Process Control Performance Assessment: From Theory to Implementation PDF
Preview Process Control Performance Assessment: From Theory to Implementation
Advances inIndustrial Control OthertitlespublishedinthisSeries: DigitalControllerImplementation RudderandFinShipRollStabilization andFragility TristanPerez RobertS.H.Istepanianand HardDiskDriveServoSystems(2ndEd.) JamesF.Whidborne(Eds.) BenM.Chen,TongH.Lee,KemaoPeng OptimisationofIndustrialProcesses andVenkatakrishnanVenkataramanan atSupervisoryLevel Measurement,Control,and DorisSáez,AldoCiprianoand CommunicationUsingIEEE1588 AndrzejW.Ordys JohnEidson RobustControlofDieselShipPropulsion PiezoelectricTransducersforVibration NikolaosXiros ControlandDamping HydraulicServo-systems S.O.RezaMoheimaniandAndrewJ. MohieddineJelaliandAndreasKroll Fleming StrategiesforFeedbackLinearisation ManufacturingSystemsControlDesign FreddyGarces,VictorM.Becerra, StjepanBogdan,FrankL.Lewis,Zdenko ChandrasekharKambhampatiand Kovaˇci´candJoséMirelesJr. KevinWarwick WindupinControl RobustAutonomousGuidance PeterHippe AlbertoIsidori,LorenzoMarconiand AndreaSerrani NonlinearH2/H∞ConstrainedFeedback Control DynamicModellingofGasTurbines MuradAbu-Khalaf,JieHuangand GennadyG.KulikovandHaydnA. FrankL.Lewis Thompson(Eds.) PracticalGrey-boxProcessIdentification ControlofFuelCellPowerSystems TorstenBohlin JayT.Pukrushpan,AnnaG.Stefanopoulou andHueiPeng ModernSupervisoryandOptimalControl SandorMarkon,HajimeKita,HiroshiKise FuzzyLogic,IdentificationandPredictive andThomasBartz-Beielstein Control JairoEspinosa,JoosVandewalleand WindTurbineControlSystems VincentWertz FernandoD.Bianchi,HernánDeBattista andRicardoJ.Mantz OptimalReal-timeControlofSewer Networks AdvancedFuzzyLogicTechnologiesin MagdaleneMarinakiandMarkos IndustrialApplications Papageorgiou YingBai,HanqiZhuangandDaliWang ProcessModellingforControl (Eds.) BenoîtCodrons PracticalPIDControl ComputationalIntelligenceinTimeSeries AntonioVisioli Forecasting SoftSensorsforMonitoringandControlof AjoyK.PalitandDobrivojePopovic IndustrialProcesses ModellingandControlofmini-Flying LuigiFortuna,SalvatoreGraziani, Machines AlessandroRizzoandMariaGabriella PedroCastillo,RogelioLozanoand Xibilia AlejandroDzul Andrzej W. Ordys, Damien Uduehi and Michael A. Johnson (Eds.) withNinaThornhill,AlexanderHorch,DaleSeborg,DavidLaing, MichaelGrimble,PawelMajecki,HaoXia,MarcoBoll, MarcusNohr,SandroCorsi,MartinBannauerandGertaZimmer Process Control Performance Assessment From TheorytoImplementation 123 AndrzejW.Ordys,PhD,CEng DamienUduehi,PhD FacultyofEngineering BGInternationalLtd. KingstonUniversity 100ThamesValleyParkDrive FriarsAvenue Reading RoehamptonVale RG61PT London UK SW153DW UK MichaelA.Johnson,PhD IndustrialControlCentre UniversityofStrathclyde GrahamHillsBuilding 50GeorgeStreet Glasgow G11QE UK BritishLibraryCataloguinginPublicationData Processcontrolperformanceassessment:fromtheoryto implementation.-(Advancesinindustrialcontrol) 1.Supervisorycontrolsystems-Evaluation2.Automatic datacollectionsystems3.Processcontrol-Data processing4.Benchmarking(Management) I.Ordys,A.W.(AndrzejW.),1956-II.Uduehi,DamienIII. Johnson,MichaelA.,1948-IV.Thornhill,N.F. 670.4’275 ISBN-13:9781846286230 ISBN-10:1846286239 LibraryofCongressControlNumber:2006936887 AdvancesinIndustrialControlseriesISSN1430-9491 ISBN 978-1-84628-623-0 e-ISBN 978-1-84628-624-7 Printedonacid-freepaper ©Springer-VerlagLondonLimited2007 MATLAB®andSimulink®areregisteredtrademarksofTheMathWorks,Inc.,3AppleHillDrive,Natick, MA01760-2098,USA.http://www.mathworks.com Apartfromanyfairdealingforthe purposesof researchorprivate study, orcriticism orreview,as permittedundertheCopyright,DesignsandPatentsAct1988,thispublicationmayonlybereproduced, storedortransmitted,inanyformorbyanymeans,withthepriorpermissioninwritingofthepublishers, or in the case of reprographic reproduction in accordance with the terms of licences issued by the CopyrightLicensingAgency.Enquiriesconcerningreproductionoutsidethosetermsshouldbesentto thepublishers. Theuseofregisterednames,trademarks,etc.inthispublicationdoesnotimply,evenintheabsenceofa specificstatement,thatsuchnamesareexemptfromtherelevantlawsandregulationsandthereforefree forgeneraluse. Thepublishermakesnorepresentation,expressorimplied,withregardtotheaccuracyoftheinformation containedinthisbookandcannotacceptanylegalresponsibilityorliabilityforanyerrorsoromissions thatmaybemade. 