control loop performance operations · pdf filewhy do you need control loop performance...
TRANSCRIPT
Control LoopPerformanceManagement(CLPM)
Your Global Automation Partner
OperationsOptimizationSolutions for
Oil & Gas
No ControlAction
Disturbance
No Flow Change
Flow Drop
Steam Flow 1Disturbance
Fuel Flow
Manual ControlExisting Mode
PID Control
Steam Flow 2Target
GeneratorSteamFlow
Flow Drop& Recovery
Flow Increasefrom Fuel
Control
Disturbance
FeedbackControl Action
Differences in Manual & PID Control
7-steps to Improve Control Loop Performance
Assess LoopPerformance
DiagnoseRoot Cause
MaintainPerformance
DevelopPhilosophy
Continuous Improvement
FixHardware
RedesignStrategy
TuneControllers
Of the four elements that make up a control loop, i.e. process, measurement, controller and control element, changes in any one can affect the performance of control loops and cause improper functioning. Factors that typially contribute to suboptimal control loops are:
Equipment Wear/Aging Changes in Operating Conditions Modifications to Plant Varying Unit Loads
This lack of properly functioning control loops disrupts plant operation and affects productivity, thus requiring continuous monitoring and improvement of control loops throughout the plant/facility’s lifetime.
Debutanizer
L C 0 2 0 4
F C 0 2 0 4
T C 0 2 0 4
C X 0 2 0 5
T C 0 2 0 3
C X 0 2 0 4
F C 0 2 2 1
T C 1 2 0 3
F C 1 3 6 1
F C 0 2 0 5
C X 0 2 0 5
L C 0 2 0 6 F C 0 2 2 2 F C 0 2 0 8
P C 0 2 0 5
F C 0 2 0 2 F C 0 2 0 9T C 0 2 0 9
F C 0 2 3 5 F C 0 2 3 4
F C 0 2 3 4
T C 2 0 2 0
L C 0 2 0 5 P C S P 0 2 0 4 P C S P 0 2 0 4 A
Regenerator
L C 0 2 0 4
F C 0 2 0 4
T C 0 2 0 4
C X 0 2 0 5
T C 0 2 0 3
C X 0 2 0 4
F C 0 2 2 1
T C 1 2 0 3
F C 1 3 6 1
F C 0 2 0 5
C X 0 2 0 5
L C 0 2 0 6 F C 0 2 2 2 F C 0 2 0 8
P C 0 2 0 5
F C 0 2 0 2 F C 0 2 0 9T C 0 2 0 9
F C 0 2 3 5 F C 0 2 3 4
F C 0 2 3 4
T C 2 0 2 0
L C 0 2 0 5 P C S P 0 2 0 4 P C S P 0 2 0 4 A
Sub-Optimal Control-Loop Performance Factors
INTECH’s Control Loop Performance Management (referred to as CLPM) is an operations improvement framework to optimize and streamline plant performance, which contributes to smoother process operation and higher overall productivity.
INTECH’s applications add value through role based security, event triggered KPI’s and multi variable loop and process analysis. INTECH provides advanced diagnosis, tuning, performance optimization and routine monitoring of control loops as part of its focus on lifetime asset and facility performance. This ensures timely identification and rectification of control problems before they adversely affect process profitability. This also makes sure that benefits of optimal loop performance do not diminish over time.
Introduction
INTECH follows a systematic approach to improve control loop performance which consists of seven steps as defined by our solution vendor partners, who are also industry standard leaders.
Symptoms of Control LoopMalfunction
Set Point
SafetyMargin Alarm Limit
Operation / Safety / Quality Limit
Poor Loop Performance and Impact of INTECH’s CLPM
Poor Loop Performance Operating Closer to Limits
Lower maintenance cost from reduced variations
Reduced operator loading from reduced alarms and more robust controls
Incremental ProfitLower safety margins neededoperation closer to constraints
Improve Controlsto Reduce Variations
Classical Optimization Method
Controllers are tuned during commissioning PI/PID parameters are initially set based on experience Setpoint changes are made to test performance Problem control loops are mostly tuned via trial & error Plants may run for their lifetime with sub-optimal controls
INTECH’s Real-Time Optimization
Control Strategy Design Control Element Performance Controller Tuning according to Specific Objectives Continuous monitoring of under-performing loops Model-based process configuration
Why do you need Control Loop Performance Management?Control Loops are an integral part of any automated process and define how efficiently a plant, facility, fileds or sub-system operates. Poor control loop performance can go undetected indefinitely and adversely affect productivity, having a negative impact on bottom line.
INTECH’s Loop Tuning helps identify origins of poor control loop performance and facilitates their remediation. It analyzes loops for problems like hysteresis, stiction, process non-linearity, and poor tuning; it then identifies and models processes’ dynamic response to calculate suitable loop PID controller settings. It also provides a choice of tuning objectives, and simulates loops’ response to visualize effects of parameter changes prior to applying them.
