The Application of Process Monitoring and Key Performance Index in Polyethylene Plant International...

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

2

How to Make Your Data Valuable?How to Make Your Data Valuable?

DataDataDataData

InformationInformationInformationInformation

KnowledgeKnowledgeKnowledgeKnowledge

BenefitBenefitBenefitBenefit

3

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

4

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

5

WinNTWinNTProcess SimulatorProcess Simulator

Platform Backbone (Now)

HW TDC2000HW TDC2000ProvoxProvox DeltaVDeltaV

Plant Information SystemPlant Information System

Lab DataLab Data Lab DataLab Data

6

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

7

Process Variation

?

Uncontrolled Variation Controlled VariationPredictable Process

Time Time

8

Overview - Cause Effect Diagram

9

Set Up Control Limit

10

Control Limit Management

11

On Line Monitoring (XB/Range)

12

Offline Analysis

13

SPC Summary

14

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

15

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

16

Set Up MSPC Control Limit

17

Real Time MSPC

18

Contribution Plot

19

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… :)

20

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

21

Productivity Index

USIFE’s Data

22

Raw Material Index / Standard Consumption

USIFE’s Data

23

Raw Material Index / Unit Cost

USIFE’s Data

24

KPI Daily Report

USIFE’s Data

25

Production Rate Analysis Tool

26

Calculated and Standard Production Rate

27

Selected Time Range for Analyzing

28

First Level Effect

29

Second Level Effect

30

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

31

Real Time ISO Spec Monitoring

USIFE’s Data

32

Real-Time SPC for Operator

33

ISO Daily Report

USIFE’s Data

34

Integrated ISO & SPC

35

Analyzing Process Capacity

36

Analyzing Process Capacity

37

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

38

Critical Equipment Operated Time

USIFE’s Data

39

Adiabatic & Reversible Process

S

T

Psuc

Pdis

Tsuc

T*

Psuc

P1

P2

T1T2

T3

T4

Tsuc

P3

P4

S1S2

S3

S4

Ssuc

Pdis

40

Compressor Performance Display

41

Calibrating Bias

USIFE’s Data

42

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

43

Heat Exchanger Performance

USIFE’s Data

44

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.

45

Any Question ?Any Question ?