罗克韦尔自动化 PlantPAx Newsletter第1期.pdf罗克韦尔自动化 PlantPAx

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详细说明：罗克韦尔自动化 PlantPAx Newsletter第1期pdf,罗克韦尔自动化 PlantPAx Newsletter第1期Process○ ptimization Process Optimization is a very important subject in todays economic climate. It is essential to run your plant as efficiently as possible to maximize profitability, but how do you know if your system is running at the maximum efficiency? Do you have the tools to analyze the performance? And do you have a control system that is capable of delivering optimum performance? in this article we examine a number of techniques from tuning Pid loops to Business Intelligence Software to help you maximize your profits Efficiency losses can be found in any number of Technologies (a Rockwell Automation points throughout your process plant. A poorly Company) Model Predictive Control performing control loop on a critical piece solution is required of plant can waste energy, waste expensive raw materials and reduce yield. It has been Optimizing control loops is only part of the estimated that approximately three-quarters of story. There are many other areas that require all control loops are performing below peak attention -shortening material addition times, efficiency. Most process plants have multiple reducing cycle times and changeover times in interacting control loops and optimizing each batch ring. Yo one individually will not optimize the entire to pull together the relevant information and process For these applications a more analyze it to find inefficiencies sophisticated approach such as Pavilion So how much could you gain from Real-time Optimization improving your control system? Applying Pavilion Technologies Model Model predictive Pavilion 8 dictive Control to a bioethanol plan Control reduced energy costs by 2-4% and reduced Dynamic MPC variability of product quality by more Nonlinear Multivariable Control than 50% Linear Multivariable Control Business Intelligence software from Incuity EMI (a Rockwell Automation Company) Inferential Sensors Pavilion8 Soft Sensors helped a leading specia lity chemical producer to improve effciency, saving approximately $300, 000 per year Basic Supervisory Control Fuzzy Designer Rockwell automation has a range of Advanced Regulatory Control Logix IMC, cC MMc solutions to address different needs, some of them are shown here Regulatory Control Logix PID, PIDE, AOI Factory Talk VantagePoint- Business Intelligence Software Application Example and Economic Benefit Factory Talk Vantage Point is based on innovative business intelligence software from Incuity, A major paint manufacturer installed Incuity integrated into the Factory Talk environment. Business Intelligence Software, such as Factory Talk oftware to help increase production whils VantagePoint, can help increase productivity by providing workers at every level in the enterprise with new insight into the manufacturing process to help them to make better decisions. For example reducing costs. The system provided deep insight into their batch processes and At the line level people need to understand how equipment is performing to be able to make facilitated information-sharing among the decisions on streamlining operations, and improving efficiency and throughput production and supervisory staff so they could better monitor production in their At the plant level people need to understand production as it relates to the customer, so that appropriate contexts they can make intelligent decisions about procurement, production scheduling and shipping The result has been that within a few months At the enterprise level people need to see production in its larger business context, and to they have been able to improve production understand the impact of fluctuating costs, changing market conditions and asset performance performance by more than 20% whilst to make the right decisions about what to make and where reducing costs by $500,000 a year. For more information visit: www.rockwellautomation.com/rockwellsoftware/performance/vantagepoint Tofindoutmorevisitusatwww.discoverrockwellautomation.com/thinkingprocess y LogIC different sizes of batches the performance of the temperature loop will vary significantly b&&E Fuzzy Logic is a technique that attempts to depending on how full the reactor is. If the systematically and mathematically emulate loop is tuned when the reactor is half full i human reasoning and decision-making may experience problems at different levels uzzy control solutions are especially useful It would have a sluggish response for complex systems where standard means completely full and may oscillate when only such as PID control don't give the required part filled. Clearly you could write a program level of control Your operators may already be to vary the gains with level but this could tweaking the process