The Application of Process Monitoring and Key Performance Index in Polyethylene Plant International...
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Transcript of The Application of Process Monitoring and Key Performance Index in Polyethylene Plant International...
![Page 1: The Application of Process Monitoring and Key Performance Index in Polyethylene Plant International Innotech, Inc. Ricky Hsu Inspiration System, Inc. Jialin.](https://reader035.fdocuments.us/reader035/viewer/2022070415/5697bf731a28abf838c7f2ae/html5/thumbnails/1.jpg)
The Application of Process Monitoring and Key Performance
Index in Polyethylene Plant
International Innotech, Inc.Ricky Hsu
Inspiration System, Inc.Jialin Liu, M. F. Yau
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How to Make Your Data Valuable?How to Make Your Data Valuable?
DataDataDataData
InformationInformationInformationInformation
KnowledgeKnowledgeKnowledgeKnowledge
BenefitBenefitBenefitBenefit
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Introduction Implement Process Data Infrastructure
Integrated HW TDC2000、 Fisher Provox and DeltaV Link Lab QC data Compile the process simulator
Process Monitoring System Statistical Process Control Multivariate Statistical Process Control Computerize Operator Experience
Key Performance Index Production Performance Index Operation Performance Index Equipment Performance Index
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Platform Backbone (Before)
Plant #1 Data SourcePlant #1 Data Source Plant #2 Data SourcePlant #2 Data Source
Process SimulatorProcess Simulator
HW TDC2000HW TDC2000Lab DataLab DataLab DataLab Data
ProvoxProvox DeltaVDeltaV
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WinNTWinNTProcess SimulatorProcess Simulator
Platform Backbone (Now)
HW TDC2000HW TDC2000ProvoxProvox DeltaVDeltaV
Plant Information SystemPlant Information System
Lab DataLab Data Lab DataLab Data
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Process Monitoring System Statistical Process Control
Why Do We Need SPC Cause Effect Diagram, Fishbone Diagram Set up XB/Range control limit On line monitoring Off line analysis
Multivariate Statistical Process Control Why Do We Need MSPC Set up PCA control limit On line monitoring Contribution plot
Computerize Operator Experience If - Then architecture Recording symptom and trigger time Display predefined SOP
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Process Variation
?
Uncontrolled Variation Controlled VariationPredictable Process
Time Time
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Overview - Cause Effect Diagram
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Set Up Control Limit
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Control Limit Management
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On Line Monitoring (XB/Range)
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Offline Analysis
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SPC Summary
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Why Do We Need MSPC?D
S1.V
ar_2
(DS)
DS1.Var_1 (DS)
MSPC UnTitled DS1.Var_1 (DS) / DS1.Var_2 (DS)
Simca-P 8.0 by Umetrics AB 2000-07-12 09:55
-0.40
-0.20
0.00
0.20
0.40
0.60
-3 -2 -1 0 1 2 3
t[2]
t[1]
MSPC.M1 (PC), Untitled, Work setScores: t[1]/t[2]
Ellipse: Hotelling T2 (0.05)
1
2
34
5
678
9
10
1112
1314 15
1617
181920
21 2223
2425
2627
Simca-P 8.0 by Umetrics AB 2000-07-12 09:54
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Principal Component Analysis
2 4 6 8 10 12 -12
-8
-4
0
-8
-4
0
4
8
12
Z A
xis
Y A
xis
X Axis
T2
Q
a(X1,Y1,Z1)b(X2,Y2,Z2)
PC2
PC1
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Set Up MSPC Control Limit
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Real Time MSPC
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Contribution Plot
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Computerize Operator Experience
Trigger Time Symptom Possible
CauseStandard OperatedProcedure
For Example:If (cooling water outlet temperature less than 55 degC)Then (step 1… step 2… :)
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Key Performance Index Production Performance Index
Productivity Index Raw Material Index Utility Index Production Rate Analysis
Operation Performance Index Real Time ISO Spec Monitoring ISO Daily Report Integrated ISO & SPC
Equipment Performance Index Critical Equipment Operated Time Compressor Performance Heat Exchanger Performance
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Productivity Index
USIFE’s Data
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Raw Material Index / Standard Consumption
USIFE’s Data
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Raw Material Index / Unit Cost
USIFE’s Data
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KPI Daily Report
USIFE’s Data
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Production Rate Analysis Tool
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Calculated and Standard Production Rate
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Selected Time Range for Analyzing
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First Level Effect
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Second Level Effect
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Key Performance Index Production Performance Index
Productivity Index Raw Material Index Utility Index Production Rate Analysis
Operation Performance Index Real Time ISO Spec Monitoring ISO Daily Report Integrated ISO & SPC
Equipment Performance Index Critical Equipment Operated Time Compressor Performance Heat Exchanger Performance
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Real Time ISO Spec Monitoring
USIFE’s Data
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Real-Time SPC for Operator
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ISO Daily Report
USIFE’s Data
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Integrated ISO & SPC
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Analyzing Process Capacity
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Analyzing Process Capacity
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Key Performance Index Production Performance Index
Productivity Index Raw Material Index Utility Index Production Rate Analysis
Operation Performance Index Real Time ISO Spec Monitoring ISO Daily Report Integrated ISO & SPC
Equipment Performance Index Critical Equipment Operated Time Compressor Performance Heat Exchanger Performance
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Critical Equipment Operated Time
USIFE’s Data
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Adiabatic & Reversible Process
S
T
Psuc
Pdis
Tsuc
T*
Psuc
P1
P2
T1T2
T3
T4
Tsuc
P3
P4
S1S2
S3
S4
Ssuc
Pdis
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Compressor Performance Display
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Calibrating Bias
USIFE’s Data
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Heat Transfer Coefficient
)()( ,2,2 inCoutC HHLMTDUAq
)()( ,, inWateroutWater HHLMTDUAq
)(
)( ,2,2
LMTD
HHUA inCoutC
)(
)( ,,
LMTD
HHUA inWateroutWater
Reactant Stream Temperature KnownReactant Stream Temperature Known
Cooling Water Temperature KnownCooling Water Temperature Known
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Heat Exchanger Performance
USIFE’s Data
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Summary
Data infrastructure provide the powerful management tool for supervisor.
Operator have to concern not only “Safety Alarm”, but also “Quality Alarm”.
When the performance can be defined and evaluated, there is some way to control it.
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Any Question ?Any Question ?