leveraging process models across the asset lifecycle t fiske arc

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

2© ARC Advisory Group

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


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


Process & equipment

Fidelity of ModelsFidelity of Models

Different Purposes Require Different Fidelity

Chemical Behavior

High

Process

Physical BehaviorFidelity

Process Signals

Process Devices

LLow

Functionality


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


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%


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


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


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


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


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


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


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


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


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


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


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


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


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


• 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


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


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


leveraging process models across the asset lifecycle t fiske arc

Technology

simulation models

worldphysical process

means process modeling

used7 arc advisory group

digital process plant

shutdowns procedures

mathematical form simulation

design simulation37