Using Software Models in Production for Predictive Quality Improvement

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Rockwell Automation TechED 2016 @ROKTechED #ROKTechED 1

Transcript of Using Software Models in Production for Predictive Quality Improvement

Page 1: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED 1

Page 2: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED

SOLUTION:

Available sooner and faster, timely

Available in real-time, enables direct quality control

Model identifies what changes results

May reduce lab frequency requirements (costs).

QC Lab with Soft Sensor®What Makes a Soft Sensor® Different?

Page 3: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED

Available sooner and faster, timely

Available in real-time, enables direct quality control

Model identifies what changes results

May reduce lab frequency requirements (costs).

VIRTUAL ONLINEANALYZER

PROCESS ADJUSTMENTS

SOLUTION:

0.34 12.01 5.10

0.45 12.34 5.34

0.12 12.67 5.23

0.14 13.03 6.02

0.46 13.67 6.70

0.67 13.69 4.98

rate temp thick

0.34

0.45

0.12

0.14

0.46

0.67

%

MeasurementREAL-TIME

QC LabWhat Makes a Soft Sensor® Different?

with Soft Sensor®

Page 4: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED

Soft Sensor® Installed Examples

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PolymersBP:HDPE:DensityBP:HDPE:Melt IndexBP:LLDPE:DensityBP:LLDPE:Melt IndexBP:LLPE:DensityBP:LLPE:Melt IndexExtrusion:LDPE:Melt IndexExtrusion:LLDPE:Melt Inde

Polycarbonate RVPolyethylene Consist. Ind.Polyethylene Melt IndexPolypropylene Melt FlowSclartech:LLDPE:Melt Ind.Spheripol PP:%C2Spheripol PP:%C2:GPRSpheripol PP:%MFR:GPRSpheripol PP:%XS:GPRSpheripol PP:Melt FlowSpheripol PP:XS:Loop RxUnipol:HDPE:DensityUnipol:HDPE:Melt IndexUnipol:LLPE:DensityUnipol:LLPE:Melt IndexUnipol:PP:Melt FlowUnipol:PP:Melt Ind. Extr.Unipol:PP:XS

ChemicalsActivated Sludge Plant: Suspended SoliAromatics: Bz in light pyrolysis gasolineAromatics: Bz. in heavy pyrolysis gasolineAromatics: MCH In benzene cutC2 Splitter: Btms. ImpuritiesC2 Splitter: Ovhd. ImpuritiesTDA Column: meta-TDA in interm. streamTDA Column: meta-TDA in ortho-TDA prod.Cumene PurityHydrofluoric Acid Concentration

Pulp & PaperBOD on effluent treatmentBrightnessDFDC gradeFluorescenceIGT on coated board machineInternal bond on coated board machine

Kappa on batch digesterPaper machine caliper Paper machine colorVKK Grade Emission MonitorNOx, O2 and CO control200+ Online at many locations

RefiningCrude Unit: AGO 680+; Kerosene D-86; Kerosene D-86 95%; Diesel Cloud Pt.; Diesel D-86 90%; Diesel Flash Pt.; Kerosene D-86 90%; Kerosene Freeze Point; Kerosene Flash Point; Kerosene Density

Debutanizer:Bottoms C4; Overhead iC5; Bot 10%Depentanizer:Overhead C7Depropanizer:Bottoms C3; Bottoms RVP; OH C6FCC Main Frac.: LCO 90%; Naphtha 90%

Hydrocracker Main Frac: LSR RVP; Diesel D-86 90%; Diesel Flash Pt.; Gas Oil D-86 5%; HSR D-86 5%; HSR D-86 90%; Kerosene D-86 90%; Kerosene Flash Pt.; LSR D-86 95%

Reformate: Aromatics composition; C4 comp; Naphthene comp; Olefin comp; Paraffin comp; RON; RVP

Page 5: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED

PlantPAx® ModelBuilder with Soft Sensor® Comprehensive data analysis and model building tool Embed and execute models online with Studio 5000® Real-time laboratory measurements for better quality control

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Page 6: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED

FactoryTalk® ProductionCentre®, FactoryTalk® Historian, Pavilion® Real-Time Optimization™ …

Pavilion8® MPC, Software CEM®, Soft Sensor®, Asset Management, …Rockwell Software® Studio 5000®, PlantPAx® MPCBuilder, PlantPAx® Model Builder with Soft Sensor® Designer

• PlantPAx® MPC• IMC,CC,MMC• FuzzyLogic• Soft Sensor® (AOI)• PID,PIDE• Motion• Discrete

Soft Sensor® in Integrated Architecture®

Workstation and Logix-based APC Products

Page 7: Using Software Models in Production for Predictive Quality Improvement

Rockwell Automation TechED 2016 @ROKTechED #ROKTechED

Unlimited data miningTime MergeFlexible Lab Bias AdjustmentPowerful data cleanup

data segregationdata preprocessing

Gain Constrained Training100s of running applications

Soft Sensor®; Virtual Online Analyzer® “We’ve got something

like that”

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