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Honeywell.com
2014 Honeywell Users Group Europe, Middle East and Africa
Operational Excellence - Maximize Profit,
Minimize Cost/Effort with CPM
Perry Nordh, Honeywell
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Document control number
Honeywell Proprietary
Agenda
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Why do great ideas not work?
Relevant History
Elements of CPM and Loop Scout that worked
Elements that didn’t work
Focus of successful Control/Optimization programs
What is Honeywell doing differently? Why?
• Monitoring and proactive
• Reactive workflow
– Keeping Operators and Engineers engaged
– What’s new in CPM R570
– CPM Roadmap
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Why do great ideas not work?
• Safety
– Flying cars
– Jet packs
• Wait for it
– CGI
– Mobile smart phones
• Attitudes
– That is a stupid idea
– “I don’t need this” or “The conclusion is wrong”
– I will do it tomorrow
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“Never put off till tomorrow what may be done day after tomorrow just as well". Mark Twain
Elements of successful Control/Optimization
• Technology
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Control technology AND monitoring technology
Minimum re-work, get the right answer the first time
The “right” amount of analysis
Decision support
• Attitudes and follow-through
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Clear and understandable displays and reports
Prioritization of effort
Workflow support
Accept the facts – your process performance could be better
• Measure to understand where you are
• Act to improve that measurement
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Some monitoring technology history…
1997
Harris, Seppala
and Desborough
30+ papers
Owen et. al
1996
13 papers
1995
5 papers
1994
3 papers
Kozub
Shah and Huang
Kozub
Thornhill et. al.
Shah and Huang
Desborough
and Sefidrou
Desborough
and Harris
Desborough and Harris
1993
Jofriet
and Bialkowski
Kozub and Garcia
3 papers
Stanfelj,
Marlin & MacGregor
5
1992
3 papers
1989
1 paper
Desborough
and Harris
Harris
What worked well?
• Loop Scout – focused on actions to maintain PID loops
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Simple to set up on the DCS
Little or no tag configuration – just upload data, set loop criticality
Simple user interface without a lot of maintenance required
Good results with valve stiction algorithm, level loop objective, criticality
• CPM – focused on the larger control engineering problem
– Excellent interactive user interface
• Small scope to enterprise wide view
• Data analysis and interactive trending
– Workflow support – dispositions and integration with tuning tool
– Complete scope monitoring
• APC monitoring
• Instrument monitoring
• Custom calculations
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What didn’t work?
• Loop Scout
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Very simple – cumbersome tracking
Always questions on cascade loops
No handling of APC or instruments
No customization – limited UI options, limited interaction
User ownership of the actions
• CPM
– Complex configuration
– Complex maintenance
• Tag changes and configuration changes
– Had trouble with valve stiction results in some cases
– User ownership of the actions
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Key Issues
• Key Problems and how Honeywell
solves them
– Safe and stable operations, sustaining
the benefits over time (keeping benefits
flowing)
• Keeping the controllers on and monitor
• Operator awareness and understanding of
what the controller is doing
– Keeping staff and aging workforce
• Focus on ease of use and ease of
deployment
– Continuous improvement and finding
new areas of benefit
• Make new controllers easier to justify
• Push into new areas of optimization
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What is Honeywell doing differently?
“Blink”
Humans are good at:
– “Recognition”
– Problem solving
– Troubleshooting
– New situations
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“Think”
Computers are good at:
– “Cognition”
– Vigilance tasks
– Repetitive tasks
– Fast response to
defined situations
– Automated procedures
Both “recognition” and “cognition” are required to sustain control benefits over time.
Data sources for research…
Loop Scout
CPM
Profit Suite
Honeywell Specialty
Materials
Honeywell Labs
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What is Honeywell doing differently?
Understand multiple sustainment models
1. Site self supporting
i.
ii.
Knowledgeable people on site
Tools and data on site
2. Corporate sustainment
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ii.
Knowledgeable people on site and/or centrally located
Tools and data centrally located and/or accessible
3. Vendor involvement
i.
