Yiannis Bessiris UNIFORMANCE® SUITE 27 September 2017 · Data Analytics for Process Intelligence....

Data Analytics for Process IntelligenceUNIFORMANCE® SUITERazvan Ionita and

Yiannis Bessiris 27 September 2017

Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.

Agenda• Uniformance Suite• Uniformance Insight

- What’s new with Insight- Display building- Shapes- Displays for Asset Sentinel- Script intro

• More than history- Assigning tags to assets (Asset Model) capability with Sentinel today- Instance based calculations- Functionality supported with instance based calculations in Sentinel (performance overview)- Creating Template based calculations- Fault models- KPIs- Uniformance Executive

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The Uniformance Suite enables…2

A global oil and gas producer to manage over 10 million data points throughout their entire enterprise daily

A large global metals and mining company with close to 2,000 concurrent users to visualize and analyze enterprise data

A global mining company to monitor their entire fleet of 400+ haul trucks, processing more than 160 million sensor readings per day

A large refiner based in Asia to monitor thousands of standard role-based KPIs across more than 100 plants


The Expanded Uniformance Suite

The foundation for the Honeywell Connected Plant

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Scalable connected historianSecure access to near real-time information

Flexible visualization anytime anywhereBetter analysis, monitoring & knowledge sharing

Contextual data & powerful analyticsDetect issues and accelerate response

Tie process intelligence to business goalsDrive decisions and actions and track improvements

Easy to Learn, Flexible to Use!

Uniformance Insight Key Features4

• Key features:• Intuitive trend• Graphics• HTML5 thin client• Ad-hoc layout manager• Smart time control• Flexible connectivity


HTML5 Thin Client5

• Standard for thin-client visualization• Supports multiple browsers• Operating system independent• Touch and tablet display use• Zero end-user client install


R102• Released March 2017• Enhanced graphics automation

- Script- Conditional color/show/hide

• Enhanced support for non-PHD data sources

• HTTPS support• 1/2/3 server support• Option to share server with Uniformance

Asset Sentinel or Production & Accounting• Strip chart trend format

R110• Sept-2017• Asset model for tag browsing• Time-series table control• Annotations against a trend & time• Workcenter and UPS display migration• UPS R340 and Insight common display

builder• SQL database cost reductions

- Support SQL Express and Honeywell runtime restricted licenses

Adding exciting new features

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New in R102 and R110


Strip Charts – R1027


Time-Series Table – R110 8


Annotations – R110 9


Script – R102, R110 10

• Implement complex animations- Script what tags are in a trend- Show/hide symbols- Complex colors

• Incorporate 3rd party controls


© 2017 by Honeywell International Inc. All rights reserved .

Try Uniformance Insight!

Opportunities• Uniformance Insight Test Drive

- Try Insight for free, with no setup costs- Use a test system hosted by Honeywell, with simulation data- www.uniformance.com/testdrive

• Trial Evaluation- Free license for a limited-time trial- Installed on your network, connected to your data- Prerequisites

A Windows server SQL Server Someone to install, or Honeywell services

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http://www.uniformance.com/testdrive


PREDICT PROCESS AND EQUIPMENTPROBLEMS WITH UNIFORMANCE ASSETSENTINEL

Yiannis Bessiris27 September 2017



Creating a Digital Representation of Physical Process - Connect / Analyze / Visualize / Act

Digital Transformation Example… Where is my bike rack?33

Where its been?

When will it get there?

Where is it at right now?

Potential issues



“Like bringing a knife to a gun fight”

Day in the Life of a Process Engineer…

Morning Meeting…

• What happened last night?• Should we shut it down?• Should we reduce throughput?• Should we change operating

conditions?



What is your process and equipment analytics platform?

