You are on page 1of 50

cpmPlus Loop Performance Manager 3.

Introduction to LPM
ABB - 1 -

Presentation Outline

Introduction / Motivation cpmPlus LPM Features


Tuning Control Performance Monitoring Supporting Utilities

cpmPlus LPM Plant-wide Disturbance Analysis

ABB - 2

cpmPlus Loop Performance Manager

1. Introduction/Motivation

ABB - 3

Why Loop Performance Monitoring?

Does my plant run optimally?

If not, how much can be accounted to the process automation, especially the control loops?

We should use available measurement data instead of just storing it.

Normal operation does not necessarily mean optimal operation


Loop optimization saves money without new capital investments

ABB - 4

Real world performance is suboptimal!

ABB - 5

An investment that has to pay off!


Typical control loop as a $25,000 asset Half of it is lost


50 % well tuned 25 % uneffective control 25 % decrease performance


ABB - 6

Half time of good performance = 6 months 2 4 hours to investigate and improve control performance Typical process contains 2000 4000 control loops Only few people with appropriate know-how Average process engineer in charge of 400 control loops 25 % of 4000 loops do harm, this means

Analysts start to get the message


Recent issue: Include control loops in asset management
Les A. Kane, Editor

Quotes:

while process equipment is an integral part of AM [asset management] programs, control loops often dont receive the same attention.

Performance of control loops degrades slowly over time with little fanfare.
Without properly tuned control loops to minimize variability, substantial benefits are lost. even a slight degradation in process control can result in millions of dollars in lost profitability. Identifying the high-payback control loops requires evaluating all control loops, which would be an insurmountable task without the aid of control loop performance monitoring and analysis software. When first installed, advanced process control typically provides substantial benefits. Sustaining those benefits due to changing conditions, however, has been a problem. its a good time to ensure control systems are part of your AM efforts.

ABB - 7

Benefits of Tuning and Auditing

Maintains control system at its peak

Loop Tuning

Enables the plant engineers to reach loops optimum performance with significant time savings (vs. manual tuning)

Loop Auditing

Provides timely indication of equipment/automation/process problems. In this way it easy to keep the loop at their , allowing to stay at the optimal performance

Also, it provides stable foundation for multivariable/advanced control

ABB - 8

cpmPlus Loop Performance Manager What is it?


Loop Tuning

Challenge

Optimal PID Tuning is critical to efficient process operation Loop Tuning is a time consuming activity Typically, only expert engineers can perform Tuning LPM Tuning makes definition of optimal PID parameters an easy, reliable & manageable task

Solution

Loop Auditing

Challenge

Loop optimization is frustrating, because after few months all results seem lost due to the process variability Plant engineers have to look at hundreds of signals and among them detect possible problems

Solution

Once Loop Optimization is performed, LPM Auditing monitors loops and allows the process engineer to immediately address problem areas

ABB - 9

Cost of bad control


Loop Tuning Execution

High
Cost

Dream
Time

Low

High
Cost

Reality

Low Time High


Cost

Realistic dream with Auditing


Time

ABB - 10

Low

cpmPlus Loop Performance Manager

2. LPM Features

ABB - 11

LPM Tuning Workflow

Which step to tune a Loop?

Log
Tune

Model
Collect

Configure

ABB - 12

LPM Features Data Collection

Configure database by loops Simultaneous data collection for multiple loops OPC connectivity Direct connection for Infi90/Symphony Data collections stored as object on navigation tree for future retrieval Possibility to exploit auditing automatic data collection for tuning purposes

ABB - 13

LPM Tuning - Identification

BASIC for not experts and ADVANCED with fully scalable complexity for expert control engineers Manual or Automatic structure selection by best fit Parameters specified - up to 4th order Identification also with Process in Close Loop Validation

BASIC

Model simulated with another data set

ADVANCED

ABB - 14

Evaluation

Ideal step response


Bode diagram

LPM Tuning

5 Tuning methods available


Time domain analysis Frequency analysis

Support many vendor specific PID controller types Ability to model, tune, and analyze Feedforward control loops. Considers feedback tuning. Special treatment of Cascade control loops

ABB - 15

LPM Advanced Tuning Features

New Tuning values can be assessed on model different from the ones used to obtain the tuning set (Simulate Mode) Data pre-processing functionalities Advanced Feedforward Loop Tuning Management HTML-based and information-richer Tuning Logs Advanced Cascade Loop Tuning Management

ABB - 16

LPM Tuning Advantage

State of the art Tuning Algorithm, but with userfriendly tool to make Advanced Control Theory accessible to every Plant Engineers Ready for every DCS

OPC connection Calculated PID parameters (Kp, Ti, Td ) with the definition of your DCS

Identification also with Loop in normal Close Loop Mode Not only basic PIDs, but also FeedForward and Cascade Loop

Control Tuning becomes easy, fast, profitable


ABB - 17

Performance Assessment: Tuning vs. Auditing

Tuning - Design stage

Assessment stage

Reasonable design

?
Is this good control? If not: why?

