Model and Build Aspen DMC3 controllers using Aspen DMC3 Builder (Includes Sustainability Module)

This course will help you prepare for the certification exam and the exam fee is waived with this course.
In this course you will acquire the skills and knowledge required to participate on or lead a team charged with the development, deployment, and maintenance of Advanced Process Control applications. You will learn how to use DMC3 Builder to identify a controller model, configure controller tuning, implement the controller online and maintain it on the Production Control Web Server. This course also aims to gain increased effectiveness in basic troubleshooting of Aspen APC controllers.

In this 2021 revision, a bonus lesson and workshop are added on how implementing APC solutions can help you achieve your sustainability goals. You will learn how implementing Aspen APC can help achieve sustainability goals including resource efficiency, reduce carbon emissions and waste reduction.

This course is a combination of APC120: Introduction to aspenONE Advanced Process Control - Operating and Maintaining Controllers Online, and APC125: Introduction to Aspen Process Controller Builder - Modeling and Building Controllers for Industrial Processes.

Audience:

  • Engineers who are maintaining existing Aspen DMCplus controllers
  • Description of the theoretical concepts that form the basis of the Aspen DMCplus family of products
  • Engineers who are designing or implementing new Aspen DMCplus controllers
  • Operating supervisors and console operators who are involved in Aspen DMCplus control projects

Training Details

  • Course Id:

    APC105

  • Duration:

    5 day(s)

  • CEUs Awarded:

    3.5

  • Level:

    Introductory

Benefits

  • Acquire the skills and knowledge required to participate on or lead a team charged with the development and deployment of an Advanced Process Control application
  • Acquire the skills and knowledge required to use and maintain Aspen DMCplus and Aspen DMC3 controllers
  • Know how to use Aspen DMCplus Model to identify a controller model before implementing the controller online
  • Increased effectiveness in basic troubleshooting of Aspen DMCplus and Aspen DMC3 controllers
  • Increased awareness of the operating characteristics and capabilities of Aspen DMCplus and Aspen DMC3 controllers

Approach

  • Introduction to basic concepts behind multivariable control
  • Demonstrations of the ways in which the online tools are used
  • Hands on workshops that allow operating and troubleshooting a typical Aspen DMCplus and Aspen DMC3 controller

Pre-requisites

  • Background in chemical process engineering and/or process operations
  • Some familiarity with Microsoft® Windows operating systems

Subsequent Courses

This course serves as a prerequisite for many of the more advanced courses.
  •  APC170 Introduction to Aspen Inferential Qualities - Developing and Deploying Inferential Soft Sensors for Industrial Processes
  •  APC210 Aspen Watch Performance Monitor: Real Time Monitoring and Maintaining Controllers Online
  •  APC240 Aspen DMCplus: APC Project Step Testing and Commissioning Using a Virtual Plant
  •  APC250 Aspen DMC3: APC Calibrate and Aspen Adaptive Modeling

