Ultramax Corporation 1 Advanced Process Management™ (APM™) 1.
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Transcript of Ultramax Corporation 1 Advanced Process Management™ (APM™) 1.
Ultramax Corporation
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Advanced Process Management™ (APM™)
1
®
Ultramax Corporation
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Maximizes the value generated by production processes by:
1. Applying better process Adjustments
2. Detecting process upsets
3. Inducing Discovery of problems and opportunities
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®
Ultramax Corporation
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BASIC FACT
“More profitability” or “more business value” is:
1. Better product quality characteristics
2. More consistency from part-to-part, day-to-day
3. Higher production rates, lower cycle times
4. Lower costs, lower losses
5. Lower undesirable byproducts (e.g., emissions)
as defined by the user for each process/product.
Many existing processes can generate far more profitabilityif management/production people have
better information to adjust the control inputs to the process
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Ultramax Corporation
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Adjusting production processesto maximize the value they generate
for the company on a daily basis
ULTRAMAX is a solution to:
Ultramax Corporation
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ULTRAMAX®
is the most advanced empirical method for adjusting production processes in order to maximize their performance
1. EFFECTIVE
2. SIMPLE
3. FAST
4. KEEPS YOU IN CONTROL
ULTRAMAX starts after the process is running fairly well.
It requires neither process models nor past process data.
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Decision Input/Output Diagram
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Decisions: Adjusted Control Inputs
Uncontrolled Inputs
Ambient conditions
Process to beOptimized
Amount Ingredients
Cycle Times
Feed Rate, Speed
Temp, Press, Voltage
Raw material charact.
Outputs, Outcomes,Consequences
Yield, Prod. Rate
Product Characteristics(level, consistency)
Cpk, Loss Functions
Scorecard, profit impactC
C
M
M
A
A
A
A
M
M
Losses, emissionsM
A = Adjust
M = Measure
C = Calculate
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Decision Input/Output Diagram
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Decisions: Adjusted Control Inputs
Uncontrolled Inputs
Ambient conditions
Process to beOptimized
Amount Ingredients
Cycle Times
Feed Rate, Speed
Temp, Press, Voltage
Raw material charact.
Outputs, Outcomes,Consequences
Yield, Prod. Rate
Product Characteristics(level, consistency)
Cpk, Loss Functions
Scorecard, profit impactC
C
M
M
A
A
A
A
M
M
Losses, emissionsM
A = Adjust
M = Measure
C = Calculate
Continued…
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Optimization Plan (I)• Identify management objectives and value
added related to:– higher throughput– better quality (averages and consistency)– lower consumption costs, losses– reduced undesirable byproducts
• Identify related process outputs to measure
(continues)
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Optimization Plan (II)(continued)
• Select control inputs to adjust:– Setpoints or biases– Physically adjusted by hand– Control parameters (gains, curves, limits)
• Select uncontrolled inputs to measure• Define scorecard, to calculate overall (short and
long term) value added by production, based on the physical measurements
• Identify the constraints within which to operate
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Sequential OptimizationAdjusted Control Inputs
Uncontrolled Inputs
Ambient conditions
Process to be
Optimized
Run Time
Amount Ingredients
Cycle Times
Feed Rate, Speed
Temp, Press, Voltage
Raw material charact.
ULTRAMAXRun Data
Outputs, Outcomes,Consequences
Yield, Prod. Rate
Prod. Characteristics
Cpk, Loss Functions
Losses, emissions
Scorecard, profit impact
M
C
C
M
M
A
A
A
A
M
M
Advice,Alerts
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Process Control / ULTRAMAX Interface
Accept/Revise/
Automate
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SCORECARD
RUNS, TIME
OLD ULTRAMAX NEWPERFORMANCE SEQUENTIAL OPTIMIZATION CYCLES PERFORMANCE
Time averaged results
Individual results
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Requirements:
1. Business2. Organizational3. Technical
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1. Business Requirements
Financial performance is materially impacted by either:– Reduced consumption of raw materials– Reduced energy consumption– Reduced variations in outputs (more
consistency)– Better product characteristics (e.g., purity)– Reduced emissions– Increased throughput
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2. Organizational Requirements
Process Managers are driven by results (rather than by procedures alone)
There is a drive to do better:– for the extra value (profitability) generated– because this requires people to better
understand the process and the business
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3. Technical Requirements
1. Measurability
2. Timeliness of data feedback
3. Graduality of variables
4. Consistency – generate similar output values for the same
settings of control and uncontrolled inputs, i.e., repeatability
– account for all factors that have important impacts on outputs
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Sequential Empirical Optimization (SEO)
Performance Characteristics
Regularly, ULTRAMAX’s SEO quickly gets as close to the optimum as the noise level.Thus, to get improvements, the noise level must be less than 1/3rd the potential improvements.
