Exceptional Process Control Opportunities

Exceptional Process Control
Opportunities - Smart and Wireless

Instrumentation, Valves, PID, and Tuning
Experitec Kansas City Technology Open House
Seminar – March 26, 2010
http://www.modelingandcontrol.com/
Slide 1
Welcome
 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 Confidential
27-Jun-01, Slide 2 Slide 2
Newest Book - The Latest on Smart and
Wireless Instrumentation
Royalties are donated to the

University of Texas Research
Campus for Energy and
Environmental Resources
for Development of Wireless
Instrumentation and Control

Top Ten Ways to Make Process 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

Fundamentals - Effect of Step Size on
Small Valve Response

Control Valve Deadband and Stick-Slip
Deadband is 5% - 50%
without a positioner !
Deadband
Pneumatic positioner
requires a negative % Stroke
signal to close valve (%) Digital positioner
will force valve
shut at 0% signal
Stick-Slip is worse near closed position
0 Signal
dead band (%)
Deadband (backlash) and stick-slip (sticktion) is greatest near the closed position

Installed Characteristic (Linear Trim)
100
90
80
70
60 Inherent Characteristic
Installed Characteristic 1
50 Installed Characteristic 2
30 Valve pressure drop ratio (∆ PR)

for installed characteristic:
20
Characteristic 1: ∆ PR = 0.5
10 Characteristic 2: ∆ PR = 0.25
0 10 20 30 40 50 60 70 80 90 100

Installed Characteristic (Equal Percentage Trim)
100
90
80
70
60 Inherent Characteristic
30 Valve pressure drop ratio (∆ PR)

for installed characteristic:
20
0 10 20 30 40 50 60 70 80 90 100

Limit Cycle in Flow Loop
from Valve Stick-Slip
Process Variable (kpph)

Square Wave Oscillation
Controller Output (%)

Saw Tooth Oscillation

Limit Cycle in Level Loop
from Valve Deadband
Level (%)
Controller Output (%)

Rounded Oscillation
Manipulated Flow (kpph)

Clipped Oscillation

Real Rangeability
Minimum fractional flow coefficient for a linear trim and stick-slip:
Sv
C x min =
X v max
Minimum fractional flow coefficient for an equal percentage trim and stick-slip:
Sv v
[ − 1]
C x min = R X v max
Minimum controllable fractional flow for installed characteristic and stick-slip:

C x min
Q x min =
2
∆PR + (1 − ∆PR ) ∗ C x min
1
Rv =
Q x min
Cxmin = minimum flow coefficient expressed as a fraction of maximum (dimensionless)
∆ Pr = valve pressure drop ratio (dimensionless)
Qxmin = minimum flow expressed as a fraction of the maximum (dimensionless)
Rv = rangeability of control valve (dimensionless)
R = range of the equal percentage characteristic (e.g. 50)
= maximum valve stroke (%)
Xvminor Event]
[File Name
Emerson = stick-slip near closed position (%)
SConfidential
27-Jun-01,v Slide 11 Slide 11
Best Practices to Improve Valve Performance
• Actuator, valve, and positioner package from a control valve
manufacturer
• Digital positioner tuned for valve package and application
• Diaphragm actuators where application permits (large valves and high
pressure drops may require piston actuators)
• Sliding stem (globe) valves where size and fluid permit (large flows and
slurries may require rotary valves)
• Next best is V-ball or contoured butterfly valve with rotary actuator and positioner
• Low packing, sealing, and seating friction
• Booster(s) on positioner output(s) for large valves on fast loops (e.g.,
compressor anti-surge control)
• Valve sizing for a throttle range that provides good linearity [4]:
o 5% to 75% (sliding stem globe),
o 10o to 60o (v-ball)
o 25o to 45o (conventional butterfly)
o 5o to 65o (contoured and toothed butterfly)
• Online diagnostics and step response tests for small changes in signal
• Dynamic reset limiting (FRSPID_OPTS) using digital positioner feedback
Volume Booster with Integral Bypass
(Furnace Pressure and Surge Control)
Signal from Adjustable Bypass
Positioner Needle Valve
Air Supply from Air Loading

Filter-Regulator to Actuator

Booster and Positioner Setup
(Furnace Pressure and Surge Control)
Open bypass just
enough to ensure
a non-oscillatory
fast response
Terminal Box
Bypass
Increase air line size
Port A Control Signal

1:1
Supply
Increase connection size
Port B Volume
Booster
Digital Valve Controller
ZZZZZZZ
Air Supply
High Capacity
Filter Regulator
Must be functionally tested

before commissioning!

