Advanced Process control instructions with Logix

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

What is APC?
APC = Advanced Process Control A traditional control system controls processes to fixed set points determined by operators. Uses generic control algorithms and instructions such as a PID controller. The purpose of an APC system is to automatically account for an expected (modeled, predicted) process response and calculate optimal control actions to minimize process variation. APC systems utilize controllers and technologies such as
Model based control Fuzzy logic and control Multivariable control Adaptive control Inferential control Process modeling and simulation

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Benefits of APC?
Economic benefits
KEY TARGET

Throughput increase Yield increase Energy savings Variation reduction

4 - 10% 0.1 10% 3 - 10% 20 90%

SPECIFICATION OR LIMIT

TIME

Reduce variation of key process and quality parameters Increase plant capacity via tighter and smarter controls React correctly and quickly to changing conditions Typical payback period is <2 years, typically 6-12 months

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Example Hierarchy of Control Strategies

Manual, On/Off, Open loop Ratio Feedback PID Cascade Feed forward (multivariable) Controller-based APC (Regulatory)
APC: Adaptive Non-linear Fuzzy APC: Model based (multivariable)

Manual

Automatic

MPC: Model Predictive Control

Minimization of variation, energy Maximization of yield, throughput

Calculate setpoints!

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

RSLogix5000 FuzzyDesigner

FuzzyDesigner
Add-On Instruction (.L5X)

RSLogix 5000

Development cycle

monitoring tuning

OPC

Design fuzzy system (FD) Generate AOI (FD) Import and instantiate AOI (RS5K) Download project to Logix (RS5K) Monitor and tune (FD, RS5K)

RSLinx Classic

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Direct Fuzzy Controller

Control system status Primary controls

Setpoints S etpoints

FUZZY FUZZY CONTROLLER CONTROLLER

Control C ontrol Variables

PROCESS PLANT PLANT

Input filter

Output filter
Process Variables

Typically handles multiple inputs and generates multiple outputs Recommended for experienced designers as control variables are direct functions of rules Number of rules increases rapidly with number of inputs and fuzzy terms for inputs Dimensionality can, however, be reduced by hierarchical structuring of the rule base of the controller, which is supported by FuzzyDesigner.
Copyright 2008 Rockwell Automation, Inc. All rights reserved. 6

Fuzzy PID Supervisor: Typical Application

plant state information

FUZZY FUZZY SUPERVISOR SUPERVISOR

PID gains

feedforward

SP PV

CV
PID PIDor orMPC MPC CONTROLLER CONTROLLER PLANT PLANT

Applied to existing or newly designed control Easy to design non-linear control Uses expert knowledge and rules to manipulate controller parameters in real time

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

MPC Function Blocks Logix v17

V17 of RSLogix 5000 is adding three new instructions for APC applications (IMC, CC, and MMC). Useful for applications with interacting inputs/outputs. Useful for applications with long deadtimes.

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Internal Model Control (IMC)

IMC_01

Controls a single process variable by manipulating a single output. Compares actual process error against error calculated by an internal first order lag plus deadtime model. Built-in autotuner makes setup easier. Suitable for long deadtime processes which are difficult to control with standard PID loops. Setup and configuration parameters very similar to PIDE

IMC Internal Model Control 0.0 PV 0.0 SPProg 0.0 SPCascade 0.0 RatioProg 0.0 CVProg 0.0 HandFB 0 ProgProgReq 0 ProgOperReq 0 ProgCasRatReq 0 ProgAutoReq 0 ProgManualReq 0 ProgOverrideReq 0 ProgHandReq

...

0.0 CVEU 0.0 SP 0 ProgOper 0 CasRat 0 Auto 0 Manual 0 Override 0 Hand

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

Coordinated Control (CC)

CC_01

Controls a single process variable by manipulating as many as three different outputs. Target values and priorities for outputs are used to optimize your process. Compares actual process error against error calculated by internal first order lag plus deadtime models for each output. Outputs not currently controlling (held at target or in manual) may be used as feedforward signals. Built-in autotuners make setup easier.

CC Coordinated Control 0.0 PV 0.0 SPProg 0.0 CV1Prog 0.0 CV2Prog 0 CV3Prog 0 ProgProgReq 0 ProgOperReq 0 ProgCV1AutoReq 0 ProgCV2AutoReq 0 ProgCV3AutoReq 0 ProgCV1ManualReq 0 ProgCV2ManualReq 0 ProgCV3ManualReq 0 ProgCV1OverrideReq 0 ProgCV2OverrideReq 0 ProgCV3OverrideReq

...

0.0 CV1EU 0.0 CV2EU 0.0 CV3EU 0.0 SP 0 ProgOper 0 CV1Auto 0 CV2Auto 0 CV3Auto 0 CV1Manual 0 CV2Manual 0 CV3Manual 0 CV1Override 0 CV2Override 0 CV3Override

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

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Modular Multivariable Control (MMC)

MMC_01 MMC ...

Controls two process variables to their setpoints using up to three controller outputs. Target values and priorities for outputs are used to optimize your process. Compares actual process errors against errors calculated by internal first order lag plus deadtime models for each output-to-input relationship. Output not currently controlling (held at target or in manual) may be used as a feedforward signal. Built-in autotuners make setup easier.

Modular Multivariable Control 0.0 PV1 0.0 PV2 0.0 SP1Prog 0.0 SP2Prog 0.0 CV1Prog 0.0 CV2Prog 0 CV3Prog 0 ProgProgReq 0 ProgOperReq 0 ProgCV1AutoReq 0 ProgCV2AutoReq 0 ProgCV3AutoReq 0 ProgCV1ManualReq 0 ProgCV2ManualReq 0 ProgCV3ManualReq 0 ProgCV1OverrideReq 0 ProgCV2OverrideReq 0 ProgCV3OverrideReq CV3Override CV2Override 0 CV1Override 0 CV3Manual 0 CV2Manual 0 CV1Manual 0 CV3Auto 0 CV2Auto 0 CV1Auto 0 ProgOper 0 SP2 0 SP1 0.0 CV3EU 0.0 CV2EU 0.0 CV1EU 0.0 0.0

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

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Hands-On Lab Hardware

Runs in an ControlLogix controller in your station

Software
RSlogix 5000 Version V17

Activities
Internal Model Control (IMC) lab Compare PID control to IMC control Coordinated Control (CC) lab Control Dissolved oxygen using three variables
Agitator speed Air flow Air Pressure

Copyright 2008 Rockwell Automation, Inc. All rights reserved.

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Questions?

Copyright 2008 Rockwell Automation, Inc. All rights reserved.