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

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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)

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2

34

5

678

9

10

1112

1314 15

1617

181920

21 2223

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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 ?