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罗克韦尔自动化 PlantPAx Newsletter第1期

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最后更新于:2017年03月15日
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2009 – Issue 1 IN THIS ISSUE PlantPAx is the new name for the Rockwell Automation Process Control System. It brings together our core control and visualization technologies with technology from acquisitions, such as Incuity, Pavilion Technologies, ICS Triplex and partners like OSIsoft and Endress+Hauser into a single solution. Key areas of the PlantPAx system include: System Engineering The PlantPAx system further strengthens our system engineering environment. It will offer process and batch control users a new library of reusable control objects with tools to simplify deployment. A future release will include the ability to populate the PlantPAx system with modules from multiple plant design and engineering tools. Control and Visualization Platforms Control strategies and accompanying visualization are configured using modular and reusable objects, simplifying design, commissioning and maintenance. Continued advances around system high availability serve to minimize or eliminate downtime and process disruptions caused by control system modifications. Performance and Process Optimization The PlantPAx system extends the scope of process optimization to include Fuzzy Logic, basic and advanced process loop tuning and at the high-end a Model Predictive Control (MPC) suite. Batch and Sequencing Rockwell Automation provides solutions from basic sequencing to the most complex and demanding batch applications. The system adheres to ISA-88 standards and presents a scaleable batch control capability. Process Safety and Critical Control Process safety capabilities include a broad range of safety integrity levels (SIL) and fault-tolerance requirements. Solutions include SIL 3 and TMR options. Asset Management and Device Connectivity As an integral element of the PlantPAx system our asset management solution provides tools for disaster recovery, tracking of user actions, regulatory compliance and improving plant-floor security. The solution includes instrument configuration, diagnostics and calibration management. The system integration with digital field devices such as HART, Foundation Fieldbus and Profibus PA for the instrumentation and DeviceNet and EtherNet/IP for industrial control devices. This provides integration ease when used with our device integration tools developed jointly with Endress+Hauser. Additional asset management capabilities include controller code change management, vibration monitoring of rotating equipment and both instrument and industrial device management with configuration and calibration records tracking for other plant-wide assets such as drives and motor control centers. Plant Information The PlantPAx system allows plant-wide process data management through its historian capability (based on the PI System from OSIsoft). Further, the new FactoryTalk VantagePoint enterprise manufacturing intelligence and reporting software helps enable aggregation, analysis and display of plant information. To find out more, visit us at www.discover.rockwellautomation.com/ thinkingprocess In this edition of Thinking Process we focus on techniques to optimize plant performance. You will find information on subjects ranging from loop tuning to model predictive control and examples of the financial savings that can be made. Rockwell Automation® Announces PlantPAx Page 1 Rockwell Automation Announces PlantPAx Process Automation System Page 2-4 SPECIAL FEATURE Process Optimization Page 5 Rockwell Automation and Endress+Hauser Integration Software and Documents Page 5 FactoryTalk® ViewPoint Web-HMI Page 5 FactoryTalk AssetCentre Adds Device Configuration and Calibration Management Capability Page 5 FactoryTalk Batch Version 10 Page 6 Six-Polymer Line Project Marks Largest Polymer Deployment in China UPDATE IMC Function Block Configuration Example The IMC Function Block SP CV PV Disturbance Estimate Process Prediction 1st Order Filter 1st Order Model Inverse of Model Process Process Disturbance – – 2 Concentration Time CV PVTime Constant 63% 300 250 200 150 100 50 0 0 20 40 60 80 100 Deadline Economic Benefits The IMC algorithm gives more accurate control of the chemical concentration to target value. This reduces the cost of chemicals whilst still meeting specification. RSTune & RSLoop Optimizer RSTune® and RSLoop Optimizer™ are critical tools for increasing your product quality. Having your loops optimized reduces inconsistency, thereby improving the quality of your product. Better control means more accurate material management and less off-specification product, increasing your profits and reducing energy costs. RSTune is a sophisticated tuning package that will optimize your PID loops. It automatically calculates the best PID values for your application and supplies you with powerful tools to increase profitability. RSLoop Optimizer has additional tools to allow you to identify potential process equipment deficiencies, analyze valve wear and optimize more complex loops. Example – Chemical Dosing In this example a chemical is dosed into a water flow with the goal of meeting a certain concentration. There is a significant delay between the injection point and the measuring point. Traditional PID algorithms don’t cope very well with the delay and typically lead to a sluggish response or oscillations. The graph