Plant Data Integrity Plant Data Integrity How to leverage How to leverage

PIPI data data

with with

IntelligentIntelligent

Validation andValidation and ReconstructionReconstruction Pieter Theron, Consulting Manager

Keops Isis, South Africa

HoneywellDCS

32 LCN

SSF FactsSSF Facts

Various SCADA

40

Raw Gas4.5 Gm3n/h

Coal70ktDAF/d

Oxygen950km3n/h

Power780 MWh

Steam7,850t/h

Fuels13,000t/d

100,000bbl/d

Chemicals7,000t/d

PI Historian75k tags, 45krt

8k calcs

SigmafineData reconAPC

RMPCT

World leader in Coal to Petro-chemical benefaction

Technology license holder for Fisher Tropsch and SAS

Major player in Gas-to-Liquor development

Sigmafine ProjectSigmafine Project

PI

GasCircuit

Oil Workup

Chemical Workup

Gas production

Excel/VB

Detail modelsBoundary models

Global model

Daily totals from .PV

Data pre-processing required Data pre-processing required (2% balance)(2% balance)

Investment not leveraged due Investment not leveraged due to data problemsto data problems Missing dataMissing data Wrong dataWrong data PI data cannot be trustedPI data cannot be trusted

Need Data IntegrityNeed Data Integrity validationvalidation configuration controlconfiguration control accountability/ownershipaccountability/ownership

IssuesIssues onon PI-Sigmafine PI-Sigmafine projectproject

Data Integrity Data Integrity RequirementsRequirements

20-FT-1001

P,V,TP,V,TP,V,T

DCS20F1001

PI20F1001.PV

X

Y

Z

Z=X+Y

Data Integrity ConceptData Integrity Concept

TDC SCADA MIMS PIIN

Tools

Network

Presentation layer

Interface layer

Configuration Control

Data Validation

Data Reconciliatio

n

Network

Data Data Validation/ReconstructionValidation/Reconstruction

Corrected Corrected datadata

Reports

0

10

20

30

40

50

60

70

80

90

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

East

West

North

Graphs

KPI’s

ConfigurationConfiguration

PI

Periodic data Periodic data validationvalidationConfigurable Configurable criterioncriterionReconstructionReconstructionAuto Model retrainAuto Model retrainUser interaction User interaction screensscreensReporting, graphsReporting, graphs

validation processvalidation processvalidation modelvalidation modelKPIKPI

Adaptive Techniques

Data Validation Business Data Validation Business ProcessProcess

Request processvalues

configurable pertag and tim e from

PI (Note 1 & 2)

RequestReceive process

values from PI(Note 3)

A ll requiredtags received?

Y

N

Update rollingdata window

(Note 4)

Notify validationm odel owner

DVC:Validation / error

detection

Reconstruction(Note 5)

Log reconstructedvalues in DIS

W rite data to P I

Log validationerrors &

reconstructionm odel results

Identify and notifyI/G

Generate processdata related

reportsPublish reports

End Process

Option for job cardgeneration

D ata Va lidation & R econstruction

Collect data from PIGED

Reconstruct

ion

Write values to PI

Notify IG + jobcard

Generate reports

Auto

Ad Hoc

Data Configuration Data Configuration MManagementanagement

Maintain baselineMaintain baselineEvent/time drivenEvent/time drivenManage change Manage change processprocess

detectinitiateaudit trail

Workflow screensWorkflow screensReporting, graphsReporting, graphs

configurationvalidationhistoryKPI

Configuration

DB

PI

TDCMIMS

E va lua te F /B ortim eout

N otify P /O tom ake fina ldec is ion

R eques t F /B

Log request fo rem ergency

change

In fo rm IG

N otify IGR eques t F /Bw ith in tim e x(N ote 6 & 7 )

Identify in te res tg roup

(N ote 5 )

Log autom aticreques t from

M irroring(N ote 4 )

R eques t 2

R ece ive Feedback

C ance lim p lem enta tion

P ub lish changereques t to M IM S

(N ote 10)

M IM S

G enera te JobC ards

U pdate reques tlog

M IM S

N otify D IS

Ins tum enta tion

Im p lem ent changeon E lem ent

M IM S

C lose W ork O rder

Im p lem ent changeon repos ito ry and

F lag va lida tionm ode l (N ote 13)

N otify IG(N ote 14)

T im e out andnotifica tion w henrep ly not rece ived

from M IM S

M IM S

P rin t W ork O rder

M IM S

N otify D IS

P roceedN

Y

E m ergency

R ece ive job cardc losure no tifica tion

from M IM S(N ote 12)

D IS M anagedT ag?

