Ultramax Corporation 1 Advanced Process Management™ (APM™) 1.

Ultramax Corporation

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Advanced Process Management™ (APM™)

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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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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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Adjusting production processesto maximize the value they generate

for the company on a daily basis

ULTRAMAX is a solution to:


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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




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



ULTRAMAXRun Data


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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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



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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


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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


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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


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


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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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