Introduction to Aspen Process Controller Builder for APC Engineers

Course Id:  APC105   |   Duration:  5.00 day(s)   |   CEUs Awarded:  3.5   |   Level:  Introductory


Course Objective

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 an Aspen DMCplus Model to identify a controller model before implementing the controller online, and gain increased effectiveness in basic troubleshooting of Aspen DMCplus and Aspen DMC3 controllers.

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.

Course Overview

  • Understand various Online tools associated with Aspen DMC3 Builder
  • Learn how to implement variable transformations and custom built controller calculations
  • Become familiarized with the APC infrastructure
  • Learn how to interact with the online controller to operate a plant
  • Learn the characteristics of Aspen DMCplus and Aspen DMC3 models and controllers
  • Understand, design and deploy an Aspen Advanced Process Control (APC) Application
  • Learn the characteristics of a Linear, Dynamic, Empirical Model
  • Learn how to use Aspen DMC3 Builder to identify a process model
  • Be able to decide when to use FIR or SubSpace Modeling
  • Understand the importance of Collinearity Analysis
  • Learn to use the Aspen DMC3 Builder software to develop control models, build control applications, and perform off-line tuning and simulation of control applications   
  • Learn the role of CV Ranks and Equal Concerns in the computation of the Steady State Targets
  • Learn to use MV/CV Costs to cause the steady state optimization to seek the most profitable operating point
  • See why multiple moves are calculated each control cycle
  • Learn how to use MV move suppression and CV Concerns to tradeoff move minimization versus CV error minimization
  • Learn how to implement variable transformations and custom built controller calculations

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

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

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

Prerequisites

  • 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

Class Schedule

Class Agenda

APC105: Introduction to Aspen Process Controller Builder for APC Engineers

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 APC 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 APC Builder - guidelines for Subspace modeling
  • Workshop: Fractionator Controller - Build a subspace model for the fractionator
Open Loop Prediction 
  • Learn how DMCplus uses the dynamic model to predict the future behavior of controlled variables
  • Learn how DMCplus accounts for differences between the prediction and the actual measurements
  • Learn how DMCplus 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 DMCplus Steady State Optimization features
  • Recognize how DMCplus 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 DMCplus Steady State Solution
  • Workshop: Fractionator Controller - Calculating Steady State Cost and configuring the Steady State Optimizer
Minimizing Dynamic Errors
  • Introduce DMCplus 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 APC 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 APC 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

Aspen Technology, Inc. awards Continuing Education Units (CEUs) for training classes conducted by our organization. One CEU is granted for every 10 hours of class participation.