How These Decisions are Made Today

Find / Import Data ReportsTag Name Tag Desc

XUTT901.PV HE91 Shell In Temp

XUTT902.PV HE91 Shell Out Temp

Analyze Data(Excel & Other Tools)

Time ConsumingT1 T2 T3

Blind Spots

• Missed Opportunities• Difficult to Sustain

• Varied Approaches & Results• Difficult to Share Information

86.1988

91.4

Manually Search & Collect

Isolated Tools& Systems

Manual Periodic Calculations

Reactive & Informal Work

Process


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ConnectConnect and store relevant real-time process and event databoth on-site & in the cloud

VisualizeInteractive visualization of trends, charts, and graphics across variety of data sources for process & manufacturing intelligence

AnalyzeCalculate, analyze, and detect risks and opportunities with asset-centric advanced analytics

ActNotifications and workflow for accelerated decision-making to maximize business performance

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Uniformance® Suite Creating the Digital Twin


Asset Sentinel Executive

Insight

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Uniformance Suite – Along with PHD… the following

Event Management

Investigations

Performance Curves

Event Management

Notifications

Business Dashboards

Process Graphics & Trends

Heat Exchanger

Gas / SteamTurbine

Compressor

Pump

Furnace

AssetLibrary

Calculations(Actual & Predicted)

Head=3960*HPFlow

User Defined Calculations

Pre-Processing / Cleansing

UniSim® - Estimate/ Predicted

Data Driven

Even Detection(Compare Actual to

Predicted)

Fault Models

Fault Prioritization(Fault Severity * Asset

Criticality)



Distillation is energy intensive can contribute to more than 50% of plant operating costs

Column Digital Twin 38

EnergyQuality/Purity

FloodingReliability


Column Digital Twin39

• Performance Monitoring- Density (using thermo properties)- Pressure drop top, bottom, feed- ROC of bottom temp- Mass Flow (In & Out)- Energy Efficiency- Reflux Feed Ratio- Flooding Factor

• Event Detection / Notifications- Flooding (high flooding factor)- Column unstable (high pressure drop)- Pressure & Flow imbalance (top & bottom)- High ROC on bottom temp - Energy – high reflux ratio (column using more

energy to maintain quality & feed)

• Constants- # Trays- Tray Spacing- Tray Hole Diameter - Avg Clear Liquid Height- # Draw products…

• Key Inputs - Composition (lab)- Flowrates (reflux, feed, overhead, &

bottom)- Pressures (feed, top, bottom)- Temp (Feed, bottom, top, bottom product,

overhead product)- Flow rate (Feed bottom, top feed, reflux

feed)



Predicting Process & Equipment Problems• Predict - Tell in advance – foretell• Key Capabilities

- Continuous monitoring vs Periodic- Run-time analytics

Data pre-processing / cleansing Basic calculations First Principles Models Data driven / parameter estimation

- Fault Detection Simple limit violations Complex logic

- Fault Management (workflow) Detect Decide Act

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• Calculation Capability- Data Driven & Scheduled- 4th Gen Scripting Language- Standard & Advanced

Performance Library Pump, Compressor, Turbine,

Heat Exchanger- Data Pre-processing- Thermo Calculation

Package- UniSim Model- Custom Code (C#)- Excel Calculations

• Rules Engine- Symptom / Faults

Performance Calculations / MonitoringExample Feed Rate Calc.

Example Column Calc.

Thermo Properties


• Symptom / Fault Model- Rule logic for triggering event- Limits

Static Dynamic From HON Limit Repository

- Event Actions OPC A&E ‘Event’ E-mail CMMS (SAP or Maximo) work request

- Define Fault Severity- Define Recommended Action- Minimize Chatter

‘Contextualized’ – rule executes only when context is true i.e. pump running

On-Delay & Off Delay

• Simple & Complex Rules

Event Detection Compressor Fault Model


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First Principles Model Calculates Expected Performance

