leveraging process models across the asset lifecycle t fiske arc
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L i PL i PLeveraging Process Models Across the Asset
Leveraging Process Models Across the AssetModels Across the Asset
LifecycleModels Across the Asset
LifecycleTom Fiske
Senior AnalystARC Advisory GroupARC Advisory [email protected]
Process Modeling and Simulation
Modeling LifecycleModeling Lifecycle
Design Phase
StartupStartup
Operations
Summary and Recommendations
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Summary and Recommendations
Process Modeling and SimulationProcess Modeling and Simulation
Models• A model is a simplified representation of a system at some point in time
or space intended to promote understanding of the real systemor space intended to promote understanding of the real system Simulation• Process simulation uses computer-based
modeling of a system to understand its g ybehavior and predict the effect of changes
• Process modelers are primarily interested in representing the behavior of a real-worldin representing the behavior of a real world physical process by means of a reproducible, mathematical form
• Simulation is a proven cost-effective way of exploring new processes and designs without having to resort to expensive pilot programs orand designs, without having to resort to expensive pilot programs or prototypes
• The level of understanding, which may be developed through simulation, is seldom achievable by any other means
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Process Modeling and Simulation Provide a Safe and Inexpensive Method of Optimizing Design and Operations
Types of ModelsTypes of Models
Model Types• First principles
Types of Simulation• Steady State• First-principles
• Empirical
Modeling Environments
• Steady State• Process Design• Process Improvements
E l t it &• Flowsheets• Open Equation
• Evaluate, monitor & troubleshoot plant performance
• Dynamic• Dynamic• Controllability studies• Start-up procedures• Operator Training• Operator Training
Simulators• Optimization
Process & equipment
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Process & equipment
Fidelity of ModelsFidelity of Models
Different Purposes Require Different Fidelity
Chemical Behavior
High
Process
Physical BehaviorFidelity
Process Signals
Process Devices
LLow
Functionality
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All Models Must be Based on Consistent Data and Information
Modeling Environment ArchitectureModeling Environment Architecture
Graphical Analysis Tool
Numerical Solver
Unit Operations ComponentsPhysical Properties Database
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Modeling Environments Are Well Suited for Engineers
Model DeploymentModel Deployment
Training & C l SControl System
Validation23%
Design Simulation
37%
Off-line
On-line Optimization
18%
Typical Applications Where Models Are Being Used
Optimization22%
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Typical Applications Where Models Are Being Used
Models Are Valuable Corporate AssetsModels Are Valuable Corporate Assets
M d l k l t t th ti t
Models Codify Knowledge and Generate Valuable Information
Models are a key element to the creation, capture, codification, and reuse of knowledgeModels are built using all available knowledge of the process including:including: • R&D, pilot plant, and any operating data• Scientific principles• Human operators’ knowledge• Human operators knowledge
Models generate• Equipment specifications
P fi ti• Process configuration• Processing parameters and product quality info
Models Contain and Generate Process and Asset Information that
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Models Contain and Generate Process and Asset Information that Must Be Managed throughout the Lifecycle of an Asset
Models Used throughout Plant LifecycleModels Used throughout Plant Lifecycle
DesignStartupStartup• Automation Validation and Checkout• Operator Training
Operations• Process Analysis and Improvements• Process MonitoringProcess Monitoring• Equipment Monitoring• Operations Decision Support
l O• Real-time Optimization• Operator Training
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Different Usage Don’t Always Use Consistent Informationand Are Often Developed Independently
Asset Creation Begins with Conceptual DesignAsset Creation Begins with Conceptual Design
Design• Steady State Simulation
Design Modelsoften not be
sed afte• Equipment Sizing and Specification• Process and Plant Configuration• Economic Analysis
used after design phase
• PFD• P&ID
• Dynamic Simulation• Controllability Studies
Integrated Front-End Engineering Design• Process Simulation
Process Design Models are
often created• Cost Evaluation• Design Tools
EPC’s are good at internal collaboration and integration
often created by different
organizations
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EPC s are good at internal collaboration and integrationEPC’s are less effective at the interfaces of other disciplines
Startup Startup
Startupp• Automation Validation and
CheckoutT i ll i lifi d d i• Typically simplified dynamic models
• Operator TrainingOperator Training• Requires realistic modeling and
use of realistic automation s stemsystem
• Justification based on faster startup
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Modeling Effort for Startup Is OftenNot Leveraged in Operations
Models Used Extensively in OperationsModels Used Extensively in Operations
Operations• Steady State Simulation• Steady State Simulation
• Process improvements• Evaluate, monitor & troubleshoot plant performance
What if anal sis and p edicti e capabilit• What if analysis and predictive capability• Simplified front-ends• KPIs
• Offline optimization• Offline optimization• Operator guidance
• Dynamic Simulation• Evaluate control strategies• Evaluate control strategies• Evaluate startups and shutdowns procedures
d l id i f i i l l
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Models Provide Basis for Digital Process Plant
Real-time Optimization (RTO)Real-time Optimization (RTO)
Resurgence of optimization solutions• Start small and expandStart small and expand
