Process Analysis, Troubleshooting, and Simulation

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Process Analysis,Troubleshooting, and Simulation
By

• Osvaldo A. Bascur
• OSI SOFTWARE, INC.

OSI SOFTWARE, INC.
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Applications
Offices
Agents
OSI SOFTWARE, INC
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OUTLINE

• PI Design Considerations
• Building the Data Hierarchy
• Storing Knowledge
• Examples
• Troubleshooting
• Process Classification
• Mass Balance
• What if situations
• Fault Detection
• Image Analysis
• Conclusions

OSI SOFTWARE, INC.
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Industrial Desktop Corporate Systems
Traditional Islands of Automation
Facilities
GIS
Accounting
Maintenance
Billing
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Foundations For Results
PROFITABILITY

• Results
• Applications
• Systems

P R O D U C T I O N
Q U A L I T Y
C O S T
M A I N T E N A N C E
E N V I R O M E N T A L
S A F E T Y
PLANT PERFORMANCE CONTROL SYSTEM
OSI SOFTWARE, INC.
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3 Tier Client Server Software Architecture
Plant Management
Operations Maintenance
Support
Engineering
Customers
PI-ProcessBook
Presentation Layer
Applications
PI-API
INTERNET
Servers
WorkFlow Server
PI-Host Server
SQL Server
File Server
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Industrial DesktopOperations, Production

• Generic Heat and Mass Balance Envelope Calculator
• Yield Accounting
• Alternative Control Strategy Development
• Process Advisor
• Control Performance Monitor
• Connectivity to Actual Data

OSI Software,Inc.
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Performance MeasuresYields, Quality, Costs,
Equip., Env., Safety
Continuous Improvement and Innovation
IMPROVE
MONITOR
In Control?
Satisfied?
Yes
Yes
No
No
Identify Root Causes
Establish Alternative
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Long Term View Information Access
D A T A
K N O W L E D G E
I N F O R M A T I O N
Engineer
Operator
Management

• Updating
• Documentation
• Manual Filing
• Training

• Interface to Systems
• Electronic Filing
• Viewers
• Computer Training

• Workflow
• Object Orientation
• Business Rules
• Empowerment

OSI SOFTWARE, INC.
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Database Design

• Plant Block Diagram
• Tags, Naming based on ISA Standard
• Tags Description Naming to simplify groupings and
  searches
• Area
• Unit
• Stream
• Attribute

TAG , Description A1TIC401_CDU1_Kero_Tem
p, F 10FIC402_CDU1_Kero_Flow, BPD 10YKERO_CDU1_K
ero Yield, 10OPST__CDU1_OpConds
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Refinery Production Diagram
Gas Plant
B l e n d i n g
Alkylation
Straight run gasoline
Gasoline
C R U D E U N I T
Naphtha
Reforming
Crude Oil
Jet Fuel
Kerosene
Diesel Fuel
Diesel
Catalytic Cracking
Hydrocracking
Gas Oil
Fuel Oil
Coking Unit
Residue
Coke
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The Process

Transformation
Outputs
Inputs
Flow Effectiveness Efficiency Cycle Time Costs
Product or Service
Methods Machines People Materials
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The Improvement Process

Transformation
Outputs
Inputs
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Crude Unit Information Out

• Straight Run Gasoline
• Naphtha flow and End Point
• Kerosene flow and End Point
• Diesel flow and End Point
• Gas Oil flow and End Point
• Other lab analysis, pour and cloud, viscosity
• Other measured variables
• Crude Unit distillation performance
• Energy used per barrel
• Value added per barrel
• Utilization

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Crude Unit Information In

• Crude Oil, TPB, process variables
• Reflux flow
• Calculated percent flooding
• Top and Bottom pump around heat flows
• Overhead vapor temperature
• Gasoline plus lighter material/crude flow
• Naphtha plus lighter material/crude flow
• Kerosene plus lighter material/crude flow
• Diesel plus lighter material/crude flow
• Gas Oil plus lighter material/crude flow
• Topped crude temperature inlet to vacuum tower
• Other atmospheric tower temperatures

