Techniques for Real-Time
Equipment and Process
Monitoring using PI Data
Archive and PI-Process Book
Jason Banfelder
Kesler Engineering, Inc.
Equipment Performance
Monitoring System
(People)
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Operator
Process Engineer
Manager
System Administrator
Modeler
– Initial construction
– Maintenance
How does the performance monitoring system
address the needs of each of these roles?
Equipment Performance
Monitoring System
(Jobs)
• Measure and Improve real time equipment
performance
– Real Time Displays
– Equipment documentation (P&IDs, procedures, etc.)
• Measure and improve long-term equipment
performance
– Reporting
– Off-line model use
• Develop and maintain equipment models
– Model explorer
• Install and maintain the monitoring system
Model Development
• Small and Simple Models: Performance
equations
– Already a part of PI
– Don’t complicate your life if you don’t need to
• Large or Complex models: KEI Sentinel
engine
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Structured models, repeated patterns
Open equation modeling
User interface
Thermodynamics
Data validation / reconciliation
Sample Model:
Air Preheater
Structured
Models
• Large and/or complex models
demand structured storage
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Tags
Equations
Thermodynamic data
Solution procedure
• Use a hierarchical model structure
– Tree is easy to visualize
– Easier to navigate than a flat list
• No need to rely on a naming convention
– Reusable parts as templates
– PI Module Database is a recognition of
this
Open Equation Models:
Parameters
• Constant
– Value is stored in RDB
• PI Tag
– Value from PI tag
– Field instrumentation, lab,
manual input, another model
– PI tag specification is stored in
RDB
• Internal Calc
– Value is an intermediate result
calculated by the Sentinel engine
• Calculated PI Tag
– Value is calculated by the Sentinel
Engine and stored in PI
Open Equation Models:
Equations
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Material Balance
Energy Balance
Thermodynamics
Definitions
– Efficiency
– Return on Investment
• Correlations
Open Equation Solver
• Analyzes structure of equations, knowns, and unknowns
• Partitions large system into smaller systems
• Faster solutions
• More stable mathematically
• Determines solution order
Model
• Solves individual equations and
systems
• Non-linear numerical solver
Parameters
• Checks validity inputs, intermediate
results, and outputs
Equations
• Deals gracefully with bad inputs or
results
• Does not abandon entire model
if some inputs are bad
Sentinel
Solver
Solver Example
12 Pass Fired Heater
• 781 parameters
– 51 inputs
• 574 equations
• Partitioned into 528 separate systems
– Largest is 47 x 47
Model Development
Thermodynamics
• Built-in rigorous thermodynamics
– enthalpy, entropy, etc.
– steam table
– three phase flash
User Interface
• Complete UI for model development
• Use the same UI
for viewing online results
– Model structure
is different
– Specialized
displays
Viewing Real Time
Performance
• Process Book is ideal for P&ID type views
• Difficult to use Process Book alone for reusable data
views
– Requires a model structure
• Reusable standard views
– Table
– Bar chart
– Pie chart
• Specialized views
– Hydrocarbon Assay
– Heater Summary
– Pass Balancing
Real Time Views Demo
Document Views
• Need more than real-time views to improve
operation.
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Procedures & Guidelines
PFDs and P&IDs
Mechanical drawings
Reports, Studies, etc.
Web pages
• Leverage Microsoft ActiveX Document
technology to deliver all of this in one window
Document Demo
Reports
• Excel based reports
– Promotes working with the results
• Reports delivered via e-mail
– Periodically
– By exception
• Available on-line
Report Demo
The Sentinel in Practice
• First Beta release installed the week
after last year’s OSI conference
• Ten Sentinel models currently running
– Fired heater
– Crude distillation unit
• Orders for 20+ more
The End
Thank You
Kesler Engineering, Inc.
http://www.KeslerEngineering.com