Ebccsp16AutomaticControl FutureChallengesSolutionsandSystems Rev
Ebccsp16AutomaticControl FutureChallengesSolutionsandSystems Rev
Site
ISA-88
Procedural Model
ISA-95 Area
Procedure
Process Unit
Cell Procedure
Unit Operation
Phase
ISA-88 Equipment Function Blocks
Module
Control
Module
Function Block Support for Batch Automation
• Measurement status and
control mode as defined
by IEC61804 are key
elements to procedure
automation.
• Support of function block
mode provides a consist
interface to sequential
logic control implemented
in sequential function
charts.
• Input-output status
provides an indication of
measurement and
actuator health and thus
may be utilized in logic to
take appropriate action on
detection of bad
measurement or actuator
malfunction.
Information Flow – Batch Automation
Wireless
Controller Safety System Gateway
Wired Field
Devices
Evaluating
processes in
real time
Impact evaluation/Quality Prediction
Process measurements
Application of Batch Analytics
• Analytic models may be defined
based on the batch stage. The inputs
and outputs used in analysis may be
different for each stage.
• Principal component analysis enables
on-line detection of process faults.
– Unmeasured/unmodeled
disturbances – The Q statistic, also
known as the Squared Prediction
Error (SPE), may be used.
– Measured/modeled disturbances –
may be quantified through the
application of Hotelling’s T2
statistic.
Quality parameter prediction are
Stage is defined in ISA88 as: “A part of a process
that usually operates independently from other
achieved by using PLS – Projections
process stages and that usually results in a planned to Latent Structures to establish
sequence of chemical or physical changes in the relationships between input and
material being processed” product quality.
Example of Fault Detection – pH Sensor Drift
• Coating of the
sensor may
VSD introduce a bias into
PC
Media 41-3 the pH
AT
41-15 PT
41-3 Vent
measurement -
resulting in a shift of
VSD
Inoculums o
VSD the pH maintained in
37 C
TC
41-7
TT
41-7
VSD Glutamine the reactor.
• May impact cell
VSD VSD
Glucose
Bicarbonate
growth rate and
product formation
7.0 pH
Splitter AT AC
AY AC AT 41-4s1 41-4s1
41-1 41-1 41-1
Glucose
2.0 g/L
pH
0.002 g/L AT AC
41-4s2 41-4s2
AC AT Glutamine
41-2 41-2 2.0 g/L
AT
DO Bioreactor 41-6
Product
Concentration
MFC LT
CO2 41-14
AY Level
41-2 VSD
Splitter MFC
Air
Drain
MFC
O2
Example of Fault Detection – pH Sensor Drift
• Fault shows up as
an explained and
unexplained
change – deviation
above 1.
• To find the cause
of the fault, select
the point of
maximum deviation
and then choose
the Contribution
Tab.
Control
Device Control
Implementation
Requirements
Modules
PV
304 Vent
System
PT
304 FC
FV
301
Unit TT
FT
306
301
FC
Equipment Feed A TV
TT
306
305
FV
Device FC Coolant
302
FT Continuous
302 LT
FC Reactor 307
Feed B LV
AT 307
303
FC Discharge
Implementation - Module Content
• Implementation modules consist of a set of
Notifications ordered tasks*. Each task provides
Commands operations with step-by-step instructions for
accomplishing the actions that are to be
performed and their verification.
Task • Each Procedure implementation module
and task has three execution work items;
Peer to
1. Command – Trigger (Event)
Task Peer 2. Perform – Actions
Human
3. Verify – Success/failure.
Task Interface
Commands • Implementation methods are any type of
and tools used to create a task e.g.
Notifications programming, continuous control, human
Task actions.
• Some types of programming that may be
used include: configurable function blocks,
sequential function charts (SFC),
Commands Notifications continuous control functions, computer
program, executable flowcharts.
• Operator displays show alerts, prompts and
status notifications on separate displays for
compliance with ANSI/ISA 18.2.
*ISA-TR106.00.01-2013 Procedure Automation for Continuous Process Operations
Automation Styles
• Procedures may be automated to provide more consistent and efficient
operation. Simpler automation required that the operator perform
more procedure and monitor the process to a greater level of detail.
• ISA106 defines three automation styles* :
– Manual – The operator is responsible for the command, perform, and verify work
items.
– Computer Assisted – The operator and control system share responsibility for the
command, perform and verify work items e.g. The computer prompts the operator
who is then responsible for the perform and verify work item
– Fully Automated – The compute is responsible for the bulk of the command,
perform, and verify work items.
1.0
0.9 orifice plate may not be reliable
0.8
0.7
which prevents the use of
0.6 automatic flow control.
0.5
0.4 • Additional operators are needed for
0.3
0.2 startup and shutdown to monitor
0.1
0
and regulate the process at low
0 1 2 3 4 5 6 7 8 9 10 flow rates where automatic control
Flow Rate (l/min)
is not usable.
Addressing Startup – Use of Flow Measurement
• In some cases automatic control may be designed to continue even
when a flow measurement used during normal operations is not usable
at the low flow rates encountered during process startup.
• Example: Boiler Drum Level
LC Feedforward
402
LC
402
FC
402 FT Steam
LT 403 Steam FV LT
FV 402
402 402
402
FT
402 Boiler Drum Boiler Drum
FC FC
Boiler Boiler
PID Function Block - Bypass
• Bypass is a standard
feature of the PID
block in Foundation
Fieldbus devices and
in some control
systems.
