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Terrence Blevins - Advanced Control Foundation: Tools, Techniques and Applications

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Terrence Blevins Advanced Control Foundation: Tools, Techniques and Applications

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In this book, the authors address the concepts and terminology that are needed to apply advanced control techniques in the process industry. The book is written for the process or control engineer that is familiar with traditional control but has little or no experience in designing, installing, commissioning and maintaining advanced control applications. Each chapter of the book is structured to allow a person to quickly understand the technology and how it is applied. Application examples are used to show what is required to address an application. Also, a section of each chapter is dedicated to a more in-depth discussion of the technology for the reader that is interested in understanding the mathematical basis for the technology. A workshop is provided at the end of each chapter that explores the technology. The reader may view the workshop solution by going to the web site that accompanies the book. The book provides comprehensive coverage of the major advanced control techniques that are most commonly used in the process industry. This includes tools for monitoring control system performance, on-demand and adaptive tuning techniques, model predictive control, LP optimization, data analytics for batch and continuous processes, fuzzy logic control, neural networks and advancements in PID to use with wireless measurements. Since many readers may work with an existing DCS that does not support advanced control, a chapter of the book is dedicated to tools and techniques that the authors have found useful in integrating advanced control tools into an existing control system. Also, one chapter of the book addresses how dynamic process simulations may be easily created in a DCS to support checkout and operator training on the use of advanced control.

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Dedication

This book is dedicated to Karen Blevins, Susan Wojsznis, and Nancy Nixon, who have provided encouragement and support throughout our careers.

Acknowledgment s

The authors wish to express their appreciation to Grant Wilson and Peter Zornio for supporting advanced control research and work on this book, and to Jim Nyquist, John Berra, Mike Sheldon, Duncan Schleiss, John Caldwell, Dawn Marruchella, Darrin Kuchle, Jay Colclazer, Nathan Pettus, Bruce Greenwald, Jim Hoffmaster, Ron Eddie and Gil Pareja from Emerson Process Management for their inspiration and support of advanced control initiatives. Also, we would like to express our deepest thanks to Bud Keyes, former Senior Vice President of Technology, Emerson Process Management for his initiative in establishing the DeltaV advanced control program. In our work, we have benefited from communications with Karl strm from Lund University, Tom Edgar from the University of Texas, Joe Qin from the University of Southern California, and Dale Seborg from the University of California, Santa Barbara on both basic and advanced control topics. The authors wish to thank Joanne Salazar, Glenn McLaughin, and Deborah Franke for their help with the web site for this book and Brenda Forsythe and Jim Sipowicz for the creative book cover design. We want to thank Joan Forbes and Cary Laird for their thorough review of the first draft and many editing suggestions. We also want to thank technical editor Scott Bogue for his excellent review of the final draft. In addition, we appreciate the input provided by ISA, and thank Susan Colwell, Manager, Publications Development, ISA, for her support in the publication of this book.

Over the years we have benefited from working with many others in the design and implementation of advanced control tools. The authors are deeply indebted to the developers of the advanced control tools that were the basis for writing this book. This includes Vasiliki Tzovla, Ron Ottenbacher, Dirk Thiele, Ashish Mehta, Yan Zhang, Peter Wojsz nis, Ian Nadas, Paul Muston, Bob Havekost, Paul Daly, Adam Qui, Chris Worek, Ken Beoughter, Dan Christensen, Ling Zhou, Ian Lloyd, and Vivi Hidayat. Also, we would like to recognize the valuable contribution of Tom Aneweer, Dennis Stevenson, Dick Seemann, Yang Zhang, Steve Morrison, Mike Ott, Chuck Johnston, Randy Reiss, Greg McMillan, Todd Maras, Michael Boudreau, David Rehbein, Pat Dixon, Quay Finefrock, Shelli Callender, and Sai Ganesamoorthi. We gratefully acknowledge the support of the many customers we have worked with in field testing advanced control products. In particular, the following individuals supported evaluation of these tools in their plants: John Traylor, Texas Eastman; Mark Sowell, Solutia; Romeo Ancheta, Husky Energy; Derrick Vanderkraats, Canfor; Bruce Johnson and Efren Hernandez, Lubrizol; Bruce Eldridge, Frank Seibert, Ricardo Dunia, Eric Chen, Robert Montgomery, and Stephen W. Briggs, University of Texas, Austin, Pickle Research Center; Scott Broadley, President, Broadley-James; and Dan Coyne and Paul Oram, BP. Our special thanks goes to the Lubrizol team led by Bob Wojewodka for their feedback on the development of data analytics.