INTECH utilizes “role-based security” to ensure its application conforms to each company’s standards for application security. Users can be assigned to roles, and each role can be assigned unique privileges.
INTECH’s solution acquires real-time data via OPC and a time-series of data for analyses. OPC read rate is user-defined so that Loop Analysis does not overload the OPC server or underlying systems.
INTECH’s built-in “Report Builder” gives automatic loop performance reports, event-triggered reports & shift schedule based reports via email. These reports can also be accessed, customized and shared online and over the cloud.
Performance Reports & KPIsINTECH’s Process Analyzer helps find, explore, and understand plant-wide oscillations & their interactions with multiple plant/process variables. This helps ensure operation at 100% capacity.
Loop Analysis Process AnalysisSecurity
Benefits of Control Loop Optimization
Noise & Interference
Damage to equipment and assets
Error Span
Valve Reversals & Hysteresis
Control Valve Traversals
Overloaded operators and excessive intervention
Reduced oscillations & disturbances
Increased protection
Optimal productivity &
operations
Leading to reductions in
Poorly configured control loops are a serious damper to productivity and lead to issues like:
Unnecessary and excessive alarms Frequent process upsets Reduced output and quality Increased operator loading Increased output variations Stiction, non-linearity or hysteresis in control elements Gradual decrease in overall productivity
INTECH’s CLPM Specifications
Technical Specs
Import alarm databases, history, configuration files and analysis results through OPC or SQL using: ADU for Honeywell connection OPC DA & HDA for all other DCSs OLEDB/ODBC actions for OSI PI Printer Port File Import
Multi-System Integration Support
Diagnostics: Hysteresis Stiction Linearity Statistical Variability
Automatic/Manual Tuning
Simulation: Robustness Disturbance-Rejection Valve Travel Set-Point Change
Loop Tuning Features:
Process Diagnostics
Loop Simulation
Integrated Reporting
Loop Rationalization
Cause & Effect Matrix
Tree Map Summary
Asset Maintenance
Corrective Action Alerting
Root Cause Analysis
Documentation Assistance
Intuitive GUI
Auto-Tuning
Loop Tuning
Asset Health Monitoring
KPI Dashboards
Error Tuning
Other Features
Statistical Min, max, span Mean, median Standard deviation Control valve Travel / day Reversals / day Loop service % time in normal mode Operator changes Alarms generated Controller saturation Power Spectrum Analysis Dominant frequencies Significance of oscillation
Correlation Analysis Process variables Error and outputCycle analysis Zero-crossing cycle detection Cross-correlation cycle analysis Cycle frequency analysis Time Series Analysis ARMA model Impulse response Settling time Overshoot Loop performance Modified Harris Index Compound CLP Index
Types of Analyses
User Interface and DashboardsINTECH’s CLPM solution provides various user interfaces to allow users to get an overview of loop performance, and have fast access to performance details and diagnostics via drill-down. Coupled with our dashboard solutions, users can access reports and analyses over the cloud on any device and from any location.
Control Loops are an integral part of any automated process and define how efficiently a plant, facility, fileds or sub-system operates. Poor control loop performance can go undetected indefinitely and adversely affect productivity, having a negative impact on bottom line.
INTECH’s Loop Tuning helps identify origins of poor control loop performance and facilitates their remediation. It analyzes loops for problems like hysteresis, stiction, process non-linearity, and poor tuning; it then identifies and models processes’ dynamic response to calculate suitable loop PID controller settings. It also provides a choice of tuning objectives, and simulates loops’ response to visualize effects of parameter changes prior to applying them.
REPORTS
Hand Held Terminal
PDC-Windows CE
Manual Logging
Manual Logging /Hand Held Terminal
Client
1. Data Acquisition
8. PDC/Historian Interface
2. Advanced Process Historian
Production Data
REPORTS
SAP PM
RAW DATA
RESULTS Process Historian
Historic Process Data
Manual Data
Historic Process Data
5. Reporting7. Processing Simulation
LEGEND:
Equipment Run Hours, Starts and KPIs Efficiencies
Process DATA
OPCDAI/F
MS-Excel Reports
Ontology Framework
Excel-Data Link
Thin Client WEB-APPS (Browser)
Process Engr. W/S
Data Analysis/
Extract
KPIs
Process Simulation
Server
3. AlarmManagement
4. Control LoopPerformanceManagement
Alarms & Events AE I/F
Loop Tuning
DAI/F
Alarms Analysis, Rationalization Module
Control Loop Performance Management Module
Visual Interfaces (GUI) - To be deployed
by INTECH
Sometimes Already Deployed or To Be Offered by INTECH
Already Deployed Systems within IT /
CCR Landscape
6. Condition based Maint.
Advanced Process Historian to SAP PM Interface
ACE (Advanced Calculation Engine) Tank Mass/Vol KPI. Run Hours total
Starts, Efficiency Calculations
Alarm & Loop Analysis Client DCS
OPC Server
INTECH’s Advanced Solutions Deployment - Software Architecture
“I commend you on your efforts in customizing the business analysis software for deployment for a Web Based Alarm Management Dashboard. It meets our objectives and has produced the desired results.”