for different conditions come complicated to ensure you dont get but this can be unreliable disruptions to the process The Fuzzy Logic tools can be applied to a wide variety of applications. The following Fuzzy Logic provides a tool set to take the example is a simple application to adjust gains knowledge about how the gains should in a temperature control loop for a reactor be varied and use it to more accurately control the process. This is done by Example- Reactor Temperature Control continuously adjusting the gains rather with Economic benefits A reactor is heated to a particular temperature applications By dong this it is possible to o a step change which is often seen in existir Reduce cycle times through faster to produce a product. This may sound response of the control loop avoid the process disruptions that would straightforward but if the reactor is used for otherwise occur Reduce energy usage Pavilion lechnology PALK Model predictive control Pavilion Technologies Model Predictive Control(MPC) technology is an intelligence PAMLION8 layer on top of basic automation systems that MPC System Architecture continuously drives the plant to achieve multiple business objectives-cost reductions PAVILION& decreased emissions, consistent quality and Controller production increases-every production minute. It continuously assesses current and Dynamic MPC predicted operational data, compares them to desired results and computes new control targets to reduce in-process variability and mprove process performance coral Custom EPCG Laboratory For more information visit www.pavtech.com Application Example and Economic Benefit Chemical Manufacturer Ethanol Producer Features Benefits Hybrid modeling based on Improves product quality Increase prime product yield. Increased Ethanol production empirical data, first principles through faster response to by4.5% capacity 3-10% equations, operator target changes or larg knowledge or any process disturbances Reduced variance in product. Increased ethanol yield combination properties by 35% Patented, Extrapolated Expedites deployment by Decreased reactor variability Reduced energy use/gallon Gain Constrained Neural using all available by 30% by2-4% Networks(EGCNN) to ensure nformation to create Reduced waste by 300 Reduce compliance risk model accuracy beyond the accurate mode tons year normal operating range Reduced frequency of lab Incorporates changing Improves product quality samples by 50%6 rocess dynamics and flexibility for new grade (dead-time, time constants and product development and gains)over wide process operating ranges Tofindoutmorevisitusatwww.discoverrockwellautomation.com/thinkingprocess Rockwell Automation and The first phase includes documents for the following instruments Endress+Hauser Integration Promass 83 Coriolis Mass flow Documents and Add-on Promag 53 Electromagnetic Flow Plan: PAx Process Autom ation Systen Instructions Available Prowirl 73 Vortex Flow for download Proline t-mass 65 Thermal flow Levelflex M Guided Radar Level Rockwell automation and Endress+ hauser Micropilot M Radar Leve have released documentation and Add-on Prosonic m ultrasonic level instructions for hart devices connected to 1756 I/0. The information includes a step-by Prosonic s ultrasonic level Liquiline m for liquid analysis PlantP step approach to integrating Endress+Hauser instruments, including information on Cerabar S Pressure hardware, software, configuring messaging Deltabar S Differential Pressure and asset management software iTEMP TMT 162 Temperature You can download the documents and iTEMP TMT 182 Temperature m三 Add-on instructions from: Documentation for profibus pa via the en2pa www.rockwellautomation.com/solutions/ Erdess hauger詔 modules and Flex I/O HART is in progress and e ak. b-h Aurigae process/integrationdocs html will be available early 2005 Factory Talk ViewPoint Web-HMI Manufacturers now can remotely monitor their Factorytalk view Point Web -lient: plant-floor operations status using Factory Talk TazteryTa View Point software from rockwell automation Factory Talk view Point software is one of the first n=回品画 commercially available, thin-client applications formation for manufacturing built using the n Microsoft Silverlight technology. The initial release extends visualization and real-time decision capabilities beyond Factory Talk view clients to browser-based remote users Factory Talk view Point software supports fully salable and animated Web displays of existing FactoryTalk View Site Edition(SE)visualization software and Allen-Bradley PanelViewm plus applications from the office, home or on the road via any Internet browser While the initial release is Internet Explorer(IE)compatible, additional browser and device support is planned For more information visit www.rockwellautomation.com/rockwell software/performance/viewpoint/ FactoryTalk