Control System Migrations Gone Wild!

Best Practices and Lessons Learned

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Thank you.
Presenters

Laurie R. Ben
Director, Modernization Business Development

James Beall
Principal Process Control Consultant

Scott Ross
Modernization Consultant (Legacy Emerson)
Introduction / Agenda

What it looks like when it goes Wild?
– Cycling Outputs
– Controlling Super Slow or Super Fast (Unstable Control)
– Controlling, but never stabilizing at Set Point

Why it happens? Common Conversion Mistakes

How to Avoid? (Tips, Tools, & Techniques)

Summary

Where to go for More Information
 What it Looks Like when it goes Wild -
Cycling Outputs
6.20 160

6.15 140

14 Fermenters on PROVOX for
6.10 PHRR220F50.PV
PH.PV 120 years
PH.OUT
FRC-R220F.51.PV
6.05 100

2 Fermenters migrated to DeltaV
6.00 80

5.95 60

pH staying in spec, but Cycling -
5.90 40 Ugly
5.85 20

5.80 0 6.20 160

On PROVOX
0 20000 40000 60000 80000 100000 120000
6.15
PHRC1F7.PV
PH.PV
PH.OUT 140
FRC-R260.51.PV
6.10 120

6.05 100

6.00 80

5.95 60

5.90 40

On
5.85 20

5.80 0
DeltaV 0 20000 40000 60000 80000 100000 120000
 Why It Happens? Cycling Outputs

Wrong PID Form Selected for Conversion Difference suggests
that even properly

Compounded By Derivative (Rate) Action converted tuning may
Control PROVOX DeltaV DeltaV Lambda=10 have too fast of
integral action
Action Classical or Tuning, Standard 00 with
Series, Standard , guessed*
as-found all Form (in- correctly process
fermenters
–) correctly converte dynamics
converted d
)
Proportional 0.5 0.5 11.75 11.4 *from analysis of as-found
cycle and experience on
(Gain)
other fermenters with
Integral Time 3 rep/min or 20 470 2040 aqueous solutions & weak
(a.k.a Reset) 20 sec base reagents. This
should be replaced by
Derivative 7.5 min or 450 19 0 data from step tests.
Time 450 sec
(a.k.a. Rate) to put in Manual for correction,
Recommend
OR 1st change the Reset, 2nd the Rate, 3rd the
Gain!
How to Avoid?
Know the PID Forms in Your Legacy Systems
1. PROVOX = “Series” form
– DeltaV is selectable – “Series” or “Standard”
• “Standard” is the DeltaV default selection
– If Derivative is not used (Rate = 0 min), then “Series”
and “Standard” are the same, so choose Standard
• “Standard” Form is more flexible from a tuning standpoint and
is more common than Series (and Parallel)
– If you have loops in PROVOX with Derivative action,
choose DeltaV Form = Series for ease of conversion
2. RS3 = Standard form, so choose
DeltaV=Standard (default) for ease of conversion
– Then, DeltaV Tuning will be simply a conversion of units
How to Avoid?
Know the PID Forms in Your Legacy Systems

Some Non-Emerson Legacy System

Forms
Standard Form Platforms Series Form Platforms
ABB Masterpiece/ADVANT Bailey Infi90*
VALMET Damatic Classic MOD 300*
Measurex Open, Vision 2000 Fischer-Porter, Micro DCI
Texas Instrument MOORE-APACS
Honeywell Honeywell
Yokogawa FOX I/A, Spec 200
Modicon 984 L&N: 440, 446-3, Electromax
V
*Note: These platforms have other PID forms available
What it Looks Like when it goes Wild!
Control Super Slow or Super Fast

PROVOX tuning was Gain=4.6, Reset=0.23 rep/min,
Rate=4.3 minutes

Tuning numbers, without units conversion were
Gain=4.6, Reset=0.23 sec, Rate=4.3 sec

