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Process Optimisation and Process Analytics

Process Optimisation and Process Analytics. Presented at APACT 2003 Acknowledgements: Peter van Vuuren, ExxonMobil Chemical John Cumbus, ExxonMobil Chemical Rob Dubois: Dow Chemical. Jeff Gunnell April 2003. Process Optimisation and Process Analytics. Aims of this presentation:

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Process Optimisation and Process Analytics

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  1. Process OptimisationandProcess Analytics Presented at APACT 2003 Acknowledgements: Peter van Vuuren, ExxonMobil Chemical John Cumbus, ExxonMobil Chemical Rob Dubois: Dow Chemical Jeff Gunnell April 2003

  2. Process Optimisation and Process Analytics Aims of this presentation: • Look at some trends in the way process plants are run in the refining and petrochemical industries • See how this is affecting the development of process control strategies • Anticipate how this will modify the demands on analytical measurements Objective Present a vision of Process Analytics systems a few years in the future… … in order to guide future developments

  3. Process Optimisation and Process Analytics A lightning overview of ExxonMobil’s oil and petrochemical industries • Hydrocarbons are acquired and become the feedstocks to refineries and petrochemical plants

  4. Process Optimisation and Process Analytics

  5. Process Optimisation and Process Analytics • Processing is carried out in a sequence of plants at ExxonMobil e.g. refining  naphthas cracking  olefins polymerisation  plastics • These units may be in physically separate processing plants • Day to day operations at each plant are often independent of each other • In most cases each plant is responsible for optimising its own profitability, with the exception of some inter-plant coordination - generally manual and sometimes infrequent

  6. Process Optimisation and Process Analytics • A lightning overview of process control at ExxonMobil INCREASING NEED FOR PROCESS ANALYTICS

  7. Process Optimisation and Process Analytics Review • In the treatment train, hydrocarbons may pass through several plants on the way to becoming end products • each plant does its best to optimise its operation • Inside each plant there are many process units • each process unit is optimised • Increasing process control sophistication has lead to improved optimisation • some process units might not be operated at their individual optimum in the greater interest

  8. Process Optimisation and Process Analytics • Economic incentives have lead to the development of process control strategies which deal with ever larger groups of process equipment • we can expect this trend to continue • This will lead to the overall optimisation of sequences of process plants • Put another way, for each component in the feedstock, we will identify its most profitable disposition

  9. Process Optimisation and Process Analytics Advanced Process Optimisation maximises the credits. Increasingly sophisticated analytical measurements are required

  10. Process Optimisation and Process Analytics • The demand for more difficult analytical measurements will increase... • ...and be matched by growth in new Process Analytical technologies... • nanotech TDL lab-on-a-chip NMR eNose spectrometer-on-chip CRD MS-on-a-chip • … but the old technologies will remain... • GC MS FT-(n)IR CEMS water • It will be impossible for one person to provide high level support such a wide range of techniques

  11. Process Optimisation and Process Analytics A major rethinking of Process Analytics design and implementation has been developing via CPAC and presented at IFPAC, Pitcon, etc. (2000-3) • NeSSI: New Sampling / Sensor Initiative • ConnI: Connectivity Initiative • Appl-I: A suite of application software

  12. Process Optimisation and Process Analytics • NeSSI modules are the foundation Modular Components, Individual Sensors

  13. Process Optimisation and Process Analytics Test ease of manufacture 76 pieces and assembly drawings given to technician

  14. Process Optimisation and Process Analytics Finished unit

  15. Process Optimisation and Process Analytics The technician (acknowledgement: the Cumbus family)

  16. Level 4 Enterprise LAN ENTERPRISE DOMAIN Level 3 LAN  PROCESS CONTROL DOMAIN INFORMATION D0MAIN Level 2 LAN = Field LAN SAM eSAM  MEASUREMENT DOMAIN Process Optimisation - 4 domains Courtesy of P. van Vuuren and R.J. O’Reilly

  17. Process Optimisation and Process Analytics Computing developments which will be used: • PDAs will become standard tools • wireless connectivity • human-machine interface for many devices • Wearable PCs will be common • Heads-up displays and improved data entry • voice entry of data • voice “action” commands • The web rules... • browser access to everything from everywhere • Security will better and easier • retinal recognition

  18. Process Optimisation and Process Analytics Organisational change will follow: Predictive maintenance will replace planned • Intelligent diagnostics will watch analyser systems...all the time... • ‘I need help’ flags will be sent in real time to wireless Personal Digital Assistants (PDAs) A typical troubleshooting task for a technician starts when her PDA buzzes and indicates a possible problem...