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TRADITIONAL CONCEPT MADE PRACTICAL by ULTRAMAX
Box & Draper’s EVOP (1969)
“A process ought to be run
not only to make product
but also to continuously
learn how to do it better.”
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ADVANTAGES OF PROCESS ADJUSTMENTSWITH ULTRAMAX’s SEO
Approaches maximum performance in 50-200 process re-adjustments
Compensates quickly for changes in known uncontrolled physical inputs
Adapts quickly to changes in the business conditions
Is easy to use, minimal statistical knowledge
Provides engineering analysis of constraints and bottlenecks
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Adjusting production processesto maximize the value they generate
for the company on a daily basis
So, ULTRAMAX is a solution to:
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with ULTRAMAX
• A Return On Investment (ROI) of one year or less(guaranteed if process requirements are met)
• Realized in 50-200 re-adjustments• With about 65 people-days investment
(including training and integration)
EXPECT, FOR EACH APPLICATION:
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Overview• Ultramax Corporation was founded in 1982
• Ultramax is located in Cincinnati, Ohio, USA
• Ultramax’s business is to provide superior solutions for process adjustments to maximize the performance of production operations by means of Advanced Process Management
• Ultramax and its Agents provide its unique, proven optimization solution to its customers by on-site training, implementation, continuing support and licensing of the Method and Technology.
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END
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ULTRAMAX For Power Generation
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ULTRAMAX enables to• Optimize (tune) any boiler regardless of design and level of
automation• Achieve the best combination (balance) of all important results
(thermal performance, emissions, costs)• Sequentially adjust control parameter settings.• Enforce necessary constraints on steam temperatures, flows
and emissions• Compensate for changing conditions such as load, fuel quality
and environment• Build predictive models based on cause-effect relationships for
operator advisory and closed-loop optimization capacity
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ULTRAMAX Dynamic Optimization
• Used by more than 25 utilities• Applied to more than 90 generating units• Applied to front-wall, opposed-wall, tangential,
cyclone, turbo units• Applied to coal, gas and oil-fired units• Expected improvements in NOx of 10-25%, heat rate
of 0.5-2%, LOI of 25-40%
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Ultramax Utility Clients
• Allegheny Power• AES Beaver Valley Cogen• Ameren• Central & South West• Cinergy• Colorado Springs Municipal• Detroit Edison• Eastern Generation• First Energy• GPU/GENCO• Hoosier Energy Rural Electric
• Illinois Power• Kansas City Power & Light• KEMA• Omaha Public Power District• Salt River Project• Scottish Power• South Carolina Electric & Gas• Tennessee Valley Authority• TU Electric• Wisconsin Public Service
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Ultramax Boiler Optimization Summary
CE Tangential, Coal 125 19% LOI down 32%Twin
CE Tangential, Coal 230 21% Boiler eff. up 3.1%Twin
CE Tangential Coal 118 20% HR down 3%.LOI down 9%.
CE Tangential Coal 900 LNB, 13%SOFA
CE Tangential Coal 600 30% HR down 2.5%LOI down 40%
CE Tangential Coal 550 CCOFA 29%
CE Tangential Coal 880 LNB, 8% Balanced two sides.Twin, Supercritical OFA
MFR. Type Fuel Size Retrofit NOx Other Benefits Reduced
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Ultramax Boiler Optimization Summary
CE Tangential, Coal 560 32% HR Down 2.5% Twin LOI down 50%
CE Tangential, Gas 230 21% Boiler eff. Up 3.1%Twin at lower loads
CE Tangential Coal 118 20% HR down 3%LOI down 9%
CE Tangential, Coal 900 LNB, 13%SOFA
CE Tangential Coal 600 30% HR down 2.5%LOI down 40%
CE Tangential Coal 550 CCOFA 29%
CE Tangential Coal 880 LNB, 8% Balanced two sidesTwin, Supercritical OFA
MFR. Type Fuel Size Retrofit NOx Other Benefits Reduced
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Ultramax Boiler Optimization Summary
FW Wall Coal 320 10% HR down 1.5%Twin gas
FW Opposed Coal 500 LNB, 28%Wall OFA
FW Opposed Coal 640 LNB 18% HR down 2%.Wall LOI down 41%
FW Opposed Coal 666 LNB 18% HR down 0.3%Wall
RS Front Wall Coal 120 LNB 17% LOI down 37%
RS Turbo, Opposed Coal 400 OFA 11%Wall
Stork Opposed Wall Coal 600 9% Low NOx design
MFR. Type Fuel Size Retrofit NOx Other Benefits Reduced
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Ultramax Boiler Optimization Summary
B&W Front Wall Coal 65 30%
B&W Cell, Opposed Coal 550 15%Wall
B&W Opposed Coal 650 LNB, 13% Boiler Eff. up 1.7%Wall OFA
B&W Front Wall Coal 200 41% HR Down 5%.Balanced LOI
B&W Opposed Wall Coal 700 20%
B&W Opposed Wall, Coal, 290 22%Twin BF Gas
B&W Cyclone, Coal 500 25%Opposed Wall
MFR. Type Fuel Size Retrofit NOx Other Benefits Reduced
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Description Problems
Engineering models time consuming, expensive(first principles)
Change one variable at a time grossly insufficient if interactions
Design of Experiments/ lengthy, statistical expertise,Response Surface Analysis static, off-line(DOE/RSM)
continues...