After
Before
Why It Happens?
Control Super Slow or Super Fast

Incorrectly Converted Parameter Units

Some Legacy Systems allow selectable Units per
Individual PID vs. System Wide

Parameter RS3 (Standard) DeltaV (Standard Form)

Gain %PB Gain = 100/%PB
Gain Gain = Gain
Reset Ti - seconds Reset = Ti
Ti - minutes Reset = 60*Ti
Ti - hours Reset = 3600*Ti
Rate Td - seconds Rate = Td
Td - minutes Rate = 60*Td
Td - hours Rate = 3600*Td
 Why It Happens?
Control Super Slow or Super Fast
Parameter PROVOX DeltaV (Series) DeltaV (Standard)
Rate<> 0
Using DeltaV Series
Conversions
Gain GainPROVOX Gain= Gain x (Reset +
GainPROVOX Rate)/Reset
Reset ResetPROVOX Reset (sec) = Reset + Rate
(rep/min) 60/(ResetPROVOX)
Rate RatePROVOX Rate (sec) = (Reset x Rate)/(Reset +
(min) 60*(RatePROVOX) Rate)
PV_Filter PV_FilterPROV PV_Filter (sec) = PV_Filter (sec) =
OX 60*PV_FilterPROV 60*PV_FilterPROVOX

(min)
If Rate = 0, TuningOXfor the DeltaV Standard will be
the same as for the Series Form
DeltaV PID Form/Units – An Example
Summary
PROVOX DeltaV DeltaV Difference
(Series) (Standard)

Gain 4 4 6 +50%

Reset 0.25 rep/min 240 sec. 360 sec. +50%

Rate 2 minutes 120 sec. 80 sec. -33%

PV 0.1 minute 6 sec. 6 sec. 0%

Filter
Non-Emerson Legacy Conversion Units*
Platform P Units I Units D Units Other Notes
Bailey Infi90* • Gain Multiplier Resets/M Minutes K I = Manual Reset
(normalize EUs) Time (min)
in K A = Derivative
• K P (Proportional Lag Constant
Gain)
MOORE- PG Minutes Minutes DG (derivative
gain) DeltaV α =
APACS 1/DG
Foxboro I/A* PB % Minutes Minutes KD (derivative
gain)
DeltaV α = 1/KD
Honeywell Gain Value Minutes Minutes Gain Value is
based on chosen
HPM* option
Honeywell Gain Constant Minutes Minutes
HG
* Important to verify the information per platform
Yokogawa PB % Seconds Second
How to Avoid

Know your Legacy Conversion Units

Export Database, use appropriate tool

Don’t make system wide assumptions
– RS3 units selectable by PID

Make sure to verify all critical loops.
PROVOX to DeltaV Conversion Tool
POINT TAG Provox(Series) DeltaV(FORM=Std) DeltaV(FORM=Series)
POINT TAG

RESET

RESET

RESET
RATE

RATE

RATE
GAIN

GAIN

GAIN
(%/%) (rep/min) (min) (%/%) (sec/rep) (sec) (%/%) (sec/rep) (sec)
TIC101 0.48 0.46 0.1 0.50 136.43 5.74 0.48 130.43 6.00
TIC102 0.5 0.1 0.1 0.51 606.00 5.94 0.50 600.00 6.00
TIC103 0.33 0.5 0 0.33 120.00 0.00 0.33 120.00 0.00
LIC202 0.96 1.4 0 0.96 42.86 0.00 0.96 42.86 0.00
PIC601 2.5 0.4 0.007 2.51 150.42 0.42 2.50 150.00 0.42
PIC602 2 0.25 0 2.00 240.00 0.00 2.00 240.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00
 RS3 Database Documented Using Control
Studio

