Wed 07-Jones, Melvin

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A Day in The Life ofa Solution Engineer

A Day in The Life ofa Solution Engineer

Melvin JonesSasol: Advanced Solutions

April 2003

Melvin JonesSasol: Advanced Solutions

April 2003



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Biography Biography

Melvin Jones

Melvin Jones graduated from the University of Pretoria as a chemical engineer, andproceeded to complete his honours in Chemical Process Control.

After completing his bursary obligations as a process engineer in the Explosivesindustry, he joined Sasol as an Advanced Control Engineer.

He has worked as a solution engineer improving and implementing advanced solutions,and currently heads a team of engineers maintaining controllers in the gas processingenvironment at Sasol Secunda. Melvin also heads a team looking at basic controlopportunities for the Secunda site.

Business Partner

Advanced Solutions



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Abstract Abstract

A Day in the Life of a Solution Engineer

•Presentation is focused on sharing the AS maintenance function.Structure:

•Knowledge management in terms of:•Database•Solution engineer rotation and handover

•Technical tool and enablers•APC monitors•Base-layer monitor •Visualisation•Auditing

•In house maintenance projects

Melvin Jones



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Background

• AS – 20+ group of control engineers• Need?

– APC mature technology at Secunda

– Service 5 business units, across 21 control rooms – Maintain 80+ APC controllers – Looking at 22 000 PID loops (currently only maintain

APC critical loops)

Volatile staff base



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Group operating methodology

Establish the function

Consolidate installed base

Next generation projects

Next generation AS



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Solution engineer enablement

• Knowledge management – Database – Solution engineer handover

• Technical tools – Daily online monitor – Visualisation environment

– Optimisation monitor – Base – layer monitor – Solution validity



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Solution engineer enablement:Knowledge management

• Database: The one file format – Process description

• Unit operation with specific handles• Overall purpose of the unit • Position in the value chain• Process equipment description• Controller philosophy

– Controller as-built (with matrix printout) – Benefit analysis – Operating instructions for controller – Process flow diagram – All information electronically



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Solution engineer enablement:Technical tools

• Daily online monitor – Provide exception instances

• Visualisation environment – Enable pattern recognition

• Optimisation monitor – Performance information

• Base-layer monitor

– Automated basic controllertroubleshooting• Solution validity

– Controller audit procedure



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Step 1: Daily online

• Internally developed excel monitor • Resolution: daily

• Summary: monthly• Log reasons for controller off

– Summarised for KPI feedback

• First focus point in solution engineersday



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37408 Measure

Month Controller Non-availability Online times Process problems UtilizationMay-02 0.00 99.39 0.54 99.93Jun-02 1.22 98.01 0.77 100.00Jul-02 2.03 86.72 11.24 99.99

Aug-02 0.17 94.13 2.52 96.82Sep-02 0.37 98.61 0.85 99.83

Oct-02 0.49 87.02 12.28 99.79Nov-02 0.69 95.55 2.96 99.20Dec-02 B2R1 0.00 99.59 0.41 100.00

B2R2 0.06 98.65 1.29 100.00B2R4 0.00 99.62 0.38 100.00B2R5 0.00 99.06 0.94 100.0012R1 2.74 97.23 0.03 100.0012R2 3.09 94.93 1.95 99.9712R4 2.77 96.66 0.57 100.0012R5 3.37 96.31 0.31 100.00

Dec-02 Total 1.50 97.76 0.74 100.00Grand Total 0.74 94.76 3.81 99.31



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Step 2: Visualisation environment

• Internally developed VB environment – ActiveX components – Honeywell VisualPHD tools

• Single package covering all controllers• Troubleshooting tool: Allows

– Quick controller performance summary – Visual interaction between critical MV’s & CV’s

– Detailed summary of controller:• Structure• Tuning • Current performance (Snapshot)



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Step 3: Optimisation monitor

• Internally developed excel monitor • Resolution: weekly• Summary: monthly

• Statistical information about: – Global controller performance – CV summary

– MV summary – Business unit average performance (summary)



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37408 MeasureMonth Period Controller Online Optimization Control OK Effiency Constraints MV constrained Limit changes Variables used StabilityOctober 2002 86.97142385 99.88561552 0.072128747 56.66666667 0.017454149November 2002 94.73901553 99.7684139 0.062109535 57.83333333 0.169476565

December 2002 98.98345685 100 0 61.4375 0 50.8279477 88.5 81.99156992 2.133333333January 2003 83.98007675 100 0 52.51428571 0 43.33202951 63.08571429 81.35266951 6.032258065February 20 Week1 12R1MSTR 0

