Process Information: Achieving A Unified View: Rocess Esign Rends
Process Information: Achieving A Unified View: Rocess Esign Rends
Process Information:
Achieving a
Unified View
Advances in computer hardware and
software, coupled with better
Thomas F. Edgar, fundamental models, will change
The University of Texas
at Austin
the way processes are designed and
plants are operated.
Computer Average Monthly Rental Maximum Core Storage Capacity Add Time Cards Read
1960 $ in 1,000 bits micro-s per min
IBM 7090 55,000 160 0.004 250
CDC 1604 34,000 32 0.005 1,300
DEC PDP1 2,200 4 0.010 Tape input
Feed enthalpy change May significantly alter internal Low reflux ratios employed
liquid/vapor ratio for low reflux columns under kinetic control
with through some sort of advanced than the hub-centric approach. This drift, or lack of precision. Plant
model-based control strategy. Pres- promotes an open application envi- maintenance will be integrated with
sure swings are usually not too diffi- ronment (open control system) and operational activities, using sophis-
cult to handle in a conventional col- makes accessible the wide variety of ticated tools such as data mining to
umn but, in a reactive distillation PC object-oriented software tools improve reliability. Maintenance
column, the temperature profile may that are now available. databases will contain full details of
change markedly. As these examples The demand for smart field de- all equipment, and knowledge-based
illustrate, new process technology vices, particularly digital ones, is ris- computers will monitor routine and
will require new operating strategies ing rapidly. It clearly is desirable to preventive repairs, utilizing expert
and the resulting plants may be be able to query a remote instrument systems to prevent failure through
more difficult to control. to determine if it is functioning prop- the proper level of maintenance.
Additional savings will accrue erly. In addition, smart instruments In the area of process modeling,
from cutting inventories and adopt- can perform self-calibration and fault industrial groups are beginning to
ing just-in-time production at batch detection/diagnosis. An instrument examine whether it is possible to
operations (2). But, keeping invento- using digital signals has the key ad- achieve a seamless transition be-
ry at a minimum will force these vantage that data can be transmitted tween models used for design and
plants to be much more agile in car- (even by wireless means) without simulation and models used for con-
rying out process changes and the normal degradation experienced trol. The CAPE-OPEN industrial
switching from one product slate to with analog signals. In smart valves, consortium in Europe and groups in
another. And, manufacturing prod- proportional/integral/derivative (PID) the U.S. are working toward an open
ucts with a short cycle time will re- control resides right in the instru- architecture for commercial simula-
quire an increased emphasis on mod- ment; this can permit the central com- tors. Standard data exchange is
eling and control in batch processing. puters to do more-advanced process needed so that models in a library
control and information management. can come from different sources.
Plant operations It is projected that installation of This will allow users to “plug and
and information technology smart instruments can reduce instru- play” company-specific libraries,
The next 20 years undoubtedly mentation costs by up to 30% com- such as physical property packages,
will see a greater emphasis in the use pared to conventional approaches. into any compliant simulator.
of information technology in plant There has been much recent ac- These steady-state flowsheet sim-
operations (4). This will be abetted tivity in defining standards for the ulators now are being extended to
by a new stage in the evolution of digital, multidrop (connection) com- handle dynamic cases (e.g., linking
plant information and control archi- munications protocol among sensors, Aspenplus to Speedup). The goal is
tectures that now is emerging. actuators, and controllers; in the to have models for real-time control
Progress in computer control during U.S., the concept is called fieldbus that run at 50–500 times real time.
the last 20 years has been spurred control. Vendors and users have been This, however, will require in-
by wide acceptance by vendors of working together to develop and test creased computational efficiency
the distributed-control hub system, interoperability standards via several and, perhaps, application of parallel
which was pioneered during the commercial implementations. computing. Models for any use
1970s by Honeywell. A distributed When data become readily avail- should be derivable from a single
control system (DCS) employs a hi- able at a central point, it will be eas- source, and dynamic models should
erarchy of computers. A single mi- ier to apply advanced advisory sys- be an extension of steady-state
crocomputer controls 8–16 individu- tems (e.g., expert systems) to moni- equations. Models should be robust
al loops; more-detailed calculations tor the plant for performance, as and insensitive to starting condi-
are performed using workstations well as to detect and diagnose tions, and should match the full op-
that receive information from those faults. Recent efforts have built erating range of the plant.
