1. DeltaV Adaptive Control Lubrizol Alliance Meeting – Oct. 04 Technology Introduction And Beta Testing Discussion For Deer Park Terry Blevins and Dewey Kuchle

2. ©2002 Fisher-Rosemount Systems, Inc. Slide 2 AgendaAgenda  Introduction To Adaptive Control  Quick Demonstration  Beta Testing –What Does This Mean For Lubrizol And Emerson

3. ©2002 Fisher-Rosemount Systems, Inc. Slide 3 Control Loop Performance - A Never Ending Cycle Process Testing (bump tests) Calculate Tuning Deploy New Controller Operate The Loop Control Degrades Over Time The more often you Tune, the better the performance. Period. Evaluate Poor Performance

4. ©2002 Fisher-Rosemount Systems, Inc. Slide 4 There Must Be A Better Way Wouldn’t it be nice to have controllers use optimal tuning all the time (continually) without having to tune at all, ever?

5. ©2002 Fisher-Rosemount Systems, Inc. Slide 5 Time O1O1 O2O2 I1I1 I2I2 Gain = O 2 - O 1 I 2 - I 1 T1T1 T2T2 Time Constant (  ) = T 3 - T 2 Input Output 63.2% (O 2 - O 1 ) T3T3 Dead Time = T 2 - T 1 Basics: Gain, Dead Time, Time Constant

6. ©2002 Fisher-Rosemount Systems, Inc. Slide 6 Permitted Range Adaptive Control – Continuous Adjustment Controller Gain Starting Point Less Aggressive More Aggressive Continuous automatic adjustment of tuning parameters means better control. Easy. But don’t forget about the time constant and the dead time.

7. ©2002 Fisher-Rosemount Systems, Inc. Slide 7 DeltaV Adapt - Fully Adaptive PID Control Tuning - Learns Process Dynamics While In Automatic Control - No Bump Testing Required - Works On Feedback And Feedforward - Patents Are Now Awarded! No Tuning Required!

8. ©2002 Fisher-Rosemount Systems, Inc. Slide 8 DeltaV Adapt – Field Trials At Eastman As Operators Make Set Point Changes Adapt Gets Smarter!

9. ©2002 Fisher-Rosemount Systems, Inc. Slide 9 Slow Response Causes Off- Spec Better Tuning Dramatically Increases Performance Set Point Change

10. ©2002 Fisher-Rosemount Systems, Inc. Slide 10 Not an overnight thing…  EMERSON technology developed in Austin.  Patents have now been awarded.  1997 - Dr. Wojsznis’ concept originated  1998 - Started research at Hawk Austin  2002 - Started product development  2003 - Prototypes at Texas Eastman in Longview Texas with good results. Results presented at ISA2003.  2004 – Pre-beta test at Solutia in Pensacola, Florida. Results are scheduled for publication in Sept issue of Chemical Process magazine – front cover, feature article.  2005 - Initial release planned for DeltaV v8.1

11. ©2002 Fisher-Rosemount Systems, Inc. Slide 11 Patents Have Now Been Awarded! Mr. Terry Blevins Mr. Terry Blevins Dr. Wilhelm Woszjnis

12. ©2002 Fisher-Rosemount Systems, Inc. Slide 12 Operating Condition Impact  Process gain and dynamics may change as a function of operating condition as indicated by PV, OUT or other measured parameters e.g. plant throughput

13. ©2002 Fisher-Rosemount Systems, Inc. Slide 13 Defining Operating Regions  Adaptive control allows operating regions to be defined as a function of an input “state” parameter  Define up to 5 regions  When the state parameter changes from one region to another, the model values (and associated tuning) immediately change to the last model determined for the new region  Limits on model parameter adjustment are defined independently for each region. Model Parameters State Parameter Value Model Parameters State Parameter Value Region 1 Region 2 Region 3 Region 4 Region 5 Region 1 Region 2

14. ©2002 Fisher-Rosemount Systems, Inc. Slide 14 Example – Non-Linear Installed Characteristics  Process gain will change as a function of valve position if the final control element has non- linear installed characteristics.  Valve position is used as the state parameter.

15. ©2002 Fisher-Rosemount Systems, Inc. Slide 15 Example – Multiple Valves - Split Range  The process gain and dynamic response to a change valve position may be different for each valve.  Typical example is heating/cooling of batch reactor, extruder, slaker, etc.  Valve position is used as the state parameter. 0 50 100 Controller Output (%) Cooling Valve Heating Valve 100 0

16. ©2002 Fisher-Rosemount Systems, Inc. Slide 16 DeltaV Adaptive Control – Field Trials  Control automatically adapts based on SP changes in Auto – Caustic loop

17. ©2002 Fisher-Rosemount Systems, Inc. Slide 17 The End Result  This capability will allow DeltaV users to assign “ballpark” tuning parameters and let adaptive PID controllers tighten them up and adapt over time.  Patented model switching technology means robust control over the long haul without sacrificing performance  Faster startups, quicker ramp-up of production, less tuning over time, and better control over the life of the system all mean better economics.

18. ©2002 Fisher-Rosemount Systems, Inc. Slide 18 But What About Previous Attempts?  Most Every Other Attempt To Build Adaptive Controllers Have Been Based On One Of Two Approaches; –Heuristics or “Rules Based” Adaptation –Pattern Recognition Both Methods Have Met With “Limited” Success

19. ©2002 Fisher-Rosemount Systems, Inc. Slide 19 So What Makes This Different?  Truly Model Based Tuning  Built On Advanced Closed Loop Modeling  Tuning Based On Science And Fact With No Shortcuts Gain Time Constant Dead time Initial Model Gain = G1 G2-Δ G2 G2+Δ G3-Δ G3 G3+Δ Multiple iterations per adaptation cycle G1+ Δ G1+ Δ G1+ Δ TC1 -Δ TC1–Δ TC1 -Δ DT1- Δ DT1 DT1+ Δ G1+ Δ G1+ Δ G1+ Δ TC1 +Δ TC1+Δ TC1 +Δ DT1- Δ DT1 DT1+ Δ G1+ Δ G1+ Δ G1+ Δ TC1 TC1 TC1 DT1- Δ DT1 DT1+ Δ G1 G1 G1 TC1 -Δ TC1–Δ TC1 -Δ DT1- Δ DT1 DT1+ Δ G1 G1 G1 TC1 +Δ TC1+Δ TC1 +Δ DT1- Δ DT1 DT1+ Δ G1 G1 G1 TC1 TC1 TC1 DT1- Δ DT1 DT1+ Δ G1-Δ G1- Δ G1- Δ TC1 -Δ TC1–Δ TC1 -Δ DT1- Δ DT1 DT1+ Δ G1-Δ G1- Δ G1- Δ TC1 +Δ TC1+Δ TC1 +Δ DT1- Δ DT1 DT1+ Δ G1-Δ G1- Δ G1- Δ TC1 TC1 TC1 DT1- Δ DT1 DT1+ Δ

20. ©2002 Fisher-Rosemount Systems, Inc. Slide 20 What Does That Mean?  In The 90’s The MIT Blackjack Team Invaded Las Vegas And Broke The House, Taking Casinos For Millions  They Did It Counting Cards Which Is Really A Form Of Modeling

21. ©2002 Fisher-Rosemount Systems, Inc. Slide 21 Delivering Results From This… To This…

22. ©2002 Fisher-Rosemount Systems, Inc. Slide 22 Delivering Results … With NO Hands!

23. DeltaV Adapt Demonstration