Type Address Tagname Descriptor AlarmPriority PlantArea PIAction DAction ControlAction Gain ProportionalBand IntegralTime DerivativeTime Option
PID =1A-09 PIC-720 C-400 TEMP CONTROL 0 12 Err PV Direct 1.11111 90. 30. S 0. S None
PID =1A-10 FIC-943 REGEN GAS FLOW 0 2 Err PV Reverse .444444 225. 30. S 0. S None
PID =1A-11 LIC-911 REGEN GAS SCRUBBER 0 2 Err PV Direct 2. 50. 10. S 0. S None
PID =1A-12 TIC-929 REGEN GAS HTR OUTLET 0 2 Err PV Reverse 2.22222 45. 7.5 M 0. S None
PID =1A-13 FIC-1001 LEAN AMINE FLOW 0 13 Err PV Reverse 1.11111 90. 30. S 0. S None
PID =1A-14 FIC-1034 LEAN AMINE FLOW BYP 0 13 Err PV Direct .5 200. 30. S 0. S None
PID =1A-15 PIC-707 RESIDUE COMP 0 12 Err PV Reverse 2.85714 35. 20. S 0. S None
C-300 HECLMN TO SECT
PID =1A-16 LIC-2089 LVL 0 22 Err PV Direct 1. 100. 6. M 0. S None
PID =1A-17 LIC-2067 S-8 LN2 SEPARATR 0 22 Err PV Direct 1. 100. 4. M 0. S None
C-100 DEMETH OVHD
PID =1A-18 PIC-2040 PRS 0 23 Err PV Direct 1.66667 60. 30. S 0. S None
PID =1A-19 PIC-731 RESID SCRB IN TO FLARE 0 12 Err PV Direct 3.33333 30. 25. S 0. S None
What it Looks Like when it goes Wild!
Poor Control, Never Stabilizing at
Setpoint

Incorrect DeltaV ARW Limits will cause poor control
action!!

Note PV-SP Offset Correct ARW

Why It Happens?
Erratic Control, SP-PV Offset

Anti- Reset Windup (ARW) Settings incorrectly converted!

ARW’s set correctly, improves process recovery from saturated
conditions

ARW settings in PROVOX are in 0-100% OUT, in DeltaV they are
in EU’s of the OUT
– reset time will automatically be decreased by 16X (faster integral action) if
the OUT is outside the low or high ARW limit AND the PID is moving the
OUT toward being back inside the ARW limits
How to Avoid?
Controlling, but Never Stabilizing

ARW limits are in Engineering

Units of the OUT_SCALE.
OUT_SCALE default is 0-100
If OUT_SCALE is other than 0-
100, be sure to initially set ARW
limits to the OUT_SCALE limits.
 How to Avoid?
Controlling, but Never Stabilizing

Know your Legacy System ARW Settings!
– RS3 has no separate ARW Limits
• Difference Function
– PROVOX ARW settings in %OUT and the out scale is
always 0-100%
DeltaV PROVOX ARW DeltaV ARW
Output Scale

0-100% 0-100% 0-100

0-1500 lbs/hr 0-100% 0-1500

Other Things to Consider

PID Structure

Other RS3 Considerations

Looking in Old Documentation

Power Infrastructure

Legacy Firmware Compatibility

Legacy Custom Firmware

Legacy Spares
 PID “Structure”

PID “Structure” has to do with whether the Gain and
Derivative act on the Error (SP-PV) or on the PV
– Remember: Integral action is always on Error
1. PROVOX PID Structure is “PI action on Error, D action on
PV”
2. RS3 allows you to choose whether the Proportional (P) Acts
on Error, PV or SP
3. RS3 allows you to choose whether the Derivative (D) acts
Error, PV or SP.

There are several DeltaV PID Structure options.

– Select “PI action on Error, D action on PV” to match PROVOX
– RS3: DeltaV does not allow P and D on SP.
– Most common is PI on error, D on PV
PID Function Block “Structure”
Parameter

Used most.
Default
Other RS3 PID Considerations

RS3 PID has a both the “positional”(default) and

a “velocity” PID implementation.

