Achieving consistency in multisite installations of PlantTriage. Peter Thomas Control Specialists Ltd - UK Authorized Solution Provider for ExperTune Inc Benefits. Facilitates site-site comparisons. Creates consistent baselines. Caters for migration of personnel. Leaves the system in a supportable state. 1
Site Locations Borealis Poorvo. Finland 700 Loops Sabic Bergen Op Zoom. Netherlands 1700 Loops Sabic Cartagena. Spain 1300 Loops Sabic Grangemouth. Scotland 100 Loops All installations took place in 2007 and were undertaken by Control Specialists Ltd. General Approach Project Plan Installation Phase Configuration Statement 2
Phase 1 Preliminary Configuration Installation of Software. OPC Configuration. Configuration of one loop. Initial contact with Control Specialists. Unit / Loop Config Spreadsheet Discussions. First Site Visit (1-2 weeks) Initial Kick-Off Meeting Overview of Plans. Definition of Goals. Identification of Key Assessments. Identification of Key Personnel. 3
Plant Definitions Plant Definitions Names Loop Scan Rates Plant Unit Operations Control Loops Unit Definitions Plant Definitions Names Loop Scan Rates Unit Configuration Names Plant Online / Off Line Batch / Non-Batch Plant Unit Operations Control Loops 4
Loop Definitions Plant Definitions Names Loop Scan Rates Unit Configuration Names Plant Online / Off Line Batch / Non-Batch Loop Configuration Plant Unit Operations Control Loops Loop Configuration Spreadsheet Loop Name Unit Economic Rating Definition of Normal Modes Loop Parameters (PV, SP, CO, Mode) Loop Parameters (P, I, D, F, Range) Controller Algorithm Process Direction Loop Scan Rate Display Group Allocation Online / Offline Status 5
Loop Configuration Spreadsheet Report Filtering Variables Cascade Type None Primary Cascade Secondary Type Flow Not Flow Loop Configuration Spreadsheet Report Filtering Variables Final Control Element Valve Pump / Compr Valve Positioner Smart Other Valve Type Smart Other 6
Loop Configuration Spreadsheet Things to check before importing Loop Modes Economic Rating Split PID Algorithm Name (Case Sensitive) Scan Rate Validity Display Group Validity Online / Offline Status Requirements Check Primary column entries Check Secondary Loop entries Check Unit Name Spelling Loop Configuration Spreadsheet Things to check before importing Check Unit Names (mbar, Mbar etc) Typos, e.g. CO Hi Limit < CO Lo Limit #Primary = #Cascade OPC Comms strings 7
Security Setup Initial Checking of Server PlantTriage Server Status Check Prior to Loop Config Import... Reboot Server & check auto start Check Windows Event logs Check PT Event Logs Check CPU, Memory, Disk usage 8
Importing Plants & Units Plants - Manually create Plants Units Save Unit Config.XLS as.csv Import Unit Confg.CSV Check PT Event Log Set Assessment period to 1 Hour Equation Builder Develop equations similar to Excel Formulas e.g. MyTag1 = (TIC1MODE = MAN) & (TIC1CO < 1) Flexible MyTag1 can then be read by Reporting PlantTriage and/or the DCS via OPC Equation Builder PlantTriage OPC Client Control Loops 9
Equation Builder Create OPC Tag & Formula XLS Save.XLS as.csv Import.CSV files Start Equation Builder Service Check PT Event Log Loop Configuration & Communications Consider partial downloads. Check PT Event Logs. Check comms loading on a unit basis. Engineering Interface to assists with this. Repeat for all loops. Resolve problems as necessary. 10
Initial Baseline & Thresholds Assessments will not work with these! Templates provided. Can be targeted to Display Groups. Check Template log for evidence. Checking Assessments Use Loop Lists to assist with this. Last Assessment Next Assessment Assessed Resolve issues as necessary. 11
Browser Interface Testing Check access to Home Page Check Tree Map Check Top 10 List Check access for all users. Check the ability to export reports to XLS Check the ability to produce.pdf reports Check the ability to email reports. Final Checks Reboot server & check auto starting. Check Windows Event Logs Check PlantTriage Event Log. Resolve issues as necessary. Backup all data from Engineering Interface. 12
Assessment Status Spreadsheet A good base-lining tool. Can be used to summarise progress. Training 5 days of classroom-based training. Targeted to specific groups. Day Title Audience 1 Introduction to PlantTriage All users 2 PID Loop Optimizer Eng / Tech 3 PID Loop Optimizer Eng / Tech 4 Using PlantTriage All users 5 Administration of PlantTriage Administrators 13
Phase 4 Resolving issues identified since Phase 2. Normal Baselines and Thresholds. Consider integration with TiPS Logmate. User Assessment. Tree Map Reports Completion of Configuration Statement. Project signoff by client. Does it work? Great execution, good work progress that was followed rigorously. Great support when issues arose. Rein De Jonge Sabic Innovative Plastics Netherlands. 14
Does it work? "After our most recent start-up, we are exceeding the expected production rates, and seeing reduced energy costs. We are on track for a full return on the PlantTriage investment within 6 months of start-up." Mikko Ronka Borealis Poorvo What next? 15
What next? Integration with normal plant operations. Annual On-Site Support. Integration - Daily Operations Meetings Daily review of PlantTriage findings for each unit operation - ensures that problems are identified and resolved quickly. Review of Opportunity Gap on the Money Loops Trending of Overall Loop Health, Time in Normal, Average %T Loops newly appearing on Biggest Payback Loops 16
Integration - Monthly & Quarterly Business Meetings System evaluations, tracking hard-number results. Review Continuous Improvement Projects. Summarise the improvements made Communicate the economic benefits. Integration - Control System Support Meetings Track overall control system performance: Time in Normal mode Control Loop Health %E. Identify, Prioritise, & Resolve Loops Needing Tuning Identify, Prioritise, & Resolve Instrumentation Issues Identify, Prioritise, & Resolve and Valve Issues Track changes in process dynamics: Active Model Capture Technology 17
Integration - Continuous Improvement Projects Track Site, Plant, Unit level performance metrics Identify, Prioritise, and Resolve issues like: o Process Constraints o Opportunity Gaps o Design and Configuration Issues o Quality Issues o Oscillation Reduction Develop deeper process understanding Process Interaction Mapping Active Model Capture Technology Annual Site Support New for 2008! Continue to get the best return on your PlantTriage investment. As an Authorised Solutions partner of ExperTune, Control Specialists Ltd will review your PlantTriage application and identify ways to deliver even greater results. The service includes an annual site service visit of 4 days duration plus 1 day off-site analysis and reporting. For more information see ExperTune Press Release or CSL Flyer. 18
www.controlspecialists.co.uk 19