below shows how the process responds to a step change. The dead-time of the loop is much larger than the time constant. In this example, the new Logix Internal Model Control (IMC) instruction will typically give a much better response than PID. The IMC function block controls a single process variable by manipulating a single control-variable output. This function block performs an algorithm where the actual error signal is compared against that of an internal first-order lag plus dead-time model of the process. The IMC function block calculates the control variable output based on the deviation from the internal model. Logix V17 Advanced Process Control – Internal Model Control (IMC) PID is the ‘standard’ solution for most control loops, but it is not a good algorithm for certain applications. If PID is not suitable for the application no amount of tuning will make the loop operate efficiently, other techniques like Internal Model Control (IMC) are required. Other Logix APC Instruction CC – Coordinated Control • The CC function block controls a single process variable with up to three control variables which need to act in a coordinated manner • It is good for situations where multiple outputs are available for control, and costs need to be minimized MMC – Modular Multivariable Control • The MMC function block controls two process variables with up to three control variables • It is good for situations where there is significant interaction between the various control variables and process variables Application Example and Economic Benefit For more information, visit: www.rockwellautomation.com/rockwell software/design/rslogix5000/ Instruction Application Economic Benefit Dissolved oxygen control by controlling flow rate, agitator and air flow Distillation column by controlling composition, reflux ratio, steam flow, pressure CC MMC Reduced energy costs Increased yield Increased throughput Increased product to specification To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess 3 FactoryTalk VantagePoint – Business Intelligence Software FactoryTalk VantagePoint is based on innovative business intelligence software from Incuity, integrated into the FactoryTalk environment. Business Intelligence Software, such as FactoryTalk VantagePoint, can help increase productivity by providing workers at every level in the enterprise with new insight into the manufacturing process to help them to make better decisions. For example: • At the line level people need to understand how equipment is performing to be able to make decisions on streamlining operations, and improving efficiency and throughput • At the plant level people need to understand production as it relates to the customer, so that they can make intelligent decisions about procurement, production scheduling and shipping • At the enterprise level people need to see production in its larger business context, and to understand the impact of fluctuating costs, changing market conditions and asset performance to make the right decisions about what to make and where For more information, visit: www.rockwellautomation.com/rockwellsoftware/performance/vantagepoint/ So how much could you gain from improving your control system? Applying Pavilion Technologies’ Model Predictive Control to a bioethanol plant reduced energy costs by 2-4% and reduced variability of product quality by more than 50%. Business Intelligence software from Incuity EMI (a Rockwell Automation Company) helped a leading speciality chemical producer to improve efficiency, saving approximately $300,000 per year. Rockwell Automation has a range of solutions to address different needs; some of them are shown here. Efficiency losses can be found in any number of points throughout your process plant. A poorly performing control loop on a critical piece of plant can waste energy, waste expensive raw materials and reduce yield. It has been estimated that approximately three-quarters of all control loops are performing below peak efficiency. Most process plants have multiple interacting control loops and optimizing each one individually will not optimize the entire process. For these applications a more sophisticated approach such as Pavilion Technologies’ (a Rockwell Automation Company) Model Predictive Control solution is required. Optimizing control loops is only part of the story. There are many other areas that require attention – shortening material addition times, reducing cycle times and changeover times in batch manufacturing. You need tools to be able to pull together the relevant information and analyze it to find inefficiencies. Application Example and Economic Benefit A major paint manufacturer installed Incuity software to help increase production whilst reducing costs. The system provided deep insight into their batch processes and facilitated information-sharing among the production and supervisory staff so they could better monitor production in their appropriate contexts. The result has been that within a few months they have been able to improve production performance by more than 20% whilst reducing costs by $500,000 a year. Process Optimization Process Optimization is a very important subject in today’s economic climate. It is essential to run your plant as efficiently as possible to maximize profitability, but how do you know if your system is running at the maximum efficiency? Do you have the tools to analyze the performance? And do you have a control system that is capable of delivering