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APCX1 Can Replace your aging Model Predictive Control Software
MPC users can now take their existing models and configure them directly into APCX1. APCX1 Web Server Edition is up to 10 times faster than previous DMC’s and includes a Data Historian that exports to most “process watch” software packages.
“One end user writes”
Our MPC licensing becomes due for renewal soon and we are looking at pricing of possible alternatives.
I see from your site you are advertising APCX1 as a direct replacement for for our current MPC software. I assume this still uses the ADMC engine ?
Do you have any installations ?
We are currently running that famous MPC software written in the 1980's, we assume there are some features which APCX1 will not support (CV error filtering maybe ?)
The price list on your site only gives pricing for ADMC, is APCX1 the same price ?
The calculation engine for APCX1 is the same as ADMC. We have tested a controller with a set point model of an Olefin Plant that had 240 manipulated variables, 554 controlled variables, and 600 coefficient models. The execution time was 5.5 seconds for the calculations on a 64 bit Dell computer that cost about $6000.00. The controller is basically a DMC controller that we have redone the math and the handling of arrays that gives us the increase in speed. We have applied ADMC to three cat crackers, a dual train crude unit, two vacuum units, and a delayed coker.
APCX1 is a subset of ADMC and the cost for APCX1 is the same as ADMC. We renamed the subset to APCX1 to make people aware of the flexibility we have with ADMC. In fact some of the ADMC controllers we have built are a mixture of SP, PV, and OP independent variables. The best value on acquiring a replacement for aging MPC software is to lease the ADMC software. The lease rate is the same as the SMS for the controller. For example, the site lease rate for eight process units would be $62,379.52/year. We set these lease rates to be commensurate with what we understood our competition was charging for maintenance. With this business approach, we felt the new controller could be sold into a saturated market. The work to reconfigure the controller, the OPC connections, and the displays is minor compared to building a controller from scratch. Our experience with the reconfiguration of the controller is about a man-week. The enhanced capabilities you acquire (if you choose to use them) with the software permits you to convert some or all of the controller models over to PV models, which eliminates errors in the SP models that results from PID tuning and reconfiguration changes. Further, it permits valves to be opened or closed all the way, which gives the process more capacity. APCX1 has essentially all the standard features found in other MPC software such as CV error filtering.
Since 1985, Cutler’s Algorithm (Multi Variable Predictive Control)
is used by over 50% of the World’s Process Applications by several vendors!
The latest 2010 version of Cutler’s Algorithm now comes in Model Specific Versions!
APCX1™ for older Set Point Models.
ADMC for the next generation PV Models™
Web Server Edition, still in beta, is available for both versions.
Easy MPC Replacement product now available!
The new APCX1™ can replace youe aging controller with a minimal amount of engineering work. Load the existing MPC model into APCX1™, Configure and Run! Since the APCX1™ engine is a modernized version; it runs up to 10 times faster than earlier DMC’s. For even greater gains, consider upgrading to a PV Model™ and harness the power of ADMC - Adaptive DMC™
CUTLER TECHNOLOGY is not Affiliated with Aspen Technology.
(DMCplus is a registered trademark of Aspen Technology; ADMC; [ADMC] and DMC are trademarks of Cutler Technology)
* Adaptive Transformations: The transformations in the controller are automatically adapted as the upstream and downstream pressures change.
* Stiction Move: The transform output is passed through an algorithm that further corrects the output change to account for Stiction.
* PV-based modeling: The models in the controller use Process Variables as their independent variables, so the prediction is updated only when the process changes. The predictions are not corrupted by sticking valves.
* PV Models are linear across a wider range than PID set point controllers with non linear valves.
* PV Models are not corrupted by PID tuning or configuration changes.
* Sub controllers: Sub controllers are fully supported by ADMC, allowing the operator very smooth transitions while turning on and off segments of the process.
* LP Optimizer: handles infeasibilities based on relative importance.
* Dynamic weighting: Variables are weighted dynamically based on their relative importance.
* Compatible with most common data historians, including PHD and PI.
* Trip limits: if the process exceeds a trip limit, the controller will automatically turn off.
* Field Proven on over half a dozen major process units.
* Data Historian Export compatible with most “Process Watch” software packages on the market today.