• Target an economically important nonlinear aspect of a plant that provides sufficient economic benefit
• Offline to online EconomicOffline to online• Multiple purpose – decision
support, Asset Mgt.• Requires highly skilled expertise
Steady State
Detection
Validate Data
Data Reconciliation
Model Parameter
Tuning
Optimization
Setpoint & Steady State
Check
Criteria
Economic UpdatingObjective
Function
Process Model
q g y pthat is different from MPC• More difficult to implement
and maintain than MPC
Detection Tuning Check
MPC
Distributed Control System
TargetsReal-time DatabaseHistorian
• Use of external suppliers and independent contractors common• Expand use to include asset and performance management• Dynamic optimization
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RTO Models Require Significant Maintenance and Upkeep
Operator Training Simulators (OTS)Operator Training Simulators (OTS)
Used for process automation testing• Low fidelity
DCS FAT d SAT• DCS FAT and SAT• Benefits include faster time to startups
Used for Operator Training • Both normal and abnormal situations
• Benefits include• Increased operator proficiency • Less unscheduled downtime• Less unscheduled downtime• Improved operational performance• Fewer abnormal situations that lead to equipment damage or worse
Used for engineering and controllability studiesBegin building models in the design phase – incremental approachImmersion technology
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OTS Models Require Significant Maintenance and Upkeep
Data and Information Value PrincipleData and Information Value Principle
HighHigh
The value of information is inversely proportional to the time it takes to become actionable
Low
Valu
e TimeHigh
V
The value of information is directly proportional to the number of people and systems collaborating
Internal ExternalPlant EcosystemEnterprise
Collaboration Breadth
Low
and systems collaborating
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Knowledge Provides Greater UnderstandingKnowledge Provides Greater Understanding
Understanding
Understanding PrinciplesND
EN
CE
Knowledge
Understanding Patterns
EXT
IND
EP
E
Information
Data
Understanding RelationshipsCO
NTE
UNDERSTANDING
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Knowledge Is a Key Enabler of the Knowledge Worker and Supports Problem Solving and Troubleshooting
Solutions within Knowledge ContextSolutions within Knowledge Context
Incr
easi
ng
Increasing Value of Knowledge
Inbound Supply Chain
Synchronization
Planning and Scheduling
Valu
e
I
Process Monitoring
Advanced Process Control
UNDERSTANDINGModeling and
Simulation
Operational Decision Support
orm
ance
and
E i t
Contextualized
Analysis Outbound
Supply Chain Synchronization
INFORMATION
KNOWLEDGE
Process Optimizationra
tiona
l Per
fo Equipment Monitoring
Data Collection
Data Predictive Analytics
DATA
Data Aggregation
Data Visualization
Reporting
Fault Detection
Ope
r
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Aggregation
Capability Range and Collaboration BreadthHighData
Common Actionable Context
Data ModelWork Processes & State
Relevant Information
Right People
ContextData Quality MgmtCommon Time
Application PortfolioDynamic Plant Reference Model
Application Portfolio
Right PlaceRight time
Common Actionable Context Leverages the
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Co o ct o ab e Co te t e e ages t e“Single Version of the Truth”
What Is Possible: Asset Lifecycle ModelingWhat Is Possible: Asset Lifecycle Modeling
C t ll d i
Datareconciliation
modelProcess design /
RTO modelController designdynamic model
ConsistentModel/
Dynamicoptimization
model
Planning /scheduling
model
Database
Engineeringanalysis
Trainingsimulator
model
MPC predictionmodel
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analysisdynamic model
What Is Possible: Asset Lifecycle ModelingWhat Is Possible: Asset Lifecycle Modeling
Process Optimization• Create models during conceptual and basic designCreate models during conceptual and basic design
• Models turned over to operations• Models reflect original design, but equipment is purchased with
over designed parameters• Models typically don’t reflect as-built
• Process is often modified and models need to be updated• Models used to identify bottlenecks and process conditions y p
and improvements, troubleshooting, what-if scenarios for new op conditions and materials
• Tie in optimizers with planning and scheduling (format for p p g g (data exchange is important)
• Information requirements:• Operating limits equipment limits material properties
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• Operating limits, equipment limits, material properties, operating states, etc.
What Is PossibleWhat Is Possible
Consistent Steady State and Dynamic Models• Plants run at various states so you need optimal path to optimal steady
statestate• Dynamic simulation vs. steady state simulation• EPC create steady state models• Automation companies create dynamic models – simple to complex for p y p p
DCS checkout and training • Need to leverage work at each stage
Process Performance Monitoring and Asset Reliability• Rigorous modeling has capability to monitor process for performance and
equipment for reliabilityOnline optimizationDecision support for operators and managers (excel)Decision support for operators and managers (excel) • Models used for asset reliability, performance, throughput, quality,
material and energy savings, determine product mix, control strategies, optimization, equipment damage
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Use of standards such as cape openRemote simulation
Summary and RecommendationsSummary and Recommendations
Models are Corporate AssetsModels are Used Throughout Asset Lifecycle• Often developed by different organizations for
different purposes and are not based on consistent data
Models Need to be Leveraged ThroughoutModels Need to be Leveraged Throughout LifecycleModels Need to be Managed Throughout Lifecycle
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Thank You for Your AttentionThank You for Your AttentionFor more information, contact the author at [email protected]
or visit our web pages at www.arcweb.com
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