Process Monitoring Framework –
an effective automation and sustainment platform for asset monitoring
ExxonMobil Research and Engineering Company
October 5-7, 2015
Ravishankar Sethuraman, Kenneth G Teague, Ken H Tyner 2015 SimSci Simulation for Business Excellence Conference Pasadena, CA
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Use of first-principle based models to optimize refineries and chemical units in real time is well established and is widely deployed in our
industry. Online use of first-principle, correlative, and other models to monitor unit performance is gaining momentum. Deployment, quality control, and sustainment of these models can be facilitated through a systematic framework built around a robust modeling and automation platform. A Process Monitoring Framework has been built around ROMeo™ to standardize application deployment and automate data input, routing, and storage. The framework supports integration of multiple models and robustly handles individual model/calculation failures. The application standardization facilitated by the Process
Monitoring Framework has helped to lower deployment costs, lower the skill level required for sustainment, and led to smoother model user
transitions. These are critical benefits to sustaining an effective monitoring program in a volatile economic environment.
Abstract
• Overview
• Essentials for effective Process Monitoring
• Process Monitoring Infrastructure
• Process Monitoring Framework – Features
• Process Monitoring Framework – Connectivity
• Model Execution Order in Framework
• Recommendations
Agenda
4
• Effective process monitoring is key to:
• Achieving the manufacturing business objectives
• Analyzing unit health
• Avoiding surprise
• Understanding past operations, and
• Planning for future
Overview
Process Monitoring
Elements Leadership
Work Processes Tools
• Continuous and uninterrupted data from tools
• Allowing user to focus on data analysis and decision-making
• Taking tools and calculations off the user desktops
• Automation of simple and repetitive tasks
• Efficiency in tool sustainment
• Standardizing deployment of tools
• Driving consistency and excellence in process monitoring
• Ability to integrate heterogeneous models within each application
• Ability to process historical data (input/output)
• Ability to perform data validity checks and instrumentation data gaps
Essentials for Effective Process Monitoring
6 Users
Unit Process engineer Subject matter specialist Reliability engineer Energy coordinator/team
Unit Monitoring Data Visualization Reports Data Analysis
Data Historian
Process / Equipment Health Monitoring Application on ROMeo™ platform
Data Validation
PM Models PM Models
PHM Models
PM Models PM Models
EHM Models Automated
scheduling/execution
Output Validation
Reporting / Data Storage
Unit Data
RTO Data Lab Data
• 50+ applications successfully deployed using the Framework
Process Monitoring Infrastructure
Process Monitoring Framework - Features
• Execute diverse/heterogeneous set of models
• Desktop proprietary models
• Spreadsheets, scripts (external/internal)
• Native ROMeo™ models
• Execute sequential or simultaneous models
• Handles flowsheet, sub-flowsheets, collections, & macros
• Improves data availability even when some calculations fail
• Manage asynchronous time-variant data input
• Current or historical
• Synchronize with lab or reconciled data availability
• Support varied input data sources
• Data from other applications
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Process Monitoring Framework – Features
• Common automation and configuration components for use by all tools including:
• Generic RTS Sequence
• Configurable database which enables certain application updates
• Standardized approach to exchange data between sources & consumers
• Real-time Optimizers, Historian, Custom models, ROMeo™ streams, lab
• Robust and flexible approach to solution strategy
• Management of model interdependency, including failure-handling
• Sequential task list (user-defined and configurable)
• Conditional execution according to availability of necessary data (e.g., lab)
• Troubleshooting efficiency
• Configuration Interface
• Tabular interface that facilitates search for relevant connections
• Good for troubleshooting & technical quality review of deliverables
• Connections can be edited or deleted without direct ROMeo™ interaction
Data Historian
Framework Database (Generic per app type)
User Config Interface
ROMeo™ Flowsheet
™ Interface External Models/
ROMeo™ Interface Native Model
(Equipment) Custom Model External Model
(Executable) External
Model Wrapper
(generic per type)
Tag Connections
EDI
RTS Model Connectivity
Order
Model Execution Order
Process Monitoring Framework Connectivity
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Initialization Validate Input
Solve
Validate Output Store Output
Task 1 Time step
Task step(s) Time step(s)
Model Execution Order in Framework
• Key platform functionality having general interest to user community:
• Central database storing
• Tag connectivity
• Model execution order
• Model connectivity
• Capability to support more intuitive application re-deployment:
• Generic ROMeo™ database templates
• Generic RTS sequence templates
• Application structure and transparency supporting credibility and sustainer training
• Consider incorporation of above functionality into the ROMeo™
platform roadmap
Recommendations
12 Disclaimer
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