CutlerTech APC Advanced Process Control Products
Adaptive Multivariable Control - ADMC
The Adaptive DMC [ADMC] controller is a state of the art DMC controller. If only set points are used as the independent variables in the controller, then its performance is essentially the same as a traditional DMC controller, except It runs about 10 times faster than other MPC's and handles LP infeasibilities in a more elegant way. When the model is identified as a PV model, the controller takes on some special features. The controller calculates a change in the PV for each independent variable. The change in the PV is fed through a piecewise linear transformation to obtain the change in the valve output. Placing the transformation external to the controller calculation permits the transform to be updated continuously. At each control interval, the PV and OP can be measured for a flow valve. The flow for the observed valve position based on the transformation calculated from the test data can be calculated. The ratio of the two flows is used to rotate the transformation to match the observed flow. The derivative of the flow vs valve position is used to calculate the change in the valve position. Upstream and downstream pressures have shown the ratio to change from .5 to 2. The prediction for the ADMC controller when using the PV is only updated when the PV changes, which prevents sticking valves from contaminating the predictions. The most important attribute of the ADMC controller is that bypass valves can be opened or closed without invalidating the controller model. Changing the configuration of one independent variable when the test configuration is imbedded in the model changes the whole model to some degree. The ADMC controller can eliminate the wrap in the process that is necessary to keep the PID controllers functioning. This feature is worth thousands of dollars a day for most plants. Since Cutler’s 1985 introduction of a commercial DMC controller, his DMC Algorithm has landed into the #1 spot and is currently used in over 50% of the World’s advanced process control applications by several vendors. ADMC is a new updated DMC Algorithm with modern Adaptive features. In a recent speed comparison between a current DMC vendor and ADMC (ADMC running in basic DMC only mode), the new ADMC engine runs up to 10 times faster than the other vendors DMC. This speed increase in the basic DMC Algorithm is a result of CTC’s proprietary improvements made to the original 1985 DMC Algorithm that is still being used by other vendors.
In the last year the ADMC software has been successfully applied to three cat crackers
and their gas plants, a crude unit, two vacuum units and a delayed coker and its gas plant.
CTC’s new ADMC Web Server is currently available. Other vendors, who sell our older DMC algorithm, used a quick “chop shop” approach to building a web server by porting everything over into Active-X. This approach is fast and easy but very problematic. Since virus programmers love Active-X, most firewalls and networks block Active-X by default. Another problem is that Active-X is incompatible with the web browsers that are very popular around the world like Apple’s Safari, Firefox and Google’s new Chrome web browser. CTC’s approach to building our new ADMC Web Server is simple. Do it the right way by building pure HTML\CSS web pages and making them accessible by all of the popular browsers in use today.
Cutler Tech's Software Suite-
ADMC, APCX1, UPID and CTC-Sim with Operator Advisor
Overview - CTC Sim with Operator Advisor
CTC-Sim is a complete plant simulation package that includes: Plant Sim, an off-line training simulator; Design Sim, a powerful database and tool set for building simulations and an Operator Advisor [OA], which assist operators in making operating decisions. [OA], using newly patented technology, offers simulation speeds of 50-100 times faster than real time! With such fast simulation speeds, the operator can check the consequences of any potential changes in real-time. The software’s “What If” function allows for safe experimentation and training on the process, using live data. [OA] can easily be integrated into DCS systems. In the off-line version of the simulator and the background mode for the on-line system, you can run scenarios and keep score!
Features-
Offline Training Simulator
Amazing speeds. New patented technology, developed by CTC, allows the simulator to run at speeds unavailable until now, typically 100 to 150 times faster than real-time. Existing simulators often run at 2 or 3 times faster than real time.
Valve and Instrument Failures. Valves and transmitters are explicitly modeled, allowing an instructor to introduce failures in these components. Typical failures available include valve hysteresis, stuck valves, measurement de lays, noise, and instrument bias.
Compatible with DCS consoles. CTC-SIM can be used on a Microsoft Windows based PC alone or may be connected to a DCS console for the operators to train. Communication with the console uses the OPC standard so that the simulator may be attached to virtually any DCS console.
Compatibility with the new ADMC Adaptive Multivariable Controller™ & APCX1 mode of ADMC
Online Operator Advisor
Background What-If™ Mode. Once the operator has decided to take action, the questions “How much?” and “When?” arise. The What-If mode allows the operator to make the moves based on the current state of the plant and see the results in minutes. Once the operator has determined the appropriate moves, they can be implemented on the actual process.