Open Loop Backup Configuration
SP_Rate_DN and SP_RATE_UP used to insure fast getaway and slow approach
Open Loop Backup Configuration
Open loop backup used for prevention of

compressor surge and RCRA pH violation
PID Controller Disturbance Response

Open Loop Backup Disturbance Response
Open Loop Backup

Conductivity Kicker for Evaporator
Rise in conductivity
Flow cutback via kicker

pH Kicker for Waste Treatment
MPC-1
MPC-2
Waste
RCAS RCAS
middle selector
ROUT
AC-1 AC-2 AY kicker AY
splitter splitter AT AT AT
AY AY AY
middle selector middle selector filter
FT FT
AY AY Attenuation
Tank
Stage 1 AT AT AT Stage 2 AT AT AT
Mixer Mixer FT

Question: Which Measurement
 Removes the most common nonlinearity in a control loop?
 Compensates for pressure disturbances?
 Is used in most cascade control systems?
 Is used in most feedforward control systems?
 Is essential to close the material balance for a process?
 Makes the following advanced control tools more effective?
– Model Predictive Control (DeltaV PredictPro)
– Adaptive Control (DeltaV Insight)
– Neural Network Predictions (DeltaV Neural)
– Projections to Latent Structures Predictions (DeltaV Analytics)
– Dynamic Models (MIMIC Advanced Modeling)
Answer: Flow
http://www.isa.org/InTechTemplate.cfm?template=/ContentManagement/ContentDisplay.cfm&ContentID=81073

Ratio Control Examples
 Coolant/Feed flow ratio for crystallizer, cooler, extruder, or exothermic reactor
temperature control
 Steam/Feed flow ratio for distillation column, evaporator, heater, dryer, or endothermic
reactor temperature control
 Distillate/Feed or reflux/feed flow ratio for column temperature control
 Reagent/Feed flow ratio for pH control
 Reactant/Reactant flow ratio for continuous and fed-batch reactor control
 Catalyst/Reactant flow ratio for continuous and fed-batch reactor control
 Makeup/Recycle flow ratio for continuous and fed-batch reactor control
 Purge/Product flow ratio for continuous and perfusion process contaminant control
 Stock/Dilution flow ratio control for stock consistency control
 Additive/Feed flow ratio for blend control (e.g., percent solids)
 Air/Fuel flow ratio for boiler or furnace combustion control (oxygen control)
 Feedwater/Steam flow ratio for boiler drum level control (three element control)
 Blowdown/Feedwater flow ratio for boiler total dissolved solids (conductivity control)
 Supply/Demand flow ratio for header pressure control
 Vent/Demand flow ratio for compressor surge control
 Lime/Liquor flow ratio for slaker control
The best setpoint and process gain is the operating point and slope
on a plot of composition, pH and temperature versus a flow ratio
http://www.modelingandcontrol.com/2009/03/what_have_i_learned_-_ratio_co.html
Coriolis Flow Measurement Opportunities
 Live Process Flow Diagrams (PFD) for Plant Performance Analysis
– The first document you have on a project is typically a process flow diagram (PFD). The PFD defines
the process. It is the ultimate source of info and sets the plant performance and design.
– What if a plant had a live online PFD? What if we had temperature, pressure, mass flow, and
inferential measurements of the composition in every important process stream?
– What if a plant had online process metrics for yield, efficiency, and production from live PFDs
 Reactant, Catalyst, Recycle, Dilution, and Reagent Ratio Control
– True mass flow independent of temperature, density, composition, phases, viscosity, velocity, and
installation enables tight control of component concentrations for reaction and neutralization
 Crystallizer, Evaporator, and Column Product Composition Control
– Inferential measurement of concentrations or percent solids in feed and product streams enable
feedback and feedforward control of composition by manipulation of heat input or temperature
 Batch Charge Control
– Coriolis meters can potentially provide more accurate batch charges than weigh tanks because
Coriolis meters retain a better long term installed accuracy than load cells since Coriolis does not
suffer from drift or installation effects and doesn’t require periodic calibration checks
 Fermentation Alcohol Yield Optimization
– Measurement and totalization of carbon dioxide vent flow provides an inferential measurement of
conversion of sugars to alcohol that can be used to optimize batch cycle time or efficiency
 Centrifuge and Dryer Moisture Control
– Measurement of percent solids in feed enables feedforward control
http://www.modelingandcontrol.com/mt/mt-search.cgi?IncludeBlogs=1&search=Live+Process+Flow
Emerson Confidential http://www.modelingandcontrol.com/EssentialBookCoriolisExcerpt.pdf
Radar Level Measurement Opportunities
 Raw material and product storage tanks require the best level
measurement accuracy, when used in the calculations for:
– Inventory accounting and optimization
– Custody transfer
– Batch charge (rate of change of level)
– Continuous feed rates (rate of change of level)
– Material balances (process holdup)
 Column distillate receivers require the best level measurement resolution,
sensitivity, and repeatability for direct material balance control
– a small change in level must quickly translate to a change in reflux flow to balance a change
in vapor flow. This inherent self-regulation provides some internal reflux control and helps
decouple the energy balance from the material balance.
– When the temperature loop makes a change in the distillate flow, the change in controller
output has no effect on column temperature until the overhead receiver controller makes a
change in the reflux flow
 Crystallizers and reactors (batch and continuous) require the best level
measurement accuracy to control and maximize crystallization and reaction
– Continuous feed rate and batch cycle time set percent conversion for a given level
– Level sets production rate for a given residence time and batch cycle time
Measurement Filter (Transmitter Damping) Effect
τ
m
τ
m
τ τ
m
m
For compressor, incinerator pressure, and polymer pressure

