Real Time Operational Perfomance and Variability Supervision
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Transcript of Real Time Operational Perfomance and Variability Supervision
Real Time Operational Perfomance and
Variability Supervision
Diego Arenas
CONTAC INGENIEROS
CONTAC
OPERATIONAL INTELLIGENCE TECHNOLOGIES
Empowering your PI RtPM infrastructure
Why real time KPI´s?
MiningChemical Energy
Ore body
ROM Ore (run of mine)
Key Variables:· Ore Grade· Ore Hardness· Ore Type· Equipment availability
Low Grade Ore
Activities:· Stripping· Drilling· Blasting· Truck loading
Waste
Electrical Energy
Sulphide Ore
Oxide Ore
Process operations are complex systems, where perfomance goals are evaluated using different business KPI´s criteria.
Calidad Costos
Rendimiento Confiabilidad
Quality Cost
Efficiency Reliability
Business KPI time-frames ranges from long term “operational management control loops”, such as mine planing-mine operation, to short term, such as concentrator recovery control vs. short term program.
Despite the KPI time frame, most of the business KPI are rooted to the operation, it can be said that business KPI are built in real time.
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Same for Steel, Pulp&paper, Petrochem, Utilities, etc.
The value fishbone, ...how the business KPI´s are built
A process bottleneck (leading to quality, throughput losses): a conveyor, or a pump or a control valve working at its maximum capacity or speed for an extended period of time
Calidad Costos
Rendimiento Confiabilidad
Quality Cost
Efficiency Reliability
A cascaded (and $$$$ amplified) variability: cyclone feed density variability that leads to a size variability that leads to a flotation recovery variability.
Quality losses (plus: energy, operational time, consumables, etc.): because of an inefficient operation of its regulatory system.
Business KPI´s are “built” in real time.
Gains and losses happen in real time
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What we know about the process behavior?
• Large number of process variables• Complex cause-effect relationships• Different (time based) Operation Modes: drift,
noise, start-up, set point changes,
disturbances, etc.
• Large data bases for Real
Time and Historical information
about process variables and
equipment vital signs.
• How to determine early alerts if the process or machine is deviating from a pattern or moving to a new one, being an “on quality pattern”, a “throughput pattern”, a “malfunction pattern”, etc.?
• How to determine the “most influencing” factors that drives the evolution of a certain process variable or equipment vital sign KPI?
The Need: an automated system capable to online analize thousands of process variable data and generate context based meaningful information
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CAPA DE PROCESOSProcess Layer
Performance Model
CAPA DE CONTROL
OutputsPerfomance
Goal
Perfomance
Perfomance Goal
Inputs
Potential Capacity ProductionCapacityFactor Factor
Factor
Factor
Factor
Factor
Critical Factor
Critical Factor
Critical Factor
Critical Factor
Inst. &CONTROL LAYER
With:
Real Time KPI index Perfomance Model
Mapping:
Op. Goals of:
Quality, Emissions
Energy, Consumables
Thoughput, etc.
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Technology
• Control charts• Tree Map• Benchmarks• Star diagram• Dispersion diagram• Histogram• Other
• Statistical• Control Loop quality• Variability• Multivariable Analysis
Perfomance Tests (RtKPI) Visualization Modules
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Technology, the architecture
DCS
PI System
AF Model
ACE
Calculation Engine
Operational Processes
Business Processes
Regulatory Systems
Perfomance Model
Real Time and Historical Information
Template Collection of perfomance tests (RtKPI)
The high level view
the detailed view
Visualization, reporting, alarming
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Real Time variability Abnormal Op. Cond. Disturbances
Identify Measure Alert
Technology, the test template collection
Monovariate Indicator
Measures
D3 Index Scheffe’s test allows detecting important disturbances, given a determined reference
Harris’s Index Compares the variance of the controller with its minimal expected variance
Oscillation Index Index of oscillation of the controller for a given setpoint. It can also be used with a pair of related variables
Time in State Time in which the the controller has been in manual mode or another pre-defined state
Saturation % of time where the analyzed variable is above or below a certain limit
IAE Index The integral of the absolute difference between the SP and the PV
ACR Index Miao’s and Seborg’s oscillation index
FFT Index Oscillation index considering the fast Fourier transform
Standard Variation Index
Complement to the Harris’s index. It measures the deviation with respect to a reference point
Multivariate Indicator
Measures
VFA “Weight” or relative influence that a set of signals has on the variability of the process
PLS Soft-sensorsComparison between expected”and measured values (residual generation)Prediction of signal values
A collection of online KPI to:
GOAL: Business
KPI
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PI-AF, PI-ACE, Technology, the implementation
The collection of RtKPI templates
A form to define the specific parameters for each RtKPI (tag´s, limits, offset, etc.)
