Professional Documents
Culture Documents
Introduction to LPM
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Presentation Outline
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1. Introduction/Motivation
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If not, how much can be accounted to the process automation, especially the control loops?
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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
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.
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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
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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
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High
Cost
Dream
Time
Low
High
Cost
Reality
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Low
2. LPM Features
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Log
Tune
Model
Collect
Configure
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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
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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
ADVANCED
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Evaluation
LPM Tuning
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
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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
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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
Assessment stage
Reasonable design
?
Is this good control? If not: why?
indices
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Info
know how
I 1, I 2, I 3,
inference engine
know how
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Hypothesis, Diagnosis
suggest remedies
Measurement PV
Basic statistics
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Data Validity
Control loop modes
Valve indices
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
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Indices plus know-how organized in a Root-Cause analysis elaborate Maintenance Suggestions Diagnoses dealt with problems in: Tuning, Actuators and Sensors, External disturbance
Overall Performance
PRECONDITIONS
Acceptable performance index
Harris index
Variability random
Oscillation index of control error
Loop automatic
Automatic mode index
fair
poor
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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
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Maintenance
Indices
Reporting
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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
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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)
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And More
Operation-Sensitive Reports: allow to monitor control loops according their operating region(s)
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Bulk Database Import for quick DB Configuration Allows to import tag configuration details from Excel spreadsheets Results in Relevant Manpower Savings
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Reports Configuration
Reports Retrieval
Tuning Logs
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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
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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)
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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
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TC
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
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Two Oscillation Clusters One PCA Cluster A few tags have been added to clusters due to process considerations
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
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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)
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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
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TC
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Good default results for non-linearity analysis (primary cycle) (ranks LC2 as highest non-linearity)
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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
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TC
Cluster 1 Cluster 2
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
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Liquid
Liquid
One Oscillation Clusters One PCA Cluster A few tags have been added to clusters due to process considerations
Cycle of interest
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Ref. to: Peak Performance: Root Cause Analysis of Plantwide Disturbances, ABB Review 1/2007
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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)
PDA
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