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Interactive Opportunity Interactive Opportunity AssessmentAssessmentInteractive Opportunity Interactive Opportunity AssessmentAssessment

Demo and Seminar (Deminar) Series for Web Labs –

Online Process Control Lab Access and Use

May 27, 2010Sponsored by Emerson, Experitec, and Mynah

Created byGreg McMillan and Jack Ahlers

Website - Charlie Schliesser (csdesignco.com)

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WelcomeWelcome WelcomeWelcome Gregory K. McMillan

– Greg is a retired Senior Fellow from Solutia/Monsanto and an ISA Fellow. Presently, Greg contracts as a consultant in DeltaV R&D via CDI Process & Industrial. Greg received the ISA “Kermit Fischer Environmental” Award for pH control in 1991, the Control Magazine “Engineer of the Year” Award for the Process Industry in 1994, was inducted into the Control “Process Automation Hall of Fame” in 2001, and was honored by InTech Magazine in 2003 as one of the most influential innovators in automation. Greg is the author of numerous books on process control, his most recent being Essentials of Modern Measurements and Final Elements for the Process Industry. Greg has been the monthly “Control Talk” columnist for Control magazine since 2002. Greg’s expertise is available on the web site: http://www.modelingandcontrol.com/

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Top Ten Reasons Why an Automation Engineer Makes a Great Spouse or at Least a Wedding Gift Top Ten Reasons Why an Automation Engineer Makes a Great Spouse or at Least a Wedding Gift

(10) Reliable from day one (9) Always on the job (8) Low maintenance - minimal grooming, clothing, and entertainment

costs (7) Many programmable features (6) Stable (5) Short settling time (4) No frills or extraneous features (3) Relies on feedback (2) Good response to commands and amenable to real time

optimization

And the Number 1 Reason:

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Top Ten Reasons Why an Automation Engineer Makes a Great Spouse or at Least a Wedding Gift Top Ten Reasons Why an Automation Engineer Makes a Great Spouse or at Least a Wedding Gift

(1) Readily tuned

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Today we are on Location of Virtual PlantsToday we are on Location of Virtual Plants

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Free Access to Virtual PlantsFree Access to Virtual PlantsFree Access to Virtual PlantsFree Access to Virtual Plants

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My Planned Uses of Virtual PlantsMy Planned Uses of Virtual PlantsMy Planned Uses of Virtual PlantsMy Planned Uses of Virtual Plants ISA 2010 Automation Week Presentation Tuning and Control Loop

Performance Emerson Exchange 2010 Short Course: Interactive Exploration of Process

Control Improvement Chapter on Industrial PID Applications in new book PID Beyond 2000:

Lessons Learned and New Approaches, Springer, 2010 KU Continuing Education Course - Process Control Improvement Tuning and Control Loop Performance, 4th Edition Momentum Press, 2011 Interactive Opportunity Assessment – Online Exploration and

Quantification of Process Control Improvements, ISA, 2011 Advanced pH Measurement and Control, 4th Edition, ISA, 2012

What are Your Uses?

– To share your opportunities, ideas, and scores, send an Email to me at Greg.McMillan@Mynah.com

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Not an Emulation but a Virtual “State of the Art” DCS Operator Screens to Create a Control Room Experience All the Power of Basic and Advanced Process Control No DCS Configuration or Parameter Access Needed Structural Changes “On the Fly” (no download required) Enough Interesting Scenarios for a Year of Exploration and

Quantification of Process Control Improvements Enough Variety of Process, Measurement, and Valve Dynamics

to study 99% of the process industry’s control applications– For very slow processes, proportionally scale down the process time constants

and dead times to keep the ratio constant of Process Lag 2 to the sum of small process and measurement time constants and delays

Features of Online Process Control LabsFeatures of Online Process Control LabsFeatures of Online Process Control LabsFeatures of Online Process Control Labs

“Hands-On Learning” Provides the Best Educational Experience”

click button for each desired lab (concurrent labs are possible)

click on arrow to return to thismain lab menu

DeltaV Operate Main Screen

Click to restore PID setpoint, PID mode, PID limits, PID tuning,PID options, process dynamics,

measurement dynamics, disturbance dynamics,

and control valve dynamics

performance metrics aregenerated in Run mode

click to select mode

click to getPID faceplate

click to gettrend chart

click to enter time forTest and Run modes(load upsets occur inTest and Run modes)

click any block in block diagramto get access to data entry screen for

PID options and run conditions (process,measurement, upset, and valve details)

