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Jump Start Guide: Smart Tune in Aspen DMC3

A Brief Tutorial (and supplement to training and online documentation)


Lucas Reis, Product Management, Aspen Technology, Inc.
Tushar Singh, Product Marketing, Aspen Technology, Inc.

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Jump Start Guide: Smart Tune in Aspen DMC3

Introduction to Smart Tune


Smart Tune is a new multi-objective, steady-state solver algorithm that sequentially optimizes Manipulated Variables
(MVs) based on priorities available in Aspen DMC3 software. Smart Tune allows the user to:
Specify controller objectives using priorities instead of LP cost factors
Utilize a new workflow wizard that significantly reduces LP tuning complexity
Gain greater insight into controller strategy through a new web based operator and engineer screen

Need for Smart Tune


The current methodology of optimizer tuning faces several challenges:
Generally the preferred optimization direction of variables is known. LP tuning is then developed to match these
objectives
Cost factors are not readily available and therefore are set by trial and error to achieve the desired result
Using actual LP costs require accurate models
Tuning needs to be revisited when the model is updated or objectives change

Using Smart Tune Creating an Aspen DMC3 Project


The Smart Tune feature is available for Aspen DMC3 controllers only. The first step is to create an Aspen DMC3 project
in APC Builder. Open APC Builder and select File > New > APC Project.

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Jump Start Guide: Smart Tune in Aspen DMC3

Select the first option, Aspen DMC3 and click OK.

Select location and enter a new name for the project.

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Jump Start Guide: Smart Tune in Aspen DMC3

This will create a new empty Aspen DMC3 project:

Importing an existing application


To use Smart Tune for an existing Aspen DMCplus application you will first need to convert it to an Aspen DMC3
application. This can be achieved by importing a DMCplus Controller Configuration file (.ccf). Select File > Import >
Application.

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Jump Start Guide: Smart Tune in Aspen DMC3

This will import the application to the project:

Click on the file name and drag-and-drop into the workspace. Your DMCplus application is now an Aspen DMC3
application.

Using Smart Tune Accessing Smart Tune


There are two options to configure (or reconfigure) the optimizer with Smart Tune.

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Jump Start Guide: Smart Tune in Aspen DMC3

Drag the filter to the Optimizer and the following dialog is displayed:
Select the first option, Use Smart Tune wizard and this will open the Smart Tune wizard.

Another access option is to right click on the Optimizer block and select the Smart Tune Configuration.

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Jump Start Guide: Smart Tune in Aspen DMC3

Using Smart Tune Desktop Workflow


To demonstrate workflow lets consider a crude unit.
We can estimate the price of inputs and product streams. For some variables we know what the optimum direction
should be, but their costs are difficult to estimate. For others we dont have a clear preference. In the case of this example
we could have something like this:
Variables with known Cost Factors:
Feed charge
Products: Jet Fuel, Diesel, etc.
Variables with preferred optimization:
Minimize overhead pressure
Maximize the overhead temperature
Variables without clear preference:
Pump around temperature
Pump around flow

Step 1 Defining Controller Structure


The first step is the controller structure definition. Here you can create (or edit) sub-controllers and define the
manipulated and disturbance variables.
After configuring this step you can either finish and save the current information or continue to the next step. In this
example, we have two sub-controllers already configured: HEATER and COLUMN.

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Jump Start Guide: Smart Tune in Aspen DMC3

Step 2 Select CV Ranks


In this step, you can group the controlled variables based on their importance. The lower the Rank Group, the higher
the priority. These ranks are used in the feasibility step and executed every cycle by the Aspen DMC3 controller. If the
solution is not feasible then lower priority (higher Rank Group) CV limits are given up first.
You can sort variables by priority and have a better view of the most important variables in your controller as shown in
the screenshot below:

Step 3 Select MV Preferences


In this step you can set optimization preference (directions) for your MVs. It is not required to assign preferences to all
manipulated variables. For those variables that you have confirmed the economic optimization, they can be used to build
constraints sets in Step 5 and drive the controller towards some specifics constraints.
In the example below, the top and bottom circulation flows and temperatures have no optimization preference. Therefore,
these MVs will be used to drive the process to specific constraints.
For this controller, feed passes, product flows and COT are maximized, furnace coil outlet temperature and column
overhead pressure minimized, while the column overhead pressure is set as a minimum move variable.