control it is critical to make sure transmitter is fast enough!
[File Name or Event] http://www.modelingandcontrol.com/2007/04/analog_control_holdouts.html
Transmitter Damping and Signal Filtering Effect
Attenuation of Oscillation Amplitude by Transmitter Damping or Signal Filters:
To
A f = Ao *
2π ∗τ f
When a measurement or signal filter time (τ f) becomes the largest time

constant in the loop, the above equation can be solved for (Ao) to get the
amplitude of the original process variability from the filtered amplitude (Af)

Sample Time Table Typical Values
Type of Process Loop Process Process Practical Ultimate
Deadtime Time Constant Sample Time Sample Time
Liquid Flow 0.05 - 0.5 sec 0.5 - 5 sec 2 sec 0.1 sec
Gas Flow 0.1 - 0.5 sec 1 - 10 sec 1 sec 0.1 sec
Liquid Pressure* 0.05 - 0.5 sec 0.2 - 1 sec 0.1 sec 0.02 sec
Column Pressure! 1 - 10 sec 10 - 100 sec 10 sec 2 sec
Furnace Pressure* 0.1 - 0.5 sec 0.2 - 20 sec 0.1 sec 0.02 sec
Vessel Pressure! 0.2 - 1 sec 10 - 100 sec 10 sec 1 sec
Surge Control 0.05 - 0.5 sec 0.2 - 10 sec 0.1 sec 0.02 sec
Liquid Level! 0.05 - 0.5 sec 10 - 100000 min 300 sec 60 sec
Exchanger Temperature 0.2 - 2 min 0.5 - 5 min 10 sec 2 sec
Batch Temperature! 1 - 10 min 5 - 100000 min 150 sec 30 sec
Runaway Temperature!! 0.5 - 5 min 1 - 100 min 10 sec 5 sec
Column Temperature 2 - 100 min 10 - 1000 min 300 sec 60 sec
Furnace Temperature 0.2 - 2 min 0.5 - 5 min 10 sec 2 sec
Vessel Temperature 1 - 10 min 5 - 50 min 150 sec 30 sec
Column Composition 1 - 50 min 10 - 1000 min 300 sec 60 sec
Furnace Oxygen 0.2 - 1 min 0.2 - 1 min 10 sec 2 sec
Vessel Composition 0.5 - 5 min 5 - 50 min 150 sec 30 sec
Inline (Static Mixer) pH 2 - 10 sec 2 - 10 sec 2 sec 0.5 sec
Vessel pH 0.5 - 5 min 1 - 50 min 30 sec 5 sec
Practical
Emerson Confidential and Ultimate sample times are for conservative and aggressive tuning, respectively
Sample Time Guideline Notes
 The term “sample time” is used in the broadest sense as the time between updates in sampled data from
digital measurements and controllers and from analyzers The table should be useful for determining whether
DCS scan or module execution times, wireless communication time intervals, model predictive control
execution time, and at-line analyzer cycle time will affect control system performance.
 * - denotes loop uses a variable speed drive with a negligible dead time, deadband, and resolution limit as the
final element. If a control valve or damper is used for these loops, you can multiply the sample times for
asterisked items by a factor of 5.
 ! - denotes an integrating response whose integrating process gain is the inverse of the process time constant
shown
 !! - denotes a runaway response that can accelerate and reach a point of no return
 For surge control, it assumed that a volume booster has been added to the each of the positioner outputs to
reduce the pre-stroke dead time to less than 0.2 seconds. A valve with excessive sticktion and backlash will
add significant deadtime to the response to unmeasured disturbances that deteriorates the ultimate limit to
possible performance.
 For inline (static mixer) pH control, the largest time constant comes from the sensor lag or the process
variable filter time with a nominal value of 5 seconds.
 For the vessel pH control it is assumed the mixing time is less than 30 sec and the reagent delivery time delay
is negligible by injection of the reagent into a recirculation line just before it enters the vessel. The lower value
for the time constant is for a set point on a steep titration curve that cause the pH to move much faster than
for a linear response. The response can look like a runaway as the pH accelerates through the neutral region.
 For level control set point changes, the deadtime observed is usually about 10 times larger than the actual