12R2MSTR 012R4MSTR 2.081268583 100 0 0 0 31.74603175 115 56.134079 012R5MSTR 1.982160555 100 0 5 0 22.99544103 94 72.91377602 0B2R1MSTR 96.82854311 100 0 31 0 65.16393443 30 83.33333333 0B2R2MSTR 99.10802775 100 0 36 0 53.61361361 100 83.33333333 0B2R4MSTR 99.70267592 100 0 41 0 39.78109453 34 83.32672613B2R5MSTR 99.70267592 100 0 37 0 53.33333333 77 79.9966964 0

Week1 Total 49.92566898 100 0 25 0 44.43890811 75 76.50632404 0Week2 12R1MSTR 012R2MSTR 012R4MSTR 012R5MSTR 0B2R1MSTR 100 100 0 31 0 62.22222222 103 83.33333333 0B2R2MSTR 100 100 0 32 0 43.19444444 170 83.33002973 0B2R4MSTR 94.74727453 100 0 39 0 36.71204188 96 83.33333333B2R5MSTR 100 100 0 36 0 40.83333333 179 80 0

Week2 Total 49.34340932 100 0 34.5 0 45.74051047 137 82.4991741 0

Week3 12R1MSTR 77.00693756 100 0 85 0 7.850707851 11 85.71428571 10012R2MSTR 63.72646184 100 0 70 0 2.877138414 1 85.71428571 9312R4MSTR 75.81764123 100 0 77 0 29.1503268 12 67.85006371 012R5MSTR 75.22299306 100 0 90 0 30.90909091 8 86.66666667 0B2R1MSTR 100 99.80178394 0.198216056 30 0 69.6031746 111 83.33333333 0B2R2MSTR 99.60356789 99.90049751 0 30 0.099502488 40.89641434 202 82.20350182 0B2R4MSTR 100 100 0 43 0 39.86111111 135 83.33333333 0B2R5MSTR 98.2160555 100 0 38 0 41.7979798 187 80 0

Week3 Total 86.19920714 99.96278518 0.024777007 57.875 0.012437811 32.86824298 83.375 81.85193379 24.125February 2003 Total 61.82276181 99.98346008 0.011012003 41.72222222 0.005527916 39.58563524 92.5 80.21389505 12.0625

Grand Total 84.28153647 99.92648707 0.029230212 54.01709402 0.03919521 44.09289319 76.65217391 81.20374873 6.64516129



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Step 4: Base-layer monitor

• Internally developed excel monitor • Enables supervisory control layer • Prevent APC being band-aid for poor base-layer • Increase general plant stability• Currently adhoc usage

– Test specifically problematic loops – Maintain APC related base layer

• Project: Base-layer world class – Continuous monitoring – Auditing



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Step 4: Base-layer monitor



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Step 5: Solution validity audit

• Controller sanity check

• Check list of: – Validation of controller structure – database vs actual – Controller understanding

• Control objectives valid?• Optimisation objectives valid?

– Controller performance• Online times• MV constraints• CV limit violations• MV base-layer audit • Optimisation limits• Inferential performance



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Internal maintenance projects

• Execute projects in record time – Mean time per controller roughly 1 month

• How?

– Solution engineers• Understand the process• Understand production’s changing requirements• Can immediately and continually make minor changes

– Low cost enables us to:• Implement imperfect controllers (80-20 principle)• Implement controllers which only enable (example)



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• Unit 32 Catpoly controllers• Originally: – 7 controllers

– When built, biggest controller in the world• 70+ CV’s• 40+ MV’s

– Performance poor due to:• Changing feed flows and compositions• Complex controller structure• Maintenance almost impossible



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• Background

DM202

VL206

Reactors

DM114

DM206

DM205 VL101

Unit feedSTD Before = 3.3STD After = 3.6

FlowSTD Before = 0.75STD After = 0.44

LevelSTD Before = 10.6STD After = 5.2





TempSTD Before = 3.3STD After = 1.8

TempSTD Before = 8.4STD After = 4.9

PressSTD Before = 8.2STD After = 0.76

Te m pSTD Before = 3.2STD After = 1.0

Te m pSTD Before = 1.3STD After = 0.55

LevelSTD Before = 15.7STD After = 10.6

PressSTD Before = 2.8STD After = 0.9

Flow Av g B ef ore = 8 .94 Av g A fte r = 3 .1

FlowSTD Before = 11.1

STD After = 3.6

VL105

VL202

LPG

Petrol / DieseltoUnit 33

IPto

Unit 34

Condensate 2 & 3ex

Unit 23 / 70 / 288



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• 4 controllers in series – 3 stabilising controllers – 1 money making controller

• Benefits: R14 mil/year • 3 month internal project

– 2 semi-dedicated resources – Cost < R100 000

Wed 07-Jones, Melvin

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