Using online simulation models for virtual data

extraction and field data comparison.

Wim Van Wassenhove
Billington Process Technology AS
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How to achieve 95 % of all the benefits of a

condition monitoring system at a fraction of the
cost of a full blown condition monitoring
system.

Billington Process Technology AS

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Agenda

Introduction to Process Models in Operations

Using models to extract virtual data
Dynamic models
Steady State models

Concept demo

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Effort

Benefit

Real-Time
Closed-Loop
Models

3-6 months model dev.

1-2 months tuning

2-5% Capacity increase

3-10% operating cost saving
Automated execution

Real-Time
Open-Loop
Models

3-6 weeks model tuning

1-2 Real time interface

Off-Line
Operations
Models

1-3 weeks model tuning

1 week of Excel linking

2-5% Operating cost saving

What if analysis capability

Process
Engineering
Models

Model unit operations

Match heat and material
balance
Equipment as unit
operations

Process engineering design

Capital alternatives
Plant Troubleshooting

3-10% operating cost saving

Real time monitoring
Calibrated what if analysis

Value

Cost

Fit for Purpose Models

Model Deployment Options

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When used in combination with transient

models

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Value of Dynamic On-line models

Use models to arm operators with information

they need to make the right decisions
Identify and operate closer to plant constraints
Monitor instrumentation drift
Soft sensor - predict properties
Temporary replacement of failed instrument
Report emissions
Evergreen model
Improve controller tuning on parallel model
Benchmark model during commissioning

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Operate closer to plant constraints - HOW

Example Constraints
Column flood limit
Compressor surge limit
Separator excessive entrainment limit

Visualise current operation versus constraint

Inform operator on proximity to constraint

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Operate closer to plant constraints - BENEFITS

Compressor surge limit

Reduced compressor power when recycling
Estimated saving during recycling: 1% on power

Separator excessive entrainment limit

Increased throughput
Increase in throughput: 2%

Column flood limit

Increased throughput
Increase in throughput: 5%

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Instrument Performance Monitoring

Track difference between model and plant

Identify instrument drift or malfunction
Example Flow meters orifice degradation
Instrument drift can cause safety risks
Pressure or level measurement

Benefit:
Assume 1 plant trip avoided over the lifetime of the
plant

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Continously calculate unmeasurable

properties

Example properties (no limits exist)

Crude oil RVP
Liquid API grade
Export gas water content
Turbine feed calorific value
Export gas wobbe index
Export gas hydrocarbon dew point

Benefits
Avoid penalties for off-spec product
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Replace failed instrument with soft sensor

Example properties
Flow rates
Pressure drops
Temperatures

Benefits
Maintenance shutdown can be delayed to a more
convenient time

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Accurate emissions reporting

Flare incidents
Only need indication of valve opening
Flow rate and composition can be calculated

Continuous emissions
TEG and MEG regeneration
Water rejection

Avoid penalties
You know when your total emissions come close to the
maximum allowable
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You plant model topology is evergreen

No lead time required before starting a study

Less money spent
No measurement campaign
No engineering hour to update/tune model

Problem solution takes less time

Reduced production losses

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Controller tuning on comparison to plant

A parallel model can just take the inputs

Compare real plant response to model(s)
Comparison to primary online model for QA
Secondary online model tests new tuning constants

Reduce risk of an improved tuning gone bad

Reduce risk of production decrease
Reduce risk of plant trips

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Benchmark model during commissioning/start-up

Model shows what one would expect to see

Deviations are indicators for problems
Pressure drop above model value
Compressor outlet temperature above expected

Benefits
Reduce startup and commissioning time by weeks
Compare ROI of the investment with an ROI where
commissioning and startup is reduced by just one week

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When used in combination with steady state

models

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Value of Steady State On-line models

Applications and benefits are similar to

dynamic models

Properties or parameters that can be

determined are often different
Dynamic model calculates expected efficiency
Steady state model calculates actual efficiency

Models can focus on a fragment of the plant only

Duplicate models could be applied to create to
use different inputs (within the same simulator
instance).
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Value of Steady State On-line models

Use models to arm operators with information

they need to make the right decisions
Monitor Equipment/Plant Performance
Soft sensor - Predict properties
Identify and operate closer to plant constraints
Visualize complex processes
Run what-if studies on demand (evergreen model)
Plan for problems coming down the pipe using lookahead simulation
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Different implementations using one TSF

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On-line open loop models

Required Execution Environment

Hide complex interfaces and technical model details
Seamless data transfer between GUI, Historian, and
Process Model simulators
Automate Complex Workflow

Several systems possible

Plant Operations existing GUIs
DCS screens
Data historian tools

Custom made GUI for existing systems

Custom made GUI using a new system
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Using a Dynamic model

Dynamic models use a hydraulic solver

Model is a more realistic representation

Dynamic models are always rating models

More robust in this respect than steady state models
But, limited in terms of data that can be fed
You input relatively little information and compare outputs with
measured data

The model is tuned to initial operation

It may take up to a day to synchronise model with plant

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Using a Steady State model

Steady state models can be for design or rating

Detailed rating models may fail under extreme
conditions
Design models can be specified with lots of plant data
Derive compressor efficiency
Derive heat exchanger fouling
Derive column efficiency or approach to flooding

Less tuning required than for a dynamic model

Model is instantly ready to produce information

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Concept of On-Line Models with BPT-TSF

Keep it simple and accesible

Model configuration stays inside model
Client Applications:

Use existing infrastructure

Process Model

Data Historian

BPT-TSF

History
Database

OPC Connection

IO interface

DCS System

Plant

Historian web application

Historian HMI tools
DCS HMI

Steady State
or
Dynamic
Model

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BPT-TSF

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BPT-TSF

Capable of treating a variety of

Real time data
Historical Data

Online connection through OPC DA

Keeps model synchronised with OPC server

Off-line connection:
Excel
OPC HDA
Manual Data entry
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Steady State HYSYS + BPT-TSF in a System

Create a Steady State model

Define data
to be used as input
to be retrieved for monitoring (add tags to historian)
Adapt model setup to reflect the above choices

Install BPT-TSF
Map Model tags to Historian tags
Define data averaging duration

Install a tool to launch the case periodically

A BPT tool (derived from PSO)
An existing tool (it really only needs to be able to launch a .bat file periodically)

Create visualization
Make informed decisions

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Dynamic HYSYS + BPT-TSF in a System

Create a Dynamic model

Define data
to be used as input
to be compared to model results
to be retrieved for monitoring (add tags to historian)

Install BPT-TSF
Map Model tags to Historian tags

Create visualization
Tune model to current operation
Launch model, arrange re-launch when something goes wrong
Make informed decisions

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Visualize results in an existing tool

Model Results

Model not in operation

Data FROM plant operation

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Demo setup

Real Topsides Dynamic case

Dummy plant inputs from signal generator
Using Predikor APIS
Sine wave on two feed flow controller setpoints

Three outputs
HP Separator pressure
Stage 1 Compressor Efficiency
Stage 1 export compressor efficiency

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Thank You
Any Question?
What do we do next?

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