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Integrated Industrial Complex
Plant performance Products Equipment Inventories

Catalytic Cracking
Gas Plant
Crude Unit
Alkylation
Coking Unit
Hydro cracking
Reforming
Blending
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Transforming Data into Info
Zero Span Communications
Data Acquisition
H I E R A R C H Y
Low High Flow Compensation
Data Validation
If ( Fgt200 and Tgt100 Then STOK If ( F lt 200)
Then ST Trouble
Classification Analysis
Model Calculation
Model Selection
DeBottleneck
Coordination
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General Structure for Plant Control
PRODUCTS
Panel Station
Regulatory Controls
Data acquisition
DRTH
Data Validation
Alarms
Alarm Summaries
Distr. RDB
Class. Analysis
Operator Console
Expert Alarms
Adv. PC
Model Estimation
Operator Console
Server
Supervisor Console
Process Coordination
Optim. PC
Management Console
Plant Optimization
Sched. PC
ISA 88-1556
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Data Analysis Tools

• Statistical Methods
• Multivariate Statistical Methods
• Principal Component Analysis
• Fuzzy Logic
• Neural Methods
• Fuzzy Neural Networks
• Adaptive Learning

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Data Analysis Strategy

• Objective Function
• Organize data
• Data Graphics
• Data Classification
• Model Relations/Fit
• Use the Model
• Optimize Process
• Adapt Model/Process

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Putting Data Analysis to Work for you

• Production
• Quality
• Equipment Monitoring
• Costs
• Maintenance
• Environmental
• Safety
• Research

Regression and Curve Fitting Anova Acceptance
Sampling Process Capability Design of
Experiments Multivariable Analysis EVOP
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Data Classification
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Excel Analysis ToolPak

• Analysis of Variance
• Correlation and covariance matrices
• Table of descriptive statistics
• One-parameter exponential smoothing
• Histograms
• Moving Averages
• Multiple linear regression
• t-tests, z-tests

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The Real Time Spreadsheet

• INFORMATION

• RAW DATA

• Compensated Flows
• Mass Balance
• Yields
• Heat Exchangers Fouling
• Energy Management
• Reagent Consumption
• Environmental
• Preventive Maintenance

• Flows
• Temperatures
• Densities
• Properties
• Compositions

To Historian
From Historian
X-Mass
PM-Trend
Transformation of DATA into INFORMATION
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Component Desktop
Excel MS Access PI-ProcessBook
ActiveX
ODBC
Product Spec Data Base
PI-API
Equipment Specs Mechanical Limits Inspections
Repair Hist.
Historical Data
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Spreadsheet and Operations Guidelines
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Mass Balance
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MS Component Object
Container/VBA Engine
Active X Control
Events
VBA Script
REAL TIME DOMAIN
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Integrated Process Management Workbench
OSI SOFTWARE, INC.
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Continuous Improvement using On-line
Fractionation Model
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Collaboration at the industrial desktop
Raw Data
DCS
Estimator
Spreadsheet TPB Auto TBP Curve Mass Balance
Adjust
Recalc
Performance Monitoring. Calibrating Cutpoints
Controller
Setpoints
Flows
Network
Historian
Optimizer
Proc,Lab Equip Data Averages Daily and
Yield Opt. Economic Performance
OSI SOFTWARE, INC.
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What does your PC do at night?

• Windows 95 and NT have command schedulers.
• With these tools and PI you could run your Real
  Time Spreadsheets and look for exceptions for
  you.
• Maybe these Process Analysis Agents can help you.
  