  19. Process Optimisation and Process Analytics Please help me... • A smart application in an analyser system has detected something strange - relevant information is sent out... • The technician taps down for more info...

  20. Process Optimisation and Process Analytics Background data and recent history is sent • Key sensor data have been monitored and unusual conditions have been detected... • The technician taps down for more details...

  21. Process Optimisation and Process Analytics Recent history is shown graphically • The technician starts to think about the cause of the problem… • …and diagnoses the cause. • A pinched valve is quickly discovered and the problem resolved

  22. Process Optimisation and Process Analytics Appl-I: Smart application functions are part of a shell which will be used by all analyser vendors…(much like Excel) • monitoring of key parameters • flow, pressure, temperature…as well as analytical • self-validation, both continuous and periodic • intelligent statistical tools identify abnormal events • users notified when trouble is suspected • data presented in a user-friendly way Excel is a registered trademark of Microsoft Corp.

  23. The technician takes her toolkit, including her wearable PC, out to the field... Courtesy of Oxford Technologies

  24. Process Optimisation and Process Analytics She has access to an on-line manual • The wearable PC means that useful information is readily available: • There are up-to-date descriptions of tasks • Video clips* show how jobs are done. • * Video Courtesy of Andy Jopek

  25. Process Optimisation and Process Analytics Links to other systems facilitate work • Equipment parts lists are linked to warehousing - both in house and external. • She identifies spares which she needs and orders them as she works using the manual and warehousing tool

  26. Process Optimisation and Process Analytics • Record keeping is built in • Intelligent checklists and voice entry make record keeping easy • The manual helps her fill in a work record - using voice data entry

  27. Process Optimisation and Process Analytics Wizards help with many tasks • On completion she runs the smart health check wizard • She requests two day data watch so she can personally check that everything is OK. A maintenance encounter is booked into her calendar

  28. Process Optimisation and Process Analytics Consider a typical engineering support problem • A micro-spectrometer system has been installed in a new plant in China... • The process control engineers have a model to predict process behavior - and they use the analyser to correct their model • In testing, the analyser and model tracked well during small excursions, however there was a discrepancy during a large excursion • The analyser response was just too slow and too small • The site team in China ask their remote Process Analytics specialist to take a look • He browses to the analyser and process database

  29. He could see the problem but not explain it...

  30. Process Optimisation and Process Analytics • In a video conference with the China team some analyser parameters are checked but nothing jumps out The specialist realizes he needs expert help...

  31. Process Optimisation and Process Analytics Connectivity tools enable remote teamworking • A virtual team is formed which includes • the process and analyser people in China • another site which has a similar installation • the analyser vendor’s design group • They have a virtual conference using: • video communications • data & screen sharing

  32. Process Optimisation and Process Analytics It certainly looks like an analyser problem... • The virtual team felt pretty sure that there was something strange about the analyser, not the process... • The vendor team asked for time to work on the data bases • They discovered that the problem was due to hysteresis in their micro-technology, coupled with an unexpected effect in their software smoothing algorithm

  33. Process Optimisation and Process Analytics The problem is fixed remotely by the vendor • A software patch is downloaded to the analyser in China • revisions are automatically updated • a sprite to monitor performance is included • The vendor also sends out an alert to other clients, along with the sprite • The vendor initiates the product improvement process

  34. Process Optimisation and Process Analytics Key points: Technician level • Technicians in plants retain the prime responsibility of maintaining analyser systems • Human knowledge, skills, thought processes are needed more than ever • Logic and intelligence in machines help technicians to use their human skills better • real-time health checks of system • data presentation helps troubleshooting • bureaucracy is unburdened

  35. Process Optimisation and Process Analytics Key points: Engineer level • Highly complex analyser technologies abound • Sites are spread all around the globe • Technical support and troubleshooting is a team game • collaboration tools facilitate virtual teams • support round the clock, round the globe • Changes in • responsibility • behaviour • relationships

  36. Process Optimisation and Process Analytics Developments we need: • NeSSI • modular sample systems • integrated with analysers sensors • in smart, field mounted units • ConnI • an architecture which links everything together • Appl-I • a common application shell Collaboration can deliver benefits for all

  37. Process Optimisation and Process Analytics Smart artificially intelligent analysers

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