Static vs. Dynamic Limits

Dynamic Limit Calculated based on expected

PerformanceActual Performance

Typical static limit



Day in the life of a Process Engineer After…

Before Morning Meeting…

• Lets see what Asset Sentinel is telling me happened last night…


Event Management – Orientation45


Event Management - Detect4646

Column Alert

Alert Details

Alert Logic Alert triggers

Fault Tree


Event Detection - Decide4747

SymptomsFault


Event Management - Decide4848

Alert Logic Alert triggers

Fault Tree

Help Tab

Recommendations

Links to supporting documentation


Performance Monitoring – Column Attribute Overview49


Process Monitoring – Performance Attributes50


Performance Monitoring – Integrated Trending51


Event Management – Act (Close-out)5252

Alert Logic

Fault Tree

Reason Code, Cause, Action

Impact• Cost – negative• Savings - positive



Digital Twin – replacing after the fact spreadsheet investigations with realtime visibility

Day in the life of a Process Engineer… After

Morning Meeting…

A predictive column imbalance alert from Asset Sentinel allowed us to

address the issue early this morning.


Major US Refining Co.Established formal process monitoring work process identifying by engineering role best practices for process & equipment health monitoringHome grown solution built on aging technology

Use Case – Pro-active Technical Monitoring

BackgroundProblem / Need

Solution

Results /

Lessons

• ~ 70% of monitoring tasks could be automated• Estimated reduction of 1 FTE to focus attention on

solving problems vs looking for problems

• Asset Sentinel calculations & templates• Fault models for alert notification• Advanced fault logic supporting different modes of

operation• Managed environment (debugging & error reporting)

• 1 Major Process unit had: ~600 Process Eng. monitoring tasks (daily-monthly)

• 57 Types (Emissions, Catalyst, Energy, Yield, Hx Mon, Compressor Mon…)

• 60 Daily Monitoring Tasks


Large Indian Refining & Petrochemical Producer

Use Case – Process Monitoring & Collaboration Network

BackgroundProblem / Need

“Previously, equipment monitoring and performance information was on spreadsheets… published once per month, but now we can use tools like Honeywell's Uniformance Asset Sentinel to check performance hourly and then make adjustments on the fly.”

Rahul Chaturvedi - Senior VP & CIO Hydrocarbons

Solution

Results /

Lessons

• Near real-time allows on-the fly adjustments & decisions (reduce LPO & maintenance costs)

• More accurate calculations (thermo properties)• Easier to maintain (standard templates)• Visible to all in web browser• Consistent approach across sites

• Asset Sentinel calculations & KPI continuously calculated

• Embedded 1st Principles Models • Templated calculations• Managed environment (debugging & error reporting)• Intuition Executive Dashboards

• Performance metrics calculated daily or Monthly (after the fact) in spreadsheets

• E.g. – 1 plant 33 spreadsheets / 4000 tags / 9000 calculations

• Difficult to maintain, share, & time consuming

Control Article

http://www.controlglobal.com/articles/2015/hug-16/


Exception Based Surveillance (EBS) Shell Deep Water Assets in Gulf of Mexico & Brazil• Fully operational for 4-5 yrs• Doubled in capacity in last 2-3 yrs• Integrated with Remote Ops

Process & Equipment Surveillance

BackgroundProblem /

Need

Solution

Results / Lessons

Work process for event detection, triage (investigation) and close-outDeveloped over 220+ 'algorithms‘ using 1st principles models, adaptive thresholding, univariate prediction & pattern recognition

Production surveillance & diagnostic system to provide predictive notifications to reduce 'deferment‘Pure data-driven models not actionable and too many false positives.

Report $30M/year reduction in deferment & costsApplication of hueristic / engineering rules reduces # of false positives and increases actionability.Evaluated 'data driven' models with limited results.POC on 'visual' analytics to accelerate 'algorithm development


Sample of Bridge Surveillance Groups - SummarySurveillance Category Surveillance Group Surveillance Types

