Process Monitoring Framework

Transcription

1 October 5-7, 2015 Process Monitoring Framework an effective automation and sustainment platform for asset monitoring ExxonMobil Research and Engineering Company Ravishankar Sethuraman, Kenneth G Teague, Ken H Tyner 2015 SimSci Simulation for Business Excellence Conference Pasadena, CA

2 Abstract Use of first-principle based models to optimize refineries and chemical units in real time is well established and is widely deployed in our industry. Online use of first-principle, correlative, and other models to monitor unit performance is gaining momentum. Deployment, quality control, and sustainment of these models can be facilitated through a systematic framework built around a robust modeling and automation platform. A Process Monitoring Framework has been built around ROMeo to standardize application deployment and automate data input, routing, and storage. The framework supports integration of multiple models and robustly handles individual model/calculation failures. The application standardization facilitated by the Process Monitoring Framework has helped to lower deployment costs, lower the skill level required for sustainment, and led to smoother model user transitions. These are critical benefits to sustaining an effective monitoring program in a volatile economic environment. 2

3 Agenda Overview Essentials for effective Process Monitoring Process Monitoring Infrastructure Process Monitoring Framework Features Process Monitoring Framework Connectivity Model Execution Order in Framework Recommendations 3

4 Overview Effective process monitoring is key to: Achieving the manufacturing business objectives Analyzing unit health Avoiding surprise Understanding past operations, and Planning for future Leadership Process Monitoring Elements Tools Work Processes 4

5 Essentials for Effective Process Monitoring Continuous and uninterrupted data from tools Allowing user to focus on data analysis and decision-making Taking tools and calculations off the user desktops Automation of simple and repetitive tasks Efficiency in tool sustainment Standardizing deployment of tools Driving consistency and excellence in process monitoring Ability to integrate heterogeneous models within each application Ability to process historical data (input/output) Ability to perform data validity checks and instrumentation data gaps 5

6 Process Monitoring Infrastructure Users Unit Process engineer Subject matter specialist Reliability engineer Energy coordinator/team Unit Monitoring Data Visualization Reports Data Analysis Automated scheduling/execution Data Validation Data Historian 50+ applications successfully deployed using the Framework PM Models PM Models PHM Models PM Models PM Models EHM Models Unit Data Output Validation Lab Data Reporting / Data Storage RTO Data Process / Equipment Health Monitoring Application on ROMeo platform 6

7 Process Monitoring Framework - Features Execute diverse/heterogeneous set of models Desktop proprietary models Spreadsheets, scripts (external/internal) Native ROMeo models Execute sequential or simultaneous models Handles flowsheet, sub-flowsheets, collections, & macros Improves data availability even when some calculations fail Manage asynchronous time-variant data input Current or historical Synchronize with lab or reconciled data availability Support varied input data sources Data from other applications Process / lab / application output tags 7

8 Process Monitoring Framework Features Common automation and configuration components for use by all tools including: Generic RTS Sequence Configurable database which enables certain application updates Standardized approach to exchange data between sources & consumers Real-time Optimizers, Historian, Custom models, ROMeo streams, lab Robust and flexible approach to solution strategy Management of model interdependency, including failure-handling Sequential task list (user-defined and configurable) Conditional execution according to availability of necessary data (e.g., lab) Troubleshooting efficiency Configuration Interface Tabular interface that facilitates search for relevant connections Good for troubleshooting & technical quality review of deliverables Connections can be edited or deleted without direct ROMeo interaction 8

9 Process Monitoring Framework Connectivity Framework Database (Generic per app type) User Config Interface Data Historian Tag Connections EDI Model Execution RTS Order ROMeo Flowsheet Model Connectivity External Model Wrapper (generic per type) Native Model (Equipment) Custom Model External Models/ ROMeo Interface External Model (Executable) ROMeo Platform 9

10 Model Execution Order in Framework Time step Time step(s) Task 1 Task step(s) Initialization Validate Input Solve Validate Output Store Output 10

11 Recommendations Key platform functionality having general interest to user community: Central database storing Tag connectivity Model execution order Model connectivity Capability to support more intuitive application re-deployment: Generic ROMeo database templates Generic RTS sequence templates Application structure and transparency supporting credibility and sustainer training Consider incorporation of above functionality into the ROMeo platform roadmap 11

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