yiannis bessiris uniformance® suite 27 september 2017 · data analytics for process intelligence....
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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
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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
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HTML5 Thin Client5
• Standard for thin-client visualization• Supports multiple browsers• Operating system independent• Touch and tablet display use• Zero end-user client install
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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
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Strip Charts – R1027
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Time-Series Table – R110 8
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Annotations – R110 9
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Script – R102, R110 10
• Implement complex animations- Script what tags are in a trend- Show/hide symbols- Complex colors
• Incorporate 3rd party controls
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 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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Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
PREDICT PROCESS AND EQUIPMENTPROBLEMS WITH UNIFORMANCE ASSETSENTINEL
Yiannis Bessiris27 September 2017
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved .
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
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved .
“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?
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved .
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
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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)
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© 2017 by Honeywell International Inc. All rights reserved .
Distillation is energy intensive can contribute to more than 50% of plant operating costs
Column Digital Twin 38
EnergyQuality/Purity
FloodingReliability
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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)
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved .
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
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• 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
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved .
Day in the life of a Process Engineer After…
Before Morning Meeting…
• Lets see what Asset Sentinel is telling me happened last night…
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Event Management – Orientation45
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Event Management - Detect4646
Column Alert
Alert Details
Alert Logic Alert triggers
Fault Tree
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Event Detection - Decide4747
SymptomsFault
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Event Management - Decide4848
Alert Logic Alert triggers
Fault Tree
Help Tab
Recommendations
Links to supporting documentation
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Performance Monitoring – Column Attribute Overview49
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Process Monitoring – Performance Attributes50
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Performance Monitoring – Integrated Trending51
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Event Management – Act (Close-out)5252
Alert Logic
Fault Tree
Reason Code, Cause, Action
Impact• Cost – negative• Savings - positive
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved .
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.
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
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
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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
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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
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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
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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
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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!
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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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Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
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
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Optimize Your Operations with Real-Time Digital Intelligence
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