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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys.

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Presentation on theme: "© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys."— Presentation transcript:

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2 © 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. SSE-09 Advanced Process Control with Connoisseur Presented by: Tom Kinney Sl id e 2

3 Slide 3 What is Connoisseur TM ? Connoisseur TM Optimizer Expert System Model Predictive Constraint Controller Neural Network

4 Slide 4 Connoisseur Toolset Adaptive CP M Inferential Neural Net Fuzzy Logic Calculations Non-linear

5 Slide 5 Multi-Variable Control and Neural Net Optimization Overlays DCS Connoisseur Environment Bias, Setpoints & MV Targets Optimizer-Neural Net Measurements CV’s, MV’s, FV’s Regulatory Control System (DCS) Model Predictive Controller

6 Slide 6 MVC/Optimizer: Model Predictive Constraint Control Responsive Control of Difficult Loops such as:  Steam Temperature Control for Ramp Rate  O 2, Control of CO, Steam Temperatures & NOx PV now Predicted Constraint Violation Constraint Future  Past Actual Variable Trajectory Through Connoisseur TM Control

7 Slide 7 Improve Control then Operate Closer to Limits Stabilize, Then Optimize! Target or Constraint Increased benefit Before Stabilization Stabilize and Re-Position Increase Production, Quality, etc. MPC/ NN The Invensys Advantage: Dynamic Optimization

8 Slide 8 Connoisseur Features As well as model-based control, Connoisseur offers many other supporting features, including: Flexibly configured LP / NLP economic optimization High-resolution trending of data Data archiving and analysis User-configurable Director calculations Multiple model types Imbedded Pseudo-random Binary Sequence testing Real-time online model adaptation Neural net inferential prediction Nonlinear Control using Neural net models Rule-based “fuzzy” control

9 Slide 9 Connoisseur Applications Mining and Metals – 17 Applications not including those installed by Xstrata with their Corporate License Chemicals, Oil and Gas – 41 Applications Pulp & Paper – 31 Applications and a standard for one of the largest worldwide Paper manufacturers Power Generation Plants – 25 Applications Food & Beverage – 15 Applications Over 260 Applications Worldwide in a Variety of Industries Chemicals, Oil and Gas – 105 Applications Pulp & Paper – 49 Applications and a standard for one of the largest worldwide Paper manufacturers Power Generation Plants – 25 Applications Mining and Metals – 30Applications not including those installed by Xstrata with their Corporate License Food & Beverage – 34 Applications

10 Slide 10 Success Story: Saudi Aramco Benefits: Increased feed capacity 5% 40% reduction in products quality variance 1% increase gasoline recovery at debutanizer Reduced specific energy consumption ROI less than two months Benefits: Increased feed capacity 5% 40% reduction in products quality variance 1% increase gasoline recovery at debutanizer Reduced specific energy consumption ROI less than two months About the Client: Largest oil company in the world Supplies 10% of world’s oil 2006 Revenue US$ 194 Billion What IOM did for the Client: Implemented Advanced Process Control (APC) using Connoisseur on a 400,000 bbl/day crude unit. Inferred Product Qualities

11 Slide 11 Success Story: Tesoro Golden Eagle FCC Benefits: Increased FCC capacity and conversion Improved main fractionator and gas plant product yields Energy savings $2,950,000 / Year Benefits Benefits: Increased FCC capacity and conversion Improved main fractionator and gas plant product yields Energy savings $2,950,000 / Year Benefits About the Client: Operates 7 U.S. Refineries: 665,000 BPD Capacity 2008 revenue US$ 28 billion What IOM did for the Client: Implemented Advanced Process Control (APC) using Connoisseur on a Fluid Catalytic Cracking (FCC) Reactor/Regenerator and Gas Plant. Maximized FCC blowers to unit constraints Optimized Main Fractionator and Gas Plant Separation

12 Slide 12 Success Story: Tesoro Golden Eagle Gas Plant Benefits: Improved gas plant product yields Energy savings $2,000,000 / Year Benefits Benefits: Improved gas plant product yields Energy savings $2,000,000 / Year Benefits About the Client: Operates 7 U.S. Refineries: 665,000 BPD Capacity 2008 revenue US$ 28 billion What IOM did for the Client: Implemented Advanced Process Control (APC) using Connoisseur on a Gas Plant Optimized Gas Plant Separation; maximized production of more valuable products Stabilized gas plant operation Reduced product quality variation

13 Slide 13 Dayton Power and Light Situation Stuart Station Units megawatt, coal-fired, B&W once-through, supercritical units Objectives Reduce NOx Improve unit heat rate Solution Coal Pulverizer Optimization Reduced Air Preheating Lower Excess Air Balanced Superheat and Reheat Steam Temperatures Benefits Heat rate improvements 0.5% NOx Reduction of 15-20% Leading to Ammonia Savings on SCR ROI less than 1 year

