Advanced Control Unleashed

Plant Performance Management for Optimum Benefit

Terrence L. Blevins Gregory K. McMillan Willy K. Wojsznis Michael W. Brown

ISA-The Instrumentation, Systems, and Automation Society

Notice The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher have any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application. Additionally, neither the author nor the publisher have investigated or considered the affect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented. Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorse any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author nor the publisher make any representation regarding the availability of any referenced commercial product at any time. The manufacturer's instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication. Copyright 2003 ISA - The Instrumentation, Systems, and Automation Society All rights reserved. Printed in the United States of America. 109876543 ISBN 1-55617-815-8 No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, NC 27709 Library of Congress Cataloging-in-Publication Data is in process.

Dedication
This book is dedicated to Karen Blevins, Cathy MacDonell Brown, Carol McMillan, and Susan Wojsznis who have provided encouragement and support throughout our careers.

Acknowledgement

The authors wish to express their appreciation to Mark Nixon and Ron Eddie from Emerson Process Management, for their enthusiastic support and commitment of resources for this book, to Jim Hoffmaster, Bud Keyes, Duncan Schleiss, John Berra, and Gil Pareja from Emerson Process Management for their inspiration and support in establishing the DeltaV advanced control program, to Karl Astrom from Lund University, Tom Edgar from the University of Texas at Austin, Dale Seborg from the University of California, Santa Barbara and Tom McAvoy from the University of Maryland for their guidance in the pursuit of new technologies, Mike Gray and Mark Mennen from Solutia Inc. for the initiation and sustenance of advanced control applications and innovations, Ken Schibler from Emerson Process Management for his help in setting the direction of the book, Robert Cameron, Michael Mansy, Glenn Mertz, and Gina Underwood from Solutia Inc. for their valuable comments, and finally, Scott Weidemann from Washington University, and Jim Cahill, Brenda Forsythe, and Cory Walton from Emerson Process Management for their essential contributions to the videos and demos on the CD. The authors extend their thanks to the developers of the advanced control tools that were the inspiration for this book. This includes Vasiliki Tzovla, Ron Ottenbacher, Dirk Thiele, Ashish Mehta, Yan Zhang, Peter Wojsznis, John Gudaz, Ian Nadas and Mei Yang. Also, we would like to recognize the valuable contribution of Tom Aneweer, Dennis Stevenson, Jay Colclazier, Darrin Kuchle, Dick Seemann, Joe S. Qin, Steve Morrison, Mike Ott, and Sai Ganesamoorthi. The discipline of Process Control and Advanced Process Control is an exciting, challenging and rewarding field of engineering. Some of us moved into this discipline by chance, while others made a conscious decision to become Process Control Engineers. Regardless of our entry point or
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motivation, we all appreciate the fact that engineers before us took the time and effort to teach us the tools and techniques that allowed us to achieve success. This book passes along the knowledge of many years and many people and acknowledges the efforts of our engineering mentors. We hope it will allow others not only to benefit from all the experience we have benefited from so greatly but also to take the technology to the next level.

About the Authors

Terrence L. Blevins has been actively involved in the application and design of process control systems throughout his career. For over fifteen 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. He is the Fieldbus Foundation team leader for the Function Block Specification. In this capacity, Terry is involved in the movement of Fieldbus Foundation function block work into international standards. Terry is the US expert to the IEC TC65 WG6 and SC65C WG7 function block committees. He wrote the fieldbus section included in the Process/Industrial Instrumentation and Controls handbook. Terry has eight patents and has written over forty papers on process control system design and applications. He received a BEE from the University of Louisville in 1971 and a Master of Science degree in Electrical Engineering from Purdue University in 1973. Presently, Terry is a principal technologist in DeltaV Product Engineering and the team leader for DeltaV advanced control product development. Phone: (512) 418-4628 E-mail: terry.blevins@EmersonProcess.com Gregory K. McMillan retired as a Senior Fellow after a 33 year career with Monsanto and Solutia Inc, where he specialized in improving loop performance, controller tuning, valve dynamics, opportunity assessments, dynamic simulation, fermentor control, pH control, and reactor control. Greg is the author of numerous articles and books, his most recent book being: Good Tuning - A Pocket Guide. He has contributed to several handbooks and is the editor of the Process/Industrial Instrumentation and Controls handbook and the coauthor of a monthly column titled "Control Talk".
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Advanced Control

Greg is an ISA Fellow and 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, and was one of the first inductees into the Control Magazine "Process Automation Hall of Fame" in 2001. He received a B.S. from Kansas University in 1969 in Engineering Physics and a M.S. from University of Missouri - Rolla in 1976 in Control Theory. Presently, Greg is an affiliate Professor at Washington University in Saint Louis, Missouri and is a consultant through EDP Contract Services in Austin, Texas. Cell Phone: (314) 703-9981 E-mail: gkmcmi@msn.com Willy K. Wojsznis has been involved in developing advanced control products over the last twelve years focusing on model predictive control and auto tuning. Over the previous nearly 25-year of his career he was developing computer control systems and applications in cement, steel, mining and paper industries. His professional work resulted in a number of successful and innovative advanced control products, fourteen patents, and above thirty technical papers. He received control engineering degree (EE) from Kiev Technical University inl964, M.S. in Applied Mathematics from Wroclaw University in 1972, and Ph.D. from Warsaw University of Technology in 1973. Presently, Willy is a part of DeltaV advanced control group. He conducts applied research in the areas of optimization, adaptive control and model predictive control. Phone: (512) 418-7475 E-mail: willy.wojsznis@EmersonProcess.com Michael W. Brown has spent his entire career in the application of Advanced Process Control technologies in the continuous processing industries. Over the previous 15 years of his career, he has served as an Advanced Process Control Consultant, providing implementation expertise and technology guidance for many operating companies. His extensive knowledge and experience in the areas of model based predictive control and real-time optimization have assisted many companies in capturing the benefits of these performance improvement technologies. His work has resulted in several technical papers, published in various control journals. Michael is a Chemical Engineer, received a B.A.Sc. from the University of Waterloo in 1987 and completed his Masters in Applied Science in 1989. Presently, Michael is the Applications Business Manager, with Matrikon Inc., where he continues to work with industry to bring Advanced Control Technology to the next level. Phone: (905) 282-9248 E-mail: mike.brown@matrikon.com

Foreword

There has been a dynamic development of control over the past 50 years. Many new methods have appeared. The methods have traditionally been presented in highly specialized books written for researchers or engineers with advanced degrees in control theory. These books have been very useful to advance the sate of the art. They are however difficult for an average engineer. The reasons are that it is necessary to read many books to get a good coverage of advanced control techniques and that the level of mathematics used requires a substantial preparation. This is a dilemma because several of the advanced control techniques have indeed been very beneficial in industrial and more engineers should be aware of them. Even if many details of the new methods are complicated the basic underlying ideas are often quite simple. Many methods have also been packaged so that they are relatively easy to use. It is thus highly desirable to present the industrially proven control methods to ordinary engineers working in industry. This book is a first attempt to do this. The book provides a basis for assessing the benefits of advanced control. It covers auto-tuning, model predictive control, optimization, estimators, neural networks, fuzzy control, simulators, expert systems, diagnostics, and performance assessment. The book is written by four seasoned practitioners of control, having jointly more than 100 years of real industrial experience in the development and use of advanced control. The book is well positioned to provide the bridge over the infamous Gap between Theory and Practice in control. Karl J. Astrom

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