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

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

3. 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

4. What is PlantTriage

5. 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

6. Gathering
Data

7. Existing Control Performance
Controls Can Fail in Many Ways

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. Assessments

15. 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

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

17. 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

18. 6-Sigma Support Define Control Measure Improve Analyze
Reduce Energy & Material Costs
Improve Quality
Actionable!

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

20. Analysis Tools

21. 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

22. Typical Results

23. Typical Results

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

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

26. www.metso.com company/metso metsoworld metsogroup metsoworld