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Process Analysis, Troubleshooting, and Simulation

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Troubleshooting, and Simulation By Todd, Dave, Jack and Osvaldo OSI SOFTWARE, INC. OSI SOFTWARE, INC. OUTLINE PI Design Considerations Building the Data Hierarchy ... – PowerPoint PPT presentation

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Title: Process Analysis, Troubleshooting, and Simulation


1
Process Analysis, Troubleshooting, and Simulation
By
  • Todd, Dave, Jack and Osvaldo
  • OSI SOFTWARE, INC.

OSI SOFTWARE, INC.
2
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.
3
Foundations For Results
PROFITABILITY
  • Results
  • Actions
  • 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 N A N C E
E N V I R O M E N T A L
S A F E T Y
PI System Environment
OSI SOFTWARE, INC.
4
3 Tier Client Server Software Architecture
Plant Management
Operations Maintenance
Support
Engineering
Customers
PI-ProcessBook
Presentation Layer
Applications
PI-API
Servers
WorkFlow Server
PI-Host Server
SQL Server
File Server
5
Industrial Desktop Operations, 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.
6
PI Database Design
  • Plant Block Diagram
  • Tags, Naming based on ISA Standard
  • Tags Description Naming to simplify groupings and
    searches
  • Area
  • Unit
  • Stream
  • Attribute

A1TIC401, CDU1 Kero Temp, F 10FIC402, CDU1
Kero Flow, BPD 10YKERO , CDU1 Kero Yield,
10OPST , CDU1 Op Conds
7
Block Flow Plant Diagram
Mixed Gas
RX
Toluene
Benzene
Sep
Still
Liquids
Hydrogen
Conversion
Water Energy
Toluene
8
Transforming Data into Info
Zero Span Communications
Data Acquisition
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
9
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
10
Data Classification
11
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
OSI SOFTWARE, INC.
12
Spreadsheet and Operations Guidelines
OSI SOFTWARE, INC.
13
Mass Balance
14
Integrated Process Management Workbench
OSI SOFTWARE, INC.
15
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.

16
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
OSI SOFTWARE, INC.
17
Process 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.
18
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
19
On-line Fault Diagnosis
OSI SOFTWARE, INC.
20
Continuous Improvement using On-line
Fractionation Model
OSI SOFTWARE, INC.
21
Integrated Process Management Workbench
OSI SOFTWARE, INC.
22
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.
23
Performance Measures Yields, Quality, Costs,
Equip., Env., Safety
Continuous Improvement and Innovation
IMPROVE
MONITOR
In Control?
Satisfied?
Yes
Yes
No
No
Identify Root Causes
Establish Alternative
24
Whats a Batch in other industries ?
  • Lube Oil Processing (LOHT, MEK, SX)
  • Reformers, Blenders
  • Catalyst tracking, Ball Mills, Liners, Pumps,
    Exchangers
  • Cement Grades
  • Blast Furnace Charges
  • Converters ( BOF, PS,RX)
  • Reagent schedules, Concentrate quality

25
Web Page http//www.osisoft.com
THANK YOU
OSI SOFTWARE, INC.
26
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.
27
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.
28
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

29
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.
30
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

31
Types of Classification Events
  • Communication or Data Quality
  • Operating Condition Triggers
  • Specs Triggers
  • Equipment Status
  • Economic Triggers
  • Environmental Conditions
  • Safety Triggers

32
Optimization Workflow
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.
33
Emerging Technologies
  • Object-Oriented Tools
  • Internet and Intranets
  • MFCL, OLE2, OCX, ACTIVE X
  • Intelligent Agents
  • MAPI, TAPI
  • Workflow Business Process Facilitation

OSI SOFTWARE, INC.
34
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.
35
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.
36
Energy Cause and Effect Diagrams and Dynamic
Trends
OSI SOFTWARE, INC.
37
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.
  • Additional Common Sense Needs.
  • Color, Foxboro Paper.

38
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

39
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

40
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

41
Process Flow Essentials
  • Stream Number
  • Temperature
  • Pressure
  • Vapor Fraction, Solids Fraction
  • Total Mass Flow Rate
  • Individual Component Flow Rates
  • Additional Information

42
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

43
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
44
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
OSI SOFTWARE, INC.
45
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46
Coordination and Integration
Operations Maintenance
Distribution / Orders / Scheduling Inventories
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
OSI SOFTWARE, INC.
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