Slide 1

Interactive Opportunity Interactive Opportunity AssessmentAssessmentInteractive Opportunity Interactive Opportunity AssessmentAssessment

Demo and Seminar (Deminar) Series for Web Labs –

PID Enhancement for Sampled Measurements

April 7, 2010Sponsored by Emerson, Experitec, and Mynah

Created byGreg McMillan and Jack Ahlers

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2 Slide 2

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/

[File Name or Event]Emerson Confidential27-Jun-01, Slide 3 Slide 3

The Latest on Smart and Wireless The Latest on Smart and Wireless Instrumentation Instrumentation

The Latest on Smart and Wireless The Latest on Smart and Wireless Instrumentation Instrumentation

Royalties are donated to theUniversity of Texas Research Campus for Energy and Environmental Resources for Development of WirelessInstrumentation and Control

[File Name or Event]Emerson Confidential27-Jun-01, Slide 4 Slide 4

Top Ten Ways to Make Top Ten Ways to Make Process Control EnticingProcess Control EnticingTop Ten Ways to Make Top Ten Ways to Make

Process Control EnticingProcess Control Enticing (10) Travel programs focusing on the process control systems of cruise ships (9) Sci-fi flicks devoted to the process control systems in star ships (8) Reality shows where teams compete to improve process control performance (7) Entourage shows where groupies use process control to keep their star from self-

destruction (6) Sport analysis programs where commentators and listeners talk about the dynamics

and feedforward control opportunities in football (5) Robot movies where advanced parallel processing robots optimize plants (4) Detective shows where a special investigator with cute compulsive obsessive habits

and an incredibly keen mind for details solves mysterious process control problems (3) “Who done it” novels where the culprit is a bad acting control valve (2) Web video with cute animal antics in the foreground and engineers talking about

process control opportunities in the background (1) “Cash for clunkers” programs to replace inefficient old distributed control systems,

transmitters, and valves

[File Name or Event]Emerson Confidential27-Jun-01, Slide 5 Slide 5

Self-Learning Web Lab Self-Learning Web Lab (Web Access Starts May, 2010)(Web Access Starts May, 2010)

Self-Learning Web Lab Self-Learning Web Lab (Web Access Starts May, 2010)(Web Access Starts May, 2010)

[File Name or Event]Emerson Confidential27-Jun-01, Slide 6 Slide 6

Loop Lab01 Demo of Base CaseLoop Lab01 Demo of Base CaseLoop Lab01 Demo of Base CaseLoop Lab01 Demo of Base Case Show access to “Operate Run” user interface Show access to PID faceplate and detail Show access to “Process History View” trend chart Make setpoint changes to show existing response Show access to valve, process, and measurement

parameters for sensitivity, noise, and dynamics

[File Name or Event]Emerson Confidential27-Jun-01, Slide 7 Slide 7

QuestionQuestionQuestionQuestion What will dramatically improve the performance of loops using at-line

analyzers making tuning easier and virtually eliminating oscillations? What can increase control valve packing life by factor of 10? What can make battery life of wireless measurements a non issue? What will eliminate the limit cycle from measurement sensitivity limits? What will smoothly handle a loss in I/O communication?

Answer : An Enhanced PIDAnswer : An Enhanced PID

[File Name or Event]Emerson Confidential27-Jun-01, Slide 8 Slide 8

Loop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time Effect Look at response of traditional PID for base case Increase measurement sample time to 20 sec and set

sensitivity out of range (e.g. 100%) Make setpoint changes to show traditional PID response

to large sample time (e.g. twice process time constant) for self-regulating process

[File Name or Event]Emerson Confidential27-Jun-01, Slide 9 Slide 9

PID integral mode is restructured to provide integral action to match the process response in the elapsed time (reset time set equal to process time constant)

PID derivative mode is modified to compute a rate of change over the elapsed time from the last new measurement value

PID reset and rate action are only computed when there is a new value

If transmitter damping is set to make noise amplitude less than sensitivity limit, valve packing and battery life is dramatically improved

Enhancement compensates for measurement sample time suppressing oscillations and enabling a smooth recovery from a loss in communications further extending packing -battery life

http://www.modelingandcontrol.com/repository/WirelessPrimeTime.pdf

Traditional and Enhanced PID (PIDPLUS)Traditional and Enhanced PID (PIDPLUS)

[File Name or Event]Emerson Confidential27-Jun-01, Slide 10 Slide 10

Loop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time Effect Look at response of traditional PID for large sample time Cut reset time in half (double reset action) Make setpoint changes to show traditional PID response

to large sample time (e.g. twice process time constant) for self-regulating process with halved reset time

[File Name or Event]Emerson Confidential27-Jun-01, Slide 11 Slide 11

Self-Learning Web Lab Self-Learning Web Lab (Web Access Starts May, 2010)(Web Access Starts May, 2010)

Self-Learning Web Lab Self-Learning Web Lab (Web Access Starts May, 2010)(Web Access Starts May, 2010)

