Transcript Slide 1

SSE-09
Advanced Process Control with
Connoisseur
Presented by: Tom Kinney
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
Sl
What is ConnoisseurTM?
Model
Predictive Constraint
Controller
Optimizer
ConnoisseurTM
Expert System
Slide 3
Neural Network
Connoisseur Toolset
Adaptive
C
P Neural Net
M
Fuzzy Logic
Calculations
454 S1   x  dNon-linear
j
D304 349 * L10
Slide 4
Inferential
Multi-Variable Control and Neural Net
Optimization Overlays DCS
Connoisseur Environment
Optimizer-Neural Net
Measurements
Bias, Setpoints & MV Targets
Model Predictive
Controller
CV’s, MV’s, FV’s
Regulatory Control System (DCS)
Slide 5
MVC/Optimizer:
Model Predictive Constraint Control
Predicted Constraint Violation
Constraint
Actual Variable Trajectory Through
ConnoisseurTM Control
PV
 Past
now
Future 
Responsive Control of Difficult Loops such as:
 Steam Temperature Control for Ramp Rate
 O2, Control of CO, Steam Temperatures & NOx
Slide 6
The Invensys Advantage:
Dynamic Optimization
Stabilize, Then Optimize!
Increase Production, Quality, etc.
Target or Constraint
MPC/
NN
Before
Stabilization
Increased
benefit
Stabilize
and Re-Position
Improve Control then Operate Closer to Limits
Slide 7
Connoisseur Features
As well as model-based control, Connoisseur offers many
other supporting features, including:
• Flexibly configured LP / NLP economic optimization
• High-resolution trending of data
• Data archiving and analysis
• User-configurable Director calculations
• Multiple model types
• Imbedded Pseudo-random Binary Sequence testing
• Real-time online model adaptation
• Neural net inferential prediction
• Nonlinear Control using Neural net models
• Rule-based “fuzzy” control
Slide 8
Connoisseur Applications
Chemicals, Oil and Gas – 105 Applications
Pulp & Paper – 49 Applications and a standard for one of the
largest worldwide Paper manufacturers
Power Generation Plants – 25 Applications
Mining and Metals – 30Applications not including those installed by
Xstrata with their Corporate License
Food & Beverage – 34 Applications
Over 260 Applications Worldwide
in a Variety of Industries
Slide 9
Success Story: Saudi Aramco
About the Client:
• Largest oil company in the world
• Supplies 10% of world’s oil
• 2006 Revenue US$ 194 Billion
What IOM did for the Client:
• Implemented Advanced Process Control (APC) using Connoisseur on a
400,000 bbl/day crude unit.
• Inferred Product Qualities
Benefits:
• Increased feed capacity 5%
• 40% reduction in products quality variance
• 1% increase gasoline recovery at debutanizer
• Reduced specific energy consumption
• ROI less than two months
Slide 10
Success Story:
Tesoro Golden Eagle FCC
About the Client:
• Operates 7 U.S. Refineries: 665,000 BPD Capacity
• 2008 revenue US$ 28 billion
What IOM did for the Client:
• Implemented Advanced Process Control (APC) using Connoisseur on a
Fluid Catalytic Cracking (FCC) Reactor/Regenerator and Gas Plant.
• Maximized FCC blowers to unit constraints
• Optimized Main Fractionator and Gas Plant Separation
Benefits:
• Increased FCC capacity and conversion
• Improved main fractionator and gas plant
product yields
• Energy savings
• $2,950,000 / Year Benefits
Slide 11
Success Story:
Tesoro Golden Eagle Gas Plant
About the Client:
• Operates 7 U.S. Refineries: 665,000 BPD Capacity
• 2008 revenue US$ 28 billion
What IOM did for the Client:
• Implemented Advanced Process Control (APC) using Connoisseur on a
Gas Plant
• Optimized Gas Plant Separation; maximized production of more valuable
products
• Stabilized gas plant operation
• Reduced product quality variation
Benefits:
• Improved gas plant product yields
• Energy savings
•$2,000,000 / Year Benefits
Slide 12
Dayton Power and Light
Situation
• Stuart Station Units 1-4
• 600 megawatt, coal-fired, B&W
once-through, supercritical units
Objectives
• Reduce NOx
• Improve unit heat rate
Benefits
Solution
• Coal Pulverizer Optimization
• Reduced Air Preheating
• Lower Excess Air
• Balanced Superheat and Reheat
Steam Temperatures
Heat rate improvements 0.5%
NOx Reduction of 15-20% Leading to
Ammonia Savings on SCR
ROI less than 1 year
Slide 13
Case Study:
Lower Colorado River Authority
Situation
• Sim Gideon Plant, TX Unit 3
• 340 megawatt, natural gas-fired,
load-following boiler
• Max ramp rate of 40 megawatts/min
Objectives
• Improve unit heat rate
• Reduce emissions of NOx
• Reduce emissions of other greenhouse
gasses
Solution
Multivariable controller designed and built
for this process optimization modeling
project, placed in a closed loop operation
Benefits (per year)
•Heat rate improvements
0.65%
•NOx reductions
12.3%
•CO2 reductions
51,524 tons
ROI less than 1 year due to heat rate improvements
Slide 14
Success Story:
Tesoro Golden Eagle Isocracker
About the Client:
• Operates 7 U.S. Refineries: 665,000 BPD Capacity
• 2008 revenue US$ 28 billion
What IOM did for the Client:
• Implemented Advanced Process Control (APC) using Connoisseur on an
Isocracker unit
• Optimized reactor operation
• Stabilized unit operation
Benefits:
- Increased catalyst life
- Improved reactor constraint management
- Enhanced unit operability
Slide 15
Iggesunds Mill - Causticizing
Slide 16
IPS
•
Capacity 378,000 MTPY
bleached pulp - hwd/swd
43% / 57%
•
High quality virgin fiber
board for food,
pharmaceauticals, etc.
