Key Learning experiences from a large PlantTriage Installation

Transcription

1 Key Learning experiences from a large PlantTriage Installation By Phil Fedenzcuk Control Engineer Ineos Grangemouth Scotland. Presented by: Peter Thomas Control Specialists Ltd - UK Authorized Solution Provider for ExperTune Inc This presentation aims to provide a User s key learning experiences from a large PlantTriage installation at INEOS Grangemouth, UK. It is hoped that it will be useful to existing PlantTriage users and others who are interested in using this technology. 1

2 Background Implementation & Pitfalls Grangemouth Site Applications & Issues PID Tuning Example Future Proposals & Suggested Enhancements Background 2

3 Background PID loops are the fundamental automation layer. Healthy performing loops help achieve superior process operation & create stable foundations for advanced control applications As commercial demands require higher throughput and tighter quality specifications, so there are greater demands on PID Loops. Operations generally do not know how their PID loops are performing. Background - Experience with CLPM/CPLA Practical experiences in Refinery Control Loop Performance Assessment UKACC Conference 1996 N.F.Thornhill et all 1999 Honeywell Loop Scout development 2005 ExperTune s PlantTriage 3

4 Background - Typical CLPM/CPLA Network PlantTriage acts as an OPC client requesting data from the TDC APP TCN or Fox I/A OPC servers. Ineos uses two PlantTriage servers covering two major sections of the Grangemouth complex 3000 Loops via 3 DCS s Implementation 4

5 Grangemouth Refinery & Power Station (OPC Client) Ethernet Switch Ethernet Switch Grangemouth PCN (Refinery & Power Station PCN) GUS TPN Server APP 59 TPN Server APP 30 TPN Server APP node TPN Server Offsite Honeywell TDC Refinery Honeywell TDC Power Station Honeywell TDC Grangemouth Chemicals Ethernet Switch Ethernet Switch Ethernet Switch APP G4 & KG PCN 36APP54 Grangemouth PCN (OPC Client) TPN Server TPN Server G4 Honeywell TDC KG Honeywell TDC Ethernet Switch Windows PC FOX OPC Ethernet Switch Ethernet Switch Windows PC FOX OPC I4PP3 PCN Solvenics PCN AIM*API AIM Hist AIM*API AIM Hist PHD TPN Server AIM*API AIM Hist AIM*API AIM Hist PP3 Foxboro I/A I4 Foxboro I/A DCS Benz Honeywell TDC E3 Foxboro I/A DCS E4 Foxboro I/A 5

6 Pitfalls Pitfalls Hardware and software required at DCS and PlantTriage Limits on loop numbers and sampling (See next slide) Impacts on DCS and other OPC applications Resources required to gather loop information. On-going Configuration of PlantTriage Design Bugs 2005 Historian Errors Windows security Engineering issues Human Issues 6

7 Applications Limits on loop numbers and sampling rates Practical limit is 400 Loops secs 50 4 secs 20 secs This is for general performance assessment only. FIC s need to be sampling at 1 sec for loop tuning. Take care not to overload the DCS OPC node. Monitor DCS loading whenever new loops are added. 7

8 Grangemouth Key Assessments Grangemouth Loop Health currently uses 5 Key assessment KPIs: 1. Absolute error 2. Oscillation 3. Normal Mode 4. Valve at limit 5. Valve Travel Loop Health Loop Health averages these 5 KPIs: % Towards Threshold = Assessment - Baseline x 100 Threshold - Baseline 8

9 Baselines and Thresholds Grangemouth Key assessments Baseline Low Threshold High Threshold Absolute error Oscillation Normal Mode Valve at limit Valve Travel Browser Interface Overview Biggest Payback Loops KPI s for Key plant PID s Tree Maps Loop Health Summary Reports Network Health Reports & Dashboards 9

10 PlantTriage Server Status PT Servers (loop license) Triage_ref (1800) Triage_chem (1500) Loops On scan Loops Off scan Total Issues with DCS loading and resources, equipment and people. Grangemouth PlantTriage Issues PlantTriage Used mainly by Control Engineers for PID Tuning and diagnosis. PlantTriage Performance Assessments little used. Challenges: resources, extra configuration, operational buy-in, judgement required to analyse statistical data. 10

11 Assessment News: Shock Horror or so what? A typical plant has... 30% of loops in manual. 17% of loops oscillating. Almost 50% of loops underperforming! Loops in Manual The more loops in auto, the better, however with demands on limited resources only the important loops should be targeted. Operations need to confirm the important loops. 11

12 Oscillating Loops The fewer loops oscillating, the better the plant performance. Oscillations can cause interactive disturbances to other loops and propagate through the plant. Oscillating loops should be investigated with the aim of reduction or elimination. loops. Loop Tuning Multivariable Applications Tuning only one loop only optimises the single-input, single output (SISO) without taking account of the interaction with other loops. 12

13 Examples Sources of Oscillation PlantTriage can suggest the source of oscillation: Oscillation Load Oscillation Tuning Oscillation Valve 13

14 Active Model Capture Technology (AMCT) Open loop test steps are required for loop tuning. AMCT picks up a suitable operational step test done by the operator and keeps it for later tuning. Active Model Capture Technology (AMCT) If there is suitable data for PID tuning as a result of a operational step change then it appears as shown. 14

15 PID Tuning Tools Before and After Tuning At Grangemouth we have successfully tuned many loops using PlantTriage. 15

16 Before and After Tuning with Performance KPI s Top trend shows PV and CO reduction in variability. Bottom trend shows improvement in performance. The performance trends are useful indicators to confirm improvement or deterioration. Proposals 16

17 Grangemouth Installation - Proposals Loop Health based on 3 Key KPIs Service Factor Oscillation Valve Travel Target only the Important loops Roll out to Operations especially Instruments group Upgrade Version 7 Shadow server bringing Loop Performance reporting to IT Office environment Suggested Product Enhancement 17

18 Define a universal Loop Health based on 3 Key KPIs Normalise all KPIs Simplify Browser Reporting Simplify scanning on/off of units Provide better data handling Keep up the good work! PlantTriage is a really good tuning and performance assessment tool Phil Fedenczuk Ineos Grangemouth April