• When bypass is
enabled then the
setpoint value is
passed direction to
the valve –
automatically taking
into account scaling,
control action
(direct/reverse) , and
valve setup (increase
open/close)
Challenge – Procedure Automation
• The installed characteristics of a
regulation valve may be non-linear.
Thus, tuning that was established at
normal operating conditions may be
significantly different that required for
automatic control at low flow rates.
• Control may be unstable at low flow
rates because of the change in
process gain introduced by the non-
linear installed characteristic. Thus, it
is quite common for a significant
number of control loops to be placed in
Manual during startup.
• After normal throughput is established
then control loops may be placed back
in Automatic.
Example – Impact of Non-linear Installed
Characteristics on Automatic Control
Accounting for Process Non-linearity
• The PID may be designed to automatically compensate for changing
process gain and dynamics. The process model may be
automatically identified when the control is running in automatic or
manual.
Identifying Process Model
It is possible to implement
techniques in a controller to
automatically establish a
model for the controller
process based on:
• Normal setpoint changes
made by the operator
when the PID is in an
automatic
• PID output changes when
the PID is in a manual
mode.
Model switching with re-
centering and interpolation
is an effective means tha is
used in industry for process
model identification.
Process Models May be Automatically Collected at
Different Operating States
Tuning May be Automatically Set Based on
Operating State
Challenge – Procedure Automation
• Procedural Automation of
Example: MPC control of a dividing wall distillation column–
process transitions is addressed
paper to be presented in the conference-see ”Model Predictive
in ISA106. However, because
Control With Event Driven Operation, Willy Wojsznis, et al
of process interaction and
dynamics smooth transitions
during throughput or grade
changes may not be possible
using single loop control.
• Model predictive control can
play a key role in automating
production transitions
• “By empowering operators with
the right human-automation
relationship tools, companies
will achieve and exceed their
goals”, Preclude operator error,
improve safety and profitability,
Eddie Habibi, InTech
Magazine/2013
Application of Process Data Analytics – Continuous Process
• The operator of a
continuous process faces
many of the same
challenges faced in batch
operation:
• A measurement of final
product quality may only
be available from the lab.
• There is no direct
indication whether
changes made during
product transition will
achieve the desired
results.
• Through the application of
data analytics the operator
can be provided a
continuous indication of
product quality and alerted
to changes in process
conditions that impact
product quality
The Nature of Continuous Data
The normal operating point of process measurement may change
with process throughput. The parameter(s) that drive change in the
process are known as state parameters (e.g. production rate). In
this example, the state parameter is the fuel demand.
The Nature of Continuous Data
Product grade can also be the state parameter in some cases. A
change in the product grade being made is a change in the state
parameter.
Example: Analytics Field Trial at Lubrizol, Deer Park, TX
Quality Parameter Prediction – Continuous Process
Analytics
Reference:
• Q. Li, E Hernandez, R. Wojewodka, T. Blevins, Application of On-line Data Analytics to a
Continuous Process Polybutene Unit, Emerson Exchange, 2013.
• T. Blevins, W. Wojsznis, M. Nixon, Advanced Control Foundation – Tools, Techniques and
Application, ISA, 2012
Technology Changes Since mid-1990’s
Dynamic Memory
35
30
25
20
15 Cost of 1 Mbyte($)
10
0
1995 1997 1999 2001 2003 2005 2007 2009 2011
End User Benefits of New Technology
Future control system should take advantage of changes in technology
History collection –new measure values, control actions, changes in batch data,
and alarms and events are automatically cached in the controller and efficiently
transferred to a server without the need for compression, configuration, or sub-
sampling. High fidelity, real time data will always be available without compromise.
Batch Control – All recipes will be maintained local within the controller eliminate
the burst loading and delays in communication of recipe from a server to the
controller
Advanced Control Applications – No need to configure a historian data to be able
to utilize these tools. The concept of “data always available” will become a reality.
Achieving Changes – Fast queries of data in the server may be used to determine
when changes were made during startup, shutdown and during transitions in
production.
Global Data Access –Control system stations and wireless hand held devices may
utilize applications that have access to all process data to better support
procedure automation of startup, shutdown and transition procedures. Data will
be structured in the server to support quick and easy transferred to the Cloud.
Summary
• Standards have played an important role in the automation of batch
processes.
• The evolving ISA106 standard will help plants address automation of
procedures for process startup, shutdown, and transitions. State-based
control is an effective method for structuring procedure. Wireless
instrumentation can in some cases be used to facilitate automation but
manual steps will still be required in many applications. Wireless
interface devices may be used to better integrate manual steps into
procedures. MPC may be applied to more effectively address
transitions.
• Process analytics can be applied to improve batch and continuous
processing. The challenge for suppliers is to simplify the
implementation and maintenance of analytics applications.
• Advances and reduction in cost of communications, controller memory,
and disk storage can be used by manufacturers to create a new
generation of control systems that support the concept of “data always
available”.
Where To Get More Information
• Y. Nazer, E. Cosman, Process Automation at Dow Unit Based Control (UBC), ARC Forum,
Orlando, Florida, 2010, http://www.arcweb.com/events/arc-industry-forum-
orlando/orlandoforum2010presentations/Unit%20Based%20Control.pdf
• B. Scholten, Integrating ISA-88 and ISA-95, ISA EXPO 2007, 2-4 October 2007, Reliant
Center, Houston, Texas, https://www.isa.org
Questions
Thank You for Attending!