KBC unit monitoring Petro-SIM and PI-AF Mike Aylott Software user conference 2018, USA

1. Proprietary Information 1
Unit PerformanceMonitoring:
v7and PI-AF
KBCSoftwareUsersConference
Houston,TX
11-12September2018
MikeAylott,KBC

2. Proprietary Information 2
Deliveringtheplan
Planning (LP) and
Scheduling Tools
Plant Unit
Operations
Plan Margin
Performance and
Capability Updates
Unit Performance Monitoring
• Monitoring and Reporting vs. Target
• Yield Performance
• KPI’s
• Mass Balances
• Troubleshoot
• Best Practices
Economic Data
Plant Capability
Data
Actual
Production
Actual MarginDelta = Lost Profit Opportunity
Operating Targets
and Parameters

3. Proprietary Information 6
UPMprocessat most sites typically boggeddown
Daily meeting
•Data in spreadsheet form, many historian variables,
limited insights
• Unreconciled data
•No predictive view of performance for current operations
Troubleshooting
•Data analysis – build specific trends of the data
•Ad hoc simulation
Updates for planning
•Data for planners, LP model updates.
•Compiling and reconciling performance data
Reporting
•Gathering data, calculating the metrics, KPI’s and
reporting
•Monthly, Quarterly reports
•Fleet monitoring
•Best Practice propagation
Time-,data-&people-intensive

4. Proprietary Information 7
Rigoroussimulationis key toUnit PerformanceMonitoring
BUT…
• Skillset – simulation considered expert
tool
• Time – Unit engineers have limited
time
• Typically used for design tasks not
operations support tasks
• Lack of integration with enterprise
systems
• Not automated
• Not integrated with business workflows
ROLE
• Predict performance
• Reconcile operating data
• Facilitate Actual vs Predict comparisons
• Standardize KPI calculations
• Generate complex KPI’s
• Generate data for planning and
scheduling tools
• Support for unit optimization
• Support for what if analysis

5. Proprietary Information 8
Petro-SIMprovidesaframeworkformodel-based
performancemonitoring
• With a set of functionalities
• Direct links to process & lab data
• Data conditioning
• Data reconciliation
• Monitoring and Normalization
modes in reactor models
• Reporting tools for KPIs
• Common reporting
• Database integration
• Monitoring module in KBC Explorer
application
• LP Submodel calculator
• Automation
• Workflows
• That enable daily automated
calculations for
• Overall mass balance reconciliation
• Standardized yield reporting
• Unit health assurance
• Simulation model assurance
• LP Submodel assurance
• And that supports
• Quantifying performance vs.
targets
• Troubleshooting deviations
• Deciding when to update models
• Standardization of best practices
September 12, 2018

6. Proprietary Information 9
UpcomingPetro-SIM7 streamlinesthetools
• Meters
• Now connect to multiple historians, reducing need to link meters on same
stream
• Meter corrections updated
• Can show additional properties in meter, allowing you to compare Measured,
Simulated and LP in one place
September 12, 2018

7. Proprietary Information 10
UpcomingPetro-SIM7 streamlinesthetools
• New mechanism for handling
LP Submodel Calculators
with Base Delta unit
operation
• Builds automatically from LP
Utility or configured manually
from your own submodel
• Solves internally: no need to
use Excel
• Generates flowsheet streams
with full composition and
property information
• Lets you readily integrate
results into meters and into
MPI utility
September 12, 2018

8. Proprietary Information 11Proprietary Information
KBCdecidedto
integratePetro-SIM
andPItoexpandUnit
Performance
Monitoring
• Goal is to make results available to
wide audience
• Common dashboards across circuit
• Mix data from multiple sources not just
Petro-SIM results
• Ability to export beyond to BI and data
analytics
• Medium is to mirror Petro-SIM
model structure in PI Asset
Framework

9. Proprietary Information 12
A DigitalTwinresolvesthe‘BUT…’
Traditional Simulation Digital Twin
An accurate representation of a
particular operating case
An accurate representation of the asset
over its full range of operation
Provide a snapshot in time
Capture the full history and future of the
asset
Built on an ad-hoc basis to answer a
question
Automated, regular model runs. Built-in
to business workflows
Owned and used by isolated groups on
an ad-hoc basis
Centralised single version of the truth,
used by everyone, outputs delivered
directly to the business, strong
governance systems
Alignswithanddrivesbusinessdata
model