Agenda

Basic Concepts
  • Differentiate between Real Time Optimization and Advanced Control
  • Understand the use cases for APC
  • Learn about various AspenTech APC solutions
  • Workshop: Democol Manual Operation
Modeling Terminology
  • Review the definition of independent and dependent variables
  • Review the definitions of a Unit Response Curve, Time to Steady State and Steady State Gain
  • Review the defining characteristics of Aspen DMCplusand Aspen DMC3 Models and Controllers
  • Define a subcontroller
Production Control Web Server (PCWS)
  • Learn how to use PCWS to interact with the controller
  • Workshop: Democol Operation with Aspen DMCplusand Aspen DMC3 controller
APC Infrastructure
  • Learn about the APC Infrastructure
Models of Aspen DMCplus and Aspen DMC3 controllers
  • Introduction to the concept of plant test and different plant step test method
  • Learn about Aspen DMCplus and Aspen DMC3 modeling procedures
  • Workshop: Model Review
Aspen DMCplus Engine
  • Learn the about three modules in an Aspen DMCplus/DMC3 Engine
  • Learn which tuning parameters are used in each of the modules
  • Workshop: Democol tuning
Aspen DMCplus Controller Online Troubleshooting
  • Learn how to troubleshoot typical problems with an Aspen DMCplus or Aspen DMC3 online controller
  • Workshop: Democol Troubleshooting
Modeling Terminology
  • Differentiate between Real Time Optimization and Advanced Control
  • Discuss the characteristics of an independent variable and a dependent variable
  • Review the definitions of a Unit Response Curve, Time to Steady State and Steady State Gain
  • Review the defining characteristics of a DMCplus Controller and the components comprising an Aspen APC Suite
  • Introduction to DMC3
APC Project Overview
  • Review the process for implementing an APC project
  • Discuss available alternatives and proper documentation procedures
Dynamic Modeling of Linear Systems
  • Review the definition of a dynamic, empirical, linear model and the technology of Finite Impulse Response (FIR) Modeling
  • Discuss the strengths and drawbacks of an FIR model
Model Identification in DMC3 Builder
  • Familiarize with the Aspen DMC3 Builder interface
  • Use the vector import tool to bring data into APC Builder
  • Review vector quality and perform data processing
  • Define and run model identification cases
  • Workshop: Fractionator Controller - Build a finite impulse response model for a simple fractionator
Model Analysis in DMC3 Builder
  • Define and Run Predictions
  • Understand and use model analysis tools
  • Workshop: Fractionator Controller - Evaluate and assemble the model
  • Workshop: Fractionator Controller - Fix collinearity issues in the model
Variable Transformations
  • Configure built in transforms to deal with non-linear data
  • Configure transforms to rescale data
  • Workshop: Fractionator Controller - Apply variable transformation
SubSpace Identification Technology
  • Review modeling technology for MPC control
  • Subspace Identification: fundamentals and features
  • Aspen DMC3 Builder - guidelines for Subspace modeling
  • Workshop: Fractionator Controller - Build a subspace model for the fractionator
Open Loop Prediction 
  • Learn how  Aspen DMC3 Builder uses the dynamic model to predict the future behavior of controlled variables
  • Learn how Aspen DMC3 Builder accounts for differences between the prediction and the actual measurements
  • Learn how Aspen DMC3 Builder corrects predictions for ramp variables
  • Learn how prediction errors can be used to assess modeling errors
  • Workshop: Fractionator Controller - Configure prediction error filter options
Steady-State Feasibility Check
  • Introduce the Aspen DMC3 Builder Steady State Optimization features
  • Recognize how Aspen DMC3 Builder uses the Steady State Predictions in Projecting the Optimum Operating Point for the Process
  • Differentiate between a Linear Program and a Quadratic Program
Economic Optimization
  • Determine how MV Costs can be used to drive the Process to an Economic Optimum
  • Determine how an external Optimizer can affect the Aspen DMC3 Builder Steady State Solution
  • Workshop: Fractionator Controller - Calculating Steady State Cost and configuring the Steady State Optimizer
Minimizing Dynamic Errors
  • Introduce Aspen DMC3 Builder Dynamic Move Calculations features
  • Discuss how computing multiple future moves improves control
  • Make tradeoffs between move aggressiveness and error minimization
  • Explain how ramps are controlled dynamically
  • Review details of the Move Calculation
  • Review the tuning and simulation workflow in Aspen DMC3 Builder
  • Workshop: Fractionator Controller - Dynamic Tuning to adjust move suppressions to achieve smooth control
Calculations and Gain Scheduling
  • Configure input and output calculations to modify controller data
  • Configure gain scheduling to modify model gains on the fly
  • Configure and manage model switching
  • Workshop: Fractionator Controller - Configure custom built controller calculations
External Targets
  • Identify and explain the application of External Targets:
  • External Target Definitions
  • RTO and IRV Style External Targets
  • External Target Attributes
DMC3 Builder Plant Connection and Tuning Configuration
  • Use the Aspen DMC3 Builder to:
    • Connect the controller to the plant
    • Enable SmartStep and Composite participation
    • Workshop: DemoCol Controller - Configure plant connections
Subcontrollers 
  • Identify and explain subcontroller concepts
  • Discuss MV and CV memberships in Subcontrollers
  • Subcontrollers and shedding
  • Introduction to Composites
Ramp Variable Techniques
  • Learn how to deal with process ramp variables by using one of the following types:
  • Balanced Ramps
  • Ramps with allowed Imbalance
  • Program Imbalance Ramps
  • Pseudo-ramps
  • Discuss the effects of the ramp horizon on ramp calculation
  • Workshop: DemoCol Controller -Observe the effects of changing tuning parameters on ramp behavior
New Features in Aspen APC Suite
  • Review the new features available with Aspen DMC3 controllers
  • Workshop: DMC3 New features
  • Workshop: Nonlinear CV – Review the nonlinear Hybrid controller in DMC3
Appendix: Controller Variable Validation
  • Learn how to deal with the Controller's variable validation process:
  • General Variables
  • Manipulated and Feedforward Variables
  • Subcontrollers and Composite
  • External Targets
Certification Exam
 

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