Control Loop Performance Monitoring - expertune.com

1 1 Copyright 2009 ExperTune, LoopPerformance MonitoringControl SystemResultsProcessCopyright 2009 ExperTune, ExperTune Process Control Improvement Software PID Tuning Control Loop Monitoring Industry Leader for more than 20 years 1,000 s of installations Award winning software World-wide sales & support network Headquartered in Hartland, Wisconsin USA2 PartnershipCopyright 2009 ExperTune, ServiceSupportTraining ExpertiseGlobal PresenceSupportDevelopmentSoftwareIn-Dep th KnowledgeCopyright 2009 ExperTune, Loop Optimization 10% - 90% Control loops in Manual 30% Control Valves with Problems 30% loops -Tuning is completelywrong 40% loops Oscillating Improper PID Loop Configuration 30% DCS Systems 95% PID on PLC s 85% Sub-Optimal Tuning 75% Control loops increasevariability3 Copyright 2009 ExperTune, Personnel More: Responsibilities Job Functions Area Less: Time Experience & Expertise Direction The good is the enemy of the best.

2 Which tools will guide plant personnel?Copyright 2009 ExperTune, Loop Performance MonitoringExisting Real-Time Data FocusedAction Monitor, AlertAnalyze, Solve4 Basics:What Can You Measure?Simple & Complex Stats Min, Max, Avg, Std. Dev. For PV & CO % Time in Normal % Time at Limit Service Factor Noise IAE, Avg. Error, etc. OscillationDiagnostics & More Process Models Most Likely Diagnosis Complete Diagnosis Instrument Valve Tuning ..More Root Cause Analysis Source of InteractionCopyright 2009 ExperTune, 2009 ExperTune, acts as a tireless SuperSenior engineer, with over 100 years PerspectiveMonitor, 24 x 7 DiagnoseHistorizePrioritizeAnalyzeRecomm end5 Batch & Continuous Continuous 24 x7 Monitoring Real-Time Historian with unlimited history Track, Monitor, Alert Reporting Trending Web-Based Unlimited Users Batch, also includes: Track by Batch Track by Product Simple or Complex Status Information Integrate with BMSC opyright 2009 ExperTune, 2009 ExperTune, ConnectivityExport DCS DCS BaselinesOn-Site TrainingFine-Tuning SystemContinuous Improvement6 What Can You Do with Control Loop Performance Monitoring ?

3 Copyright 2008 ExperTune, Picture:TreeMapCopyright 2009 ExperTune, EarlyCopyright 2009 ExperTune, Reports& Diagnostics Loop Diagnosis Oscillating loops Valves with Stiction Sensors with Problems Oversized Valves Undersized Valves Process Constraints loops Need Tuning PV Filter Errors Valves Damaged by Tuning 2009 ExperTune, 2009 ExperTune, Inc. Oscillation Confidence? Period Strength Significance Cause (Valve, Tuning, Load)TuningCopyright 2008 ExperTune, MappingCopyright 2009 ExperTune, Study Combined-Cycle Gas Turbine 51% Oscillating 20% Valve problems 15% Tuning IssuesCopyright 2008 ExperTune, Inc. PlantTriage found many of these opportunities very quickly. It is like having a staff of engineers working for me. Zhenhai LiuSenior Consulting Engineer, Invensys10 Active Model CaptureCopyright 2009 ExperTune, Study Results Stability Reduced Risk of Trip $50,000 each Production Increase $ MM/yearCopyright 2008 ExperTune, Inc.

4 With the controls stabilized, operators are pushing the process toward more profitability. Control Engineer11 Case Study #2 430 MW Gas-Fired Steam Power Station Western Load & Voltage Control : Varies substantially for peak reductions Problems: Stability Issues Operator Fear / Low Confidence Unable to Operate at Design ConditionsCopyright 2009 ExperTune, the IssuesCopyright 2008 ExperTune, Pressure Oscillation& Root CauseCopyright 2008 ExperTune, Study Results Stability Operator Confidence Operation at Design Value: Ramp Rates Throttle Pressure Steam TemperatureCopyright 2008 ExperTune, 2009 ExperTune, of PlantTriage Control Loop Performance MonitoringCopyright 2009 ExperTune, AccessLeverage Company Expertise14 Corporate Agreements Company-Wide Licensing Discounted Per-Loop PricingCopyright 2009 ExperTune, Performance reporting, now linked to engineer bonus $1-$5 Million per refineryPlantTriage in 11 plants worldwideCorporate Control Room toLeverage Process ExpertsCopyright 2009 ExperTune, Results Energy Savings to 2% Production increase 1-10% Reduced Maintenance Cost Reduced Waste/Scrap Return on Investment Typical 2-3 months Often within days15 Copyright 2009 ExperTune, & A