Techniques for Real-Time Equipment and Process Monitoring using PI Data Archive and PI-Process Book

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Techniques for Real-Time Equipment and Process
Monitoring using PI Data Archive and PI-Process
Book

• Jason Banfelder
• Kesler Engineering, Inc.

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Equipment Performance Monitoring System(People)

• Operator
• Process Engineer
• Manager
• System Administrator
• Modeler
• Initial construction
• Maintenance
• How does the performance monitoring system
  address the needs of each of these roles?

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Equipment Performance Monitoring System(Jobs)

• Measure and Improve real time equipment
  performance
• Real Time Displays
• Equipment documentation (PIDs, procedures, etc.)
• Measure and improve long-term equipment
  performance
• Reporting
• Off-line model use
• Develop and maintain equipment models
• Model explorer
• Install and maintain the monitoring system

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Model Development

• Small and Simple Models Performance equations
• Already a part of PI
• Dont complicate your life if you dont need to
• Large or Complex models KEI Sentinel engine
• Structured models, repeated patterns
• Open equation modeling
• User interface
• Thermodynamics
• Data validation / reconciliation

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Sample ModelAir Preheater
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Structured Models

• Large and/or complex models demand structured
  storage
• Tags
• Equations
• Thermodynamic data
• Solution procedure
• Use a hierarchical model structure
• Tree is easy to visualize
• Easier to navigate than a flat list
• No need to rely on a naming convention
• Reusable parts as templates
• PI Module Database is a recognition of this

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Open Equation Models Parameters

• Constant
• Value is stored in RDB
• PI Tag
• Value from PI tag
• Field instrumentation, lab, manual input, another
  model
• PI tag specification is stored in RDB

• Internal Calc
• Value is an intermediate result calculated by the
  Sentinel engine
• Calculated PI Tag
• Value is calculated by the Sentinel Engine and
  stored in PI

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Open Equation ModelsEquations

• Material Balance
• Energy Balance
• Thermodynamics
• Definitions
• Efficiency
• Return on Investment
• Correlations

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Open Equation Solver

• Analyzes structure of equations, knowns, and
  unknowns
• Partitions large system into smaller systems
• Faster solutions
• More stable mathematically
• Determines solution order

• Solves individual equations and systems
• Non-linear numerical solver
• Checks validity inputs, intermediate results, and
  outputs
• Deals gracefully with bad inputs or results
• Does not abandon entire model if some inputs are
  bad

Sentinel Solver
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Solver Example

• 12 Pass Fired Heater
• 781 parameters
• 51 inputs
• 574 equations
• Partitioned into 528 separate systems
• Largest is 47 x 47

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Model DevelopmentThermodynamics

• Built-in rigorous thermodynamics
• enthalpy, entropy, etc.
• steam table
• three phase flash

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User Interface

• Complete UI for model development

• Use the same UI for viewing on-line results
• Model structure is different
• Specialized displays

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Viewing Real Time Performance

• Process Book is ideal for PID type views
• Difficult to use Process Book alone for reusable
  data views
• Requires a model structure
• Reusable standard views
• Table
• Bar chart
• Pie chart
• Specialized views
• Hydrocarbon Assay
• Heater Summary
• Pass Balancing

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Real Time Views Demo
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Document Views

• Need more than real-time views to improve
  operation.
• Procedures Guidelines
• PFDs and PIDs
• Mechanical drawings
• Reports, Studies, etc.
• Web pages
• Leverage Microsoft ActiveX Document technology to
  deliver all of this in one window

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Document Demo
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Reports

• Excel based reports
• Promotes working with the results
• Reports delivered via e-mail
• Periodically
• By exception
• Available on-line

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Report Demo
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The Sentinel in Practice

• First Beta release installed the week after last
  years OSI conference
• Ten Sentinel models currently running
• Fired heater
• Crude distillation unit
• Orders for 20 more

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The End
Q A
Thank You Kesler Engineering, Inc. http//www.Kesl
erEngineering.com