Batch Version 10 Factory Talk AssetCentre Calibration Management capability has also Version 10 of Factory Talk batch has seen a been added into FactoryTalk AssetCentre. The number of enhancements to improve Adds Device Configuration productivity, reduce costs, and simplify recipe software tool is used to efficiently manage development. Enhancements include and calibration calibration activities that are associated with process devices. This is useful for enabling Smart Binding-Confiqurable real-time Management Capability regulatory compliance and good dynamic unit selection for optimal procedural flow manufacturing practice. The latest release of assetcentre now includes It allows the user to Timer Steps- Reduce engineering and the capability to configure and manage alidation effort through use of product process devices. The solution, jointly Schedule calibrations timer steps developed with Endress+Hauser is based on Manage calibration standards Recipe SFC Structure Validation-Test FDT/DTM technology. AssetCentre is an FDT Manage certifications procedures for recipe structure errors frame application capable of supporting a Document as found/as left information and Improved Client Capabilities -Simplifie wide variety of process instruments and other automatically calculates tolerance control recipe configuration options feld devices through plug-in drivers(DTMs Perform paperless calibrations RSLinx Classic OEM-Now induded with from device manufacturers. This capability For more information visit every FactoryTalk Batch and Back-up key license enables online access to device configurations, For more information visit: device troubleshooting and diagnostics www.rockwellautomation.com/rackwell www.rockwellautomation.com/rockwell software/assetmgmt/assetcentre/ software/production/batch/ Tofindoutmorevisitusatwww.discover.rockwellautomation.com/thinkingprocess Six-Polymer Line Project SeCCo chose Pavilion Technologies who The benefits of Pavilion' s Polymer Solution implemented its Pavilion Polymer Reactor directly translates into reduced costs and Marks Largest Polymer and Extruder(MPC) control applications, an mproved revenue potential for SECCO, Deployment in China inte bining powerful allowing the plant to better react to technology for modelling control, monitoring shifting market conditions and growing The highly dynamic polymer industry presents analysis, visualization and integration, to market demands. The stability and robustness major challenges such as high operating provide targeted solutions and deliver faster of the solution is evident in the 97% control costs, increasing raw materials costs and time-to-value than alternative solutions utilization rate. To sustain benefits and growing local and global competition With the help of Pavilion8, SECCO quickly further leverage the solution secco has In order to maintain its competitive standing maximized production rate and qualit signed a three-year maintenance and support and meet China's growing market demands, reduced transition time and material costs contract for Pavilion to optimize all six of the seCCo defined a long-term strategy of and improved its ability to adapt to changing polymer lines increasing production rates, reducing cost market demands and conditions and improving product quality for its six Due largely to the success of Pavilions Economic Benefits polymer lines real-time virtual Online Analyser (VOA) coupled to the control and optimization Increased production capacity by 4% on average strategies, Shanghai SECCO Petrochemicals Variation in Melt flow rate quickly achieved project goals and realized Decreased reactor variability by 20% a major return on investment in just Improved product consistency by 35% ■ Before MPc four months on average ■ After MPC Achieved standard operations on transitions Reduced the reactor purge and cost Low Density Polyethylene(LLDPE)Production Capacity 104% Density 102% ■ Before MPC ■ After MP 100% 98% 96% 17.49189186919.29198920.19219216 Baseline MPC Events ACHEMA 2009 4CHEMA 2009 ACHEMA is the leading international event This year we will be showcasing the Frankfurt am Main/ Germany -15.5.2009 for chemical engineering, environmental Plant PAx process automation system and protection and biotechnology in Frankfurt demonstrating the continued expansion 11 May to 15 May 2009. At the last event, held of the system based on a combination of in 2006, around 180,000 professionals from 98 he core Rockwell Automation Integrated countries attended to find out more about the Architecture technologies and those latest developments and trends leveraged from co-investments with partners nd ac panies. The PlantPAx proces a range of applications across consumer and resource-based industries Publication No. PROCES-SA0O1A-EN-F February 2009 6

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