In Advanced Control Foundation: Tools, Techniques, and Applications, the authors address key concepts and terminology needed to apply advanced control techniques in the process industry. This book targets process or control engineers who are familiar with traditional control but have limited or no experience in designing, installing, commissioning and maintaining advanced control systems. Each chapter aims to help readers quickly understand the technology and its applications. Examples illustrate what's needed for specific use cases, and a dedicated section in each chapter offers a more detailed discussion for those interested in the mathematical basis behind the technology. A workshop is included at the end of each chapter to deepen the reader's understanding of the technology. The workshop solutions are available at the website URL provided in the book.
This book provides comprehensive coverage of the key advanced control techniques most commonly used in the process industry. It includes tools for monitoring control system performance, on-demand and adaptive tuning methods, model predictive control, linear programming (LP) optimization, data analytics for batch and continuous processes, fuzzy logic control, neural networks and advancements in proportional–integral–derivative (PID) control for use with wireless measurements.
Because many readers may work with existing distributed control systems (DCSs) that do not support advanced control, a chapter of this book is dedicated to tools and techniques that the authors have found useful in integrating advanced control tools into an existing control system. Additionally, one chapter of the book discusses how dynamic process simulations can be easily created in a DCS to support checkout and operator training in the use of advanced control.
Table of Contents:
Acknowledgments vii
About the Authors xvii
Foreword xxi
Chapter 1 INTRODUCTION 1
Chapter 2 MAXIMIZING RETURN ON CONTROL SYSTEM INVESTMENT 7
2.1 Economic Incentive, 9
2.2 Reducing Process Variation – Achieving Control Objectives, 19
2.3 Advanced Control, 29
2.4 Balancing Complexity with Benefits, 32
Chapter 3 EVALUATING CONTROL SYSTEM PERFORMANCE 35
3.1 Evaluating Control Performance, 38
3.2 Improving Control Utilization, 42
3.3 Addressing Process Variability, 52
3.4 Application Example, 58
3.5 Workshop Exercises – Introduction, 62
3.6 Evaluating Control System Performance Workshop, 64
3.7 Technical Basis, 65
Chapter 4 ON-DEMAND TUNING 77
4.1 Process Identification, 77
4.2 On-Demand Tuning Workshop, 89
4.3 Technical Basis, 90
Chapter 5 ADAPTIVE TUNING 113
5.1 Adaptive Control – Examples, 114
5.2 Application Example, 119
5.3 Adaptive Tuning Workshop, 125
5.4 Technical Basis, 126
Chapter 6 FUZZY LOGIC CONTROL 145
6.1 Application Example, 150
6.2 Fuzzy Logic Control Workshop, 152
6.3 Technical Basis, 153
Chapter 7 NEURAL NETWORKS FOR PROPERTY ESTIMATION 171
7.1 Example – Pulp and Paper Industry, 173
7.2 Property Estimator Application Example, 176
7.3 Neural Networks for Property Estimation Workshop, 182
7.4 Technical Basis, 183
Chapter 8 INTELLIGENT PID 195
8.1 Recovery from Process Saturation, 197
8.2 Control Using Wireless Transmitter, 199
8.3 Application Examples, 206
8.4 Intelligent PID Workshop, 215
8.5 Technical Basis, 217
Chapter 9 CONTINUOUS DATA ANALYTICS 223
9.1 Application Example, 237
9.2 Viewing Data Analytics On-line, 245
9.3 Continuous Data Analytics Workshop, 247
9.4 Technical Basis, 248
Chapter 10 BATCH DATA ANALYTICS 261
10.1 Batch Production Challenges, 262
10.2 Data Analytics Application Example – Modeling and On-line Operation, 275
10.3 Batch Data Analytics Workshop, 285
10.4 Technical Basis, 286
Chapter 11 SIMPLE MPC 307
11.1 MPC as a Replacement for PID, 309
11.2 Commissioning MPC, 310
11.3 MPC Replacement for PID with Feedforward, 316
11.4 MPC Replacement for PID Override, 317
11.5 Using MPC to Address Process Interactions, 318
11.6 Application Examples, 320
11.7 MPC Application Development Procedure, 333
11.8 Simple MPC Workshop, 340
11.9 Technical Basis, 340
Chapter 12 MPC INTEGRATED WITH OPTIMIZATION 363
12.1 Application Example – Multiple Effect Evaporator, 365
12.2 Application Example – CTMP Refiner, 376
12.3 Application Example – Heavy Oil Fractionator, 385
12.4 MPC Integrated with Optimization Workshop, 408
12.5 Technical Basis, 408
Chapter 13 ON-LINE OPTIMIZATION 437
13.1 Why Optimization – A Look at Boiler Load Allocation, 438
13.2 Energy Optimization in a Pulp and Paper Mill, 446
13.3 On-line Optimization Workshop, 465
13.4 Technical Basis, 466
Chapter 14 PROCESS SIMULATION 471
14.1 Process Simulation Techniques, 471
14.2 Developing a Process Simulation from the P&ID, 473
14.3 Simulating Process Non-linearity, 480
14.4 Other Considerations, 483
14.5 Process Simulation Workshop, 486
14.6 Theory – Simulation Based on Step Response, 488
Chapter 15 INTEGRATING ADVANCED CONTROL INTO A DCS 495