Control & Automation Leader
“[We] commend INTECH’s knowledge of alarm management, dedication, commitment and effort. Most importantly, works have been completed safely and INTECH has been able to work successfully in our diverse environment”
Central Maintenance Coordinator
“INTECH personnel have the correct skills & knowledge to enable them to carry out all tasks and additional works… full training and familiarization of Control Loop tuning software has been carried out to our complete satisfaction.”
Instrument Superintendent CM
What Our Customers Say...
OEMEnd User EPC
Vendor Expertise Standards & Certifications
* Notice: All registered logotypes, trademarks, brands, product and services marks used in this document are acknowledged as properties of their respective companies/owners and such companies/owners have not consented to their use by INTECH (Term INTECH is used for INTECH Process Automation Inc. and its affiliates). INTECH is not affiliated with these logotypes, trademarks, brands, product and services marks and any use by INTECH should not be construed as an endorsement of INTECH or its services. The services described herein are provided
solely by INTECH. © 2015. All rights reserved by INTECH Process Automation Inc. facebook.com/Intechprocessautomationlinkedin.com/company/intech-process-automation
CIS
Americas
Europe Office
World HQINTECH Process Automation Inc.4903 W. Sam Houston Parkway N. Suite A-100Houston, TX 77041, USATel: +1 713 849 1000 Fax: +1 713 856 0785
INTECH Process Automation SARL168 Avenue Charles de Gaulle, 92 522 Neuilly-sur-seine Cedex, [email protected]
INTECH Process Automation Perú S.A.C.Calle Juan Del Carpio N° 195,San Isidro, LIMA-PERU Tel: 511 606 6849, Cel: 51 982117562
INTECH Process Automation LLP.5A Erniyazova Str. Atyrau, KazakhstanTel: +7 7122 32 01 16Fax: +7 7122 32 00 52
Middle EastInternational HQINTECH Process Automation FZCOP.O. Box 61479, Office No. 16618 Lob 16,Jebel Ali, Dubai, United Arab EmiratesTel: +971 4 8808423Fax: +971 4 8876553P.O. Box 61479, WT01FD06,Jebel Ali, Dubai United Arab EmiratesTel: +971 4 8810056Fax: +971 4 8810057
North Africa OperationsTel: +971 55 607 3230, +971 553768482
INTECH Process Automation Inc. Br.G-201 Al-Salah Tower, P.O. Box 4270, Al-Khobar - 31952,Kingdom Of Saudi ArabiaTel: +966 13 8966052, +966 13 8966053
INTECH Process Automation FZCO Br. 470, Italian City, Erbil, Iraq Tel: +964 780 131 2198, +964 750 309 3766Mnawi Basha, Basra, IraqTel: +964 780 131 2198, +964 770 831 9073
Asia PacificINTECH Process Automation Pte. Ltd.21 Merchant Road #04-01, Royal Merukh S.E.A Building,Singapore 058267 Tel: +65 6828 9128Fax: +65 6828 9112
PT INTECH Process AutomationRukan Permata Senayan, Blok C Nomor 5, 4th FloorJalan Tentara Pelajar, Kebayoran Lama,Jakarta Selatan. 12210 Indonesia.Telephone & Fax : +62 21 579 49 444
South AsiaINTECH Process Automation (Pvt.) Ltd.2nd Floor, Club and Community Center,PCSIR Society Phase II,Lahore Pakistan 54782Tel: +92 42 111 468 324, 3531 2509/11Fax: +92 42 3531 4149
INTECH Process Automation (Shanghai) Co. Ltd.Room 1605C, 16F Feidiao International Building, No.1065 Zhaojiabang Road, Xuhui District,Shanghai 200030 – P.R.C.Tel: +86 21 2426 1951Fax: +86 21 2426 1877
Africa
Sales Email: [email protected] E-mail: [email protected]
INTECH Process Automation Nigeria Ltd.64B, Abacha Link Road, G.R.A. III, Port Harcourt, Rivers State, NigeriaTel: +234 0 84462776Dream Plaza, 4th Floor, 7, Bishop Aboyade Cole Street,Off Adetokunbo Ademola Street, VI Lagos, NigeriaTel: +234 805 9330560
INTECH Process Automation Inc.(Sucursal de Angola)Esc. n. 309/310, 3º Andar - Edíficio Cunene,Belas Business Park, Talatona, Luanda,Republica de AngolaTel: +244 222 720 471Fax: +1 281 377 3455
www.intechww.com