9 8 7 6 5 4 3 2 1 SpringerScience+BusinessMedia springer.com Advances inIndustrialControl SeriesEditors ProfessorMichaelJ.Grimble,ProfessorofIndustrialSystemsandDirector ProfessorMichaelA.Johnson,Professor(Emeritus)ofControlSystems andDeputyDirector IndustrialControlCentre DepartmentofElectronicandElectricalEngineering UniversityofStrathclyde GrahamHillsBuilding 50GeorgeStreet GlasgowG11QE UnitedKingdom SeriesAdvisoryBoard ProfessorE.F.Camacho EscuelaSuperiordeIngenieros UniversidaddeSevilla CaminodelosDescobrimientoss/n 41092Sevilla Spain ProfessorS.Engell LehrstuhlfürAnlagensteuerungstechnik FachbereichChemietechnik UniversitätDortmund 44221Dortmund Germany ProfessorG.Goodwin DepartmentofElectricalandComputerEngineering TheUniversityofNewcastle Callaghan NSW2308 Australia ProfessorT.J.Harris DepartmentofChemicalEngineering Queen’sUniversity Kingston,Ontario K7L3N6 Canada ProfessorT.H.Lee DepartmentofElectricalEngineering NationalUniversityofSingapore 4EngineeringDrive3 Singapore117576 ProfessorEmeritusO.P.Malik DepartmentofElectricalandComputerEngineering UniversityofCalgary 2500,UniversityDrive,NW Calgary Alberta T2N1N4 Canada ProfessorK.-F.Man ElectronicEngineeringDepartment CityUniversityofHongKong TatCheeAvenue Kowloon HongKong ProfessorG.Olsson DepartmentofIndustrialElectricalEngineeringandAutomation LundInstituteofTechnology Box118 S-22100Lund Sweden ProfessorA.Ray PennsylvaniaStateUniversity DepartmentofMechanicalEngineering 0329ReberBuilding UniversityPark PA16802 USA ProfessorD.E.Seborg ChemicalEngineering 3335EngineeringII UniversityofCaliforniaSantaBarbara SantaBarbara CA93106 USA DoctorK.K.Tan DepartmentofElectricalEngineering NationalUniversityofSingapore 4EngineeringDrive3 Singapore117576 ProfessorIkuoYamamoto KyushuUniversityGraduateSchool MarineTechnologyResearchandDevelopmentProgram MARITEC,Headquarters,JAMSTEC 2-15NatsushimaYokosuka Kanagawa237-0061 Japan To my wife Anna and my sons Szymon and Bart Andrzej Ordys To my lovely wife Diane Elizabeth and my son and little x-man Zachary Xavier, you are my inspiration for everything, I thank God for both of you Damien Uduehi To my brother, David and his wife, Manya for their love and support over the years Michael Johnson Foreword The industrial imperative for control systems stems from a need to meet quality, safety, environmental and economic goals related to asset utilization. The justification for control projects and subsequent analysis of the effectiveness of commissioned schemes is assessed against these criteria. The installed cost of control systems is considerable, and several studies have reported what many practicing control engineers know - many control systems fail to meet their basic objectives. Indeed, a great many control loops may actually increase, rather than reduce variability. During the past fifteen years there has been considerable academic and industrial interest in developing methods to analyze and improve the performance of control systems. Typical objectives are to identify poorly performing loops and to diagnose causes for this unacceptable performance. Most of the academic developments have focused, quite appropriately, on developing the underlying theory and the mathematical and statistical tools - descriptive statistics, time series and spectral methods, that are required for this analysis. There is great industrial interest in this topic. Commercial packages are available and a number of industrial perspectives on the topic of performance monitoring and analysis have been reported. Not unexpectedly, considerable effort is required to translate the underlying theory into practice. Control Performance Assessment: From Theory to Implementation provides both a business and technological