lower-level devices. In this scheme, upon the traditional single-variable A new generation of model-based
set points, often determined by real- statistical-process-control (SPC) ap- control theory that is tailored to the
time optimization, are sent from the proach, extending it to multivariable successful operation of modern
higher-level computers to the lower- problems (that is, ones with many plants has emerged. These advanced
level microprocessors. Now, with the process variables and sensors) using algorithms include model predictive
focus on enterprise integration, some multivariate statistics and such tools control (MPC), robust control, and
automation vendors are implement- as principal component analysis. adaptive control, where a mathemat-
ing Windows NT as the new solution These techniques can handle sensor ical model is explicit in developing
for process control, utilizing PCs in validation to determine if a given a control strategy. The success of
a client-server architecture rather sensor has failed or exhibits bias, MPC in solving large, multivariable
Digital instrumentation will be more As I’ve already mentioned, future state process models are stimulating
reliable and self-calibrating, while batch plants will adopt just-in-time the use of nonlinear programming
composition measurements hereto- production. The plant computer sys- tools. The methodology for schedul-
fore unavailable will be produced on- tem will monitor the status and ing of multipurpose batch and con-
line. Many plants already have incor- availability of equipment, people, tinuous production facilities has
porated several of these ideas, but no and materials, as well as mainte- been under investigation for over 20
plant has reached the highest level of nance needs and other elements years; it has progressed from rule-
sophistication over the total spectrum necessary to support automated based and heuristic randomized
of control activities. scheduling. Both continuous and search methods to mixed-integer
Figure 2 (6) illustrates a possible batch processes will have fully auto- programming methods.
hierarchical CIM structure that mated handling systems for raw ma- An excellent video on how real-
could be used in merging business terials, package components, and time decisions in manufacturing will
optimization with plant and process finished products. Robotics will be be made in the 21st Century was is-
operations and control. Each layer used extensively to replace manual sued by DuPont and Digital Equip-
will have different models and time labor. This, combined with complete ment in 1991 (7). Although this
scales and will include checks of the process automation, will minimize video is almost nine years old, it cap-
model against data obtained by the the need for manual intervention. tures many of the elements of pro-
computer systems. Consistent, ro- At the planning and scheduling cess engineering discussed above and
bust models will serve as the central level, multiperiod linear program- illustrates the effect of globalization
repository of process knowledge. ming tools capable of handling on future manufacturing issues. It
This will require advances in model large-scale systems have been used also demonstrates how modeling and
building, which is a major obstacle since the 1970s, especially in the simulation can assist in dealing with
because of the level of expertise re- petroleum/petrochemical sector. issues of off-specification products,
quired to formulate and use mathe- Now, real-time, plant-wide optimiza- improved control strategies, and ab-
matical models. tion applications based on steady- normal situation management.
The growth in complexity of the
■ Figure 2. automated plant environment can be
One possible mitigated through the use of artifi-
Enterprise structure for cial intelligence (AI) tools to assist
Data model-based
operators and engineers. The con-
computer-integrated
manufacturing. cept of the thinking computer, popu-
larized 32 years ago by Stanley
Planning Supply, Logistics Kubrick with the indelible image of
HAL in the film “2001. A Space
Capacity, Manpower
Odyssey,” has inspired numerous
Scheduling
predictions. While there have been
significant improvements in AI
Plant-wide Plant-wide technology since 1967, they have
Management Optimization been modest compared with some of
the predictions made then. Even so,
Automation in 1998 the IBM Deep Blue chess
Consistent Process Control
Robust Unit
Transient Automation computer defeated one of the best
Models Management chess players in the world (Gary
Abnormal Situation Management
Intelligent Decisions Kasparov). Speculation certainly re-
mains active. Kurzweil contends in
his latest book (8) that, with the dra-
Soft Sensors
Knowledge Rectification matic advances in computing power,
Statistical Analysis machines will surpass humans in in-
telligence at some point in the next
century, threatening the human race
Sensors as a species. Human cognition will
Process On-line Monitoring be augmented by downloading
Redundancy thoughts and memories into comput-
ers, moving to some form of ma-
chine consciousness. Such ideas are