14 Slide 14 Situation Sim Gideon Plant, TX Unit megawatt, natural gas-fired, load-following boiler Max ramp rate of 40 megawatts/min Objectives Improve unit heat rate Reduce emissions of NO x Reduce emissions of other greenhouse gasses Solution Multivariable controller designed and built for this process optimization modeling project, placed in a closed loop operation Benefits (per year) Heat rate improvements 0.65% NO x reductions 12.3% CO 2 reductions 51,524 tons ROI less than 1 year due to heat rate improvements Case Study: Lower Colorado River Authority

15 Slide 15 Success Story: Tesoro Golden Eagle Isocracker Benefits: - Increased catalyst life - Improved reactor constraint management - Enhanced unit operability About the Client: Operates 7 U.S. Refineries: 665,000 BPD Capacity 2008 revenue US$ 28 billion What IOM did for the Client: Implemented Advanced Process Control (APC) using Connoisseur on an Isocracker unit Optimized reactor operation Stabilized unit operation

16 Slide 16 Iggesunds Mill - Causticizing Capacity 378,000 MTPY bleached pulp - hwd/swd 43% / 57% High quality virgin fiber board for food, pharmaceauticals, etc. IPS Confidenti al

17 Slide 17 Iggesunds Causticizing MPC IPS Confidenti al MV Predictive Controller & Optimizer Fuzzy Logic Controller Weak wash dilution Flow GL Density GL Temperatur GL Lime addition to Slaker Constraint Management Selected CV´s TTA GL Clarifier Temperature GL to Slaker Temperatur Slaker Diff Temp (Slaker-GL) Carbonate Green Liquor Clarifier 1st Causticizer Inlet – CE % 1st Causticizer Outlet – CE % Pressure Filter Outlet – CE % Sodium Carbonate in GL Sulfidity GL Steam to Slaker Residual Carb.% - kiln lime Residual Carb.% – lime to slaker* * Purchased lime Controlled Variables (CV) Manipulated Variables (MV) Feed Forward Variables (FV)

18 © 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Coming Soon!! SimSci-Esscor APC V2.0

19 Slide 19 Objectives of Updating the Offering Program focusing on delivering key enhancements: - Next Generation User Interface for APC -A Common Look and Feel with other SimSci-Esscor Product Offerings -Great improving the Ease-of-Use of the entire offering -Inclusion of tools to reduce the work to build an APC application - A powerful trending package, to enable more process insight and reduce the time to develop a solution - SimSci-Esscor APC V2.0 will preserve and leverage the existing robust calculation engine

20 Slide 20 Case Studies are supported, allowing many potential models to be developed and overlaid on one set of CV/MV pairs

21 Slide 21

22 Slide 22 All CV,MV Pairs for a proposed Model Clearly Shown on one palette

23 Slide 23 Controller Design made easy by dragging and dropping variables into this table

24 Slide 24 All Controllers are organized in 1 easy to manage tree structure Interface to Global Optimizer Included is provisioned, future release Interface to put controllers on line from one place Interface to Performance Monitoring Included, future release

25 Slide 25 June 2012 Nov 2012 March 2013 August 2013 More Releases in Future Roadmap of Simsci-Esscor APC 2.0, Next 12 mos. Start February 2012

26 Slide 26 September 2014 September 2015 September 2016 September 2017 Roadmap of Simsci-Esscor APC 2.0, 5 Year Plan Start September 2013

27 Slide 27 New Technology, Currently being Prototyped Solving the APC understanding gap Slid e 27 As an APC user, I want to see… When the APC controller makes a move What changes to expect from the move Why the move was made … so that I can understand the move and keep the controller on line Move Advisor

28 Slide 28 Move Advisor User Stories Slid e 28 Plant and Operations Managers I want information on the economic impact (KPI) of APC operations APC Engineer I want to know if an unusual APC controller move has taken place or is about to take place, to confirm that the controller is operating correctly Process Operator and Engineer I want to know what, when and why an APC Controller move has taken place or is about to take place

29 Slide 29 Move Advisor Prototype design for preliminary feedback Slid e 29 Detail View News View

30 Slide 30 Move Advisor Components Slid e 30 Collect - Variable Names, Relationships, Scan Interval Scan - Values, Limits, Costs, Status Analyze - Track moves and Create messages Report - News, Detailed Data Data Source Connoisseur Romeo NextGen Interface Excel Web Viewer PC App / InTouch

31 Slide 31 Summary\Overview Deliver Next Generation User Interface for APC Provide a unified approach to develop APC solutions Provide a best-in-class trending and user experience Retain strengths of Connoisseur’s robust calculation engine Set the Stage for a platform of unmatched flexibility and Ease of Use Thank you!


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