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Jump Start Guide: Smart Tune in Aspen DMC3

Note: You can click on Finish at any time and the information is always saved.

Step 4 Prioritize MVs


The next step is to prioritize the MVs that you assigned a preference in each sub-controller.
For example, our first objective is to maximize feed flow. Since the HEATER sub-controller contains the feed pass MVs,
the HEATER sub-controller priority should be set to 1. This ensures that the HEATER sub-controller will be optimized
before the COLUMN sub-controller.

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Jump Start Guide: Smart Tune in Aspen DMC3

After setting the priority for a sub-controller we can specify its priority for MVs from within. This can be done by clicking
on the sub-controller and then modifying the MV priority on the right side of the window as shown below for the
COLUMN sub-controller. Within the COLUMN sub-controller, JET_FLOW (Jet Product) has the highest priority. In this
case, the controller will honor JET_FLOW preference (maximize) whenever it is possible and will only minimize this MV
when all other degrees of freedom are exhausted.
After JET_FLOW, LD_FLOW and HD_FLOW (light and heavy diesel flows) have the same priority and are followed by
OVH_TEMP and then OVH_PRESS (overhead temperature and pressure).

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Jump Start Guide: Smart Tune in Aspen DMC3

Step 5 Select CV Constraints

It is now possible to use the manipulated variables that were not assigned to an optimization group and build constraints
sets.
Using the TOP_CIRC_FL MV, run the ATM tower reflux against its low limit. Since there is a model relationship between
the REFLUX_ATM CV and each MV listed, setting the Low limit for REFLUX_ATM will set the direction for all the
manipulated variables, as we can see from the icons on the left of each MV after selecting the Low option:

We are now able to move to the next step and check the LP Strategy for this application.

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Jump Start Guide: Smart Tune in Aspen DMC3

Step 6 Evaluate LP Strategy


The LP Strategy allows you to evaluate the controller behavior when running against CV constraints.
The legend at the top of the screen contains the basic information needed to interpret the controller strategy.

For example, lets investigate what the LP Strategy is telling us for the JET_95_PCT (Jet 95% Point) CV when it exceeds
its high limit (highlighted in the image above). In this case, we will be looking at the Hi column.
From the LP Strategy, if the Jet_95_PCT CV exceeds the upper limit, the controller will first minimize OVH_TEMP MV (in
accordance with the MV preference), then increase the OVH_PRESS and as a last option decrease the JET_FLOW MV

Since JET_FLOW has the highest MV priority it will be moved last if it has to break its MV preference set in step 3.
Notice what happens when we lower the priority of JET_FLOW MV to 4:
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Jump Start Guide: Smart Tune in Aspen DMC3

The yellow background indicates the changes in LP strategy after the priority was changed to 4 for JET_FLOW. In the case
of JET_95_PCT we can see that, JET_FLOW is minimized first before moving OVH_PRESS to control the JET_95_PCT
against its upper limit.
The priorities can also be adjusted online. Clicking the apply button will accept the changes.

Step 7 Initialize Tuning


In this last step you can populate the tuning parameters for the application based on the typical moves and operating
limits. The user can also choose to initialize dynamic tuning.
At this point, the controller is ready to be deployed online.

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Jump Start Guide: Smart Tune in Aspen DMC3

Using Smart Tune Online Features


LP Strategy (See Step 6) is also available for online Aspen DMC3 controllers using the Aspen APC Web Interface.
The figure below shows an example of the online Strategy. You can modify the MV priorities online and apply the
changes. The online view can be used to compare the current controller strategy with any changes that were made.

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Jump Start Guide: Smart Tune in Aspen DMC3

Additional Resources
To learn more about the capabilities of Smart Tune, please visit the following links:

Public Website:
Aspen DMC3 Webpage

Videos:
AspenTech YouTube APC Playlist

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About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy,
chemicals, engineering and construction, and other industries that manufacture and produce products
from a chemical process. With integrated aspenONE solutions, process manufacturers can implement
best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.

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