17PS

Honeywell Forge APC-4516
Process Controller Implementation

Profit Stepper
Honeywell Confidential
Copyright © 2012 Honeywell International Inc.
Honeywell Restricted
1 September 26, 2022
Profit Stepper Function Honeywell
• Data Collection
• Process Stepping
• Model Identification
– Open Loop
• Directly from process
– Closed Loop
• From Profit Controller
– Mix of Open and Closed loop
• Saves data in XTP file
• XTP file is used by PSES to perform model ID
• The stepper can be configured in
– PSES
– PSRS
Honeywell Restricted 2 September 26, 2022
Profit Stepper – Open Loop Step Testing Honeywell
• Uses GBN signal– Generalized Binary Noise
– Proposed by Tulleken
• Open Loop
– Writes directly to the regulatory control point
Profit Stepper – Closed Loop Step Testing Honeywell
• Closed Loop
– Writes to the selected Profit Controller MV
– PC Engine superimposes the excitation signal
• MV = MVProfit Controller + MVProfit Stepper
– Honors MV limits
– No guarantee that the full MV move can be implemented
• User can select mixed Open/Closed loop testing
– Univariate – one MV at a time (Sequential)
– Multivariate – several MVs at the same time
Profit Stepper – Mixed Step Testing Honeywell
Profit Stepper – Step Testing Honeywell
• Uses GBN – Generalized Binary Noise
– Proposed by Tulleken
– Similar to PRBS – Different Theoretical Properties
– Two levels: +m/2 and -m/2
– Excitation magnitude = m
– MV settling time = average holding time
• Initial MV Settling time from XM file or entered by user
• Recalculated when ID runs
• Signal adapts to settling time – Frequency Adaptive Algorithm
• Move filtering can be applied (be careful)
• For closed loop identification, each MV can have two adaptive step
signals:
– Gain Adaptive Algorithm
– Frequency Adaptive Algorithm
• Gain Adaptive Algorithm
– GBN signal can have multiple levels
– Next MV move flipped if it results in less relative MV/CV violation
• Rule based decision
– Conventional two level signal generated at beginning
• Frequency Adaptive Algorithm

– The frequency of the GBN signal changes, responding to the identified models.
– More energy is automatically focused on the frequencies that are more important
for the profit controller.
– The frequency is updated using the average settling time of sub-models that:
• Have a key relationship with the MV
• Have a current model rank better than 3.
Average holding time = 10

Excitation magnitude = 10
Base value = 575
Open Loop vs. Closed Loop Identification Honeywell
• Open Loop Identification
– The process is tested without control.
– The process can be excited well.
– The process can be move to unwanted operating conditions.
• Close Loop Identification

– Often preferred from Operational point of view.
– The process is tested when its fully or partially controlled by controller (the
FIR model might fail).
– It can be tricky and difficult due to correlations between the input and
disturbances.
– The controller reduces the process excitation.
Creating an stepper in PSES1 Honeywell
• Create a new Profit Stepper project
• Append a new stepper application to existing Controller project
• Append a new stepper application to existing Controller project
Closed Loop Model Identification1 Honeywell
• Enter Name, Description, Version and browse for computer machine
• After adding the controller, build the platform
• Save the platform in the Platform folder
• Successful Stepper application built.
• To Start Stepping Operation go to the Stepper Operation page.
• Configuring the Stepper
• Configuring the Stepper
Stepper Configuration Options1 Honeywell
• Step Magnitude:
– Type the magnitude of the step signal.
– Units of the Manipulated Variable depends on the selected MV
– Only positive numbers
• Settling time:
– Type the settling time for stepping.
– The unit of the settling time is minutes.
– Type only positive numbers.
– For Profit Controller, a default settling time is calculated based on the existing models
in the xml file using the average settling time of all the non-null, non-integrator sub
models for the given MV.
• Base Value:
– Editable for Open-loop MVs
– Default base value is the current read value of the open MV. If user change the base
value during the step testing, the signal will be reset to the new MV base value.
Stepper Configuration Options2 Honeywell
• Filter:
–Filter for the step signal. The unit of the filter is minutes. You can type only positive numbers.
• MaxHold / MinHold:
–This tuning parameter prevents long steps in maximum holding
–The unit of the MaxHold / MinHold is minutes
–Do not adjust these until you have looked at the signal
–Can degrade the signal significantly
• First Step:
–Editable before step testing starts.
–First Step determines the next step value every time the MV testing is stopped and restarted.
–Default: Select Default if both CV and MV directions have no violations.
–Positive: Select Positive to step up from the set point value
–Negative: Select Negative to step down from the present value
• Gain Adaptive/Frequency Adaptive:
–Discussed in previous slides.
• Stepping Individual MVs
• Starting Data collection
• Starting Stepping
If the related controller is not running, the

