Performance Supervision System An Overview © 2015 Metso Minerals Industries, Inc

Agenda What is PlantTriage? Gathering Data Assessments Analysis Tools Typical Results

Industry Challenges Performance is critical Reduced staffing Throughput, Quality, Reliability, Costs Reduced staffing Fewer In-Depth Skills Large areas of responsibility Huge amounts of data

What is PlantTriage

Metso ExperTune The PlantTriage Control Loop Monitoring system watches a plant 24 hours a day, then prioritizes and diagnoses each improvement opportunity. What does PlantTriage do for a plant? Directs you to most pressing problems Isolates control valve mechanical issues Finds root cause of oscillations Finds root cause of process upsets Continual, automatic, PID tuning

Gathering Data

Existing Control Performance Controls Can Fail in Many Ways

Short Term Long Term PlantTriage How it improves efficiency % Time in Normal Noise Band Operator Intervention SP Changes Mode Reversals Valve Statistics Travel OP at Limit IAE Variability Short Term Robustness Oscillating Period Strength Process Model Pp, Ppk ExperTune Index Harris Opportunity Gap Customer Satisfaction Reputation Profitability Loyalty Total Costs Unit Long Term Throughput Material Cost Reliability Energy Cost Quality

Specific Measures Specific Actions  Predictable Results Noise Oscillation Valve Stiction Opportunity Gap Sensor Repair Tuning Repair Adjust SP Quality Improvement Energy Savings Process Stability Profits

How are you doing? How many of these things are currently measured in your plant? Most plants only have access to the long-term measures. Past history Not enough detail Not directly able to be fixed

Performance Supervision System PlantTriage Gathering Real-Time Data Performance Supervision System OPC Server OPC - HDA Process Historian 1 2 Control System Digital Fieldbus Instruments Digital Profibus HART Instruments 4-20 mA Analog Instruments

Unlimited Web-based Clients What’s Included? Unlimited Web-based Clients Flexible Reporting Diagnostics Trending Expert System TreeMap Biggest Payback Process Interaction Advanced PID Tuner Performance Assessment Engine Integrated Historian Equation Builder OPC Client DCS OPC Server PLC

Data Flow Diagnostics Assess. Data- base Browser Interface Equation Builder Assessment Engine Status info Raw Data History OPC Server AMCT Analysis Tools PV SP OP Mode DCS

Assessments

Over 100 Assessments Assessments Loop Assessments Unit & Plant-Level Assessments 6-Sigma Tools Opportunity Gap Process Shift User-Defined Assessments Oscillation Significance Over 100 Assessments

Assessments – Controls Robustness Relative Response Time ExperTune Index Average Error Integral Absolute Error Settling Time Model Quality …more… 16

Oscillation Detection Automatic Detection Identifies Strengths, Periods Tracks top three oscillations Osc. Source? Valve Tuning Load Compare Across Loops Root Cause in Hours, not Days! Oscillation EQUALS Inefficient Operation

6-Sigma Support Define Control Measure Improve Analyze Reduce Energy & Material Costs Improve Quality Actionable!

Customization Customized Reporting Custom Assessments Save Loop Lists, Column Sets, Reports Share Loop Lists, Column Sets, Reports Custom Assessments User-Defined Assessments

Analysis Tools

Analysis Tools Fully Integrated Loop Optimization Valve Diagnostics Example: Stiction Instrument Assessments Example: PV Noise Controller Tuning pH/non-Linearity Simulation Cascade, Feed forward 21

Typical Results

Typical Results

Typical degradation of Optimizations WITH and WITHOUT Proper Support Typical Results Typical degradation of Optimizations WITH and WITHOUT Proper Support

Results Assisting with Allocating Resources Benchmarking Efficiencies Quality Capacity Allocation of Resources Corporate Engineering Capital Spending Identify the greatest opportunities

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