yr/valve for a reduction of 500 strokes per day (2083%/hr) in valve travel/valve* Avoid needless repairs A major refinery saved 100k$ on their upcoming turnaround by identifying 88 valves which didn t require maintenance 53 *Is Your PID Controller Performance Up to Par? 2013 webinar by Hank Brittain

51 APC project benefits Less inspection time Unbiased results Evidence to show to I/E techs Prioritize mechanical issues Hand off to others Easier analysis Expert guidance for situations that are unclear Tune with more confidence of valve conditions Less re-work 54

52 Sustain Maintain: CPM Standard MPC Metrics Utilization Is it turned on and in use? Performance Is it performing as expected? Model mismatch Is the model a cause for deteroriation in performance? Constraints violation Which MV constraints are limiting the performance? 55

53 Profit Suite Vision Lifecycle Management Integration of information for better diagnostics, analytics Enabling the work processes One Operating Window for implementation and sustainment Virtualization Dash board for the currently connected application 56 Profit Lifecycle

54 Delivering Value as a Cohesive Solution Profit Controller UniSim Lifecycle Simulation Tools Past Future CV Optimal Response Setpoint Predicted Control Performance Monitor Unforced Response Control Funnel MV Assumed Values TaiJi PID Profit Stepper Minimum Effort Move Profit Optimizer: Real-time, Dynamic Optimization Optimum * 57

55 How can Honeywell help? Experienced personnel Familiar with the right technology Deliver the necessary services Ensure long-term sustained benefits 58