Is your control Loop

better than mine?!

Performance Monitoring at Five TiO2 plants!

Arshad Jamil
Standards
Global Process Control Leader, DuPont Titanium
Certification Technologies
Education & Training
Publishing
Wilmington, Delaware
Conferences & Exhibits
Presenter

Arshad Jamil is a global process control leader for

DuPont's Titanium Technologies business, based in
Wilmington, Delaware. Arshad has 20 years of
experience in various DuPont businesses in the area of
process control and instrumentation, alarm management,
automated performance and process monitoring, process
engineering, process safety management, and major
capital projects implementation. Arshad has a BS in
Chemical Engineering from NED Engineering University,
Pakistan, and MS in Industrial Engineering from Texas
A&M. He is a certified 6 Sigma Black belt.

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About the Company

DuPont Titanium Technologies is the world's largest

manufacturer of titanium dioxide, serving customers
globally in the coatings, paper and plastics industries.
The company operates plants at Delisle, Miss.; New
Johnsonville, Tenn.; Edge Moor, Del.; Altamira, Mexico;
and Kuan Yin, Taiwan; all of which use the chloride
manufacturing process.

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General TiO2 Chloride Process Flow Diagram

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Motivation for Site Comparisons

• Similar unit operations

• Early detection of degradation in performance.
• Some sites overall perform better than the others
• Need to leverage and `steal’ good work done at one site
to the other.
• Benchmark internally to establish `entitlement’ and
externally for continuous improvement.
• Provide easy to use tools/reports so plant support people
do not have to login and generate ad hoc reports.

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Which control loops to monitor?

Among the hundreds and hundreds of control loops in our

Plants, how did we choose which ones to be monitored
across all plant sites?
- For an `apples to apples’ comparisons, a team identified
the critical loops for various process areas to be
monitored at all plant sites.
- Each site then configured those agreed upon control
loops in the DuPont Performance Surveyor™application.
- It took sometime to address `area/plant running’ checks
and triggers issues.

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What is being monitored and how often?

• Three key metrics being monitored for each control loop

are:
– Utilization (% of time in the intended mode)
– Saturation (% of time controller output saturated)
– Compliance (% of time PV within the specified limits)
• A weekly business-wide report is automatically
generated and the link is emailed to a wide distribution
list.
• Sites use the weekly reports in routine area/site meetings
to review `problem’ loops for addressing the root cause.
• A monthly 12 month rolling average trend chart is issued
to the business operations organization.

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Key Control Loops – Performance Metrics by Plant

Performance Surveyor Scorecard Performance Surveyor Scorecard

Key Control Loops Utilization Key Control Loops Saturation
Monthly Average Trend (Higher the Better) Monthly Average Trend (Lower the Better)

Altamira
100.00
DeLisle
20.00 Altamira
95.00 Edgemoor 16.00 DeLisle
Edgemoor
90.00 Johnsonville 12.00
%

Johnsonville

%
Kuan Yin 8.00 Kuan Yin
85.00
Goal 4.00 Goal
80.00 0.00
A u 09
Fe 09

Ju 09
J u 09

No 9
D e 09
M 09
Ap 09
M 09
J a 08

S e 09
Oc 9

A u 09
F e 09

Ju 09
Ju 0 9

N o 09
D e 09
Ma 09
A p 09
M a 09

S e 09
Oc 9

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Performance Surveyor Scorecard
Key Control Loops Compliance
Monthly Average Trend (Higher the Better) Note:
% Utilization --% loops in Auto, higher the
100.00 better
Altamira
95.00 % Saturation -- % controller output saturated,
DeLisle
90.00 Edgemoor lower the better.
85.00 % Compliance with limits, these are tighter
%

Johnsonville
80.00 Kuan Yin than SOC Level 3 limits, higher the better
75.00 Goal
70.00
A u 09
Fe 09

Ju y09
Ju 09

N o 09
D e 09
Ma 09
Ma 09
A p 09
Ja 08

S e 09
Oc 9

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Learnings

– PS info has been valuable for detecting

instrumentation / control valve issues and diagnosis
(stiction, sizing, process restrictions)
– Daily monitoring of critical process analyzers has
helped increase uptime of those analyzers.
– Site to site visibility and comparisons have helped
improve metrics for sites which initially were
performing poorly.
– Use of Performance Surveyor™ tools is being
expanded with focused monitoring of energy and
quality-related variables.
– A DuPont-wide PSUG has quarterly meetings to
share experiences and examples for leveraging.
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DuPontTM Performance SurveyorTM Description:

• Internally developed - predates commercial tools like Honeywell

LoopScout, Matrikon Process Doctor, etc.

• Deployed on single central server for entire Corp.

• Provides once/day assessment using high freq. process data

(typically 1 min data)

• Generates 30 daily performance metrics which are archived

• Web interface for user interaction: various tabular and trend displays

• Generates email alerts, reports, of degraded or suspicious behavior

• Executes for multiple time zones around the world

• Handles continuous and batch process data

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