Slightly tight design


ABB - 18

Control loop monitoring non-invasive!

indices

ABB - 19

LPM Auditing - General concept

based on available signals only(SetPoint, PV, CO)

Info

available information can be incorporated


performance indices, measures

know how

I 1, I 2, I 3,

inference engine

know how

ABB - 20

Hypothesis, Diagnosis

suggest remedies

Kinds of Performance Indices in LPM


Controller Output CO Target SP

Measurement PV

Basic statistics

Nonlinearity indices Property indices Housekeeping


ABB - 21

Data Validity
Control loop modes

Tuning Performance indices Special indices Continuous indices Oscillation indices

Valve indices

Kinds of Diagnoses in LPM


Performance indices Auditing Rules

Maintenance Diagnoses

Diagnoses
Tuning Problem Loop Oscillatory SetPoint oscillatory Significant external disturbance Significant non-linearity Valve stiction Valve leakage or zero error Valve size incorrect
ABB - 22

Indices plus know-how organized in a Root-Cause analysis elaborate Maintenance Suggestions Diagnoses dealt with problems in: Tuning, Actuators and Sensors, External disturbance

Excessive valve action Data unrealiable

Overall Performance
PRECONDITIONS
Acceptable performance index
Harris index

Acceptable setpoint crossings index


Setpoint crossing index (not for Level Control)

Acceptable Overall performance


excellent good

Variability random
Oscillation index of control error

Controller output within range


Saturation index

Loop automatic
Automatic mode index

fair
poor

Acceptable cascade tracking


Cascade tracking index (if in cascade)

Acceptable response speed


ACF to horizon index

ABB - 23

Auditing workflow
Loop configuration Assign TAG connection Signal ranges Loop Type Auditing configuration Assign Data collection schedule Batch / continuous auditing Loop category configuration Assign Sampling rate Batch duration Report configuration Assign Report layout

Configuration file

Configuration Start auditing


Setpoint CO,PV Database

Data collection Indices calculation

Indices Trend Plot

Indices Reports Excel, HTML

Diagnoses Report Excel, HTML

Output Periodical reports

ABB - 24

Process Engineer Investigate Problem Activate Maintenance

Maintenance Operator Repair device Tuning

Maintenance

Example oscillation investigation...


cycling load static friction F FC tight tuning
Diagnoses

ABB - 25

Indices

Verify overall Performance Detect oscillation Decide among the 3 causes

Oscillation details (period, amplitude) Amount of problem for every causes

Trend plot for every index

LPM Auditing - KPI Reporting & Analysis

Reporting

Pre-defined report templates Both numerical and chart-based assessment

ABB - 26

Advanced Auditing Features

Advanced Indices & Diagnosis trend facility (on multiple even non consecutive periods) User-defined Indices Enhanced KPI and Diagnosis set Server Status Monitor to supervise all the auditing functions

What Is Changed report to immediately eye-catch recently developed events


Possibility to generate a Detailed Loop Report, with in-depth charts and numerical figures

ABB - 27

Detailed Report

Time domain view (PV,SP,CO) Power spectrum view (PV) Statistical view (PV, CE) CE vs. CO, during oscillation becomes a ring. From the shape it is possible to detect stiction Impulse response of Disturbance Rejection Sensitivity study for Prediction horizon (good situation when lines is increasing with steps)

ABB - 28

And More

Operation-Sensitive Reports: allow to monitor control loops according their operating region(s)

Examples: production campaign types, loads,


Capability to extract and utilize for Tuning purposes data automatically collected during Auditing normal operation

ABB - 29

Bulk Database Import for quick DB Configuration Allows to import tag configuration details from Excel spreadsheets Results in Relevant Manpower Savings

ABB - 30

Infi90/AC800F Bulk Import Tool


Available as an add-on to standard LPM Functions

ABB - 31

LPM auditing - Everything also by Web


Facility to get and manage all LPM information from any location in the net

From the LPM Home Page it is possible to navigate to

Reports Configuration

Reports Retrieval

Tuning Logs

ABB - 32

LPM Auditing: Advantages

Automatic data-collection enable actual continuous loop performance assessment rather than sporadic sampling, maximizing the chance to identify and correct insurgent productionrelated problems Simple, straightforward diagnostic indications are made available for the basic user or for quick assessment

Diagnostic results are based on sophisticated indices which are able to provide explanations or in depth analysis for advanced user or when needed
Both Diagnosis and Indices are saved and stored in user-configurable Reports so to not require continuous attention from plant crew and to provide a comprehensive plant history track record

