© 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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Slide 3
What is ConnoisseurTM?
ConnoisseurTM
Optimizer
Expert System
Model Predictive Constraint
Controller
Neural Network
Slide 4
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 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 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!•