15.1 Integrating with Plant Systems, 501
15.2 Network and System Setup, 505
15.3 Application Example, 507
Bibliography, 509
Appendix A 511
Glossary of Terms 517
Index 527
About the Author :
Terrence L. "Terry" Blevins has been actively involved in the application and design of process control systems throughout his career. For more than 15 years, he worked as a systems engineer and group manager in the design and startup of advanced control solutions for the pulp and paper industry. Terry was instrumental in the establishment of Emerson Process Management's Advanced Control Program. From 1998-2005 Terry was the team lead for the development of DeltaV advanced control products. He is the Fieldbus Foundation team lead for the development and maintenance of the Function Block Specification and editor of the SIS Architecture and Model Specifications. In this capacity, Terry is involved in the adoption of Fieldbus Foundation function block work by international standards. Terry is the US expert to the IEC SC65E WG7 function block committee that is responsible for the IEC 61804 function block standards. He is a voting member and chairman of ISA SP104-EDDL (Electronic Device Description Language) committee and is the technical advisor to the United States Technical Advisory Group (USTAG) for the IEC65E subcommittee. He is also a member of the USNC TAG (IEC/SC65 and IEC/TC65). Terry authored "An Overview of the ISA/IEC Fieldbus," Section 11, Standards Overview, Fifth Edition of the Process/Industrial Instruments and Controls Handbook and coauthored four sections in the Fourth Edition of the Instrumentation Engineer's Handbook, Process Control and Optimization. He coauthored the ISA bestselling books Advanced Control Unleashed and Control Loop Foundation. He has over 45 patents and has written over 70 papers on process control system design and applications. Terry received a Bachelor of Science in Electrical Engineering from the University of Louisville in 1971 and a Master of Science in Electrical Engineering from Purdue University in 1973. In 2004, he was inducted into Control Magazine's Process Automation Hall of Fame.
Presently, Terry is a principal technologist in the future architecture team of DeltaV Product Engineering at Emerson Process Management.
Willy Wojsznis has been involved in the development of advanced control products over the last twenty years focusing on model predictive control, data analytics, and auto tuning. Over the previous nearly 25-years of his career he developed computer control systems and applications in the cement, steel, mining, and paper industries. His professional work resulted in a number of successful and innovative advanced control products, over thirty patents, and over forty technical papers. He received a control engineering degree (EE) from Kiev Technical University in 1964, an M.S. in Applied Mathematics from Wroclaw University in 1972, and a Ph.D. from Warsaw University of Technology in 1973. He coauthored the ISA bestselling book Advanced Control Unleashed. In 2010, he was inducted into Control Magazine's Process Automation Hall of Fame. Presently, Willy is part of the DeltaV future architecture team. He conducts applied research in the areas of optimization, adaptive control, data analytics, and model predictive control.
Mark Nixon has been involved in the design and development of control systems throughout his career. Mark started his career as a systems engineer working on projects in oil and gas, refining, chemicals, and pulp and paper. In 1998, he moved from Canada to Austin, TX, where he has held a variety of positions in both research and development. From 1995 to 2005 Mark was lead architect for DeltaV. In 2006 he joined the wireless team, taking a very active role in the development of the WirelessHART specifications and the development of the IEC 62591 standardization. Mark's current research includes control using WirelessHART devices, data analytics for batch processes, wireless technology in the process industry, web based user interfaces, operator interfaces, and advanced graphics. He is currently active in the Center for Operator Performance (http://www.operatorperformance.org), WirelessHART, ISA88, Foundation Fieldbus standards (http://www.fieldbus.org/), and ISA101. He has written numerous papers and currently holds over 70 patents. He coauthored WirelessHART: Real-Time Mesh Network for Industrial Automation and has made contributions to the Industrial Instruments and Controls Handbook and Modern Measurement and Final Element Essentials for the Process Industry. He coauthored the ISA bestselling book Control Loop Foundation. In 2012, he was inducted into Control Magazine's Process Automation Hall of Fame. Mark received his Bachelor of Science in Electrical Engineering from the University of Waterloo in 1982.
