© 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.

SSE-09Advanced Process Control withConnoisseur

Presented by: Tom Kinney

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What is ConnoisseurTM?

ConnoisseurTM

Optimizer

Expert System

Model Predictive Constraint

Controller

Neural Network

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Connoisseur Toolset

Adaptive

C P

M

Inferential

Neural Net

Fuzzy Logic

Calculations

10*349304

1454

LD

dxSj Non-linear

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Multi-Variable Control and Neural Net Optimization Overlays DCS

Connoisseur Environment

Bias, Setpoints & MV Targets

Optimizer-Neural Net

Measurements

CV’s, MV’s, FV’s

Regulatory Control System (DCS)

Model Predictive Controller

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MVC/Optimizer: Model Predictive Constraint Control

Responsive Control of Difficult Loops such as:

Steam Temperature Control for Ramp Rate

O2, Control of CO, Steam Temperatures & NOx

PV

now

Predicted Constraint ViolationConstraint

Future Past

Actual Variable Trajectory ThroughConnoisseurTM Control

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Improve Control then Operate Closer to Limits

Stabilize, Then Optimize!

Target or Constraint

Increased benefit

BeforeStabilization

Stabilizeand Re-Position

Increase Production, Quality, etc.

MPC/NN

The Invensys Advantage: Dynamic Optimization

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Connoisseur FeaturesAs 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

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Connoisseur Applications

Over 260 Applications Worldwide in a Variety of Industries

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

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Success Story: Saudi Aramco

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

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

About the Client:• Largest oil company in the world• Supplies 10% of world’s oil• 2006 Revenue US$ 194 BillionWhat IOM did for the Client:• Implemented Advanced Process Control (APC) using Connoisseur on a

400,000 bbl/day crude unit.• Inferred Product Qualities

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Success Story:Tesoro Golden Eagle FCC

Benefits: • Increased FCC capacity and conversion• Improved main fractionator and gas plant

product yields• Energy savings• $2,950,000 / Year Benefits

Benefits: • Increased FCC capacity and conversion• Improved main fractionator and gas plant

product yields• Energy savings• $2,950,000 / Year Benefits

About the Client:• Operates 7 U.S. Refineries: 665,000 BPD Capacity• 2008 revenue US$ 28 billionWhat 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

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Success Story:Tesoro Golden Eagle Gas Plant

Benefits:• Improved gas plant product yields • Energy savings• $2,000,000 / Year Benefits

Benefits:• Improved gas plant product yields • Energy savings• $2,000,000 / Year Benefits

About the Client:• Operates 7 U.S. Refineries: 665,000 BPD Capacity• 2008 revenue US$ 28 billionWhat 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

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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

Solution• Coal Pulverizer Optimization• Reduced Air Preheating• Lower Excess Air• Balanced Superheat and Reheat

Steam Temperatures

Benefits

Heat rate improvements 0.5%

NOx Reduction of 15-20% Leading to Ammonia Savings on

SCR

ROI less than 1 year

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Situation• Sim Gideon Plant, TX Unit 3 • 340 megawatt, natural gas-fired,

load-following boiler• Max ramp rate of 40

megawatts/minObjectives• Improve unit heat rate • Reduce emissions of NOx

• Reduce emissions of other greenhouse gasses

SolutionMultivariable 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

Case Study:Lower Colorado River Authority

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Success Story:Tesoro Golden Eagle Isocracker

Benefits:

- Increased catalyst life

- Improved reactor constraint management

- Enhanced unit operability

About the Client:• Operates 7 U.S. Refineries: 665,000 BPD Capacity• 2008 revenue US$ 28 billionWhat IOM did for the Client:• Implemented Advanced Process Control (APC) using Connoisseur on an

Isocracker unit• Optimized reactor operation • Stabilized unit operation

Slide 16IPS Confidential

Iggesunds Mill - Causticizing

• Capacity 378,000 MTPY bleached pulp - hwd/swd 43% / 57%

• High quality virgin fiber board for food, pharmaceauticals, etc.

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Iggesunds Causticizing MPC

IPS Confidential

MVPredictiveController

&Optimizer

Fuzzy LogicController

Weak wash dilutionFlow GLDensity GLTemperatur GLLime addition to Slaker

Constraint ManagementSelected CV´s

TTA GL Clarifier Temperature GL to

Slaker Temperatur Slaker

Diff Temp (Slaker-GL)

Carbonate Green Liquor Clarifier1st Causticizer Inlet – CE %

1st Causticizer Outlet – CE %Pressure Filter Outlet – CE %

Sodium Carbonate in GLSulfidity GL

Steam to Slaker

Residual Carb.% - kiln limeResidual Carb.% – lime to slaker*

* Purchased lime

Controlled Variables (CV) Manipulated Variables (MV)

Feed Forward Variables (FV)

© 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.

Coming Soon!!

SimSci-Esscor APC V2.0

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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

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Case Studies are supported, allowing many potential models to be developed and overlaid on one set of CV/MV pairs

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All CV,MV Pairs for a proposed Model Clearly Shown on one palette

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Controller Design made easy by dragging and dropping variables into this table

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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

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APC Internal Version – Phase 1- Create Project Environment- Connect (OPC DA)- Auto-discovery of tags

APC Internal Version – Phase 2- Data Processing- Process Test- Modeling

APC Internal Version – Phase 3- Case Studies - Director Calculation- Controller Design

APC Beta Release Version – Phase 4- Promote- Migration- Reports- Beta Test Ready

June 2012

Nov 2012

March 2013

August 2013

MoreReleases in

Future

Roadmap of Simsci-Esscor APC 2.0, Next 12 mos.

StartFebruary

2012

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APC V2.1 Enhanced Performance Reporting- Web Based Performance Reporting-User Defined KPIs-Web Based Reports-Move Advisor V1.0-

APC V2.2-Enhanced Support for Sub-Controllers-Move Advisor V1.1

APC V2.3-Larger Matrix Size-Embedded Support-Enhanced Integration with OTS systems

APC V3.0-Enhanced Support for Embedded APC-Move Advisor V2.0-Enhanced Support for RTO Integration

September 2014

September 2015

September 2016

September 2017

Roadmap of Simsci-Esscor APC 2.0, 5 Year Plan

StartSeptember

2013

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New Technology, Currently being Prototyped

Solving the APC understanding gap

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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

Move Advisor

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Move Advisor User Stories

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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

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

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Move Advisor Prototype design for preliminary feedback

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Detail View

News View

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Move Advisor Components

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Collect - Variable Names, Relationships, Scan Interval

Scan - Values, Limits, Costs, Status

Analyze - Track moves and Create messages

Report - News, Detailed Data

Data SourceConnoisseur

RomeoNextGen

InterfaceExcel

Web ViewerPC App / InTouch

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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!•