perspective on this topic. Throughout the monograph, control assessment, monitoring and diagnosis are viewed as essential approaches for satisfying the business constraints under which control schemes are implemented. Benchmarking is used extensively in many private and public sector institutions. Drawing upon the extensive literature and practice in this area, the authors of this monograph provide compelling arguments for interpreting control performance monitoring and assessment in this light. In doing so, they identify a number of advantages and limitations of existing theory and provide a framework for interpreting and extending performance measures. The contributors of Control Performance Assessment: From Theory to Implementation have considerable industrial and academic experience. After presenting the business imperative for benchmarking, the basic algorithms and a x Foreword number of performance measure extensions are clearly explained and illustrated using case studies of realistic complexity. A concise compilation of academic research on performance monitoring, analysis and diagnosis is included. This monograph is intended for practicing engineers and advanced degree students. It is part of the series Advances in Industrial Control whose aim is to report and encourage technology transfer in control engineering. Practicing engineers will appreciate the business perspective, the applications to difficult problems and the recognition of the challenges in applying the theory to industrial processes. The industrial perspective on this topic will be of considerable interest to graduate students who wish to advance the theory and practice of controller performance monitoring and analysis. T.J. Harris Department of Chemical Engineering Queen’s University Kingston, Ontario Canada Preface In the commercial sector, benchmarks, which are derived from observations across a range of processes and companies, have been applied in different forms to assess the performance of business processes. The results of these benchmarking exercises are used to formulate best practice and other strategies to improve business process performance. This performance assessment paradigm is long standing and from it can be extracted a generic assessment framework: model, specify, measure, analyse and improve performance. Among the philosophies that embody this framework, those of business process re-engineering and business process benchmarking are probably the best known. In the manufacturing and production sectors, optimisation and control strategies have been used to obtain improved process performance. Optimisation has been an important tool in generating the designs for advanced control systems and has been used to provide operating guidelines at the higher levels in the process control hierarchy. But, there has been no real overarching process performance assessment and improvement methodology available as there has been in the business process domain. For example, little has been done to try and link control system performance to company financial performance goals and there is an absence of a simple, transparent holistic philosophy for determining what control performance could actually be achieved by an installed control system. The situation for manufacturing and process industry systems (for example, petrochemical refineries or chemical plants) is of thousands of control loops, simple and complex, all contributing to the overall productivity of the plant and ultimately, the financial success of the company. It has always been known that if these loops could be optimised then each concomitant improvement in performance would lead to energy savings, reduction in raw material usage, improved product quality and tolerances and lower material wastage. The obstacles to achieving these outcomes were (and still are) the sheer logistics of tuning thousands of loops and the lack of technical input to comprehend the structural raison d’etre for the control system installed.
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