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

Archive and PI-Process Book

Jason Banfelder

Kesler Engineering, Inc.

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?

Equipment Performance Monitoring System

(Jobs)• Measure and Improve real time equipment

performance– Real Time Displays– Equipment documentation (P&IDs, 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

Model Development

• Small and Simple Models: Performance equations– Already a part of PI– Don’t complicate your life if you don’t need to

• Large or Complex models: KEI Sentinel engine– Structured models, repeated patterns– Open equation modeling – User interface– Thermodynamics– Data validation / reconciliation

Sample Model:Air Preheater

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

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

Open Equation Models:Equations

• Material Balance• Energy Balance• Thermodynamics• Definitions

– Efficiency– Return on Investment

• Correlations

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

Model

ParametersParameters

EquationsEquations

SentinelSolver

SentinelSolver

Solver Example

12 Pass Fired Heater

• 781 parameters– 51 inputs

• 574 equations

• Partitioned into 528 separate systems– Largest is 47 x 47

Model DevelopmentThermodynamics

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

User Interface• Complete UI for model development

• Use the same UI for viewing on-line results– Model structure

is different– Specialized

displays

Viewing Real Time Performance

• Process Book is ideal for P&ID 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

Real Time Views Demo

Document Views

• Need more than real-time views to improve operation.– Procedures & Guidelines– PFDs and P&IDs– Mechanical drawings– Reports, Studies, etc.– Web pages

• Leverage Microsoft ActiveX Document technology to deliver all of this in one window

Document Demo

Reports

• Excel based reports– Promotes working with the results

• Reports delivered via e-mail– Periodically– By exception

• Available on-line

Report Demo

The Sentinel in Practice

• First Beta release installed the week after last year’s OSI conference

• Ten Sentinel models currently running– Fired heater– Crude distillation unit

• Orders for 20+ more

The End

Thank YouKesler Engineering, Inc.

http://www.KeslerEngineering.com