DeltaV Adaptive Control Lubrizol Alliance Meeting – Oct. 04 Technology Introduction And Beta...
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Transcript of DeltaV Adaptive Control Lubrizol Alliance Meeting – Oct. 04 Technology Introduction And Beta...
DeltaV Adaptive ControlDeltaV Adaptive ControlLubrizol Alliance Meeting – Oct. 04 Lubrizol Alliance Meeting – Oct. 04
Technology Introduction And Beta Testing Technology Introduction And Beta Testing Discussion For Deer ParkDiscussion For Deer Park
Terry Blevins and Dewey KuchleTerry Blevins and Dewey Kuchle
©2002 Fisher-Rosemount Systems, Inc. Slide 2
AgendaAgendaAgendaAgenda Introduction To Adaptive Control
Quick Demonstration
Beta Testing
– What Does This Mean For Lubrizol And Emerson
©2002 Fisher-Rosemount Systems, Inc. Slide 3
Control Loop Performance - A Never Ending CycleControl Loop Performance - A Never Ending CycleControl Loop Performance - A Never Ending CycleControl Loop Performance - A Never Ending Cycle
Process Testing(bump tests)
Calculate Tuning
Deploy NewController
OperateThe Loop
ControlDegradesOver Time
The more often you Tune, the better the
performance. Period.
The more often you Tune, the better the
performance. Period.
Evaluate PoorPerformance
©2002 Fisher-Rosemount Systems, Inc. Slide 4
There Must Be A Better WayThere Must Be A Better WayThere Must Be A Better WayThere Must Be A Better Way
Wouldn’t it be nice to have controllers use optimal
tuning all the time (continually) without having
to tune at all, ever?
©2002 Fisher-Rosemount Systems, Inc. Slide 5
Time
O1
O2
I1
I2
Gain = O2 - O1
I2 - I1
T1 T2
Time Constant ( ) = T3 - T2Input
Output
63.2% (O2 - O1)
T3
Dead Time = T2 - T1
Basics: Gain, Dead Time, Time ConstantBasics: Gain, Dead Time, Time ConstantBasics: Gain, Dead Time, Time ConstantBasics: Gain, Dead Time, Time Constant
©2002 Fisher-Rosemount Systems, Inc. Slide 6
Permitted Range
Adaptive Control – Continuous AdjustmentAdaptive Control – Continuous AdjustmentAdaptive Control – Continuous AdjustmentAdaptive Control – Continuous Adjustment
Controller Gain
Starting Point
Less Aggressive
More Aggressive
Continuous automatic adjustment of tuning parameters means better control. Easy.
Continuous automatic adjustment of tuning parameters means better control. Easy.
But don’t forget about the time constant and
the dead time.
But don’t forget about the time constant and
the dead time.
©2002 Fisher-Rosemount Systems, Inc. Slide 7
DeltaV AdaptDeltaV AdaptDeltaV AdaptDeltaV Adapt
- Fully Adaptive PID Control Tuning
- Learns Process Dynamics While In Automatic Control
- No Bump Testing Required
- Works On Feedback And Feedforward
- Patents Are Now Awarded!
No Tuning Required!
©2002 Fisher-Rosemount Systems, Inc. Slide 8
DeltaV Adapt – Field Trials At EastmanDeltaV Adapt – Field Trials At EastmanDeltaV Adapt – Field Trials At EastmanDeltaV Adapt – Field Trials At Eastman
As Operators Make Set Point Changes Adapt
Gets Smarter!
As Operators Make Set Point Changes Adapt
Gets Smarter!
©2002 Fisher-Rosemount Systems, Inc. Slide 9
Slow Response Causes Off- Spec
Better Tuning Dramatically Increases
Performance
Set Point Change Set Point Change
©2002 Fisher-Rosemount Systems, Inc. Slide 10
Not an overnight thing…Not an overnight thing…Not an overnight thing…Not an overnight thing… EMERSON technology developed in Austin.
Patents have now been awarded.
1997 - Dr. Wojsznis’ concept originated
1998 - Started research at Hawk Austin
2002 - Started product development
2003 - Prototypes at Texas Eastman in Longview Texas with good results. Results presented at ISA2003.
2004 – Pre-beta test at Solutia in Pensacola, Florida. Results are scheduled for publication in Sept issue of Chemical Process magazine – front cover, feature article.
2005 - Initial release planned for DeltaV v8.1
©2002 Fisher-Rosemount Systems, Inc. Slide 11
Patents Have Now Been Awarded!Patents Have Now Been Awarded!Patents Have Now Been Awarded!Patents Have Now Been Awarded!
Mr. Terry Blevins
Mr. Terry Blevins
Dr. Wilhelm Woszjnis
Dr. Wilhelm Woszjnis
©2002 Fisher-Rosemount Systems, Inc. Slide 12
Operating Condition ImpactOperating Condition ImpactOperating Condition ImpactOperating Condition Impact Process gain and dynamics may change as a function of operating
condition as indicated by PV, OUT or other measured parameters e.g. plant throughput
©2002 Fisher-Rosemount Systems, Inc. Slide 13
Defining Operating RegionsDefining Operating RegionsDefining Operating RegionsDefining Operating Regions Adaptive control allows operating
regions to be defined as a function of an input “state” parameter
Define up to 5 regions
When the state parameter changes from one region to another, the model values (and associated tuning) immediately change to the last model determined for the new region
Limits on model parameter adjustment are defined independently for each region.
