© 2011 Aspen Technology, Inc. All rights reserved

Francois van Niekerk, APC Business ConsultantDecember 9, 2011

aspenONE® Advanced Process Control Driving life cycle efficiency

© 2011 Aspen Technology, Inc. All rights reserved

© 2011 Aspen Technology, Inc. All rights reserved

AspenTech : 30 Years of Innovation

Commercial Software § Distillation Algorithm and Electrolyte Properties§ Heat Exchanger Design, Cost Estimation and

Dynamics§ Production Planning

PC/Desktop Revolution § PC-based Simulation, Economic Evaluation,

Heat Exchanger Design and Energy Analysis§ Basic Engineering Collaborative Environment§ Polymer Process Modeling§ Model Predictive Control (APC)§ Planning Tool§ Retail Gasoline Distribution

Enterprise Integration § Integrated Engineering, Manufacturing & Supply

Chain§ Integrated Simulation, Economics, Heat

Exchanger Design and Energy Analysis§ Integrated Basic

Engineering § Integrated Manufacturing§ Integrated Supply Chain§ Solvent Screening§ Enterprise Master Data Model§ Token-based Licensing Model

1970s 1980s 1990s 2000s

© 2011 Aspen Technology, Inc. All rights reserved

Industry Dynamics

© 2011 Aspen Technology, Inc. All rights reserved

How Manufacturing Industry is Responding

§ Organisations need to decide how to capture and retain knowledge and pass it on.

§ Simplicity, ease-of-use and continuity is the key

§ New generation of technologies are ready to be used in an industrial environment

© 2011 Aspen Technology, Inc. All rights reserved

APC Best Practices

“ARC believes that companies able to methodically implement, use, and maintain APC applications at the lowest cost and generate the highest value over its lifecycle will have a distinct competitive advantage.”

Source: Best Practices for Advanced Process Control, January 2008, Tom Fiske

© 2011 Aspen Technology, Inc. All rights reserved

Deploy APC on Production Units

With the high penetration of APC on large units, leading companies are looking for opportunities to apply APC in other areas including small-to-midsize process units.”

Current Level of APC Adoption for Continuous Processes

Source: Best Practices for Advanced Process Control, January 2008, Tom Fiske

Deliver APC benefits across more units

“ARC believes that companies able to methodically implement, use, and maintain APC applications at the lowest cost and generate the highest value over its lifecycle will have a distinct competitive advantage.”

© 2011 Aspen Technology, Inc. All rights reserved

Improving Controller Lifecycle Benefits

• Performance monitoring• Automated step testing• Continuous Improvement

Maintaining APC application value requires planning to ensure the tools, people and process are in place.

Source: Best Practices for Advanced Process Control, January 2008, Tom Fiske

© 2011 Aspen Technology, Inc. All rights reserved

Characteristics to Sustain APC Benefits

Reduce variability and push constraints

Reduce variability and push constraints

Monitor and detect changes in controller performance and models using KPIs

Monitor and detect changes in controller performance and models using KPIs

RepairRepairDiagnoseDiagnoseDetectDetectControlControl

Determine reasons for eroding performance through detailed analysis

Determine reasons for eroding performance through detailed analysis

Evaluate improvements, build, and test new controller models

Evaluate improvements, build, and test new controller models

“…to methodically implement, use, and maintain APC applications at

the lowest cost and generate the highest value over its lifecycle will

have a distinct competitive advantage.” – ARC Insights

“…to methodically implement, use, and maintain APC applications at

the lowest cost and generate the highest value over its lifecycle will

have a distinct competitive advantage.” – ARC Insights

© 2011 Aspen Technology, Inc. All rights reserved

Implementing & Deploying APC

Reduce variability and push constraints

Reduce variability and push constraints

Monitor and detect changes in controller performance and models using KPIs

Monitor and detect changes in controller performance and models using KPIs

RepairRepairDiagnoseDiagnoseDetectDetectControlControl

Determine reasons for eroding performance through detailed analysis

Determine reasons for eroding performance through detailed analysis

Evaluate improvements, build, and test new controller models

Evaluate improvements, build, and test new controller models

“In recent years the MPC landscape has changed

drastically, with a large increase in the number of

reported applications, significant improvements in

technical capability, and mergers between several of

the vendor companies..” – Qin, Badgwell 2003

“In recent years the MPC landscape has changed

drastically, with a large increase in the number of

reported applications, significant improvements in

technical capability, and mergers between several of

the vendor companies..” – Qin, Badgwell 2003

© 2011 Aspen Technology, Inc. All rights reserved

Ref: “Identification for industrial model-based control”, V Alstad; NTNU, 2005 Continuous

Batch

© 2011 Aspen Technology, Inc. All rights reserved

Monitoring Benefits & Detecting Changes

Reduce variability and push constraints

Reduce variability and push constraints

Monitor and detect changes in controller performance and models using KPIs

Monitor and detect changes in controller performance and models using KPIs

RepairRepairDiagnoseDiagnoseDetectDetectControlControl

Determine reasons for eroding performance through detailed analysis

Determine reasons for eroding performance through detailed analysis

Evaluate improvements, build, and test new controller models

Evaluate improvements, build, and test new controller models

Ref: “APC Program Management at Air Products & Chemicals”, D Espie & G Shen Air Products; OPTIMIZE2011, Washington, 2011

Ref: “Sustained Performance Program”, M Al-RashidiKNPC; AC&O User Conference Houston, 2009

© 2011 Aspen Technology, Inc. All rights reserved

Diagnosing Reduced Performance

Reduce variability and push constraints

Reduce variability and push constraints

Monitor and detect changes in controller performance and models using KPIs

Monitor and detect changes in controller performance and models using KPIs

RepairRepairDiagnoseDiagnoseDetectDetectControlControl

Determine reasons for eroding performance through detailed analysis

Determine reasons for eroding performance through detailed analysis

Evaluate improvements, build, and test new controller models

Evaluate improvements, build, and test new controller models

© 2011 Aspen Technology, Inc. All rights reserved

Quickly repair & update controller

Reduce variability and push constraints

Reduce variability and push constraints

Monitor and detect changes in controller performance and models using KPIs

Monitor and detect changes in controller performance and models using KPIs

RepairRepairDiagnoseDiagnoseDetectDetectControlControl

Determine reasons for eroding performance through detailed analysis

Determine reasons for eroding performance through detailed analysis

Evaluate improvements, build, and test new controller models

Evaluate improvements, build, and test new controller models

Ref: “Rapid DMCplus controller refits” D CimaChevron; AC&O User Conference Houston, 2009

© 2011 Aspen Technology, Inc. All rights reserved

How Manufacturing Industry is Responding

§ Organisations need to decide how to capture and retain knowledge and pass it on.

§ Simplicity, ease-of-use and continuity is the key

§ New generation of technologies are ready to be used in an industrial environment

© 2011 Aspen Technology, Inc. All rights reserved

Francois van Niekerk, APC Business ConsultantDecember 9, 2011

aspenONE® Advanced Process Control Driving life cycle efficiency

© 2011 Aspen Technology, Inc. All rights reserved