10. Proprietary Information 13
Processmodelandplantdataviewaligned
PI System
Petro-SIM
Explorer
UPM Portal
Petro-SIM
UI
Monitoring
Service
Petro-SIM
Engine
Petro-SIM
Database
PI
Archive
PI
Vision
PI Asset
Framework
PI-RDBMS
Picks up results on timer
PI System PI SystemPetro-SIM
Model structure information
PI System
Specialist’s Petro-SIM Portal
SERVERDESKTOP

11. Proprietary Information 14
Petro-SIM– OSIsoftintegration- WhatDoesThisMean?
• Exploits PI Asset Framework technology to mirror Petro-
SIM model structure in PI world
• Automated creation of PI AF template from Petro-SIM
• Automated update of PI AF template if Petro-SIM model
changes
• Automated notification to Petro-SIM if PI tag changes
• Automated population of Petro-SIM model with current PI
data
• Automated population of PI database with Petro-SIM
outputs
• Automated calculation of unit performance analytics
• Petro-SIM reports presented via PI Vision portal
• Drill-down into Petro-SIM models from PI Vision
14

12. Proprietary Information 15
PIAFBuilderautomatescreationof PI AFdatamodel
• Petro-SIM to PI
model mapping
managed by Petro-
SIM Explorer
application
• You can configure
how much is
mapped across
and which data is
stored as PI tags
• Application setup
run for each
application
mapped to AF with
re-sync on
basecase change

13. Proprietary Information 16
UPMPortalbuiltaroundPI Visiondashboards
• Dashboards in
PI Vision can
incorporate
results from
Petro-SIM
alongside other
PI data
• Key UPM results
consumed
through PI
Vision
• Expert users can
perform deeper
analysis through
direct
interaction with
Petro-SIM

15. Proprietary Information 18
UPMprocesshasevolvedtoenablebetterdecisions,faster
Daily meeting
•Consistent calculation of unit metrics, and
performance analysis
•Indications of change in key unit performance
metrics (e.g. mass balance, yields, …)
•View of predicted, plan vs actual
Troubleshooting
•Consistent view of unit data
•Consistent tools for troubleshooting issues
•Simple to share information with SME’s and engage
Updates for planning
•Identify and communicate variations between plan,
prediction and actuals
•Dramatically reduced effort to update models and
improve the frequency of updates
•Update yield vectors in a timely way
Management view
•Consistent view of unit performance across units
Coordination with COE
•Consistent calculation of metrics, analytics for each
unit
•Comparison of unit performance across units / sites
•Better troubleshooting & optimization

16. Proprietary Information 19
Screenshots
September 12, 2018

17. Proprietary Information 20
Petro-SIMExplorerPIAFBuilder
• PI AF Builder tool
accessed from an
Application’s
Maintain page
• Lets you configure
which types of
object and
attribute map
across to AF
• Lets you configure
application name,
location etc. in AF
September 12, 2018

18. Proprietary Information 21
PISystemExplorer–Let’syouseewhatgetsbuilt
• Element
tree
contains
mapped
items
based on
underlying
templates
also built
by PI AF
Builder tool
• Structures
for overall
balance
report and
any Petro-
SIM multi-
case
reports you
have get
mapped
across also
September 12, 2018

19. Proprietary Information 22
DatamappedtoPIPointsforperformance
• Values for
mapped
elements &
attributes
pumped
into PI
Archive
using PI
RDBMS tool
running on a
schedule
September 12, 2018

20. Proprietary Information 23
DatanowavailabletoPIVisiondashboards
• Dashboard
can display
any value
available in
your AF
structure or
in PI Archive
September 12, 2018

21. Proprietary Information 24
AndtoanyPI-awaretool
• Microsoft Excel
• PI Process Book
• Third-party BI
tools through PI
Connectors
• Etc.
September 12, 2018

22. Proprietary Information 25September 12, 2018