Example Industrial Unit

Process Inputs and Outputs

Feed flows
Feed temperatures F1

Damper Position
Open/Close

F2

TS
AO

XD

AC

Oxygen
Carbon Monoxide
NOx

F3
F4

T1i

PB

TB

T1o

Outlet temperatures
T2o

T2i

T3o

T3i
T4i

T4o

TW 48 tube metal temperatures

Furnace
Fuel gas TG
Fuel flow
Fuel temperature
Fuel pressure
TO
Fuel oil

Summary

FG
FO

PG

PO

Honeywell Proprietary

80 analog inputs
7 analog outputs
16 digital inputs

INGLISH Slide 1 4/26/2013

Example Industrial Unit

Process Control and Asset Functions

Regulatory Control

Pass flow loops

Excess air control
Dual-fuel firing

F1

TS
AO

F2

XD

F4

Advanced Regulatory

T1i

PB

TB

T1o
T2o

T2i
T3i

Furnace pass balancing

Efficiency optimization

T3o

T4i

T4o

TW

Safety and Environmental

AC

F3

Emissions calculations
Heat transfer rates

TG

FG

TO FO

PG

PO

Asset Calculations
Honeywell Proprietary

INGLISH Slide 2 4/26/2013

Example Industrial Unit

Unit Location

Furnace is 300 meters from control room

Plant uses trenches and cable trays

Control Room

Operator stations and engineering

Controllers are in control room
Connect to information systems
Maintenance from separate center

Honeywell Proprietary

INGLISH Slide 3 4/26/2013

Criteria for Traditional Installation

Wiring

Control Functions

All to control center -- use marshalling racks

Use overhead cable trays
Through junction boxes
Use as much standard as possible
Regulatory by the DCS algorithms
Advanced using programming

Program

Normal Company Practices

For design and documentation

For checkout of system

Honeywell Proprietary

INGLISH Slide 4 4/26/2013

Traditional Solution
Following the Criteria

103 separate pairs of wire

6 multiconductor cables

F1

TS

F2

XD

F3
F4

3 high-level analog input boards

2 low-level analog input boards
1 analog output board
1 digital input board

T1i

TB

T2i
T3i
T4i

TW

Temperature multiplexors

Honeywell Proprietary

INGLISH Slide 5 4/26/2013

Traditional Solution
Complete Control Picture

Efficiency Optimization

Emissions Limiting

Furnace calculations

Regulatory Control

7 PID blocks
1 constraint override set

F1

7 algorithm blocks

F2

1 dual fuel firing set

F3

Special program

Asset Management

Standard program

F4

16 algorithm blocks

Advanced Regulatory

TS
XD

T1i
T2i

TB

T3i
T4i

1 multivariable algorithm

TW

Honeywell Proprietary

INGLISH Slide 6 4/26/2013

Advanced Regulatory Control

Furnace Pass Balancing

Safety

F2

Limit hot-spots on tubes

No failures or ruptures

F3
F4
T2i

T3o

T3i
T4i

Maximum heat gain

T4o

TW TW TW TW TW

Control Difficulty

T1o
T2o

T1i

Efficiency

F1

Coupled control problem

Change in one valve position
affects flow in all passes

F1
F2
F3

F4

Honeywell Proprietary

m11 m12 m13 0 0 0 0 0

0 m22 m23 m24 0 0 0
0 0 0 m32 m33 0 0 0
0 m42 0 m43 m44 y yy
0 0
m53 m54 m55 m56
0 0 0 0 0 0 0 mm-2n-2
0 0 0 0 0 0 0 mzz mm-1
0 0 0 0 zz z mm-2n-2 mm

V1
T1o
V2
T2o
V3
T3o
V4
T4o

INGLISH Slide 7 4/26/2013

Fieldbus Solution
Complete Control Picture

Efficiency Optimization

Emissions Limiting

Standard program

Analog signals

Special program

Asset Management

Regulatory Control
1 PID block

Furnace calculations

F1

TS
AO

F2

XD

AC

F3
F4

T1i

TB

T2i
T3i

Regulatory Control

1 PID block -- air control

1 constraint override set
z

7 algorithms or 15 function blocks

Regulatory Control
1 PID block

1 dual fuel firing set

z

16 algorithms or 24 function blocks

Advanced Regulatory

T4i

Flow controls 1-4

Fuel gas

TG

FG

TO

FO

Pass balancing
z

1 algorithm or 420 function blocks

1 PID block
P
PG

Fuel oil

Honeywell Proprietary

INGLISH Slide 8 4/26/2013