one-seventh of that with manual control.
Click on illustrations for larger images.
Achieving and maintaining steady-state operation is challenging in a real plant environment, which is inherently dynamic due to its hundreds or even thousands of interacting PVs. Ensuring that all elements of a production process are “quiet” and stable prior to and during bump testing often is impractical and sometimes impossible. In addition, the need for steady-state operation prior to the performance of dynamic bump tests can significantly impact a facility’s economics by decreasing throughput, reducing quality, increasing off-specification production, wasting feedstock and human resources, and incurring other expenses.
To avoid these issues, Evonik turned to Loop-Pro tuning technology from Control Station, Inc., Tolland, Ct. Version 5, officially released in July 2008, features a patent-pending “Non-Steady State Model Fitting Innovation” (NSSMFI). This breakthrough eliminates the requirement for steady-state operation prior to the performance of bump tests.
Control Station’s approach doesn’t utilize a specific data point or average data point as a “known” and, therefore, isn’t constrained by it. Rather, the NSSMFI adjust the model to fit across the entire range of data under consideration rather than linking it to a specific starting point. So, Loop-Pro can consider all possible model adjustments and optimize the model’s fit relative to all of the data under analysis. This freedom results in a model that more accurately describes the full range of dynamics within a process because it goes beyond simply characterizing the initial reaction to a bump test. It also supports more rapid optimization of a facility’s PID controllers as users no longer have to wait for a process to steady out before beginning their bump tests.
The Galena facility, which already had been using Loop-Pro, upgraded to Version 5 upon its release. Installation and activation of the software was completed in minutes; Control Station’s solutions engineering team provided web-based training that equipped Evonik with the know-how to effectively apply the technology. Using bump-test data from a data historian, plant staff successfully tuned a variety of control loops in a matter of hours. For example, it took under one hour to analyze and tune the cascade loops. Similarly, less than three hours were needed to bump the process and improve the associated controller’s performance.
Figure 3 -- Disturbance rejection: (before, top;
With the introduction of tuning parameters from Loop-Pro, simple PID controllers for the cascade loop effectively eliminated the overshoot problem and dramatically decreased settling time (Figure 2b). The plant documented a 9.3% reduction in production cycle time on each of the two batch reactors tuned in the month of August — this 2.5-hour decrease includes a 30-minute drop in the feed cycle.
Manual tuning of those loops had been challenging under normal conditions. With an oversized valve in place, Evonik staff were hard pressed to determine good tuning parameters and to control oscillations within the process. Loop-Pro V. 5 produced tuning parameters that accurately characterized the dynamics of both the process and the oversized valve. The result was faster settling time and, more importantly, control within the process’ required range of operation (Figure 3).
In August, the software tool was used to successfully diagnose and optimize other systems across the facility, including control loops associated with venting, conductivity, level and temperature.
Loop-Pro has provided significant financial benefits, thanks to the faster batches. Additionally, manual operation during startup is no longer required. Widespread application of Loop-Pro technology at the site is expected to further enhance both productivity and profitability. In the hyper-competitive specialty chemicals market, these changes are welcome news for Evonik and the Galena staff.
John Gaines is a senior controls engineer for Evonik Jayhawk Fine Chemicals, Galena, Kan. Dennis Nash is president and CEO of Control Station, Inc., Tolland, Conn. E-mail them at firstname.lastname@example.org and email@example.com.