Model Parameters
State Parameter Value
Model Parameters
State Parameter Value
Region 1
Region 2
Region 3
Region 4
Region 5
Region 1
Region 2
©2002 Fisher-Rosemount Systems, Inc. Slide 14
Example – Non-Linear Installed Example – Non-Linear Installed CharacteristicsCharacteristicsExample – Non-Linear Installed Example – Non-Linear Installed CharacteristicsCharacteristics
Process gain will change as a function of valve position if the final control element has non-linear installed characteristics.
Valve position is used as the state parameter.
Flow vs Stem Position
0102030405060708090100
Stem position %
Flow
FC 3-5
FT 3-5
Bottoms
FC 3-5FC 3-5
FT 3-5
Bottoms
©2002 Fisher-Rosemount Systems, Inc. Slide 15
Example – Example – Multiple Valves - Split Range Multiple Valves - Split Range Example – Example – Multiple Valves - Split Range Multiple Valves - Split Range
The process gain and dynamic response to a change valve position may be different for each valve.
Typical example is heating/cooling of batch reactor, extruder, slaker, etc.
Valve position is used as the state parameter.
0 50 100 Controller Output (%)
Cooling Valve
Heating Valve
100
0
FC 1 - 2 TC 1 - 2
TT 1 - 2
Heater Cooler
FY 1 - 2
©2002 Fisher-Rosemount Systems, Inc. Slide 16
DeltaV Adaptive Control – Field TrialsDeltaV Adaptive Control – Field TrialsDeltaV Adaptive Control – Field TrialsDeltaV Adaptive Control – Field Trials Control automatically adapts based on SP
changes in Auto – Caustic loop
©2002 Fisher-Rosemount Systems, Inc. Slide 17
The End ResultThe End ResultThe End ResultThe End Result This capability will allow DeltaV users to assign “ballpark”
tuning parameters and let adaptive PID controllers tighten them up and adapt over time.
Patented model switching technology means robust control over the long haul without sacrificing performance
Faster startups, quicker ramp-up of production, less tuning over time, and better control over the life of the system all mean better economics.
©2002 Fisher-Rosemount Systems, Inc. Slide 18
But What About Previous Attempts?But What About Previous Attempts?But What About Previous Attempts?But What About Previous Attempts? Most Every Other Attempt To Build Adaptive
Controllers Have Been Based On One Of Two Approaches;
– Heuristics or “Rules Based” Adaptation
– Pattern Recognition
Both Methods Have Met With “Limited” Success
Both Methods Have Met With “Limited” Success
©2002 Fisher-Rosemount Systems, Inc. Slide 19
So What Makes This Different?So What Makes This Different?So What Makes This Different?So What Makes This Different? Truly Model Based Tuning
Built On Advanced Closed Loop Modeling
Tuning Based On Science And Fact With No Shortcuts
Gain
Time Constant
Dead time
Initial Model Gain = G1
G2-Δ G2 G2+Δ G3-Δ G3 G3+Δ
Multiple iterations
per adaptation
cycle
G1+ Δ G1+ Δ G1+ Δ TC1 -Δ TC1–Δ TC1 -Δ DT1- Δ DT1 DT1+ Δ
G1+ Δ G1+ Δ G1+ Δ TC1 +Δ TC1+Δ TC1 +Δ DT1- Δ DT1 DT1+ Δ
G1+ Δ G1+ Δ G1+ Δ TC1 TC1 TC1 DT1- Δ DT1 DT1+ Δ
G1 G1 G1 TC1 -Δ TC1–Δ TC1 -Δ DT1- Δ DT1 DT1+ Δ
G1 G1 G1 TC1 +Δ TC1+Δ TC1 +Δ DT1- Δ DT1 DT1+ Δ
G1 G1 G1 TC1 TC1 TC1 DT1- Δ DT1 DT1+ Δ
G1-Δ G1- Δ G1- Δ TC1 -Δ TC1–Δ TC1 -Δ DT1- Δ DT1 DT1+ Δ
G1-Δ G1- Δ G1- Δ TC1 +Δ TC1+Δ TC1 +Δ DT1- Δ DT1 DT1+ Δ
G1-Δ G1- Δ G1- Δ TC1 TC1 TC1 DT1- Δ DT1 DT1+ Δ
©2002 Fisher-Rosemount Systems, Inc. Slide 20
What Does That Mean?What Does That Mean?What Does That Mean?What Does That Mean? In The 90’s The MIT Blackjack
Team Invaded Las Vegas And Broke The House, Taking Casinos For Millions
They Did It Counting Cards Which Is Really A Form Of Modeling
©2002 Fisher-Rosemount Systems, Inc. Slide 21
Delivering ResultsDelivering ResultsDelivering ResultsDelivering Results
From This…From This…To This…To This…
©2002 Fisher-Rosemount Systems, Inc. Slide 22
Delivering ResultsDelivering ResultsDelivering ResultsDelivering Results
… With NO Hands!
… With NO Hands!
DeltaV AdaptDeltaV AdaptDemonstrationDemonstration