Secondary (inner loop) PID’s setpointis primary (outer loop) PID’s output

AC1-1 is primary PID and AC1-2 is secondary PID

Feedforward signal added to PID outputuse a measurement of the disturbance

AC1-1 is primary PID and AC1-2 is secondary PID

University of Texas Unit Operations Lab Reactor

Click forDynamics

See article “Virtual Plant Provides Real Insights” in Chemical Processing,http://www.chemicalprocessing.com/articles/2008/255.html

Click forDynamics

click on open folder to select your lab trend chart if your lab trend chart is not already open

configured upsets occur in Run and Test modesperformance metrics are computed in Run mode

click on value to get data entry screen with pull down menu for mode

click on value to get data entry screen to enter new value(pull down menu for PID structure has 8 choices)

click on value to get data entry screen to enter new value (process dynamics can only be changed in Explore mode)

primary process and secondary process Lag2 has values for PV increasing and PV decreasing (the minimum Lag2 for process simulator stability is 1 sec)

for an integrating process type, the integrating process gain is the process gain multiplied by factor divided by Lag2 (units of 1/sec)

create nonlinear gain byclicking on factor valuesand entering multiplier of

primary process gain

Lag2 must be largest time constant in primary process

Lag2 must be largest time constant in secondary process

click on value to get data entry screen to enter new value

refresh time is time between communications to PID (periodic reporting)sensitivity is minimum change in measurement for communication (exception reporting)

Feedforward Gain and “Dynamic Compensation” (Lead-Lag) are accessible in Feedforward Loop Lab 03

click on value to get data entry screen to enter new value

configured upsets do not occur in Explore mode

click on value to get data entry screen to enter new value

create nonlinear valve byclicking on %Flow values

and entering % of max flow

“Valve Step %” is step size ofstair-case response

(valve’s resolution limit)

“Valve L/L Lag” is Lag time of Lead/Lag & “Valve L/L Lead” is Lead time of Lead/Lag

applied to valve signal to kick actuator thrudeadband (backlash) and stick-slip (stiction)

permissible value range is 0 – 100

negativenumber

Click on magnifying glass to getdetail view of limits and tuning

Click on Duncan to get DeltaV Insight for “On-Demand” and “Adaptive” tuning

“On-Demand Tuning” automatically identifies dynamics from relay oscillation introduced

click on PID tagand then Tune

“Adaptive Tuning” automatically identifies dynamics from setpoint or manual output change or injected pulse(For More Info See Emerson Exchange 2009 Presentation on DeltaV Insight for Loop Monitoring and Tuning)

click on PID tagand then Tune

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Online Process Control Lab AccessOnline Process Control Lab AccessOnline Process Control Lab AccessOnline Process Control Lab Access Objective – Show access to web site and virtual plant Activities:

– Go to http://www.processcontrollab.com/

– Show How to Connect screen

– Show Request Access to a Virtual Plant

– Make a Remote Desktop connection to the assigned Virtual Plant

– Click on DeltaV Operate

– Put all of the Process Control Labs in the Run mode

– Click on Trend Chart icon and open up charts for all of the Labs

– On Main DeltaV Operate screen discuss the Restore button

– In the Process Control Lab website show Help screen

– In the Process Control Lab website show Instructions screen

– Go back to Remote Desktop Connection for Virtual Plant

– Minimize screens and in FlexLock select Logoff Windows

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Help Us Improve These Deminars!Help Us Improve These Deminars!Help Us Improve These Deminars!Help Us Improve These Deminars!

WouldYouRecommend.Us/105679s21/

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Join Us June 9, Wednesday Join Us June 9, Wednesday 10:00 am 10:00 am CDTCDTJoin Us June 9, Wednesday Join Us June 9, Wednesday 10:00 am 10:00 am CDTCDT

PID Tuning for Self-Regulating Processes (How to Compensate for Nonlinearities in Flow, Liquid Pressure, and Heat Exchanger Loops)

Look for a recording of Today’s Deminar Look for a recording of Today’s Deminar later this week at:later this week at:www.ModelingAndControl.com

www.EmersonProcessXperts.com

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QUESTIONS? QUESTIONS? QUESTIONS? QUESTIONS?