Enhance operational efficiency with

Advanced Process Control (APC)

Integration of APC in SIMATIC PCS 7

SIMATIC PCS 7
Answers for industry.
 Modern closed-loop control systems
in the process industry

In todays competitive global marketplace, manufacturers in the process industry are

being driven to continuously optimize their production processes.

In view of this, calls for innovative strategies for improving the efficiency of process

control, and therefore optimizing plant operations are becoming louder and louder.

Advanced Process Control The key to unlocking increased efficiency

Closed-loop regulatory control in the process
industry is based largely on the use of PID
(Proportional-Integral-Derivative) control. It is
well understood, easy to implement, and easy
to integrate into the process control system, but
soon reaches its limits in a plant with complex
process dynamics. Advanced Process Control
(APC) opens up new possibilities for optimizing
these complex processes.
With APC, even the most complex relationships
between process parameters and variables can
be described mathematically and used to pro-
mote process optimization. APC enables more
efficient operation of a plant by significantly re-
ducing the consumption of energy and raw ma-
terials, optimizing product yield and quality, and
by contributing toward more flexible production.
Until now, APC has had a reputation for being ex-
pensive and complicated to implement and main-
tain. With the innovative process control system,
SIMATIC PCS 7, this is not necessarily so even de-
manding APC applications can be implemented
easily and cost-effectively. Depending on the prob-
lem or objective, different APC methods are opti-
mum. SIMATIC PCS 7 includes a standard library
containing a wide range of different types of APC
control functions, making it possible to address the
majority of complex closed-loop control tasks in
the process industry. This provides the user with
easy access to this advanced functionality at no ex-
tra cost. APC modules are supported via standard
customer support channels and are included in the
standard product lifecycle management process.
We also offer additional APC functions as optional
add-ons to a PCS 7 system. These add-ons are
designed and tested to ensure flawless opera-
tion and seamless integration with PCS 7.

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Intelligent plant optimization is included

Benefits achievable with SIMATIC PCS 7s APC Functions

Minimize process deviations (typically by up
to 200%) and compensate for them faster
Increase yield (on the order of 2 to 10%)
Increase throughput (typically by 1 to 5%)
while maintaining consistent product quality
Reduce power consumption (typically by 3 to
10%) and the utilization of raw materials
Reduce the number of manual interventions
required by the operator thus reducing oper-
ator workload and improving operator
efficiency.
Transition quicker and better between differ-
ent operating points, providing faster product
changeover and minimal loss of production
Extend the life of the plant using the existing
automation system at the same time reduc-
ing maintenance overhead
Achieve a better understanding of the process
through modeling and prediction

The standard library of the SIMATIC PCS 7 process control system contains numerous

pre-engineered templates for implementation of sophisticated closed-loop control functions.

They represent the ideal starting point for the cost-effective implementation of APC methods

even in small and medium-size plants.

Simple and economical Ready to use immediately

With PCS 7s comprehensive suite of APC func- A real highlight of the APC functionality integrated
tionality, numerous benefits can be delivered. into SIMATIC PCS 7 is how easy it is to begin using.
The investment costs and personnel resources In fact the Control Performance Monitoring func-
typically required for implementation of APC are tionality helps you identify which loops are the
minimized APC functions can be configured worst performers, so that you know where to
easily and without external support for a num- begin. An APC control module template is then
ber of applications. These include: the closed- selected from the library based on the type of
loop control of reactors, distillation columns and closed-loop control problem, and the parameters
coupled systems; and the open-loop control of are configured and loaded. The standard APC con-
grade-change, load-change and product-change trol modules can be modified easily facilitating the
processes. In all cases, the robust APC functional- creation of custom modules which meet project-
ity provided with PCS 7 can be used to consider- specific requirements.
able advantage: Undesirable variations in critical
process variables and other critical-to-quality
parameters can be reduced drastically and the
consumption of raw materials and energy can
be minimized. The tight integration of APC func-
tionality into PCS 7 helps minimize operator train-
ing and improve efficiency. Customers also can
achieve significant increases in product through-
put, yield and quality.

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 Modular system for implementing
APC functions

As a long-term supplier to the process industry, Siemens can also help you to increase the efficiency

of your plant cost-effectively. We offer a wide variety of comprehensive, pre-engineered control

modules in the standard library of SIMATIC PCS 7. We also support a wide range of optional APC

add-on modules, which can be purchased separately. In contrast to third-party suppliers whose

APC methods are linked to the process control system via interfaces, these add-ons consist of function

blocks and HMI elements which can be integrated seamlessly into SIMATIC PCS 7.

... available at no extra charge in the standard

library of SIMATIC PCS 7

In addition to the large number of standard Control performance monitoring

pre-engineered control modules, for example, Gain scheduling
monitoring measured values or controlling Butterworth low pass filter
on-off valves or motors, the standard library Override control
also contains control modules (templates) for Lead-lag / Feed-forward
basic analog control functions, such as: PID tuning
Smith predictor
PID control Model-based predictive control
Cascade loop control
Split-range control
Ratio control seamlessly integrated into SIMATIC PCS 7
as an add-on product
The standard library also contains a variety of
APC control modules provided at no extra cost. Fuzzy control
APC functionality consists of PCS 7 function Soft sensor/Neural Networks
blocks, which run in the controller, along Operator training simulator
with pre-built faceplates for operation and
monitoring through the HMI.