optimum performance? In this article we examine a number of techniques from tuning PID loops to Business Intelligence Software to help you maximize your profits. To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess Features • Hybrid modeling based on empirical data, first principles equations, operator knowledge or any combination • Patented, Extrapolated Gain Constrained Neural Networks (EGCNN) to ensure model accuracy beyond the normal operating range • Incorporates changing process dynamics (dead-time, time constants and gains) over wide process operating ranges Benefits • Improves product quality through faster response to target changes or large process disturbances • Expedites deployment by using all available information to create accurate models • Improves product quality and flexibility for new grade and product development 4 Economic Benefits • Reduce cycle times through faster response of the control loop • Reduce energy usage Application Example and Economic Benefit Chemical Manufacturer • Increase prime product yield by 4.5% • Reduced variance in product properties by 35% • Decreased reactor variability by 30% • Reduced waste by 300 tons year • Reduced frequency of lab samples by 50% Ethanol Producer • Increased Ethanol production capacity 3-10% • Increased ethanol yield by .1-.2% • Reduced energy use/gallon by 2-4% • Reduce compliance risk Logix – Fuzzy Logic Fuzzy Logic is a technique that attempts to systematically and mathematically emulate human reasoning and decision-making. Fuzzy control solutions are especially useful for complex systems where standard means such as PID control don’t give the required level of control. Your operators may already be ‘tweaking’ the process for different conditions but this can be unreliable. The Fuzzy Logic tools can be applied to a wide variety of applications. The following example is a simple application to adjust gains in a temperature control loop for a reactor. Example – Reactor Temperature Control A reactor is heated to a particular temperature to produce a product. This may sound straightforward but if the reactor is used for different sizes of batches the performance of the temperature loop will vary significantly depending on how full the reactor is. If the loop is tuned when the reactor is half full it may experience problems at different levels. It would have a sluggish response when completely full and may oscillate when only part filled. Clearly you could write a program to vary the gains with level but this could become complicated to ensure you don’t get disruptions to the process. Fuzzy Logic provides a tool set to take the knowledge about how the gains should be varied and use it to more accurately control the process. This is done by continuously adjusting the gains rather with a step change which is often seen in existing applications. By doing this it is possible to avoid the process disruptions that would otherwise occur. Pavilion Technology – Model Predictive Control Pavilion Technologies’ Model Predictive Control (MPC) technology is an intelligence layer on top of basic automation systems that continuously drives the plant to achieve multiple business objectives – cost reductions, decreased emissions, consistent quality and production increases – every production minute. It continuously assesses current and predicted operational data, compares them to desired results and computes new control targets to reduce in-process variability and improve process performance. For more information, visit: www.pavtech.com To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess Rockwell Automation and Endress+Hauser Integration Documents and Add-on Instructions Available for Download Rockwell Automation and Endress+Hauser have released documentation and Add-on instructions for HART devices connected to 1756 I/O. The information includes a step-by- step approach to integrating Endress+Hauser instruments, including information on hardware, software, configuring messaging and asset management software. You can download the documents and Add-on instructions from: www.rockwellautomation.com/solutions/ process/integrationdocs.html The first phase includes documents for the following instruments: • Promass 83 Coriolis Mass Flow • Promag 53 Electromagnetic Flow • Prowirl 73 Vortex Flow • Proline t-mass 65 Thermal Flow • Levelflex M Guided Radar Level • Micropilot M Radar Level • Prosonic M Ultrasonic Level • Prosonic S Ultrasonic Level • Liquiline M for Liquid Analysis • Cerabar S Pressure • Deltabar S Differential Pressure • iTEMP TMT 162 Temperature • iTEMP TMT 182 Temperature Documentation for Profibus PA via the EN2PA modules and Flex™ I/O HART is in progress and will be available early 2009. Manufacturers now can remotely monitor their plant-floor operations status using FactoryTalk ViewPoint software from Rockwell Automation. FactoryTalk ViewPoint software is one of the first commercially available, thin-client applications for manufacturing, built using the new Microsoft Silverlight technology. The initial release extends visualization and real-time decision capabilities beyond FactoryTalk View clients to browser-based remote users. FactoryTalk ViewPoint software supports fully scalable and animated Web displays of existing FactoryTalk View Site Edition (SE) visualization software and Allen-Bradley® PanelView™ Plus applications from the office, home or on the road via any Internet browser. While the initial release is Internet Explorer (IE) compatible, additional browser and device support is planned. For more information, visit: www.rockwellautomation.com/rockwell software/performance/viewpoint/ Internet Explorer Firefox Mobile Devices Safari FactoryTalk ViewPoint Web Clients FactoryTalk ViewPoint Server FactoryTalk View SE Server 1 FactoryTalk View SE Server 2 Control Network Information Network FactoryTalk View SE Client 5 To find out more, visit us at www.discover.rockwellautomation.com/thinkingprocess FactoryTalk ViewPoint Web-HMI FactoryTalk AssetCentre Adds Device Configuration and Calibration Management Capability The latest release of AssetCentre now includes the capability to configure and manage process devices. The solution, jointly developed with Endress+Hauser is based on FDT/DTM technology. AssetCentre is an FDT frame application capable of supporting a wide variety of process instruments and other field devices through plug-in drivers (DTMs) from device manufacturers. This capability enables online access to device configurations, device troubleshooting and diagnostics. Calibration Management capability has also been added into FactoryTalk AssetCentre. The software tool is used to efficiently manage calibration activities that are associated with process devices. This is useful for enabling regulatory compliance and good manufacturing practice. It allows the user to: • Schedule calibrations • Manage calibration standards • Manage certifications • Document as found/as left information and automatically calculates tolerance • Perform paperless calibrations For more information, visit: www.rockwellautomation.com/rockwell software/assetmgmt/assetcentre/ FactoryTalk Batch Version 10 Version 10 of FactoryTalk batch has seen a number of enhancements to improve productivity, reduce costs, and simplify recipe development. Enhancements include: • Smart Binding – Configurable real-time dynamic unit selection for optimal procedural flow • Timer Steps – Reduce engineering and validation effort through use of product timer steps • Recipe SFC Structure Validation – Test procedures for recipe structure errors • Improved Client Capabilities – Simplified control recipe configuration options • RSLinx® Classic OEM – Now included with every FactoryTalk Batch and Back-up key license For more information, visit: www.rockwellautomation.com/rockwell software/production/batch/ 6Publication No. PROCES-SA001A-EN-E February 2009 Baseline MPC 108 % 106 % 104 % 102 % 100 % 98 % 96 % 94 % 917.4 918.6 919.2 919.8 920.4 921 921.6918 Before MPC After MPC y Six-Polymer Line Project Marks Largest Polymer Deployment in China The highly dynamic polymer industry presents major challenges such as high operating costs, increasing raw materials costs and growing local and global competition. In order to maintain its competitive standing and meet China’s growing market demands, SECCO defined a long-term strategy of increasing production rates, reducing costs, and improving product quality for its six polymer lines. Events ACHEMA 2009 ACHEMA is the leading international event for chemical engineering, environmental protection and biotechnology in Frankfurt – 11 May to 15 May 2009. At the last event, held in 2006, around 180,000 professionals from 98 countries attended to find out more about the latest developments and trends. This year we will be showcasing the PlantPAx process automation system and demonstrating the continued expansion of the system based on a combination of the core Rockwell Automation Integrated Architecture™ technologies and those leveraged from co-investments with partners and acquired companies. The PlantPAx process automation system has built strong interest for a range of applications across consumer and resource-based industries. SECCO chose Pavilion Technologies who implemented its Pavilion8® Polymer Reactor and Extruder (MPC) control applications, an integrated software suite combining powerful technology for modelling, control, monitoring, analysis, visualization and integration, to provide targeted solutions and deliver faster time-to-value than alternative solutions. With the help of Pavilion8, SECCO quickly maximized production rate and quality, reduced transition time and material costs, and improved its ability to adapt to changing market demands and conditions. Due largely to the success of Pavilion’s real-time Virtual Online Analyser® (VOA) coupled to the control and optimization strategies, Shanghai SECCO Petrochemicals quickly achieved project goals and realized a major return on investment in just four months. The benefits of Pavilion’s Polymer Solution directly translates into reduced costs and improved revenue potential for SECCO, allowing the plant engineers to better react to shifting market conditions and growing market demands. The stability and robustness of the solution is evident in the 97% control utilization rate. To sustain benefits and further leverage the solution, SECCO has signed a three-year maintenance and support contract for Pavilion to optimize all six of the polymer lines. Economic Benefits • Increased production capacity by 4% on average • Decreased reactor variability by 20% • Improved product consistency by 35% on average • Achieved standard operations on transitions • Reduced the reactor purge and cost Density 1.5 Before MPC After MPC 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 Variation in Melt Flow Rate Low Density Polyethylene (LLDPE) Production Capacity
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