following message is generated:
• Starting Stepping
• Stepper Trend
• Model Identification Options

– Automatic model identification (Iterative Model ID).
– Manual Model identification (ID Now).
• Set Model Options
• Identified Models
• Variable Overview
• Model Highlights – how good are the models?
• Final Model Matrix
• Multiple Curves Matrix View
• Use of Lock Model feature
– Important to lock models when high rank is achieved
– Try to locate blocks of process interactions in model matrix
• Lock in the good models
• May lock models from start of model ID if high confidence in models
• Frequency Adaptive feature
– Only uses the Key Models.
• Gain Adaptive feature:
– Only uses Key or Locked models.
• Automatic Lock
• Importing/Exporting Stepper Parameters

• The Stepper parameters can be saved in an XML file
(by default use the same Stepper name).
• Use the Actions menu to import an existing XML file
to load (and overwrite) the current parameters.
• The XML file is saved in:
C:\ProgramData\Honeywell\URT\Platforms\
Profit Stepper in PSOS1 Honeywell
• Stepper interaction with Profit Controller can be monitored on PSOS
• Once the Stepper is running in closed loop, its status shows up in PSOS
• The controller view in PSOS with stepper
Open Loop Step testing1 Honeywell
• Add an stepper into the project as instructed previously.
Open Loop Step-Testing3 Honeywell
CV/MV/DV
DCS tag or
Must match the module
BLC Display Location name BLC
name of OPC Template
Server
Mixed Closed/Open Loop Step-Testing1 Honeywell
• Select a controller for closed loop identification
• Select variables for open loop identification
• N.B. “mixed” Mode Open or Closed in MV List box for each MV
• Also notice the Controller name for close loop points.
• Adding variables on the fly – For both open loop and closed loop
Hints and Tips 1 Minimum Computer Spec Honeywell
• Closed Loop Model Identification
is very CPU/RAM intensive, refer
to manual for minimum
hardware/software requirements
• It is recommended to ALWAYS
run Profit Stepper sessions on a
GUS, ES-T or an Engineering
workstation. NOT on an APC
server where controllers or
applications are running

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Honeywell Forge APC-4516

Process Controller Implementation

• Frequency Adaptive Algorithm

Average holding time = 10

• Close Loop Identification

• Create a new Profit Stepper project

• Append a new stepper application to existing Controller project

• Append a new stepper application to existing Controller project

• Enter Name, Description, Version and browse for computer machine

• After adding the controller, build the platform

• Save the platform in the Platform folder

• Successful Stepper application built.

• To Start Stepping Operation go to the Stepper Operation page.

• Configuring the Stepper

• Configuring the Stepper

• Stepping Individual MVs

• Starting Data collection

If the related controller is not running, the

• Model Identification Options

• Set Model Options

• Model Highlights – how good are the models?

• Final Model Matrix

• Multiple Curves Matrix View

• Importing/Exporting Stepper Parameters

• The controller view in PSOS with stepper

• Add an stepper into the project as instructed previously.

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