process deadtime due to level measurement sensitivity limits and noise. For unmeasured disturbances the
deadtime observed is often about 20 times larger than the actual process deadtime because of the amount of
time it takes the controller output to work through the resolution limit and deadband of the control valve.
http://www.modelingandcontrol.com/2009/09/largest_opportunities_in_proce_1.html
Advances in Smart Measurements
 Technological advances in sensing element technology
 Integration of multiple measurements
 Compensation of application and installation effects
 Online device diagnostics
 Digital signals with embedded extensive user selected information
 Wireless communication
The out of the box accuracy of modern industrial instrumentation has improved by an order
of magnitude. Consider the most common measurement device, the differential pressure
transmitter (DP). The 0.25% accuracy of an analog electronic DP has improved to 0.025%
accuracy for a smart microprocessor based d/p. Furthermore, the analog DP accuracy often
deteriorated to 2% when it was moved from the nice bench top setting to service outdoors in
a nasty process with all its non-ideal effects of installation, process, and ambient effects [1]
[16].
A smart d/p with its integrated compensation for non-ideal effects will stay close to its inherent
0.025% accuracy. Additionally a smart DP takes 10 years to drift as much as the analog d/p
did in 1 year.

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
(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
(1) Readily tuned

WirelessHART Network Topology
 Wireless Field Devices
Plant Automation – Relatively simple - Obeys Network Manager
– All devices are full-function (e.g., must route)
Application Host
 Adapters
– Provide access to existing HART-enabled
Field Devices
Plant Automation – Fully Documented, well defined requirements
Network  Gateway and Access Points
NetworkManager
– Allows access to WirelessHART Network from
the Process Automation Network
– Gateways can offer multiple Access Points for
Gateway increased Bandwidth and Reliability
– Caches measurement and control values
Device
– Directly Supports WirelessHART Adapters
– Seamless access from existing HART
Applications
 Network Manager
Field Field– Manages communication bandwidth and
Device Device routing
Router – Redundant Network Managers supported
– Often embedded in Gateway
Device – Critical to performance of the network
 Handheld
Router – Supports direct communication to field device
Device – For security, one hop only communication
Field
Device
Wireless
27-Jun-01, Slide 30 HART Slide 30
WirelessHART Features
 Wireless transmitters provide nonintrusive replacement and diagnostics
 Wireless transmitters automatically communicate alerts based on smart diagnostics
without interrogation from an automated maintenance system
 Wireless transmitters eliminate the questions of wiring integrity and termination
 Wireless transmitters eliminate ground loops that are difficult to track down
 Network manager optimizes routing to maximize reliability and performance
 Network manager maximizes signal strength and battery life by minimizing the number
of hops and preferably using routers and main (line) powered devices
 Network manager minimizes interference by channel hopping and blacklisting
 The standard WirelessHART capability of exception reporting via a resolution setting
helps to increase battery life
 WirelessHART control solution, keeps control execution times fast but a new value is
communicated as scheduled only if the change in the measurement exceeds the
resolution or the elapsed time exceeds the refresh time
 PIDPLUS and new communication rules can reduce communications by 96%