The authors greatly appreciate the effort of Emerson Process Management Systems and Solutions control engineers progressing advanced control applications in petrochemical, oil and gas, chemical, life science, pulp and paper, power, and other industries. Our thanks go to James Beall, Lou Heavner, Pete Sharpe, Doug White, Jim Dunbar, Elizabeth Alagar, and many others.

It has been gratifying to work with Terry Chmelyk, Don Umbach, John Peterson, and Mike Begin and the rest of Spartan Controls team in field testing new advanced control technologies. The lime kiln example in this book is an example of their work in this area. Also, we greatly appreciate the work done by the Spartan Control and Emerson Process Management teams in applying real-time optimization and MPC in a wide variety of applications. The application examples derived from the valuable field experience of Chris Hawkins, George Buchanan, Andrew Riley from Emerson Process Management, UK, Terrance Chmelyk, Saul Mtakula, Manny Sidhu, and Carl Sheehan from Spartan Controls, Barry Hirtz from Canfor, and by Stewart McLeod from Catalyst Paper greatly enriched this book

We are indebted and thankful as well to many of those not listed here who impacted the development of Emerson Process Managements advanced control products or contributed to the successful application of these products and inspired us to write this book.

About the Author s

Terrence L. Terry Blevins has been actively involved in the application and design of process control systems throughout his career. For more than 15 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 Managements Advanced Control Program. From 1998-2005 Terry was the team lead for the development of DeltaV advanced control products. He is the Fieldbus Foundation team lead for the development and maintenance of the Function Block Specification and editor of the SIS Architecture and Model Specifications. In this capacity, Terry is involved in the adoption of Fieldbus Foundation function block work by international standards. Terry is the US expert to the IEC SC65E WG7 function block committee that is responsible for the IEC 61804 function block standards. He is a voting member and chairman of ISA SP104-EDDL (Electronic Device Description Language) committee and is the technical advisor to the United States Technical Advisory Group (USTAG) for the IEC65E subcommittee. He is also a member of the USNC TAG (IEC/SC65 and IEC/TC65). Terry authored An Overview of the ISA/IEC Fieldbus, Section 11, Standards Overview, Fifth Edition of the Process/Industrial Instruments and Controls Handbook and coauthored four sections in the Fourth Edition of the Instrumentation Engineers Handbook , Process Control and Optimization . He coauthored the ISA bestselling books Advanced Control Unleashed and Control Loop Foundation . He has over 45 patents and has written over 70 papers on process control system design and applications. Terry received a Bachelor of Science in Electrical Engineering from the University of Louisville in 1971 and a Master of Science in Electrical Engineering from Purdue University in 1973. In 2004, he was inducted into Control Magazines Process Automation Hall of Fame.

Presently, Terry is a principal technologist in the future architecture team of DeltaV Product Engineering at Emerson Process Management.

Phone: (512) 418-4628 E-mail: terry.blevins@emerson.com

Willy Wojsznis has been involved in the development of advanced control products over the last twenty years focusing on model predictive control, data analytics, and auto tuning. Over the previous nearly 25-years of his career he developed computer control systems and applications in the cement, steel, mining, and paper industries. His professional work resulted in a number of successful and innovative advanced control products, over thirty patents, and over forty technical papers. He received a control engineering degree (EE) from Kiev Technical University in 1964, an M.S. in Applied Mathematics from Wroclaw University in 1972, and a Ph.D. from Warsaw University of Technology in 1973. He coauthored the ISA bestselling book Advanced Control Unleashed. In 2010, he was inducted into Control Magazine s Process Automation Hall of Fame. Presently, Willy is part of the DeltaV future architecture team. He conducts applied research in the areas of optimization, adaptive control, data analytics, and model predictive control.

Phone: (512) 418-7475 E-mail: willy.wojsznis@emerson.com

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