pr15 - realizing profitability and efficiencies in your operations by leveraging model predictive...
TRANSCRIPT
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
PR15 - Realizing Profitability and Efficiencies in Your Operations by Leveraging Model Predictive Control (MPC)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
Where Can it be applied most profitably?
How Does Model Predictive Control Increase Efficiencies?
What is Model Predictive Control?
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 3
Regulatory
Supervisory/Advanced
Optimizer
Superheater/Dehydro Unit Styrene Distillation
DCS Controllers DCS Controllers
Sensors
(Inputs) Sensors
(Inputs)
Actuators
(Outputs)
Actuators
(Outputs)
20
CVs
20
MVs
12
MVs
23
CVs
Operator Operator Plant Manager
Plant
I just had the
splitter lined-out
Steam/EB Ratio EB Feed
Bed Temperatures
Increase
styrene
production
Process Engineer
Conventional Control Architecture
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 4
Superheater/Dehydro Unit Styrene Distillation
Sensors (Inputs)
Sensors (Inputs)
Actuators (Outputs)
Actuators (Outputs)
DCS Controllers DCS Controllers
Operator Operator
Steady-state Global Optimizer
North MPC
South MPC
D123 MPC
D567 MPC
Optimal
targets
Raw materials prices
Fuel price
Steam price
Production rate
Other constraints
Process
Engineer What’s wrong
with the
analyzer?
Something
wrong with
the level?
Plant
DCS
Performance
monitor
Optimizer
CV
SP CV
SP
MVs MVs MVs MVs CVs CVs CVs CVs
APC and Online Optimization Answer
Supervisory/Advanced
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
MPC versus PID Control
Coordinate multiple interacting PIDs
Predictably manage external disturbances
Handle long or complex process dynamics
Maximize performance up to process limits
PID tuning is subjective and requires time and experience
We do this because it makes
processors money:
Higher production, yields,
efficiency and product quality
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
now
CV
MV
MV
1 Horizon
CVSP
MVSP
0
How a Receding Horizon works
7
measured
calculated (predicted)
calculated and sent out as MV
CV
Constraints
CV MV Process
Controller
Model
CV prediction MV prediction
MPC
Setpoints
1
0
2
1
0
2
1
2
)(
)()(
)()(
Horizon
k
MoveSupp
Horizon
k
SPCoef
Horizon
k
SPCoef
kMVMV
kMVkMVMV
kCVkCVCVJ
The Task: Minimize Error by calculating MVn over the Horizon
0
1 Horizon 0
Horizon 0 1
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
MPC in Integrated Architecture
8
Production Center, FTHistorian, Pavilion® RTO …
Pavilion8® MPC, Software CEM®, VOA®, Asset Management, …
Rockwell Software Studio 5000®, PlantPAx™ MPCBuilder,
PlantPAx™ ModelBuilder
• PlantPAx® MPC
• IMC,CC,MMC
• FuzzyLogic
• SoftSensor® (AOI)
• PID,PIDE
• Motion
• Discrete
M P C
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Control Structure with MPC
Process
Soft Sensor® MPC
Lab
Pavilion8®
Server
Or Logix
PID PID PID PLC/DCS
Production Rate max
Higher Yields,
Lower energy
SP SP SP
Controlled Variables
Disturbance Variables
PV
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
MPC Opportunities
Coating Oven
Distillation Column
Compressor
Chemical Reactor
Boiler
Furnace
Dryer
Drilling Rig
….
10
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 11
MPC On MPC Off MPC On
100,000 Gal
Fermenter
Temperature
Control
Long or complex process dynamics
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 12
Two Exchanger Passes FC132 FC133
Isomax Product
Fractionator T-1302
FC211 FC212 FC213 FC214
Heater Passes
Heater Passes FC382 FC383 FC384 FC385 FC386 FC387
FC 382
055 TI
052 TI
FC 211
FEED FROM iSOMAX REACTORS
051
FC 132
TI
30
TI 060
17
STRIPPING
H-1304
251 PC
254 TC
STEAM
FC378 FC379 FC380 FC381
305 FI
067 TI
37
FUEL GAS
257T FC
31
25
270 TC 24
H-1303
21
TI 069
12
PV 230
054 TI
Debutanizer T-1301
5
1
226 FC
053 TI
PC 230
FC 225
TC 396
9
1
435 FI
FC 310
269 TC
313 PC
FUEL GAS
Diesel Stripper
T-1303 079
LC 276
FC280 FC281 319
H-1305
FC 280 Heater
Passes
290 TC TI
FC
TI 070
FC 272
Kerosene Stripper
T-1304
TI 081
FC 301
PC 260
FRACTIONATOR BOTTOMS
DIESEL TO STORAGE
KEROSENE TO STORAGE
FC 308
475
HEAVY STRAIGHT RUN TO TANK 217
FC
FC 336
292 FC
Naphtha Splitter T-1305 TI
25
085
083 TI
1
338 TI
FUEL GAS
PV 313B
TC 325
PV 313A
FC 323
HEAVY STRAIGHT RUN TO PLATFORMER
FC 332
LIGHT STRAIGHT RUN TO BLENDING
FI 351
TO FLARE
LIGHT ENDS RECOVERY
LIGHT ENDS RECOVERY
LIGHT ENDS RECOVERY
Isomax Unit
Fractionation
Direct Quality Control with Soft Sensors
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 13
Diesel 95% Boiling Point Soft Sensor
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 14
Light Naphtha RVP Soft Sensor
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Distillation Column MPC Stability
Reduce Product Variability by 85%
EB - Before EB - After
15
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Reactor MPC Temperature Stability
Reduce Temperature Variability by 84% - 94%
RXC - Before RXC - After
16
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 17
MPC for a Closed Circuit Cement Mill
Fineness (CV)
Fresh Feed (MV)
Reject Flow
(CCV)
Mill Level (CCV)
Water Injection (DV)
Damper
(MV) & (DV)
Motor Power (CCV)
Separator Speed (MV)
Elevator Power (CCV)
MV – Manipulated Variable
CV – Controlled Variable
CCV – Constraint Variable
DV – Disturbance Variable
Charge Wear Rate
(DV)
Feed Hardness
Grinding
Additives (DV)
Feed
Temperature
Mill Pressure
(CCV)
45um Residue (CV)
Product
Pump (CCV)
Mill Fan
(MV)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Reduce Energy, Increase Capacity
18
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
19
Dryer Line Optimization
MV – Manipulated Variable
CV – Controlled Variable
CCV – Constraint Variable
DV – Disturbance Variable
Evap Feed
TVR Steam (MV)
HPP Speed(MV)
Air Temp (MV)
Air Temp (MV)
Air Humidity (DV)
Moisture
Powder Rate (CV)
Exhaust Temp
Exhaust RH
(Sticky Point) (CCV)
Nozzle Pressure (CCV)
Damper Position (CCV)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
20
Dairy Spray Drying > 30 Installations
3.46 3.05 4.05
8.1
5.2
4.1
0
2
4
6
8
10
Rate Moisture Err x 100
D2 CV Means Typical Benefits
Improved capacity utilization
8% increase in throughput
16% increase in RH
40-60% reduction in moisture variability and
equivalent yield
Reduced variability
40-60% in outlet temp
40-50% in solids rate
30% in RH
50% in moisture
ROI Consistently greater than 60%