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Smart Data in Plant Operation:Information from Process and Plant Data generate added Value in Operation and Maintenance

Wolfgang Morr, Bayer Technology Services GmbH

11. Europäische Druckgerätetage; 2015 Dr. W. Morr BTS-OSS-MIT

Agenda Operating Process Plants

Application Examples

The broader View

Summary / Outlook

Safety

Product Quality

Resource Efficiency

Availability

FlexibilityPolycarbonate Production Plant, Bildquelle: Bayer


Operating Process Plants

Vessels Piping Distillation columns Dryers Pumps Compressors Valves Heat Exchanger Centrifuges ………

DependableFunction

Polycarbonate Production Plant, Bildquelle: Bayer

Plant Asset Management



Safety

Product Quality

Resource Efficiency

Availability

Flexibility

Vessels Piping Distillation columns Dryers Pumps Compressors Valves Heat Exchanger Centrifuges ………

DependableFunction

Polycarbonate Production Plant, Bildquelle: Bayer




Safety

Product Quality

Resource Efficiency

Availability

Flexibility

ProductsRaw MaterialsIntermediate Products

Define

Measure

Analyse

Improve

Control

Condition Monitoringt

t 0 Online Condition Monitoring


Plant Asset Management in Process Industries



Source: Ochs, NAMUR General Meeting 2010



(Intelligent)Field Device

Machine Process Unit PlantSite

Device MonitoringSelf

MonitoringApplication of

dedicated Sensor Systems

Use of available Sensors and model / reference

characteristics

Target-KPI with selection of corresponding

indicators

Final Control Elements / Sensors

Source: Seintsch, NAMUR-Hauptsitzung 2010

Step response: Indicator for wear

Considerable device diagnostics is standard today

But:Usually no Integration with other information



• Final control elements: partial stroke test• Manually or automatically triggered control signal

steps • Comparison of step responses

Integration with other sources of information is topic of current development activities BMWi funded Research Project:

SIDAP- „Skalierbares Integrationskonzept zur Datenaggregation, -analyse und -aufbereitung von großen Datenmengen in der Prozessindustrie“.(Förderkennzeichen: 01MD15009A)

Picture: Dr. Matthias Steffen, BTS-OSS-MIT-RI

Manufacturer

Other Users

Basic RecipeProduction Orders Actual Data / HMI

Measurement history



Compilation of information on devices in different operating conditions Broad data base enables early reaction in the case of systematic issues (concerning

the device or the characteristics of its application)

Advantages for users and manufacturers!



Final Control Elements / Sensors

Bildquelle: Bently Nevada™ Diagnose-Tag, 23. Mai 2013

Example: Vibration Analysis

Online or selectively for trouble-shooting

Also for remote diagnostics by experts

But:Usually no Integration with other information

Rotating Equipment



Rotating Equipment

Picture source: Siemens

Shift Book

Operating Conditions

Vibration Analysis

DCS Alarms



Curriculum

Rotating Equipment

Bildquelle: Siemens

Feasibility Study regarding recognition of patters in DCS alarm histories (currently BTS / TUM)

Extension to manual shift book entries intended Advantages expected for offline-analysis and online-

diagnostics



Plant and Process Models Data driven Methods

Rigoroses Modell

Comparison and

Forecast

History

Trainiertes neuronales Netz

Comparison and

Forecast

Knowledge about plant and process

Sources: Wikipedia, Bayer, Ross (Automation 2012)

Monitoring of Process Units und Plants



Weather Raw Material Intermediate Products

Operators Sales Forecast




Inclusion of further (external and internal) information:

Enhanced analytical capabilities (online und offline)

Improved evaluation of situations

Digital (online-) plant models will become recipients as well as suppliers of additional Information





In retrospect: Development of navigationMid July 1865: Laying of second telegraph cable between Europe and North America starts (4200 km)

End of July 1865: Cable snaps after almost 2000 km

August 1866: Recovery of cable, repair and laying to Newfoundland

Source: Wikipedia

The broader View


Locating the cable requires precise navigation capabilities

19th Century Precision: approx. 500 m Value of equipment equivalent to a

single family home Only a few thousand experts had the

necessary know-how

Source: Wikipedia

Today Precision: a few meters No significant costs Billions of people can use the technology

The broader View

No. of Nodes on the Internet

201020001990198019701960

4

300

1.000

100.000

1.000.000

10.000.000

1.000.000.000

500.000.000

An increase of 100 Mio. nodes now takes less than half a year.

An increase of 100 Mio. nodes now takes less than half a year.

It took roughly 30 years to connect 100 Mio. nodes to the Internet.

It took roughly 30 years to connect 100 Mio. nodes to the Internet.

1

01990 2010

Internet Traffic(in TB/s)

100.000.000

0

109

2*109


Source: Wikipedia

The broader View

Evolution of high performance computer during the last 50+ years

Internet of Things / Industrie 4.0 will very soon enable solution that today seem to be impossible or uneconomical

1

01990 2010

Internet Traffic(in TB/s)


Source: Wikipedia

The broader View


How big is „Big Data“?

Typical applications handle petabytes of data(1000 Terabyte, 1015 Byte)

Amount of data stored world-wide: approx. 1 zettabyte (1021 Byte)

Specification of the position of each of the roughly 200 billion stars in our galaxy with a precision better than 500 m:approx. 5 Terabyte (5 * 1012 Byte)

The broader View

Integration of external information with systems for plant and process monitoring will generate added value.

Smart Data / Big Data - Methods will be key for many applications.

Many technologies are already available, just the application in a production environment is missing.

New sensors / final control elements and their drastically increasing networking capabilities („Internet of Things“) will contribute essentially to the development.

In order to improve dependability, flexibility and performance of process plants it is necessary to include also information about the “vicinity” of the assets.


Summary / Outlook

Thank you!

Wolfgang Morr


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