Honeywell Forge APC-4516

Process Controller Implementation

Identifier Test Cases

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Example Case1 Honeywell

• Case DEMO
– Data Source: Mat File DEMO_DAT
– Size: 4 CV's 3 MV's 3 DV's
UVP26371.PV UFC26034.OP FC26030.PV
UPT26369.PV TC26371.OP TI26303.PV
PC2622o.PV PC26220.OP UFY26371.PV
LC26112.PV
– Use as introduction to RMPCT identifier
– Use default identification parameters, except for:
• FIR is velocity form

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Example Case2 Honeywell

• Case HIGH_O
– Data Source: Pnt Files
U1 U2 Y1 Y2
Y3 Y4 Y5 Y6 Y7
– Size: 7CV's 2 MV's
Y1_VAR U1_VAR
Y2_VAR U2_VAR
Y3_VAR
Y4_VAR
Y5_VAR
Y6_VAR
Y7_VAR
– Series of SISO problems
– Illustrates effects of
• Varying noise levels in CV signals
• Drift in CV signals
• Input signal power spectrum
– Shows importance of model form (positional or velocity)

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Example Case3 Honeywell

• Case C2T01
– Data Source: Pnt Files
AD654A AD654F AD656CP FM215L
FM215LV FM215V FM239L FM239LV
FM239V PI746D PI747D TC010SP
XD056A XD057A XD067B
– The single MV is underlined and is not in Case C2F01
– Matrix Size: 13 CV's 1 MV
– Illustrates use of default identification parameters
– Use in conjunction with C2F01 case for model merge

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Example Case4 Honeywell

• Case C2F01
– Data Source: Pnt Files
AD654A AD654F AD656CP FD232
FM215L FM215LV FM215V FM239L
FM239LV FM239V PI746D PI747D
XD056A XD057
– The single MV is underlined and is not in Case C2T01
– Matrix Size: 13 CV's 1 MV
– Illustrates use of default identification parameters
– Use in conjunction with C2T01 case for model merge

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Example Case5 Honeywell
• Case INTEG
– Data Source: Mpt File INTEG
– Size: 4 CV's 2 MV's
UFC26034.PV X1C26034.OP
LC26371.PV X2C26034.OP
LC26220.PV
PFC26034.PV
– Illustrates mix of integrating and stable process dynamics
– Shows importance of proper settling time
– Illustrates simultaneous MV moves

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Example Case6 Honeywell

• Case GASI (optional)

– Data Source: Pnt Files
ULEADI YLEADI
– Size: 1 CV 1 MV
PIC11A.PV PIC11B.OP
– Illustrates integrator with lead term
– Shows importance of proper settling times
– Shows PRBS MV signal

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Example Case7 Honeywell

• Case SIN (in directory SYNC_I)

– Data Source: Mpt File L6STEP
– Size: 1 CV 1 MV
81L6.PV 81L6.OP
– Integrator with noise
– Illustrates importance of selecting proper settling time(s)

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Example Case8 Honeywell

• Case SMALL
– Data Source: Mpt File SMALL
– Size: 2 CV's 2 MV's
UTC26034.OP TC26371.OP
UFC26034.OP PC26220.OP
– Illustrates
• Identification of fast process
• Handling of discontinuous data
– Settling time is important

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Example Case9 Honeywell

• Case LONG
– Data Source: Mpt File LONG
– Size: 1 CV 2 MV's 1 DV
SQRTNC4.PV F08030.PV FEEDIC4.PV
F08029C.PV
– Illustrates
• Identification of very slow processes
• Well designed MV steps
– Shows effect of number of coefficients

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Example Case10 Honeywell

• Case SCRUB1 (Optional)

– Data Source: Mpt File SCRUB3ST
– Size: 5 CV's 3 MV’s 9 DV's
82AC910.PV 82F64.SP 82FC911.PV
82L6.OP 82F8.PV 82T13.PV
82T9.PV 82H487.OP 82T567.PV
82F18.OP 82T10.PV
82L6.PV 82T11.PV
82F48A.PV
82F48B.PV
82F17.PV
82F10.PV

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Example Case10 (cont.) Honeywell
– Ill designed problem
– Plot CV's and MV's
– Illustrates how not to design step tests

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Example Case 11 Honeywell

• Case SMALL0
– Data Source: Mpt File SMALL0
– Size: 2 CV's 2 MV's
UTC26034.OP TC26371.OP
UFC26034.OP PC26220.OP
– Illustrates
• Identification of fast process
• Handling of discontinuous data
• Handling null process models
– Settling time is important

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Example Case12(a) Honeywell

• Case Prestep
– Data Source: Pnt Files
FC0004OP TI0808PV TI0809PV TI0810PV
TI0811PV TI0812PV TI0813PV TI0814PV
ZAI008PV ZSUMPV ZYSGPV FC0002SP
FC0003SP FC0006SP FC0007SP FC0030SP
PC0011SP SC0100SP TC0004SP TC0013SP
TC009ASP ZAI002PV
– Matrix Size: See next page
– Illustrates
• Typical pre-test data
• Effect of incorrect model structure
– Integrator like performance
– Based on real data

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Example Case12 (b) Honeywell

– Size: 11 CV’s 9 MV’s 2 DV's

52FC0004.OP 52FC0002.SP 52SC0100.PV
52TI0808.PV 52FC0003.SP ZAI0002.PV
52TI0809.PV 52FC0006.SP
52TI0810.PV 52FC0007.SP
52TI0811.PV 52FC0030.SP
52TI0812.PV 52PC0011.SP
52TI0813.PV 52TC0004.SP
52TI0814.PV` 52TC0013.SP
ZAI0008.PV 52TC009A.SP
ZSUM.PV
ZYSG.PV
– Suggested Settling Times:
• 30 60 120 180 210

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Test Case Honeywell

• Case TEST
– Data Source: Pnt Files
PV01 PV02 PV03 DP01
MV01 MV02
– MATRIX Size:
– 3 CV's 2 MV’s 1 DV
PV01.OP MP01.SP DP01.PV
PV01.OP MP02.SP
PV03.OP
– Illustrates that anything is fair in a test
– Based on synthesized data
– There is an exact solution to this problem

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Laboratory Case(1) Honeywell

ST01
C V # 1 ( PV ) TI01 C V # 3 ( O P)
ST01
LC03

D V # 1 ( PV )
ST01 ST01
FI06 FC04
OV HD
M V # 1 ( S P) P RO D
F EED

M V # 2 ( S P)
ST01 ST01
LC07 FC05

ST01
UI02
S T EA M

C V # 2 ( PV ) BT M S
P RO D

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Laboratory Case(2) Honeywell

• Case ST01
– Data Source: Pnt Files
ST01TI01 ST01UI02 ST01LC03
ST01FC04 ST01FC05 ST01FI06
– Size: 3 CV's 2 MV's 1 DV
ST01TI01 ST01FC04 ST01FI06
ST01UI02 ST01FC05
ST01LC03
– Based on synthesized data
– There is an exact solution to this problem
– Future work
• Build Controller
• Off-line Simulation
• LCN Commissioning & Simulation

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Application Design1- Revisit Honeywell
• Verify the models with ChemE principles
– Check for the model directions
– Check for the relative magnitude
– Can the gains be checked by a heat or mass balance ?
– Check the model gains with an optimization simulation
– Be careful with very fast models
• Confirm the control objective with the models
– Revisit the primary CV selection
– Run some simulations with the core CV's first
– Include other CV's as necessary (as you proceed)

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Application Design2 - Revisit Honeywell
• Refine the optimization objective
– Speed vs dynamic violations
– Operations vs economics

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