Iggesunds Causticizing MPC
Carbonate Green Liquor Clarifier
1st Causticizer Inlet – CE %
1st Causticizer Outlet – CE %
Pressure Filter Outlet – CE %
Fuzzy Logic
Controller
Constraint Management
Selected CV´s
Controlled Variables (CV)
TTA GL Clarifier
Temperature GL to Slaker
Temperatur Slaker
Diff Temp (Slaker-GL)
Residual Carb.% - kiln lime
Residual Carb.% – lime to slaker*
Manipulated Variables (MV)
MV
Predictive
Controller
&
Optimizer
Weak wash dilution
Flow GL
Density GL
Temperatur GL
Lime addition to Slaker
Feed Forward Variables (FV)
Sodium Carbonate in GL
Sulfidity GL
Steam to Slaker
* Purchased lime
Slide 17
IPS
Coming Soon!!
SimSci-Esscor APC V2.0
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
Objectives of Updating the Offering
Program focusing on delivering key enhancements:
- Next Generation User Interface for APC
-A Common Look and Feel with other SimSci-Esscor Product Offerings
-Great improving the Ease-of-Use of the entire offering
-Inclusion of tools to reduce the work to build an APC application
- A powerful trending package, to enable more process insight and
reduce the time to develop a solution
- SimSci-Esscor APC V2.0 will preserve and leverage the existing
robust calculation engine
Slide 19
Case Studies are supported,
allowing many potential
models to be developed and
overlaid on one set of
CV/MV pairs
Slide 20
Slide 21
All CV,MV Pairs for a
proposed Model Clearly
Shown on one palette
Slide 22
Controller Design made
easy by dragging and
dropping variables into this
table
Slide 23
All Controllers are organized
in 1 easy to manage tree
structure
Interface to Global Optimizer
Included is provisioned,
future release
Interface to put controllers
on line from one place
Interface to Performance
Monitoring Included, future
release
Slide 24
Roadmap of Simsci-Esscor APC 2.0, Next 12 mos.
August 2013
More
Releases in
Future
March 2013
APC Beta Release
Version – Phase 4
Nov 2012
APC Internal
Version – Phase 3
APC Internal
Version – Phase 2
June 2012
- Data Processing
- Process Test
- Modeling
APC Internal
Version – Phase 1
- Create Project Environment
- Connect (OPC DA)
- Auto-discovery of tags
Start
February
2012
Slide 25
- Promote
- Migration
- Case Studies
- Reports
- Director Calculation
- Beta Test Ready
- Controller Design
Roadmap of Simsci-Esscor APC 2.0, 5 Year Plan
September 2017
September 2016
APC V3.0
September
2015
APC V2.3
-Larger Matrix Size
APC V2.2
September
2014
-Enhanced
Support for SubControllers
-Move Advisor
V1.1
APC V2.1
Enhanced Performance
Reporting
- Web Based Performance
Reporting
Start
September
2013
-User Defined KPIs
-Web Based Reports
-Move Advisor V1.0
-
Slide 26
-Enhanced
Support for
Embedded APC
-Move Advisor
V2.0
-Enhanced Integration-Enhanced
with OTS systems
Support for RTO
Integration
-Embedded Support
New Technology, Currently being Prototyped
Solving the APC understanding gap
Move Advisor
As an APC user, I want to see…
When the APC controller makes a move
What changes to expect from the move
Why the move was made
… so that I can understand the move and keep the controller on line
Slide 27
Slid
Move Advisor User Stories
Process Operator and Engineer
I want to know what, when and why an APC
Controller move has taken place or is about
to take place
Plant and Operations Managers
I want information on the economic impact
(KPI) of APC operations
APC Engineer
I want to know if an unusual APC controller
move has taken place or is about to take
place, to confirm that the controller is
operating correctly
Slide 28
Slid
Move Advisor
Prototype design for preliminary feedback
News View
Detail View
Slide 29
Slid
Move Advisor Components
Collect
-
Variable Names,
Relationships, Scan Interval
Scan - Values, Limits, Costs, Status
Data Source
Connoisseur
Romeo
NextGen
Analyze - Track moves and
Create messages
Interface
Report - News, Detailed Data
Slide 30
Slid
Excel
Web Viewer
PC App / InTouch
Summary\Overview
•
•
•
•
•
Deliver Next Generation User Interface for APC
Provide a unified approach to develop APC solutions
Provide a best-in-class trending and user experience
Retain strengths of Connoisseur’s robust calculation engine
Set the Stage for a platform of unmatched flexibility and Ease of Use
Thank you!
•
Slide 31