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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 ?