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Software Agent at Work
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PI-SPC for key variables
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PI Batch Data Analysis
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Large Data 2D Sets Analysis
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Process Knowledge Table
Manipulated Controlled Variables Variables T
Chamber Chiller PLL Press Gas 1 Fast Down Slow
Up Slow Up Gas 2 Fast Down Slow UP Slow Up Gas
3 Power Fast Down Fpower Rprower Impedance Up
Down Fast Down Fast Up
Building Environment, Cleaning, Age, Tuning.
Classif.
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Decision Table
Measured Snap Mov-Avg Rate (Time) (e)2 Variable S
hot (time) (Time) Avg. Std (time) Temp1 high hig
h hrate med mx min Flow1 H/L H/L low Level l
ow hrate min Flow2 mhigh Pres2 mhigh Additi
onal Step, Phase xyz SLOW MOVING FUZZY
VARIABLES Age low old/mold/new/unknown Cleaning
low recent/medium/close comp. high few/many
,very many
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On-line Fault Diagnosis
OSI SOFTWARE, INC.
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Major Effects
Fundamental Changes in How People Work
Explosive Changes in Technology
Increase in productivity, collaboration between
groups
From typical reporting to ACTION----gt ActiveX
OSI SOFTWARE, INC.
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PEOPLE ORGANIZATION

• Work Flow Processes
• Responsibility
• Accountability
• Reward Systems
• Renewal Systems

OSI SOFTWARE, INC.
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Operator Request
Operator Sampaio
Maintenance, Ronaldo
Industrial Desktop
Industrial Desktop
E-Mail
Process Monitoring
Maintenance Planing and Scheduling
Repository Manager
Repository Manager
Process Historian
OSI SOFTWARE, INC.
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Maintenance Report
Maintenance, Ronaldo
Engineering, Dunga
E-Mail
Industrial Desktop
Is installed pump as purchased?
Pump current process history and statistics
Current pump meet design specifications?
Repository Manager
Maintenance Equip. History
Process Historian
Process Design Method
OSI SOFTWARE, INC.
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Troubleshooting

• Simplify detection of causes
• Be able to attach trends to a viewer
• Be able to activate spreadsheets with life data
• Send data from trend to a spreadsheet
• Embedded special procedure
• Email related parties of situation
• Define action plan

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Maintenance Schedule
Maintenance, Dunga
Industrial Desktop
Will a larger impeller work?
Do we have the impeller?
Pump Design
Reserve Impeller
When is the first available time to reserve it?
Schedule work order for next Tuesday
Record cost to process
Repository Manager
Mechanical Database
Maintenance Training
Maintenance Procedures
Maintenance Personnel
Maintenance Schedule
Warehouse inventory
OSI SOFTWARE, INC.
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Engineering Decision
Engineering, Dunga
Maintenance, Ronaldo
E-Mail
Industrial Dektop
Is Heat and Material balance within limits?
Pump Process History within limits?
Are there any operating models that would violate
limits?
Repository Manager
Process Heat and Material Balance.
Process Historian
Process Design
OSI SOFTWARE, INC.
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CONCLUSIONS

• Technology
• Three Tier architecture, Control/Information
• Servers
• Applications
• Presentation PI-ProcessBook
• Bridging the Gap
• Plant Workflow
• People Empowerment

OSI SOFTWARE, INC.
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Web Page http//www.osisoft.com
THANK YOU
OSI SOFTWARE, INC.
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References

• Kauffman, AIChE Modular Instruction, Series G
  Design of Equipment, 1986.
• Instrument Symbols and Identification, ISA-S5-1,
  1975.
• Graphical Symbols for Process Flow Diagrams, ASA
  Y32.11, ASME, 1961.
• Color, Foxboro Paper.
• Bascur, O.A., 1988, A Control Data Framework with
  Distributed Intelligence, ISA-88-1556,
  Proceedings of the ISA 88, Houston, TX, October
  16-21, 1998.
• Berk, K.N., and Carey, P., 1998, Data Analysis
  with Excel,Brooks/Cole Publishing.
• Scholtes, P.R., 1988, The Team Handbook, Joiner
  Associates.
• Harrington, H.J., 1993, Mejoramiento de los
  Procesos de la Empresa, McGrawHill.

