1. Adaptive Control Beta Site Feedback

2. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 2 Presenters Peter Wojsznis Terry Blevins Bruce Johnson Clair Meger Terry Chmelyk

3. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 3 Introduction DeltaV Adaptive Control Overview Pre-beta and Internal Testing –Solutia –UT Pickle Research –Fisher Controls Customer Beta Test –Husky Energy –Canfor –Eastman Chemical –Lubrizol –Results Achieved Summary References

4. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 4 DeltaV Adaptive Control Fully Adaptive Controller Tuning –PID Feedback and Feedforward Adapts to Changing Process –Identifies Process Dynamics While In Automatic Control –Calculates optimal tuning parameters –No Bump Tests Required Remembers Tuning for Different Operating Conditions Easy to Use – Out of the Box –Can be applied to all controllers “Always in Control”

5. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Beta Implementation - Adaptive Control New control block in the advanced control palette. Parameters are automatically assigned to the historian. No more difficult to use than PID. Initial values for model, limits, and time to steady state are automatically defaulted based on block tuning.

6. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 6 Adaptive Control - Internal Structure Control Process Controller Redesign Supervisor Model Evaluation Model Par. Interpolation Set of Models PID Controller w/Dyn Comp Feedforward Excitation Generator Manipulate Measured Disturbance Adaptive Control Block SP

7. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 7 DeltaV Adaptive Control Operational Features Process models are automatically established for the feedback or feedforward paths. Model adaptation utilizes a data set captured after a setpoint change or injected pulse (Automatic Mode), or a significant change in the disturbance input change in controller output (manual Mode). Multiple models are evaluated and a new model is determined

8. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 8 Adapt 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

9. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 9 Triggering of Identification Operator SP change in control system will trigger the Adapt block to collect to create model

10. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 10 Viewing Latest Feedback Model

11. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 11 Feedforward View – Dynamic Comp Deadtime, Lead and Lag are also shown if Dynamic Compensation is selected in ADAPT_OPTS

12. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 12 Accessing Feedback Models by Region To access the last good model identified in each region of operation, then select Region and the Feedback tab. Value of state parameter

13. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 13 Control Setup Window Trigger to adapt Controller Output pulse injection (used in phase 2 of beta) How fast to adapt Process type: Integrating – Non Integrating; Minimum time to steady state Adaptive mode of operation

14. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 14 Common Causes of Uncertain or Bad Model Actuator is sticking (coarse resolution) or has deadband. The measurement has uncertain or bad status. Initial Tuning for the existing loops or (manual entered) Time to Steady state is significantly off from the required value(s). Loop feedback and feedforward action (direct or reverse) is set incorrectly The identified model is outside the limits on process gain, time constant, and/or deadtime defined in the region view. State parameter is constantly switching between regions.

15. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 15 Actuator Deadband and Resolution May be evident from trend plot. Also, reference the Health view to quantify deadband and/or resolution. Deadband Deadband and Resolution

16. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 16 Health View Quantifies deadband or resolution and Loop Oscillation May be configured to create a module alarm

17. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 17 Adaptive Control Test Program Pre-Beta Sites Solutia – Pensacola, FL, May, 2004 5 loops J.J.Pickle Center, UT, Austin, TX Dec, 2004 3 loops Internal Beta Sites Fisher Control, Marshalltown, IA Sept, 2004 Rosemount, Eden Prairie and Chanhassen, MN March, 2005 Ovation, Pittsburgh, PENN April, 2005 Customer Beta Sites Canfor – Prince George, CAN Feb, 2005 47 loops Husky Energy – Prince George, CAN Feb, 2005 45 loops Eastman Chemical – Longview, TX, Mar, 2005 147 loops Lubrizol – Houston, TX 350 loops, April, 2005 350 loops

18. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 18 Pre-Beta – Solutia, Pensacola, FL

19. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 19 Pre-Beta at Solutia, Pensacola, FL LT TT Cooling Tower Water TC TT FT FC LC AT AC HMD (Base) 65AC681 (pH) 65TC688 65TC684 65TC685 65LC682 Strike Kettle Process and Instrumentation

20. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 20 Pre-beta – Solutia, Pensacola, FL Kettle control – regular PID control

21. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 21 Pre-beta – Solutia, Pensacola, FL Kettle control – Adapt control

22. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 22 Pre-Beta at J.J Pickle Research Campus DeltaV is installed at UT’s J.J. Pickle Research Campus, Austin, Texas on a 18”distillation column and 6” reactive distillation columns Emerson Process Management is: – Funding a PhD graduate student under the guidance of Professor Tom Edgar to demonstrate and test DeltaV advanced control on the reactive column. –Participating in a DOE project to explore a technique for early detection of column flooding – Professor Bruce Eldridge.

23. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 23 Pre-beta - J.J.Pickle Research Campus Flow loop

24. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 24 Pre-beta - J.J.Pickle Research Campus Flow loop

25. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 25 Internal Beta – Fisher Controls, Marshalltown, IA

26. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 26 Internal Beta – Fisher Controls

27. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 27 Valve Installed Characteristics – Gain Change of 7X Over Test Range

28. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 28 Automated Test

29. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 29 Models Automatically Identified by Regions

30. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 30 Customer Beta Test Program Phase 1 – first three months –Install beta system and provide initial training for instrumentation and control –Monitor the process models and recommended tuning that is automatically identified by DeltaV Adapt. No impact on operations Phase 2 – Second three months –Provide more extensive training for operators, instrumentation and control, and management –Commission adaptive closed loop control on some of the loops monitored in phase 1. Operators may operate adaptive loops using their normal interface to the control system.

31. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 31 Phase 1 Objectives Identify loops that must address changes in process gain and dynamics as a function of operating condition as indicated by PV, OUT or other measured parameters e.g. plant throughput Quantify process variability for existing PID control

32. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 32 Beta Implementation– DeltaV to DeltaV Parameters Accessed Using OPC and Mirror Application Station

33. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 33 Beta Module – DeltaV to DeltaV

34. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 34 Pre-Configured Modules for Each Site Pre-Configured Modules for Each Site

35. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 35 Beta Implementation – DeltaV to ABB OPC I/F ABB Controller Parameters Accessed Using OPC and Mirror ABB OPC Server PID Loop Any ABB Operator Console

36. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 36 Beta Module – DeltaV to ABB

37. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 37 Canfor, Northwood Mill, Canada Beta addresses a wide variety of loops in the Pulping Group and Power House Beta system interfaces to existing Provox control system using OPC

38. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 38 Canfor –Loop Types Addressed 8 – Consistency 5 – Density 15 Level 5 pH 4 Pressure 10 Temperature

39. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 39 What have we learned so far? Seeing good model quality on self-regulating and integrating processes Very encouraged with the insights we are gaining about modeling dynamics across the operating range of the loops Model identification alone is a powerful tool for tuning or control design Health view has been enhanced and we are excited about the diagnostic capabilities for troubleshooting

40. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 40 B Digester Temperature Loop Gain change by factor of 10 TC change by factor of 3 DT change by factor of 2.5

41. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 41

42. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 42 Husky Energy, Prince George, Canada Beta addresses all DeltaV loops implemente d in the refinery Beta system interfaces to the DeltaV control system using OPC

43. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 43 Husky Energy - Initial Results Two(2) process control engineers and one(1) Norpac’s field support person attended training on DeltaV Adaptive control After the first full day of operation, DeltaV adaptive control automatically identified feedback and feedforward models for 25 of 42 loops based on typical operator changes in setpoint. Preliminary model evaluation indicates good match to the real process. Identification of remaining loops will continue over next 3 months. Monitoring will be extended to cover plant expansion for clean fuel production – may be an opportunity to quantify expected time that can be saved on new plant startup.

44. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 44 Husky Energy –Loop Types Addressed 12 – Flow 14 - Level 10 - Pressure 6 - Temperature

45. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 45 17-TIC-008 HP Receiver Condenser Temperature (A Fin Fan Cooler for the High Pressure Receiver) 20-LIC-001 Rich Amine Flash Tank 23-FIC-023 Stabilizer Bottoms A/C Gasoline (Flow Through an Air Cooler (A/C) from Stabilizer Tower) 23-LIC-020 CGHT (Cat Gas Hydrotreater Treater) Stabilizer Level 23-PIC-173 HDS Reactor Heater Fuel Gas (Fuel Pressure Control Loop 23-PIC-179 Splitter Tower Heater Fuel gas (Fuel Pressure Control Loop) 23-TIC-123 Splitter Overhead Air Cooler Out (Fin fan Control Loop) Husky Energy – Some interesting loops

46. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 46

47. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 47

48. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 48

49. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 49

50. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 50 Eastman Chemical – Longview, Texas Beta addresses a wide variety of loops in the hydrocarbon- cracking units, for the manufacture of solvents, alcohol, ethers, and polyethylene Beta system interfaces to existing DeltaV control system using OPC

51. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 51 Eastman –Loop Types Addressed 39 Flow 50 Level 31 Pressure 24 Temperature 1 Position

52. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 52 Lubrizol – Deer Park, Texas Beta addresses a wide variety of loops in continuous and batch processing in the manufacturing of lubricants Beta system interfaces to existing DeltaV and ABB control systems using OPC

53. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 53 Lubrizol –Loop Addressed 180 Loops – DeltaV 170 Loops – ABB

54. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 54 Results – Automatic Model Identification in First Two Months - Phase 1 of the beta test 51% 3% 10% 36% No Models One Region Two Regions Three Regions Lubrizol – DeltaV Control Network 14% 51% 19% 16% Lubrizol – ABB Control Network 22% 14% 45% 19% Canfor 39% 48% 12% 1% Eastman Chemical 12% 65% 21% 2% Husky Energy

55. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 55 SummarySummary The DeltaV adaptive control technology is being extensively tested at 4 customer beta sites and three internal sites within Emerson. Data on process variation and the identified process models has been collected on over 700 control loops. Process models have been automatically identified for a wide variety of loops. Performance improvement will be quantified in Phase 2 of the beta. Please direct questions or comments on the DeltaV Adaptive control products to John Caldwell (John.Caldwell@EmersonProcess.com).John.Caldwell@EmersonProcess.com

56. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 56 Where To Get More Information “The Next Generation – Adaptive Control Takes a Leap Forward”. Gregory McMillan, Mark Sowell, Peter Wojsznis, Chemical Processing, September, 2004 Utilizing DeltaV Adaptive Control (Presentation), Peter Wojsznis, Terry Blevins, Darrin Kuchle, Gregory McMillan, Willy Wojsznis, Emerson Exchange, 2004 Theoretical Analysis of a Class of Multiple Model Interpolation Controllers (Presentation), Dale Seborg and Joao Hespanha, AIChE Annual Meeting, San Francisco, November 21, 2003 “Adaptive Feedback/Feedforward PID controller”, Willy Wojsznis, Terry Blevins, and Peter Wojsznis, ISA Conference, 2003 “User Interface For Adaptive Controller”, Peter Wojsznis, Yan Zhang, and Terrence L. Blevins, ISA Conference, 2003