Background Training Mode. The off-line training capability is also present with the on-line advisor. Scenarios and grading of performance, based on previous data bases, are available. The real-time monitoring and prediction of the future continues.
Benefit of OA™
In plants where advanced control has been successfully applied, the operators seldom have an opportunity to run the unit. This leads to the general decay of the operator’s skill in running the plants. Unfortunately, the time when the operators are called upon to run the unit is when conditions are at their worst. By using the offline training simulator as well as the online operator advisor, the operators will be able to maintain their skill at higher levels as well as make the correct moves on the unit when it is necessary. The following benefits may then be realized:
· Improved Process Safety
· Improved Product Quality
· Reduced Unit Downtime
· Higher Stream Factor for MultivariableControls Improve Profitability
OPERATOR ADVISOR PREDICTION OF QUALITY CHANGES, DUE TO FEED CHANGE, WITH CORRECTIONS ALONG PATH TO BRING BACK TO SPECIFICATION
UPID is an exciting new product that allows you to develop models for both operator training simulators and advanced process control applications in ways never before possible. UPID uses newly patented technology developed by Dr. Charles Cutler, the creator of the Dynamic Matrix Control algorithm and one of the pioneers in advanced process control. By removing the dynamics of the regulatory PID controllers, the models can be reconfigured in a multitude of ways. With UPID, it is possible to adapt a DMC controller model to a new regulatory control configuration without the time and expense of retesting the unit!
QUALITY ESTIMATES FOR EACH STEP RESPONSE CURVE
Features
Change Regulatory Control Configuration Quickly. UPID allows you to test the unit in one configuration and control the unit in another configuration. If you retune a loop or change the configuration of a PID controller, your model will change, many times quite drastically. In the past, reconfiguration required a retest to build a new model. With UPID, the reconfiguration can be performed in software, sparing you the time and cost associated with an expensive plant test.
Build Operator Training Simulations. When paired with Cutler Technology Corporation’s CTC-Sim™ product, UPID may be used to develop operator training simulations at a fraction of the price of other simulators. By using the plant test data you already have, you can build an operator training simulator with much less engineering manpower than a differential-equation-based simulator.
Compatible with most MPC Models. UPID was developed jointly with AspenTech and is compatible with their MPC Model, allowing those familiar with that software a quick and easy transition.
Designed for use with [ADMC] Adaptive Multivariable Controller™ - UPID creates the model files used in ADMC. UPID can build either Open or Closed Loop models for ADMC.
Licensing
UPID is licensed on a process unit basis in three different ways: UPID for Advanced Process Control (UPID-APC), UPID for Simulation (UPID-SIM), and UPID Special Edition (UPID-SE). The operation of the software is the same for all three versions.
UPID for Advanced Process Control (UPID-APC). UPID-APC is licensed to produce models for use in model predictive controllers such as Aspen Tech’s DMC plus controller and CTC’s ADMC.
UPID for Simulation (UPID-SIM). UPID-SIM is licensed to produce model files for use in operator training simulators such as Cutler Technology Corporation’s CTC-Sim product.
UPID Special Edition (UPID-SE). UPID-SE is licensed to allow the user full functionality of the UPID technology, with the exception that the files produced can be used only in conjunction with a UPID licensed process. This product is intended primarily for central engineering staff that supports many process units with UPID licenses.
Benefits
Keep Your Controllers Up and Running in Tip-Top Shape. When the regulatory controllers are retuned, the plant responses change as well. While the controller may continue to operate, the model no longer accurately represents the process which means you are not receiving the maximum benefits from the controller.
Avoid Costly Retests. Decide to change the configuration of your regulatory system? Time to retest! But with UPID, you can perform the configuration changes in software, saving the expense and hassle associated with plant step testing.
Build Operator Training Simulators at Minimal Cost. With the success of advanced process control, the operators only occasionally control the unit. With the reduction of time controlling the unit, operators skills decline. This effect makes operator training essential to operate the unit when the advance controller is off. UPID and CTC Sim allow you to develop operator training solutions in a timely and cost-effective manner.
Contact us:
Cutler Technology Corp. - Tel. 210-525-8701 - Fax. 210-525-8987 - 26545 IH10 West - Suite 101 - Boerne, Texas 78006
charles.cutler@cutler-tech.com
Cutler Technology is not Affiliated with Aspen Technology