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 Gain scheduling
Additional measured variable (X)

Suitable for non-linear processes

3 complete parameter records are available for 3 operating points
Application examples:
Control parameter records
- pH control (neutralization) with non-linear titration curve
Setpoint Actual value
Control
Process - Temperature control of boilers
Manipulated variable
- Batch processes with chemical reactions (non-linear response kinetics)

Override control
Decision logic

Two (or more) PID controls share a common final control element
Setpoint PID control 1 Access to the final control element is determined based on the status of
+ (e.g. FIC)
the process
Process Application examples:
Setpoint PID control 2 - Primary process variable: Flow control
+ (e.g. PIC) - Secondary process variable: Pressure limiting (for safety)

Lead-lag/feed-forward control
Disturbance variable Disturbance
transfer
function Used to compensate for measurable, large disturbances which directly affect
Compensation the operation of the control loop
C(s )
Compensation takes effect before the disturbance can have a negative effect
Setpoint +
Actual
value
on the process
Process +

+
PID control
+ g(s) + Pre-engineered template (CFC) based on standard function blocks
Manipulated variable Application examples:
- Temperature control of an industrial furnace (disturbance variable: flow)
- Boiler reactor flow balance based on feed composition (disturbance variable:
concentration of inflow)

PID tuning

Optimize the control tuning of standard PID control loops

PID Tuner Applicable to standard PCS 7 PID control modules and also to user-created
Control custom function blocks
parameter
Actual Simulation of closed control loops
value
Setpoint
PID control Process Application example:
+
Manipulated variable
- Optimization of the control parameters of PID controls (in any applications)

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 Control performance monitoring

Control Performance Index Online monitoring of the control loops performance

Identification of control loops in a plant:
ConPerMon - Which are not performing optimally (the first step before implementing APC)
- In which faults are developing
Configurable alarm limits help to identify issues with deviation and over-
Setpoint Actual value
PID control Process shoot allowing you to perform preventative maintenance and determine
+
Manipulated variable
the cause of faults
Visualization using faceplates and status symbols within the HMI
Application example:
- Large-scale plants with many control loops, e.g. refineries

Smith predictor

For processes with long dead times that are known and (usually) constant.
Utilizes the Internal Model Control principle of model-based control
Manipu-
lated Actual - The process model runs in parallel with the real process
Setpoint variable Process value
PID control Process
g(s)
e s - An estimate of the process variable affected by dead time is made in
+ +
the model and is fed into the PID control module
Dead time
Model + - Deviations from the model output and actual measured value are also
e s
gm(s) fed back and taken into account
PI(D) control design
- Based on the dead time-free part of the process model
- Supplies much more accurate control settings
Application examples:
- Polymerization
- Closed-loop control of analysis values (based on the analysis dead time)

Model-based predictive control (MPC)

The most powerful APC function

Scalable MPC applications
G(1,d) - Up to 4 x 4: internal (lean) MPC
+ CV1
- More than 4 x 4: external full-blown MPC
G(1,1)
+ + Lean and easy to use, function blocks reside in the controller which means
MV1 G(2,1) there is no need for communication monitoring nor back-up strategies
DV1 ModPreCon
Application examples:
G(1,2)
MV2 - 2 x 2 applications: Two component distillation, paper manufacturing,
G(2,2)
+
+ +
dual-tank system
CV2
- 3 x 2 applications: Steel bleaching
G(2,d)
- 3 x 3 applications: Continuous reactor, evaporator, distillation column
- 3 x 4 applications: Cement mill
- 4 x 4 applications: Three component distillation, LPG evaporator,
multi-burner furnace

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Practical example:
Configuring MPC in four easy steps

The advantages of PCS 7s APC implementation are best

illustrated on the basis of an example in this case, the
Model-based predictive controller (MPC): The lean
multi-variable MPC processes up to four controlled
and manipulated variables as well as one disturbance
variable in a standard function block. This control can
be completely configured in just four steps:

Step 1: Implement function block

Implementation is easy with Drag & Drop: In SIMATIC
Manager, the central project management system, drag
the MPC block out of the library onto a CFC chart and
connect it SIMATIC PCS 7 will automatically generate
the corresponding HMI faceplate, complete with alarms.

Step 2: Perform a step test

With a step test, the MPC modeling tool will automati-
cally learn the dynamics of the plant: A unit change is
applied to a setpoint.

By disturbing the process, the response, which is

presented in the trend display, can be analyzed
mathematically in order to create the model.

Step 3: Modeling with just a few clicks

Only a few actions are required to create the models
relationship between the controlled and manipulated
variables. The parameters are weighted to configure
the MPC as aggressive or conservative.

Step 4: Compile and load into the running system

The function block containing the model can be com-
piled at the click of a button, then loaded into the CPU
and tested. The operator now has a robust, model-
based predictive control that can be operated seam-
lessly alongside traditional PID control.

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Further information on our portfolio on the Internet:

www.siemens.com/simatic-pcs7

The information provided in this brochure contains merely

Siemens AG
Industry Sector
Industry Automation
P. O. Box 48 48
90026 NRNBERG Printed in Germany
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www.siemens.com/automation
Subject to change without prior notice 09/08
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Siemens AG 2008
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