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Variable level of input and access to data
What is Honeywell doing differently?
Understand Workflows
• Monitoring and proactive
– Monitoring tools in place
– Expectation that monitoring will catch degradation
• Reactive workflow
– Like it or not – we cannot prevent everything
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Reliability Maturity Continuum
Reliability-Centered Maintenance
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Closely related to “Total Productive Maintenance”
considers all asset management options: predictive, preventative, reactive
determines the maintenance requirements of the physical assets within their current
operating context
ensures requirements are met as cheaply and effectively as possible
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Reliability %
Predictive Maintenance
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AKA “On-condition”, “Condition-Based Maintenance”
Maintenance based on non-invasive tests and condition measurements
Monitor & trend, then do only what is needed
Repairs are cheaper because they are scheduled
Safely eliminate some preventative maintenance
Increases awareness of equipment condition, identifies impending failure
Preventative Maintenance
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AKA 1950’s “modern maintenance”
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When done, it can easily be overdone
Can introduce new problems
Used on expensive or critical items that can’t be monitored by other
means
Eliminate for all that can be monitored
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Reactive Maintenance
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AKA “Run-to-Failure” and “Unscheduled Maintenance”
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Maintenance expense $$
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Most expensive alternative
Keep WELL under 30% of maintenance program
Used on not critical low-cost / easy to replace components
Reactive maintenance is costly
Relative Cost
of Maintenance
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5
0
Reactive
Preventative
Sources: John S. Mitchell “Equipment Lifecycle Management”;
Lightfoot et al., “The use of SPC in PM at the USPS”
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Predictive
How can Honeywell technology help?
• Technology inherently addresses the Deploy / Sustain challenges
customers are facing – it lends itself to minimizing lifecycle costs.
• Technology specifically built to reduce implementation effort and
lifecycle burden of profit-generating APC applications.
• Enables a lifecycle support program instead of providing a box of
tools that the user must figure out how to configure/use.
• Every development of an extended technology or new tool has a
goal to minimize the lifecycle cost.
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CPM Algorithm improvements: Oscillation period
• Oscillation Period or frequency
- Duration of one complete cycle between peak to peak
- Reported in minutes
• Common oscillation in loops
- Interacting loops may oscillate at the same frequency
• Methods used in CPM
- Spectral based period
estimation
 Power spectrum
- Time domain based method
 Zero cross over
 Auto-correlation function
(ACF)
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Combining oscillation methods
• Each oscillation method output is considered as a
measurement point
– Kalman approach is applied to get more accurate measurement
of oscillation period
Spectral
method
time series cross-over
method
Oscillation
periods
Weighted average
of oscillation periods
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ACF
cross-over
method
Weights are determined
based on individual
algorithm accuracy against
hand classified data
Combining Valve Stiction Algorithms
Kalman filter approach
Weights are determined based
on individual algorithm accuracy
against hand classified data
Method 1
Shape-based
Valve stiction
probabilities
Weighted average
of valve stiction probabilities
Method 2:
Wavelet based
Method 3:
Non-Linear
Index based
Flow and Pressure loops:
•All three methods are combined to give
one single stiction probability
Level and Temperature loops
•Only Method 3 is used.
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PID Monitoring: Do something with the answer
• If there is no action taken (fixing, tuning, etc.)
– There is no value to the process or operations
• Actions that create a performance improvement:
1. Tune: TaiJi PID (all systems), OperTune (Experion)
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TaiJi PID is an additional license and separate install
OperTune is included with Experion systems
More to come in 2015….
2. Fix: create a work order for I&E staff
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Note: investigating is an action, but doesn’t have any
net affect on the process or operations
APC monitoring: is it any different?
• If there is no action taken (fixing, tuning, etc.)
– There is reduced APC value to the process or operations
• Actions that create a performance improvement:
1. Tune:
 Profit Stepper
 Adjust performance ratios/ranking and tradeoff values
 Adjust optimization coefficients (linear or quadratic)
2. Fix: create a work order for I&E staff
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Note: investigating is an action, but doesn’t have any
net affect on the process or operations
Preventing issues with APC has to be a primary focus
Keeping controllers on…
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Keeping Operations Engaged and Informed
• New in R430: PSOS performance index
– a weighted sum of seven established attainment metrics plus
three possible user entered metrics.