Wireless Opportunities
 Wireless temperatures and differential pressures for packed absorber and
distillation column hot spot and flow distribution analysis and control
 Wireless temperatures and differential pressures for fluidized bed reactor hot
spot and flow distribution analysis and control
 Wireless pressures to debottleneck piping systems, monitor process filter
operation, and track down the direction and source of pressure disturbances
 Wireless temperatures and flows to debottleneck coolant systems
 Wireless instrumentation to increase the mobility, flexibility, and maintainability
of lab and pilot plant experiments.
 Wireless pH and conductivity measurements for
– Selecting the best sensor technology for a wide range of process conditions
– Eliminating measurement noise
– Predicting sensor demise
– Developing process temperature compensation
– Developing inferential measurements of process concentrations
– Finding the optimum sensor location

Top Ten Signs of a WirelessHART Addiction
(10) You try to use the network manager to schedule the activities of your children
(9) You attempt to use RF patterns to explain your last performance review
(8) You use so much resource allocation in your network manager, you eat before
you are hungry
(7) You propose your wireless device for the “Miss USA” contest
(6) You develop performance monitoring indices for your spouse
(5) You implement network management on your stock portfolio
(4) You carry pictures of your wireless device in your wallet
(3) You apply mesh redundancy and call three taxis to make sure you get home
from your party
(2) You recommend a survivor show where consultants are placed in a plant with
no staff or budget and are asked to add wireless to increase plant efficiency
(1) Your spouse has to lure you to bed by offering “expert options” for scheduling

Separations Research Program
University of Texas (UT) at Austin
 The Separations Research
Program was established at the
J.J. Pickle Research Campus in
1984
 This cooperative
industry/university program
performs fundamental research
of interest to chemical,
biotechnological, petroleum
refining, gas processing,
pharmaceutical, and food
companies.
 CO2 removal from stack gas is
a focus project for which
WirelessHART transmitters are
being installed

Wireless Lab pH and Conductivity
(Inferential Measurements of Solvent and CO22)

Life Depends Upon Process Conditions
Months
>100% increase in life

from new glass designs
for high temperatures
25 C 50 C 75 C 100 C
Process Temperature

New High Temperature Glass Stays Fast
Glass electrodes get slow as they age. High temperatures cause premature aging

Smart Wireless pH Configuration
pH / ORP Selection
Preamplifier Location
Type of Reference Used
Ranging
Temperature Comp Parameters

Solution pH Temperature Correction
Isopotential Point Changeable for Special pH Electrodes

Smart Wireless pH Dashboards

Column Steam Flow Control Performance
Wired versus Wireless
 The same
WiredMeasurement UsedinControl dynamic control
response was
observed for SP
changes
 Filtering of 10
sec was applied
to wired
measurement,
zero filtering for
WirelessHART
measurement.
 Original plant
PID tuning was
WirelessMeasurement UsedinControl
used for both
wired and
wireless control
GAIN =0.12
RESET = 20.3
RATE = 0

Column Pressure Control Performance
Wired versus Wireless
 The same
WiredMeasurement UsedinControl
dynamic
control
response was
observed for
SP changes
 Original plant
PID tuning was
used for both
wired and
wireless
control
GAIN=2.5
WirelessMeasurement UsedinControl
RESET=4
RATE=1
 Same filtering
of 2 sec was
applied to
wireless and
wired input

Column Steam and Pressure Control
Performance Wired versus Wireless
 Comparable control
performance as
measured by IAE was
achieved using
WirelessHART
Measurements and
DeltaV v11 PID option
vs control with wired
measurements and
PID.
 The number of
measurement samples
used in control with
WirelessHART and v11
PID option versus
Wired transmitter and
PID was reduced by a
factor of 10X for flow
control and 6X for
pressure control –
accounting for
differences in test
duration.
Installation at Broadley James
 Hyclone 100 liter