SOLUTION METHODS FOR PROCESS ADJUSTMENTS
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SOLUTION METHODS FOR PROCESS ADJUSTMENTS
... continued
EVOP, SIMPLEX if on-line: expensive, inflexible
Neural Net Models requires a lot of valid historicaldata, static, very limited extrapolation outside of past experience
Hand adjustments based on sub-optimal, crew dependent,experience (tweaking) people turnover
Dynamic Optimization (D.O.) a new way of thinking
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The Optimization PlanO2 Trim
Windbox A-A, E-E
Windbox A-B, E-F
Windbox B-C, F-G
Windbox C-D, G-H
Windbox D-D, H-H
Coal/Air Damper A&E
Coal/Air Damper B&F
Coal/Air Damper C&G
Coal/Air Damper D&H
Reheat Burner Tilt
Superheat Burner Tilt
Reheat Air Prop. Damper
Superheat Air Prop. Damper
Controlled Inputs Outputs
Illinois PowerHennepin Power
Station, Unit 2
CE, Tangential,Twin Furnace
235 GMW
NOx
Superheat LOI
Reheat LOI
Superheat Temperature
Reheat Temperature
Throttle Pressure
Superheat O2
Reheat O2
Superheat CO
Reheat CO
Boiler Efficiency
Objective Function
AdviceULTRAMAX
DecisionRun Data
A
A
A
A
A
A
A
A
A
A
A
A
A
A
M
M
M
M
M
M
M
M
M
M
M
C
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0.3
0.4
0.5
0.6
0.7
1 11 21 31 41 51 61 71 81 91
RUN NUMBER
NO
x (
lbs
/MB
tu)
NOx
NOx Mvg. Avg. (5)
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-8.00
-6.00
-4.00
-2.00
0.00
2.00
4.00
6.00
1 11 21 31 41 51 61
Run Number
Go
al (
NO
x a
nd
Eff
icie
ncy
)
Goal - Actual
Goal - Moving Average (5)
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Aux. Air. DD& HH
Coal Air: D & H
Aux. Air: CD & GH
Coal Air: C & G
Aux. Air: BC & FG
Coal Air: B & F
Aux. Air: AB & EF
Coal Air: A & E
Aux. Air: AA & EE
O2 Trim Setpoint
RH Air Prop. Damper
SH Air Prop. Damper
Current Advice InputValues Values Values
098.6 100.0
099.4 100.0
099.1 060.0
026.8 025.0
041.4 030.0
023.3 025.0
041.0 030.0
025.9 025.0
041.0 030.0
002.0 003.3
071.8 070.0
10.0 070.0
CONTROL INPUTS
Current Average PredictedValues Data Values
0.502 0.504 0.450
986.5 986.2 997.5
01007 01007 01000
001.9 001.9 003.0
003.0 002.9 003.0
091.4 088.5
NOx (#/MMB)
SH TEMP (F)
RH TEMP (F)
SH 02 (%)
RH 02 (%)
BLR EFF (%)
OUTPUT VALUES
ULTRAMAX OPERATING SCENARIO
200 GMw - ALL COAL MILLS IN SERVICE
ULTRAMAX UTILITIES
LOAD RH O SH O RH DRAFT SH DRAFT RH TEMP SH TEMP DRUM LVL DRUM PRS THROTTLE BACK PRS VACUUM223 MW 8 0 pct 1.9 pct -0 6 ‘H2O -0.4 ‘H2O) 1007 DEGF 986 DEGF -0.1 ‘H2O 221 4 PSIG 1998 PSIG 2.27 ‘HG 27.65 ‘HG
Operator Command Received.