Surface Engineering

Chemical Performance Surveillance 8

Compressor Optimization Surveillance 4

Compressor Reliability Surveillance 16

Instrumentation System Surveillance 3

Process System Surveillance 16

Pump and Generator Surveillance 15

Water Injection Surveillance 13

Water Separation Surveillance 8

Subsea Engineering

Chemical Performance Surveillance 8

Choke Performance Surveillance 7

Christmas Tree Surveillance 1

Electric Submersible Pump Surveillance 26

Flowline Surveillance 5

HPU Surveillance 6

Multiphase Flow Meter Surveillance 37

EPU Surveillance 10

POD Electrical and Hydraulic Surveillance 7

Valve Surveillance 2

Subsurface Engineering

Annulus Pressure Surveillance 5

Choke Performance Surveillance 7

Gas Lift Surveillance 6

Operating Guidelines Surveillance 4

Rate and Phase Surveillance 1

Sand Management Surveillance 1

Shut In Well Surveillance 5

• 30M data elements processed per day• 230K daily executed anomaly detections


Historian

Seeq (Visual Analtyics)Asset Sentinel

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Asset Sentinel / Seeq Integration

Trends & Graphics

Event Investigations

Heat Exchanger

Gas / SteamTurbine

Compressor

Pump

Furnace

AssetLibrary

Calculations

Head=3960*HPFlow

User Defined Calculations

Pre-Processing / Cleansing

Event Mgt.

Fault Models

Asset Model Visual Rule Discovery

Asset Model

Conditions,Series,

Patterns

Cleansed / Enriched Data

OPC-HDA & DAS

OPC-HDA & DAS

OPC-DAPHD Other


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Seeq Integration with Sentinel – ‘Enriched Data’Display in Sentinel

‘container’ for selected asset Sentinel Calculated

Expected Compressor Performance

Sentinel Compressor Low Flow Capsules

Actual Compressor Performance


Digital Transformation Benefits60

Apply High Skill Resources to High Skill Tasks

Single Version of the Truth Enabling Process Intelligence

Reduce Missed Opportunities &Accelerate Response

Formalize Work Processes& Standard Work

Detect

DecideAct Inform

& Improve

0%

50%

100%

Current FutureData Gathering Analyzing Solving

T1 T2 T3

Alerts!


Depth & Breadth of Capabilities of Solution

Industry

MonitoringApplications

Type of Equip / Complexity

Process Health Efficiency Safety Energy

Instrument

Valve Pump

Heat Exchanger

Compressor

Haul Truck

Turbine

Unit

Software

Oil & Gas Refining & Chemicals Pipelines Power Mining

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Value – Reduce Unplanned Capacity Loss / Lost Profit Opps

Rare Frequent

High

Cos

t Im

pact

Low

Frequency

Process Deviations

Unit Shutdown

Degraded Efficiency

Non-Critical Eq. Failure

Critical Eq. Failure

Reduced Capacity Loss

Original Capacity Loss

Mitigation Strategies

Leading Cause

Contact Honeywell for a Demo or An Asset Sentinel Test Drive

Check it out!63

• Visit Uniformance Asset Sentinel Website• Visit UOP Connected Performance Services for examples of Asset Sentinel at work• Brochure, Case Studies, and More• See it at Honeywell Users Group Americas and EMEA• Watch product demo videos on the Uniformance YouTube playlist at

www.hwll.co/UniformanceVideos• Watch the Lundin Edvard Grieg Video Case Study • Visit Uniformance.com for quick access to more information or to request a product

demonstration

https://www.honeywellprocess.com/en-US/online_campaigns/Uniformance/Pages/uniformance-asset-sentinel.html

https://www.uop.com/cps/

https://www.honeywellprocess.com/en-US/explore/products/advanced-applications/uniformance/uniformance-asset-sentinel/Pages/default.aspx

https://www.honeywellprocess.com/en-US/online_campaigns/hug/Pages/americas/index-americas.html

https://www.honeywellprocess.com/en-US/online_campaigns/hug/Pages/emea/index-emea.html

http://www.hwll.co/uniformancevideos

http://www.hwll.co/UniformanceVideos

http://bit.ly/LundinAS

http://www.uniformance.com/

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Optimize Your Operations with Real-Time Digital Intelligence

Uniformance.com

http://www.uniformance.com/

Yiannis Bessiris UNIFORMANCE® SUITE 27 September 2017 · Data Analytics for Process Intelligence....

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