Checkout on March 10 – April 2 Entries on Integrated and Peak Errors on the websitehttp://www.modelingandcontrol.com/

[File Name or Event]Emerson Confidential27-Jun-01, Slide 12 Slide 12

Peak and Integrated Error Check ListPeak and Integrated Error Check ListPeak and Integrated Error Check ListPeak and Integrated Error Check List

[File Name or Event]Emerson Confidential27-Jun-01, Slide 13 Slide 13

Loop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time Effect Look at response of traditional PID for halved reset time

for large sample time Change to enhanced PID (PIDPLUS)

[File Name or Event]Emerson Confidential27-Jun-01, Slide 14 Slide 14

Control Studies of Reset Factor & Wireless PID for Control Studies of Reset Factor & Wireless PID for Real Time Real Time IntegratingIntegrating Process Process (20 sec analyzer sample time)(20 sec analyzer sample time)

Control Studies of Reset Factor & Wireless PID for Control Studies of Reset Factor & Wireless PID for Real Time Real Time IntegratingIntegrating Process Process (20 sec analyzer sample time)(20 sec analyzer sample time)

Reset Factor = 0.5

Standard PID Standard PID Standard PID

Reset Factor = 1.0 Reset Factor = 2.0

Enhanced PID Enhanced PID Enhanced PID

Reset Factor = 0.5 Reset Factor = 1.0 Reset Factor = 2.0

Improvement in stability is significant for any integrating process with analyzer delay

[File Name or Event]Emerson Confidential27-Jun-01, Slide 15 Slide 15

Control Studies of Lambda Factor & Wireless PID for Control Studies of Lambda Factor & Wireless PID for Real Time Real Time IntegratingIntegrating Process Process (20 sec analyzer sample time)(20 sec analyzer sample time)

Control Studies of Lambda Factor & Wireless PID for Control Studies of Lambda Factor & Wireless PID for Real Time Real Time IntegratingIntegrating Process Process (20 sec analyzer sample time)(20 sec analyzer sample time)

Gain Factor = 1/1.5

Standard PID Standard PID Standard PID

Gain Factor = 1/2.0 Gain Factor = 1/2.5

Enhanced PID Enhanced PID Enhanced PID

Gain Factor = 1/1.5 Gain Factor = 1/2.0 Gain Factor = 1/2.5

Improvement in stability is significant for any integrating process with analyzer delay

[File Name or Event]Emerson Confidential27-Jun-01, Slide 16 Slide 16

Loop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time EffectLoop Lab01 Demo of Sample Time Effect Look at response of enhanced PID to see if it decayed

the oscillations started by traditional PID Make setpoint changes to show enhanced PID response

to large sample time (e.g. twice process time constant) for self-regulating process with halved reset time

[File Name or Event]Emerson Confidential27-Jun-01, Slide 17 Slide 17

Control Studies of Reset Factor & Wireless PID for Control Studies of Reset Factor & Wireless PID for Real Time Real Time Self-RegulatingSelf-Regulating Process Process (40 sec analyzer sample time)(40 sec analyzer sample time)

Control Studies of Reset Factor & Wireless PID for Control Studies of Reset Factor & Wireless PID for Real Time Real Time Self-RegulatingSelf-Regulating Process Process (40 sec analyzer sample time)(40 sec analyzer sample time)

Standard PID Standard PID Standard PID

Reset Factor = 0.5 Reset Factor = 1.0 Reset Factor = 2.0

Enhanced PID Enhanced PID Enhanced PID

Reset Factor = 0.5 Reset Factor = 1.0 Reset Factor = 2.0

Improvement in stability and control is dramatic for any self-regulating process with analyzer delay

[File Name or Event]Emerson Confidential27-Jun-01, Slide 18 Slide 18

Control Studies of Lambda Factor & Wireless PID for Control Studies of Lambda Factor & Wireless PID for Real Time Real Time Self-Regulating Self-Regulating Process Process (40 sec analyzer sample time)(40 sec analyzer sample time) Control Studies of Lambda Factor & Wireless PID for Control Studies of Lambda Factor & Wireless PID for

Real Time Real Time Self-Regulating Self-Regulating Process Process (40 sec analyzer sample time)(40 sec analyzer sample time)

Standard PID Standard PID Standard PID

Gain Factor = 1/1.5 Gain Factor = 1/2.0 Gain Factor = 1/2.5

Enhanced PID Enhanced PID Enhanced PID

Gain Factor = 1/1.5 Gain Factor = 1/2.0 Gain Factor = 1/2.5

Improvement in stability and control is dramatic for any self-regulating process with analyzer delay