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Whats a Batch in other industries ?

• Lube Oil Processing (LOHT, MEK, SX)
• Reformers, Blenders (RVP, Octane, Ox)
• Catalyst tracking, Ball Mills, Liners, Pumps,
  Exchangers
• Cement Grades
• Blast Furnace Charges
• Converters ( BOF, PS,RX)
• Reagent schedules, Concentrate quality

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Integrated Process Management Workbench
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PERFORMANCE RESOURCES FOR MANAGEMENT, MONITORING
AND CONTROL
Continuous Improvement and Innovation
Implement Current Case IMPROVEMENTS
Examine Current Case For IMPROVEMENTS

Control ?
YES
NO
Establish alternate operation Develop Initiatives
or other Projects
Document New Operation
Monitor Index
Satisfied?
NO
Identify Root Causes
YES
NEW OPERATIONS In Control Effect of
variables known and Operations Documentation
Exists
Incentive to Change?
Execute Control Procedures to Eliminate Root
Causes
Implement
Control and Monitor Loop
Improvement Loop
OSI SOFTWARE, INC.
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Energy Management Diagram
Natural Gas
Cooling Water
Steam
Fuel Gas
Air
Electricity
Flare
Vac. Heater
110 Controls and Lights
240 Pumps and Comp.
Tank Heaters
Crude Heater
Tail Gas
Blow Line
Flare Pilot Pressure
Pilots Htrs
Crude Tower Bottoms
Htr. Outlet Temp.
Excess Oxygen
Flow
Temp. Supply
Temp. Return
High Pressure
Excess Oxygen
Low Pressure
Twr Pressure
Preheat Train
Heater Outlet
Pump arounds
Energy Management Performance Control and
Monitoring
Pumps
Crude Heater Velocity Steam
Vac Heater Velocity Steam
Vacuum Kill Steam
Stripp Steam
Heat Tracing
Vac Jets
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KEY STEPS

• Define Plant Business Areas
• Define Performance Indices
• Develop Cause and Effect Hierarchies
• Implement Control and Performance Monitoring
• Training in Business Process and Problem Solving

OSI SOFTWARE, INC.
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PI Database Design

• Process Flow Diagrams
• Simplified Diagram from Feed to Product Include
  Utility tags
• Based on ISA, ASME and AIChE Standards
• PFCD, add instrument tag names of key variables
• Equipment Naming Standards
• Organize PE Tags for Applications
• Mass Balance, Quality tags, Run Time Tags
• Equipment Tags, Performance Indices Tags

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Process Data Classification

• Define process step or phases,
• Identify time derived variables,
• Identify time derived variables limits,
• Use Performance Equations to process data
  classifier and determine events, and
• Record Process Events and send notification if
  requested.

OSI SOFTWARE, INC.
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Troubleshooting

• Simplify detection of causes
• Be able to attach trends to a viewer
• Be able to activate spreadsheets with life data
• Send data from trend to a spreadsheet
• Embedded special procedure
• Email related parties of situation
• Define action plan

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Types of Classification Events

• Communication or Data Quality
• Operating Condition Triggers
• Specs Triggers
• Equipment Status
• Economic Triggers
• Environmental Conditions
• Safety Triggers

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Emerging Technologies

• Object-Oriented Tools
• Internet and Intranets
• MFCL, OLE2, OCX, ACTIVE X
• Intelligent Agents
• MAPI, TAPI
• Workflow Business Process Facilitation

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Industrial Desktop

• Intelligent Software Agents
• Scripting Language
• Business Process Workflow
• On line Training
• On line Help
• On line What if Analysis
• Static, Dynamic Simulator

OSI Software,Inc.
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On-line What if Simulator

• Generic Heat and Mass Balance Fractionation
  Envelope Calculator
• Alternative Control Strategy Development
• Recipe Improvement
• Process Advisor
• RT Process Optimization