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Technology, the implementation
Applying the RtKPI to a perfomance Model
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The implementation
Throughput and quality KPI
Factor A
Factor B Factor C
Ore Size
Sump Pump
Density Control Class. Harris Index
Perfomance
Calidad Costos
Rendimiento Confiabilidad
Quality Cost
Efficiency Reliability
The model is a context based representation of the Factor-Critical Factor-Cause&Effect relationships
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The technology, summary
Allows for a direct mapping between the Business KPI and its Real Time drivers.
Allow for the implementation of an automatic, online perfomance supervision system, working in a 24x7 shift…
A scalable and modular technical architecture. Plants, Lines, Processes, Equipment models can be implemented.
Since the calculated index are sent back to the plant historian, the values can be trended, alarmed, shown on process diagrams, reported, e-mailed, etc.
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The Implementation
DCS
PI System
AF Model
ACE
Calculation Engine
Operational Processes
Business Processes
Regulatory Systems
Perfomance Model
Real Time and Historical Information
Template Collection of perfomance tests (RtKPI)
Configurable RT Analysis
• Read data from PI
• Calculate Rt KPI
• Send calculated data to PI (as PI Tag´s)
---RT-Continuously-24x7---
AD-HOC -Project specific-(PI-PB, DL, WebParts, etc.)
RtIndex visualization, reporting and alarming
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Implementation example
Reminder:
1. Core system: KPI templates, PI-AF/ACE calculations are standard
2. Reporting and visualization are built using standard PI-RtPM tools
3. Nevertheless, even PB and DL are project specific, since the construction are made using PI-AF context based models, it can be reused for other applications.
Again: what will be shown is a PB+DL app. , it can be modified, reused, re-done, etc., using the RT Indexes being calculated by the standard PI-ACE/AF RT KPI templates
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ImplementationCONTAC
Índices Utilizados
Índices Monovariables
HarrisCompara la varianza del error con respecto a la mínima varianza alcanzable.
IAE (ITAE, ISE, ITSE)
Integral del valor absoluto del error.
Miao SeborgÍndice de oscilación basado en la auto covarianza.
Forsman StattingÍndice de oscilación. Comparación de áreas del error entre cruces por cero.
D3Test de Scheffe’s, detecta variaciones de una señal con respecto a una referencia.
Tiempo en un estado
Tiempo en que el controlador ha estado en modo manual u otro pre definido.
DistribuciónTiempo que una variable ha permanecido en determinados rangos de sus valores posibles.
Desviación Estándar
Medida de dispersión para un conjunto de datos.
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RtKPI Portal (a PI-PB/AF app.)
Navigation tree
Date selection
Selected controller or variable
Variable values distribution histogram
Controller state statistics
Other reports
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RtKPI Portal (a PI-PB/AF app.)RtKPI Portal (a PI-PB/AF app.)
IAE Trend
(cummulated deviation)Forsman Index Trend
(oscillations)
Miao Index Trend
(oscillation)
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AutoCovariance Test
(variability-oscillations)
Variable values trend
RtKPI Portal (a PI-PB/AF app.)RtKPI Portal (a PI-PB/AF app.)CONTAC
Report Configuration
RtKPI Report (a PI-DL/AF app.)RtKPI Report (a PI-DL/AF app.)
Model Selection
PI-Server
Database and PI-AF Model Name
ex.: Plant, Area, Process, Water, Energy, Quality, etc.
Color highlighting configuration
Date selection
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Report
RtKPI Report (a PI-DL/AF app.)RtKPI Report (a PI-DL/AF app.)CONTAC
Report Views
RtKPI Report (a PI-DL/AF app.)RtKPI Report (a PI-DL/AF app.)CONTAC
DEMO
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OPERATIONAL INTELLIGENCE TECHNOLOGIES
Empowering your PI RtPM infrastructure
Real Time Operational Perfomance Supervision
OPERATIONAL INTELLIGENCE TECHNOLOGIES
Empowering your PI RtPM infrastructure
Luis Yacher S.;Felipe Kripper; Felipe Lineo
CONTAC INGENIEROS
CONTAC