Single Use
Bioreactor (SUB)
 Rosemount
WirelessHART
gateway and
transmitters for
measurement
and control of
pH and
temperature.
(pressure
monitored)
 BioNet lab
optimized
control system
based on DeltaV

Elimination of Ground Noise Spikes by Wireless
Incredibly tight pH control via 0.001 pH wireless resolution

setting still reduced the number of communications by 60%
Temperature compensated wireless pH controlling at 6.9 pH set point
Wired pH ground noise spike

Traditional and Wireless PID (PIDPLUS)
 PID integral mode is
restructured to provide
integral action to match the
process response in the
elapsed time (reset time is
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
 PID algorithm with
enhanced reset and rate
action is termed PIDPLUS
http://www.modelingandcontrol.com/repository/WirelessPrimeTime.pdf
Wireless Temperature Loop Test Results

Wireless pH Loop Test Results

Control Studies of pH Resolution and Feedforward
(Bioreactor batch running 500x real time)
Feedforward Feedforward
Batch 1 Batch 2 Batch 1 Batch 2
Batches 1 and 2 have 0.00 pH resolution and standard PID

Emerson Confidential Batches 3 and 4 have 0.01 pH resolution and standard PID
Control Studies of pH Resolution and Feedforward
Batches 5 and 6 have 0.02 pH resolution and standard PID
[File Name or Event] Batches 7 and 8 have 0.04 pH resolution and standard PID
Control Studies of pH Refresh Time and Feedforward
Batches 9 and 10 have 30 sec x 500 refresh time and standard PID

Emerson Confidential Batches 11 and 12 have 30 sec x 500 refresh time and wireless PID
Control Studies of Glucose Sample Time and Feedforward
Glucose
Concentration
Batch 1 Batch 2 Batch 3 Batch 4 Batch 5 Batch 6

Continuous FF-No Continuous FF-Yes 11 hr Sample FF-No 11 hr Sample FF-Yes 11 hr Sample FF-No 11 hr Sample FF-Yes
Standard PID Standard PID Standard PID Standard PID Wireless PID Wireless PID
x1000
Batch 1: Glucose Probe (Continuous - No Delay) + Feed Forward - No + Standard PID