(N ote 2 )

Y

N

R eques t 1 :C onsensus reached?

orR eques t 2 : K eep ex te rna l

C onfigura tion?(N ote 8 & 9 )

N

YR eques t 1 T ype?

N

Y

R eques t 1 T ype?NY

R eceive F /BU pdate log w ith

m essage

N otify IG w ithc ross re ference to

job card #

Log request fo rchange to C onfig

E lem ent(N ote 1 & 3 )

R eques t 1

R outineM ain tenance

YN

P ub lish job cardreques t to M IM S

U pdate reques tlog

R ece ive job cardgenera tion

notifica tion fromM IM S

E nd process

External to D IS

R eceive job cardgenera tion

notifica tion fromM IM S (N ote 11)

Configuration Management Configuration Management Business ProcessBusiness Process

Receive requestand determine

type

Issue jobcard and update log

Notify IG and manage

consensus process

Final decision by Process Owner for no consensus issues

ERP jobcard creation, printingsign-off and notification

Jobcard request, status feedback, configuration database update,

request completion and notification to IG

Manual

Auto

Emergency

Mirroring Business ProcessMirroring Business Process

R equest M irroringfo r spec ified tags

(N ote 1 & 2)R eques t

Job cardex is t and

open

Y

NIdentify re levantsys tem s and

reques tcon figura tion data

R ece iveconfigura tion data

from sys tem s

C om pareconfigura tion

C om pare?

Y

N

C om pare a llfie lds

(N ote 3 )Y

N

F ie lds injobcard?(N ote 5 )

Y NR eporting to I/G

(N ote 4 )

E nd P rocess

R equest D C M(N ote 7 )

Log for K P I toM E T IM(N ote 6 )

Collect configuration datafrom relevant systems

Compareconfigwith

baseline

Openjobcard?

All fields?

Nochanges

Change management process & reporting

IntegrationIntegration

Two partsTwo partsServer sideServer sideClient sideClient side

Common functionsCommon functionsconfigurationconfiguration

Specific functionsSpecific functionsreal-timereal-timerelationalrelational

BenefitsBenefitsEase of Ease of maintenancemaintenanceApplication specificApplication specificCustomisableCustomisable

TDC SCADA MIMS PI

DIS interface layer

DIS Server

System Integration System Integration ArchitectureArchitecture

API-DTS, time driven - upload config - 1min data

PI

DEC C- flat files, time driven, - upload config

Honeywell TDC 3000

IN Tools

ODBC - DTS, time driven - upload config

ODBC - flat files, transaction driven, - jobcards create, confirm, close

MIMS

Outlook Mailserver

VB Controls - transaction driven

Users

New Plant Data modelNew Plant Data model

Data Reconciliation

Data Validation and Reconstruction

Data Archive

Raw Real time Data

DataConfigurationManagement

Instrumentation

Optimization models

BenefitsBenefits Controlled changes to Controlled changes to

configurationconfiguration Automatic synchronizationAutomatic synchronization Electronic workflow using Electronic workflow using

OutlookOutlook Valid data for decision makingValid data for decision making Reconstructed data for Reconstructed data for

modelingmodeling Unlock value of reconciliationUnlock value of reconciliation AccountabilityAccountability $$

ConclusionConclusion Accountability for plant data Accountability for plant data

requiredrequired Configuration control ensures Configuration control ensures

time value of measurementstime value of measurements Data validation ensures Data validation ensures

reliability reliability Data Integrity unlock value ofData Integrity unlock value of

Plant DataPlant Data Value added applicationsValue added applications

• ReconciliationReconciliation• ModelingModeling• APCAPC

Questions ?