DeltaV has only the “positional” PID
implementation.
– Warning: If using Velocity in RS3 it may act differently when the
output comes out of a limit when you migrate to positional

Check feed forward scaling systems
– Both RS3 and DeltaV use a “Feed forward Gain” but the DeltaV
PID block has a “feed forward scale”.
RS3 PV Filtering

PV filtering is provided on the Analog-In block
– It is a first order filter, enter the time constant in seconds

Additional filtering is provided in the PID block if Derivative
is activated (PID, PD or ID), even if Rate = 0.

PID filter is non adjustable and its first order time constant
is the greater of (2*Sample time) or (Rate/8).
– Note: “sample time” is the greater of the ControlBlock sample
time, if configured, or the Controller Processor card scan time.
– Units are selectable as seconds, minutes or hours.

PID filter applies to the value being acted upon by the
Proportional, Integral and Derivative terms.
– Different than DeltaV where this filter (α*Rate) is applied only to
the value going to the Derivative function
Looking in Old Documentation
Bailey
Potential Confusion: Control System Terminology

Clue: Parallel Blocks

Clue: S Domain
Transfer Functions

Bailey Documentation Function

Code 156
Looking in Old Documentation
Multiple Form Options may Exist ...

Bailey Documentation Function

Code 156
Looking in Old Documentation
Honeywell

Potential Confusion: Control System Terminology

Interactive = Real = Classic
Non-interactive = Ideal = Standard

Remember Bailey Non-Interactive meant Parallel

 I
1
Error = SP - PV
TR s OUTPUT = P + I + D

P
+ PV
SP
KC + PROCESS

-
TD S
D

Honeywell Documentation

Clue: Standard S Domain

Transfer Functions
 Power Infrastructure

Power infrastructures
are as old if not older
than the DCS

BEWARE: Electrolytic
capacitors and expected
failure rates
 Legacy Firmware Compatibility

Revisions of FIC’s and
FIM’s firmware must
be compatible with
tested solution

Too Late! once
ControlFile is removed

No easy way to get
cards updated
– Send in to Emerson for
repair ($$$$ and time)
– Take to another
location and/or system,
install and upgrade
– Tapes with the
firmware images must
be sourced prior to the
migration
 Legacy Custom Firmware

PROVOX External Interface Cards (EIC’s)

Lots of custom firmware that interface to weigh scales, third
party devices (corrosive meters, flow computers, etc.), and
PLC’s.

Special interfaces must be investigated prior to the migration
– Special firmware may be needed for DeltaV programmable serial card
(PSC)

Original device documentation will be required in order to
write the special firmware
– In a few cases the device may have multiple protocol outputs
Legacy Spares – Harvesting Spare Parts

Do complete inventory of Legacy spares

Make sure they match your existing system

‘The Myth of Harvested Spare Parts’
– ‘Control System Migration Lessons Learned’, ARC Report April 2013
– As many as 1/3 or more of all ‘used’ spare parts are not serviceable
– Environmental conditions or use or abuse will shorten life span
• ‘parts from a dismantled legacy system, even if cleaned and placed on shelf
may still be DOA, when plugged into running system’
‘Don’t rely on very old parts from previous
decommissioned systems as a long term strategy’
Summary

What it looks like when it goes Wild?

– Cycling Outputs
– Controlling Super Slow or Super Fast (Unstable Control)
– Controlling, but never stabilizing at Set Point

Common Conversion Mistakes

Tips, Tools, & Techniques

Other Gotcha’s!
Where To Get More Information

Business Card or Sign up Sheet:
– Give us your name and email address. We will mail you the
PROVOX Conversion Tool and more in-depth presentations on
RS3 and PROVOX Conversions

“Interesting and Useful Features of the DeltaV PID, Ratio
and Bias/Gain Control Blocks”
– by James Beall, 2010 Emerson Exchange
– We can send a copy if you don’t have it!

Entech Training: Course 9030, Course 9032

See us at the Exhibit Hall! (Monday - Wednesday this week)
Thank You for Attending!
Enjoy the rest of the conference.