Batch 2: Glucose Probe (Continuous - No Delay) + Feed Forward - Yes + Standard PID
Batch 3: Glucose Analyzer (11 Hr Sample Delay) + Feed Forward - No + Standard PID
Batch 4: Glucose Analyzer (11 Hr Sample Delay) + Feed Forward - Yes + Standard PID
Batch 5: Glucose Analyzer (11 Hr Sample Delay) + Feed Forward - No + Wireless PID
Emerson Confidential Batch 6: Glucose Analyzer (11 Hr Sample Delay) + Feed Forward - Yes + Wireless PID
Control Studies of Reset Factor & Wireless PID for
Real Time Integrating Process (20
(20 sec
sec analyzer
analyzer sample
sample time)
time)
Standard PID Standard PID Standard PID
Reset Factor = 0.5 Reset Factor = 1.0 Reset Factor = 2.0
Wireless PID Wireless PID Wireless PID
Improvement
[File Name or Event] in stability is significant for any integrating process with analyzer delay
Control Studies of Lambda Factor & Wireless PID for
Real Time Integrating Process (20
(20 sec
sec analyzer
analyzer sample
sample time)
time)
Lambda Factor = 1.5 Lambda Factor = 2.0 Lambda Factor = 2.5
Improvement
[File Name or Event] in stability is significant for any integrating process with analyzer delay
Control Studies of Reset Factor & Wireless PID for
Real Time Self-Regulating Process (40
(40 sec
sec analyzer
analyzer sample
sample time)
time)
Improvement
[File Name or Event] in stability and control is dramatic for any self-regulating process with analyzer delay
Control Studies of Lambda Factor & Wireless PID for
Real Time Self-Regulating Process (40
(40 sec
sec analyzer
analyzer sample
sample time)
time)
Improvement
[File Name or Event] in stability and control is dramatic for any self-regulating process with analyzer delay
Conclusions from Wireless PID Control Tests
 Wireless PID and new communication rules can increase battery life
 Wireless pH eliminates spikes form ground noise
 Wireless PID provides tight control for set point changes
 Feedforward of ammonia formation rate and oxygen uptake rate (OUR) offers
significant improvement. OUR decouples interaction between pH and DO loops
 Wireless PIDPLUS dramatically improves the control and stability of any self-
regulating process with large measurement delay (sample delay). The wireless
PID is a technological breakthrough for the use at-line analyzers for control
– The Wireless PIDPLUS set point overshoot is negligible for self-regulating processes
with large sample delays if controller gain is less than the inverse of process gain
 Wireless PIDPLUS is stable for self-regulating process with large sample delay if
controller gain is less than twice the inverse of the process gain
– As the analyzer sample time decreases and approaches the module execution time, it is
expected that the wireless PID behaves more like a standard PID
 Wireless PIDPLUS significantly reduces the oscillations of integrating processes
but the improvement is not as dramatic as for self-regulating processes
 Integrating processes are much more sensitive than self-regulating processes to
increases in sample time, decreases in reset time, and increases in gain
 Detuned controllers (large Lambda Factors), makes loops less sensitive to sample
time (see Advanced Application Note 005 “Effect of Sample Time ….”)
 If the controller gain is increased or the wireless resolution setting
is made finer, the PIDPLUS can provide tighter control. For a loss of
communication, the PIDPLUS offers significantly better performance
than a wired traditional PID particularly when rate action and
actuator feedback (readback) is used
Self-Regulating Process Response
% Controlled Variable (CV) Response to change in controller output with controller in manual
or
% Controller Output (CO)
CV
Kp = ∆ CV / ∆ CO
Self-regulating process gain (%/%)
CO
0.63∗ ∆ CV ∆ CV
∆ CO
Time (seconds)
observed θ o
τ p
process self-regulating process
deadtime time constant
Most continuous processes have a self-regulating response (PV lines out in manual)
Lambda (closed loop time constant) is defined in terms of a Lambda factor (λ f):
λ = λ f ∗τ p Closed loop time constant
for setpoint change
Integrating Process Response
or
% Controller Output (CO) CV
Ki = { [ CV2 / ∆ t2 ] − [ CV1 / ∆ t1 ] } / ∆ CO
Integrating process gain (%/sec/%)
CO
∆ CO
ramp rate is ramp rate is

∆ CV1 / ∆ t1 ∆ CV2 / ∆ t2
Time (seconds)
observed θ o
process
deadtime
Most batch processes have an integrating response (PV ramps in manual)

Lambda (closed loop arrest time) is defined in terms of a Lambda factor (λ f):
λ = λ f / Ki Closed loop arrest time
for load disturbance
Runaway Process Response
or
% Controller Output (CO)
Kp = ∆ CV / ∆ CO
Runaway process gain (%/%) Acceleration
1.72∗∆ CV
∆ CV
∆ CO
Noise Band
Time (seconds)
observed θp τ p’
process runaway process
deadtime time constant
Exothermic reactors, strong acid-base pH systems, and compressor surge

can exhibit a runaway response (PV accelerates in manual)
Adaptive Control Tuning
for Integrating Process (Batch Temperature)

Adaptive Control Models

Adaptive Control Learning Setup

Adaptive Control
Gain 40 Reset 500
0.30 oC overshoot
Output comes off high limit at 36.8 oC

Adaptive Control
Gain 40 Reset 5000
0.12 oC overshoot
Output comes off high limit at 35.9 oC
Zero overshoot found to occur for Gain = 66 and Reset = 5000

Integrating and Runaway Process Tuning
 It is difficult to prevent overshoot in processes without self-regulation
 Controller gain adds self-regulation via closed loop response
 Examples of integrating processes (ramping response) are
– Liquid and solids level
– furnace, column, or vessel pressure
– batch composition, pH, or temperature
 Examples of runaway processes (accelerating response) are
– exothermic reactor temperature
– strong acid - strong base pH
– compressor speed during surge
 An overdrive of the controller output beyond its resting value is needed to reach a set
point or compensate for a disturbance (achieved by high controller gain)
 The maximum allowable controller gain for many integrating processes is well beyond
the comfort level of most users. Measurement noise and resolution often sets the
practical high limit to the controller gain rather than process dynamics
 Too much reset action (too small of a reset time) causes severe overshoot
 A higher controller gain creates more overdrive for small setpoint changes and gets
controller off it’s output limit sooner for large setpoint changes
 There is a window of allowable controller gains.
– Instability from too high of a controller gain (not likely for industrial processes)
– Slow rolling oscillations from too low of a controller gain (common case) that slowly decay
for integrating processes but can grow for runaway processes till it hits physical limits
Top 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 we checked our wallet we didn’t have $100,000K
(1) Actual plant doesn’t fit in our suitcase