OSI SOFTWARE, INC.
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Energy Cause and Effect Diagrams and Dynamic
Trends
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Equipment - ASME -XX-YZZ A/B

• XX are the identification
• C Compressor Turbines C-101
• E Heat exchanger E-101
• H Fired Heater H-101
• P Pump P-101 A/B
• R Reactor R-101
• T Tower T-101
• TK Storage Tank TK-101
• V Vessel V-101
• ZZ are the number designation in an equipment
  class
• A/B identifies parallel units

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What is the ISA-S5-1, XYY

• First Letter
• A Analysis
• B Burner Flame
• C Conductivity
• D Density
• E Voltage
• F Flowrate
• H Hand (manually)
• I Current
• J Power
• K Time or time schedule
• L Level

• Second and Third Letter
• Alarm
• Control
• Element
• High
• Indicate
• Control Station
• Light or Low

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ISA Standard ISA-S5-1

• First Letter
• M Moisture or Humidity
• O
• P Pressure or Vacuum
• Q Quantity of Event
• R Radioactivity or ratio
• S Speed or Frequency
• T Temperature
• V Viscosity
• W Weight
• Y
• Z Position

• Second or Third Letter
• Middle
• Orifice
• Point
• Record or Print
• Switch
• Transmit
• Valve, damper or louver
• Well
• Relay or compute
• Drive

FIC 101
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Conventions for Process and Utility Streams

• lps Low Pressure Steam 3-5 barg (sat)
• mps Medium Pressure Steam10-15 barg
• hps High Pressure Steam 40-50 barg
• htm Heat Transfer Media (organic)
• cw Cooling Water
• wr River Water
• rb Refrigerated brine
• cs Chemical Waste
• ss Sanitary Waste
• el Electric Heat
• ng Natural Gas
• fg Fuel Gas
• fo Fuel Oil
• fw Fire Water

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Process Flow Essentials

• Stream Number
• Temperature
• Pressure
• Vapor Fraction, Solids Fraction
• Total Mass Flow Rate
• Individual Component Flow Rates
• Additional Information

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Topology, Stream Data and Control Strategy

• Simplicity
• Major Control Loops
• Attaching information flags
• stream ID
• Temperature
• Pressure
• Liquid Flow Rate
• Gas Flow Rate
• Mass Flow Rate

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REAL TIME INFORMATION SYSTEM
Base Recoveries Volume, Quality, , Limits
Loss /Downtime Process Data Orders
Reservoir/Prod/Pipe Planning
Reservoir Model
Scheduling
Crude Treatment, Crude Mov., H2OTreat, Inj.
Data Reconciliation
Relational Data Base
Performance Monitoring
Real Time Data Historian
Process Optimization Control
Leak Detection Expert Control
Equipment Performance
Well Production
Gas Allocation
Tanks, Pipelines
DCS, SCADA
LAB, Equipment
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Coordination and Integration
Operations Maintenance
Distribution / Orders / SchedulingInventories
S U P P L I E R S
C U S T O M E R S
Yields Costs
Feed Stock Inv.
Fuels
Oil Movts. Tanks
Data Reconciliation LP Model Plant Wide
Optimization Inventory Plans
Lubes
Specials
Performances Rules
Just in Time Training
Process Safety Management
Performance Monitoring
Process Targets Suggest Setpoints
Specs
Training
Markets Needs
Engineering
Proposals
Project Schedule
Measurement
Project Area 1
Task 1
Task 2
Project Area 2
Task 1
Task 2
Resources / Cost Control
Simulation
Design/ Cost
Approvals
Performance Assessment
Engineering Standards
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Block Flow Plant Diagram
Mixed Gas
RX
Toluene
Benzene
Sep
Still
Liquids
Hydrogen
Conversion
Water Energy
Toluene
The most effective way of communicating
process information.
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Process Improvement
History
Now
Future
Time