ULTRAMAX MODEDISABLED
COLLECTION TIMER
15.00MINUTES
GET SET ADVICE UMAX
RELEASE COLLECTFROM UMAX DATA
ULTRAMAX CONTROL
REJECT LASTDATA COLLECTION
14-Aug-199612:13:03drop200
DIAG 2930 UNIT 2 ULTRAMAX ADVICE CYCLE
MASTER RH MILLS RH MILLS RH COAL RH GAS SH MILLS SH MILLS SH COAL SH GAS NAT GAS FUEL FILM SCAN DESELECT MENU CONTROL OVERVIEW AIR CNTL CONTROLS CONTROLS OVERVIEW AIR CNTL CONTROLS CONTROL MASTER OVERVIEW CONTROL
RH WBFOP SH WBFDP CONB AIR/ FW CONTROL BOILER MFT STM TEMP DRAFT PURGE CONTROL
SCENARIOMENU
2 2
Select Switch Page Zoom Poke Recall
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LOAD RH O SH O RH DRAFT SH DRAFT RH TEMP SH TEMP DRUM LVL DRUM PRS THROTTLE BACK PRS VACUUM223 MW 8 0 pct 1.9 pct -0 6 ‘H2O -0.4 ‘H2O) 1007 DEGF 986 DEGF -0.1 ‘H2O 221 4 PSIG 1998 PSIG 2.27 ‘HG 27.65 ‘HG
Select Switch Page Zoom Poke Recall
14-Aug-199612:13:38drop200
DIAG 2932 UNIT 2 ULTRAMAX OPER. SCENARIO
MASTER RH MILLS RH MILLS RH COAL RH GAS SH MILLS SH MILLS SH COAL SH GAS NAT GAS FUEL FILM SCAN DESELECT MENU CONTROL OVERVIEW AIR CNTL CONTROLS CONTROLS OVERVIEW AIR CNTL CONTROLS CONTROL MASTER OVERVIEW CONTROL
RH WBFOP SH WBFDP CONB AIR/ FW CONTROL BOILER MFT STM TEMP DRAFT PURGE CONTROL
UltraMaxMenu SCENARIO SELECTION ________
SCENARIO SCENARIO DESCRIPTION
1 230 GMw - ALL COAL MILLS IN SERVICE2 200 GMw - ALL COAL MILLS IN SERVICE3 200 GMw - A,B,C,D/E,F,H MILLS IN SERVICE4 150 GMw - A,B,C/E,F,G MILLS IN SERVICE5 150 GMw - A,B,D/E,F,G MILLS IN SERVICE6 150 GMw - A,C,D/E,F,G MILLS IN SERVICE789101112131415161718 80 GMw - B,C/F,G MILLS IN SERVICE19 80 GMw - B,D/F,G MILLS IN SERVICE20 80 GMw - C,D/F,G MILLS IN SERVICE21 80 GMw - B,C/F,H MILLS IN SERVICE22 80 GMw - B,C/G,H MILLS IN SERVICE23
2 2
Select Switch Page Zoom Poke Recall
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END
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Process Improvements
Level 1
Level 2
Level 3
Process Improvement
Change inProduct
Change inProcess
Management
Empirical Models
SequentialOptimization
FixedModels
First-PrincipleModels
Change inProcess
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ULTRAMAX is Unique TechnologyIn this sequential approach, models are updated continually
as new production data is generated. Information in data is used profitably right away.
Models are based on Bayesian statistics
Models are quadratic, goal oriented and locally accurate (produced by uniquely weighed regression)
Models and Advice compensate for known uncontrolled inputs (material quality, requirements, ambient conditions), and for gradual unknown process changes.
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Some Technical Advantages
Bayesian Statistics:
Extract more useful information when there is limited data than regular statistics or Neural Networks.
There is a trend towards optimization beginning after the first few readjustments.
Quadratic Models:
Extrapolate better towards the optimum in unexperienced operating conditions (than Neural Networks).
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Some technical advantagesLocally Accurate Models (weighted data):More accurate models, not distorted by fitting data away
from the optimum.In general:Much faster optimization than any alternative.Requires no historical data nor prior models to start
optimizing, but can use them. No off-line “training”.Model coefficients meaningful and available for
examination.
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END
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On-line Operator Support• Implement on-line as open-loop advisory or
closed-loop• Tailored to fit existing control equipment• Accurate models for various operating
scenarios• Models updated daily for continuous accuracy• Models available for engineering analysis• Staff trained to manage technology
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ULTRAMAX Is A Solution That Is...
ProvenEasy to useFlexible in applicationAble to deal rapidly with changeEasily managed by plant personnel
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Ultramax Offers:
Closed-loop, Advisory, and Stand-alone optimization
Transient optimization for load-following units
Training to become “experts”
Problem-solving is done by the customer
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