ABB - 33

cpmPlus Loop Performance Manager

3. Plantwide Disturbance Analysis

ABB - 34

Plant-wide disturbance analysis - intro


Analysis process data off-line Searches for data pattern in time (oscillations) and frequency (specra) to identify

Oscillations Interactions

Identifies most likely root-cause (with no info on plant topology/interconnections) Integrated in LPM, could use auditing data or external data (e.g. plant historian)

ABB - 35

Plant-wide disturbance analysis - intro

ABB - 36

PDA Application Case 1 Cascaded Distillation Columns:


1

TI FC
Internal Condenser
2

TI

FC
Internal Condenser

PDI

39

TI
2 1 3

PDI 20

PI
3

Column 1

32

TC TI
3

Steam

FC

TC

FC

Column 2

19

TI TI

16

22

10
3

TI TI

4 1
5 1

TC
3

FC
1

FC

5 9

TI

LC
Steam

LC
2

PI
Decanter

Steam

PI

FC

LC

ABB - 37

TC

PDA Application Case 1: Dataset Details

Primary cycle

Column 1 level through column 2 distillate Cause is LC2 valve movement problem Many variables cycling together

Secondary cycle

Top of column 1 (distillate FC2 and temperatures) Cause is FC2 valve movement problem Dataset window chosen

ABB - 38

96 hours total data, sample time = 30 sec

PDA Application Case 1: Clustering

Three main Clusters detected:

Two Oscillation Clusters One PCA Cluster A few tags have been added to clusters due to process considerations

Oscillation Clustering: manually added 1 related tag to grouping (primary cycle)


ABB - 39

PDA Application Case 1: Clustering

Three main Clusters detected:

Two Oscillation Clusters One PCA Cluster A few tags have been added to clusters due to process considerations

Default grouping: secondary cycle, had to add ti2.pv and ti3.pv tags manually
ABB - 40

PDA Application Case 1: Clustering

Three main Clusters detected:

Two Oscillation Clusters One PCA Cluster A few tags have been added to clusters due to process considerations

PCA cluster default grouping, manually added 2 related tags to grouping (primary cycle)
ABB - 41

PDA Application Case 1: Main Clustered Disturbances


1

TI FC
Internal Condenser
2

TI

FC
Internal Condenser

PDI

39

TI
2 1

PDI
20 19

PI
3

TI TI

Column 1

32

TC TI
3

Steam

FC

TC

FC 4

Column 2

16

22

10
3

TI TI

4
1
5

TC
3

FC
1

FC
1
Steam Decanter

5 9

TI

LC
Steam

LC
2

PI LC 2

PI

FC

ABB - 42

TC

PDA Application Case 1: Root Cause Analysis

ABB - 43

Good default results for non-linearity analysis (primary cycle) (ranks LC2 as highest non-linearity)

PDA Application Case 1: Root Cause Analysis

ABB - 44

FC2 cycle (secondary cycle) analysis: non-linearity correctly identifies FC2

PDA Application Case 1: Disturbance Propagation


1

TI FC 2
Internal Condenser

TI

FC
Internal Condenser

PDI

39

TI 2

PDI
20 19

PI
3

TI TI

Column 1

32

TC

Steam

FC

TC

FC 4

Column 2

16

22

TI 3

10
3

TI TI

4
1
5

TC
3

FC
1

FC
1
Steam Decanter

5 9

TI

LC
Steam

LC
2

PI LC 2

PI

FC

ABB - 45

TC

Cluster 1 Cluster 2

PDA Application Case 2 Vaporizer System:


Vapor Header
1

PC

Steam

Steam

Steam

Steam

SP

PC
2 5

PC
LC

FC
9 7 7

FC
9

LC

LC

PI
7

LC

PI
9

Liquid

Liquid

ABB - 46

Liquid

Liquid

PDA Application Case 2: Clustering

Two main Clusters detected:

One Oscillation Clusters One PCA Cluster A few tags have been added to clusters due to process considerations
Cycle of interest

ABB - 47

PDA Application Case 2: Root Cause Analysis

Ref. to: Peak Performance: Root Cause Analysis of Plantwide Disturbances, ABB Review 1/2007

ABB - 48

Good results for non-linearity, clearly identifies LC2 as root cause

cpmPlus - LPM Conclusions


Tuning

Auditing

With LPM Process Engineers (also non expert in control theory) can optimize Loop behavior Benefits: increase process profit, more stable working condition, more safety operations Very valuable insight on process corrrelations, oscillations and root causes with a few points and click Could use your historian data (with reasonable data compression)

Control Performance Monitoring is non-invasive, simple to perform and very efficient

LPM detects automatically problem at the beginning of their occurrence


Performance monitoring nowadays answers the most important questions to help the plant personnel to pinpoint and remove problems

PDA

The right information to the right people

Complementary to tuning and auditing

ABB - 49

You might also like