[File Name or Event]Emerson Confidential27-Jun-01, Slide 19 Slide 19

Loop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity Effect Look at setpoint response of enhanced PID with halved

reset time for large sample time Set measurement sample time to out of range (e.g.1000

sec) and set sensitivity to large value (e.g. 2%) Change to traditional PID and make setpoint change to

show traditional PID response to poor sensitivity

[File Name or Event]Emerson Confidential27-Jun-01, Slide 20 Slide 20

Top Ten Reasons I Use a Virtual PlantTop Ten Reasons I Use a Virtual PlantTop Ten Reasons I Use a Virtual PlantTop Ten Reasons I Use a Virtual Plant (10) You can’t freeze, restore, and replay an actual plant batch (9) No separate programs to learn, install, interface, and support (8) No waiting on lab analysis (7) No raw materials (6) No environmental waste (5) Virtual instead of actual problems (4) Batches are done in 14 minutes instead of 14 days (3) Plant can be operated on a tropical beach (2) Last time I checked our wallet I didn’t have $100,000K (1) Actual plant doesn’t fit in my suitcase

[File Name or Event]Emerson Confidential27-Jun-01, Slide 21 Slide 21

Dynamic Process Model

OnlineData Analytics

Model PredictiveControl

Loop MonitoringAnd Tuning

DCS batch and loopconfiguration, displays,

and historian

Virtual PlantLaptop or DesktopPersonal Computer

OrDCS Application

Station or Controller

Embedded Advanced Control Tools

EmbeddedPAT Tools

Process Knowledge

Virtual Plant SynergyVirtual Plant SynergyVirtual Plant SynergyVirtual Plant Synergy

[File Name or Event]Emerson Confidential27-Jun-01, Slide 22 Slide 22

ExploreDiscover

PrototypeDeploy

The consistent platform offered by the virtual plantcan insure maximum flow of knowledge gained ateach step in the commercialization process from bench top to pilot plant to industrial plant operation

Train

Virtual Plant ContinuityVirtual Plant ContinuityVirtual Plant ContinuityVirtual Plant Continuity

[File Name or Event]Emerson Confidential27-Jun-01, Slide 23 Slide 23

Loop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity Effect Look at response of traditional PID with halved reset time

for poor measurement sensitivity Change to enhanced PID (PIDPLUS) and make setpoint

change to show enhanced PID response for poor sensitivity

[File Name or Event]Emerson Confidential27-Jun-01, Slide 24 Slide 24

Demographic Time BombDemographic Time BombDemographic Time BombDemographic Time Bomb Average age of process industry worker is over 50 Half of the current work force will retire (more than

500,000 workers) in 5 to 10 years Irreplaceable knowledge loss

Newer generation of workers with less mechanical inclination and exposure

Scenario for control engineers and technicians may be even more severe due to suspension in hiring in 1980s Process plants in danger of closing due to lack

of qualified personnel Delayed retirement plans will be accelerated

as equity markets recover

[File Name or Event]Emerson Confidential27-Jun-01, Slide 25 Slide 25

Feed 1

Feed 2

Condenser

Cooling water Fcw

Reflux Drum

Lc, Vc_out

Reflux L_R

Distillate product L_D

CW Out

V_DA_VD1

A_Vlv1

Reboiler

A_v

L_B + V_B

V_B

Buttom product L_B

Heating steam

HE condensate

Side withdraw 2

Side withdraw 1

Heavy liquid L_HvLiq

Vnt

V_D1

DeltaV Simulate Product Family

Virtual Plant EssentialsVirtual Plant Essentials Virtual Plant EssentialsVirtual Plant Essentials

MiMiC Simulation Software

[File Name or Event]Emerson Confidential27-Jun-01, Slide 26 Slide 26

Dynamic, Accurate Simulations “High Fidelity” Advanced IEC Objects and Functions with Streams

Thermo / Flash / Stream Property Functions Advanced Modeling Core Objects

– Vessel, Valve, Pump, PRV, HX, DHX, Stream T– PF Solver

Energy Management Objects– Boiler with Furnace, Steam Header, Desuperheater, Fuel,

Turbine Distillation Objects– Column, Reboiler, Stripper Separator Objects

– 2-phase, 3-phase Separator, Physical Absorber

Process Model DevelopmentProcess Model Development

[File Name or Event]Emerson Confidential27-Jun-01, Slide 27 Slide 27

Graphics and Simulation ControlGraphics and Simulation Control Graphics and Simulation ControlGraphics and Simulation Control

[File Name or Event]Emerson Confidential27-Jun-01, Slide 28 Slide 28

Loop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity EffectLoop Lab01 Demo of Sensitivity Effect Look at response of enhanced PID with halved reset time

for poor measurement sensitivity to see if it stopped the limit cycle from the traditional PID

[File Name or Event]Emerson Confidential27-Jun-01, Slide 29 Slide 29

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

WouldYouRecommend.Us/105679s21/

[File Name or Event]Emerson Confidential27-Jun-01, Slide 30 Slide 30

Join Us April 21, Wed 1:00 CDTJoin Us April 21, Wed 1:00 CDTJoin Us April 21, Wed 1:00 CDTJoin Us April 21, Wed 1:00 CDT

PID Control of Valve Sticktion and PID Control of Valve Sticktion and BacklashBacklash

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

[File Name or Event]Emerson Confidential27-Jun-01, Slide 31 Slide 31

QUESTIONS? QUESTIONS? QUESTIONS? QUESTIONS?