Virtual Plant Synergy
DCS batch and loop
configuration, displays,
and historian
Embedded Embedded
PAT Tools Advanced Control Tools
Dynamic Loop Monitoring

Process Model Virtual Plant And Tuning
Laptop or Desktop
Personal Computer
Or
DCS Application
Station or Controller
Online Model Predictive
Data Analytics Control
Process Knowledge
Virtual Plant Continuity
Train
Deploy
Prototype
Discover
Explore
The consistent platform offered by the virtual plant

can insure maximum flow of knowledge gained at
each step in the commercialization process from
bench top to pilot plant to industrial plant operation

Demographic Time Bomb
 Average age of energy industry worker 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 more severe due to suspension in hiring in 1980s
etrochemical / energy plants in danger of closing

due to lack of qualified operators
elayed retirement plans will be accelerated as

DeltaV Virtual Plant / Control System
DeltaV Simulate Product Family
A_Vlv1
Condenser
CW Out Cooling water Fcw

Vnt
V_D1
A_VD1 Lc, Vc_out

V_D
Reflux Drum
Reflux L_R
MiMiC Simulation Software

Heavy liquid L _HvLiq
Feed 2
Distillate product L_D
Side withdraw 2
Feed 1
Side withdraw 1
V_B
Reboiler
A_v Heating steam
27-Jun-01, Slide 70
HE condensate
Slide 70
Components – DeltaV Simulate
 The DeltaV Simulate Experience

Complex Dynamic
Process Model Development Modeling
 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

Self-Learning Web Labs
(Starts April 7, 2010 12:00 CDT)

Self-Learning Web Labs
(Starts April 7, 2010 12:00 CDT)

Where To Get More Information
 MYNAH Website – www.mynah.com
– DeltaV Operator Training Systems with MiMiC
– DeltaV Software Acceptance Testing with MiMiC
– Pre-recorded E-Seminars
– Understanding Simulation Fidelity Paper and Podcast
– Simulation System Integrity Paper and Podcast
– Delivering the Virtual Plant Paper and Podcast
– Simulation Objections Answered Paper and Podcast
– Using Simulation to Optimize the Results of Automation
Projects, Dr. Tom Fiske, ARC
– MYNAH YouTube Series
 Martin Berutti, MYNAH Technologies
martin.berutti@mynah.com, +1.636.681.1567
Skype: mberutti

Exceptional Process Control Opportunities

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Exceptional Process Control

Opportunities - Smart and Wireless

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Royalties are donated to the

[File Name or Event]

[File Name or Event]

[File Name or Event]

Stick-Slip is worse near closed position

[File Name or Event]

30 Valve pressure drop ratio (∆ PR)

[File Name or Event]

30 Valve pressure drop ratio (∆ PR)

[File Name or Event]

Process Variable (kpph)

Controller Output (%)

[File Name or Event]

Controller Output (%)

Manipulated Flow (kpph)

[File Name or Event]

Minimum controllable fractional flow for installed characteristic and stick-slip:

Air Supply from Air Loading

[File Name or Event]

Port A Control Signal

Digital Valve Controller

Must be functionally tested

[File Name or Event]

Open Loop Backup Configuration

Open loop backup used for prevention of

[File Name or Event]

Open Loop Backup

[File Name or Event]

Flow cutback via kicker

[File Name or Event]

[File Name or Event]

[File Name or Event]

For compressor, incinerator pressure, and polymer pressure

Attenuation of Oscillation Amplitude by Transmitter Damping or Signal Filters:

When a measurement or signal filter time (τ f) becomes the largest time

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

[File Name or Event]

>100% increase in life

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Temperature Comp Parameters

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[File Name or Event]

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 Hyclone 100 liter

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Incredibly tight pH control via 0.001 pH wireless resolution

Temperature compensated wireless pH controlling at 6.9 pH set point

Wired pH ground noise spike

[File Name or Event]

[File Name or Event]

[File Name or Event]