48.8%
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Keeping Engineers Engaged: Performance
• Effective Utilization Metrics
– MV Effective Service Factor
– CV Effective Service Factor
• Performance Metrics
– Limit Tracking
– High/Low Limit Activation
– Average/Peak Violation
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• Constraint Performance Metrics
– Oscillation Index
– Low/High Limit
– Limit Changes
• Dynamic Performance Metrics
– RPI
– Standard Deviation
Keeping Engineers Engaged: Diagnostics
• Model Performance Metrics
– Model Quality Index
– Phase Index
– Non-Linearity Index
• MV/DV Correlation
• Limit changes
– CV/MV Limit Changes
– Limit change history
• Color coded limit activation view
• Optimization view
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APC : CV Detailed Report
• CV Detailed Report
– Prediction vs. Measurement Trends
– Frequency Response
– Autocorrelation of Prediction Errors
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How does CPM work?
Data
Analysis &
Reporting
Benchmarking
Tuning Issue
Information &
Reports
Mechanical Issue
Process Issue
Disposition
(Workflow
Tracking)*
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*CPM Standard
Closing the Loop - Dispositions
Track it until it is fixed…
Asset Name Description Asset Type
LIC401
HT401
LEVEL
CONTROL
OX801 BTU
BTUC801 CONTROL
OX1D
UDL3
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OXID
U3_DCMP
Service
Factor
Asset Group Weight
Oscillation
Index
Std Dev
Percent
Saturation
RPI
MV
Effective
Service
Factor
Effective
Service
Factor
Model
Quality
Index
Disposition
Flagged Date
Disposition Entry
Disposition
Date
Weeks In
Current
Disposition
Disposition Comment
Regulatory
OX401
1
100
2.07
0.84
0.09
22.03
77.97
N/A
N/A
10/30/2014 23:10
10/30/2014 23:10
Requires
Attention
Std Dev value 2.07 violated
high limit benchmark value
2.00. Oscillation Index value
1 0.84 violated high limit
benchmark value 0.40. RPI
value 0.09 violated low limit
benchmark value 0.40.
Regulatory
OX801
1
100
2.36
0.11
0.22
47.76
52.24
N/A
N/A
10/30/2014 23:10
10/30/2014 23:10
Requires
Attention
Std Dev value 2.36 violated
high limit benchmark value
1 2.00. RPI value 0.22 violated
low limit benchmark value
0.40.
Requires
Attention
Service Factor value 46.84
violated low limit benchmark
value 90.00. MV Effective
Service Factor value 25.19
3 violated low limit benchmark
value 50.00. Model Quality
Index value 0.28 violated
low limit benchmark value
0.50.
Requires
Attention
Service Factor value 46.11
violated low limit benchmark
value 95.00. MV Effective
Service Factor value 18.44
13 violated low limit benchmark
value 80.00. Model Quality
Index value 0.32 violated
low limit benchmark value
0.50.
MPC
MPC
Oxidation
VT307
1
1
46.84
46.11
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
25.19
18.44
0.28
0.32
5/22/2014 23:10
5/22/2014 23:10
10/16/2014 23:10
8/7/2014 23:10
Disposition
Follow-Up
Date
CPM R570 Key Areas
• CPM R570
o Simplified Templates to support generic bulk builder
o Bulk-Build functionality for DCS ( HWL DCS and 3rd party DCS)
o Honeywell DCS first, other DCS systems as point releases
o Latest version of OI
o Support for IE9/10/11
o Java support update (Java 7 with latest update support)
o Integrated with ePHD for trending/exporting/integration/scalability
o PID metric/algorithm improvements based on latest research
o Improved oscillation index
o Valve stiction
o MPC monitoring templates for Profit Controller & Generic APC
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