IIOT - Analyse des données et intelligence artificielle pour l'operation optimale de l'usine par Samy Achour, Integration Objects

Experts in Smart Manufacturing
& Industry 4.0 Integrationobjects.com

Agenda
Experts in Smart Manufacturing & Industry 4.0 Integrationobjects.com
• Company Overview
• Industry 4.0
• KnowledgeNet Concept and
Architecture
• Case Studies
• Wrap Up

Industry Evolution

Upgrade to Cross System
Integration
ü Prescriptive Analyticsü Smart Decision Support
üArtificial Intelligence üIndustrial Internet of Things
× Alarm Fatigue × Unplanned Shutdowns
× Work interruption
× High maintenance costs
× Accidents & Incidents
From Reactive to Proactive

KnowledgeNet
IIoT Platform
KNet
Analytics
KNet
Online
and many more!
Actionable Knowledge
Intuitive Visualization
Real-Time Process Monitoring
KPIs Deviation Prediction
Drill Down
Advisory System
Process
Maps
Real-Time
Data
Online data processing
Real-time performance insights
Decision support
Automatic root cause analysis of
performance gaps and abnormal
conditions.
Equipment
Datasheet Alarms
Performance Insights
Optimization Scenarios
Operating Envelops Identification
Historical Data Playback Results
Best Practices
Performance Gaps Prediction
Abnormal Conditions Prediction
Asset Health
Quality Deviation
Operating
Manuals
Laboratory
Data
Thermo
Library
Historical
Data
Knowledge
Offline data analysis
Extract valuable knowledge
Build predictive models
Innovative Approach
FMEA

Enabling Decision Making with
Prescriptive Analytics & AI

KNet - Innovative Approach
Plant
Control
Systems
Problem in the plant
Problem in valve 123Follow the check listStep 1
Step 2
Workflows
Expert Rules
Operating
Manuals
KPI
Calculations
Plant
Historians Databases
Legacy
Applications
Data
Data
Information,abnormalconditions
Correctiveactions
Data
Data
Alarms
Data
Data
Alarms
Operations
Engineers
Plant
Manager
Plant
Operator
LIMS
Best Practices
Root Cause
Analysis
FMEAs
Advanced Analytics
Emerson Plantweb Optics

KnowledgeNet IIoT Platform
Data Source
Reasoning Engine
Application Plugins
Enterprise Application Integration
Single Platform for multiple
applications
Rapid Application Deployment
Significant cost reduction of
ownership

KNet Glue it all together
ü Prescriptive Analytics
ü Manufacturing Intelligence
üDecentralized Decision Making
üIndustrial Internet of Things
Platform
üCyber Security
KNet
RELIABILITYOPERATIONS
Maintenance
& Reliability
Quality
Safety &
Environmental
Production
Energy
Process
Engineering
ü Application Enterprise Integration

15
CCR Refinery Expert – Business Case
Required efforts to
diagnose CCR issues
No online expert
knowledge share
High operating costs Ineffective equipment
maintenance
Slow reaction time
Backward looking
information

16
Top 15 Abnormal Conditions
Business criteria
Energy Consumption
Safety
Asset Reliability
Quality
Production Schedule
Production Yields

Playback Results over 18 Months
Platforming reaction
problems affecting RON
Spent catalyst coke high
Platformate stabilization
performance poor
Regeneration loop
performance poor
H2 to HC ratio low
Regeneration gas
temperature low
Regenerated catalyst
drying inappropriate
Reactor N inlet
temperature
inappropriate
Catalyst circulation time
long
Spent catalyst flow high
Reactor 1 flow
distribution problems
O2 flow to burning zone
low
Catalyst reduction
inadequate

Occurrences Overview
(from January 1st 2013 à June 30th 2014)
18
Abnormal Condition Occurrences Total Activation Time Average
Platforming reaction problems affecting RON 8 12 Days. 3hr:45min 1 Day. 12hr:28min:7sec
Spent catalyst coke high 68
20 Days. 11 hr: 55
min
7 hr: 14 min
Platformate stabilization performance poor 68 24 Days. 4 hr: 35 min 8 hr: 32 min
Regeneration loop performance poor 25 16hr 38min:24sec
H2 to HC ratio low 35 3 Days. 1hr:55min 2hr:6min:42sec
Regeneration gas temperature low 7 6 Days. 16hr:50min 22hr:58min:34sec
Regenerated catalyst drying inappropriate 35 13Days. 5hr:30min 9hr:4min:17sec
Reactor N inlet temperature inappropriate 41 3 Days 14hr:10min 2hr:6min:5sec
Catalyst circulation time long 68 2 Days 16hr:10min 56min:37sec
Spent catalyst flow high 23 22hr:15min 58min:2sec
Reactor 1 flow distribution problems 50 9 Days. 17hr:50min 4hr:40min:36sec
O2 flow to burning zone low 25 5 Days. 8hr:50min 5hr:9min:12sec
Catalyst reduction inadequate 37 1 Days. 21hr:0min 1hr:12min:58sec

Process View
A symbol appears
when there is an issue
in the corresponding
section

Scenarios View
Predicted /
detected
scenarios
Scenario
Name
Risk indicator:
deviation, severity,
activation time
Category
of the
scenario
Tiles for key
indicators
monitoring

Scenarios View
Total Active
Scenarios
Predicted vs.
detected
Number of
scenarios per
Priority
Double-click
to get details

Detailed Abnormal Conditions View
Active root causes along with
corrective actions and impact
First layer of root cause
analysis model
Expand to drill-down to the
active root cause

Legend
True
Inferred True
Unknown
Inferred False
False

Statistical Report
Top 3 most frequent
scenarios Scenarios per priority
Total number of occurences Accumulated activation period

H2 to HC Ratio Low - KRCA Example

Success Story: Abqaiq Intelligent
Energy System
§ Largest oil processing and
crude stabilization facility
§ Main oil processing center
for Arabian Extra Light (AXL)
and Arabian Light (AL) crude
oils, with a capacity of more
than 7 million bpd

Power Generation
Import / Export Energy Management System
Combustion Gas
Turbine Generators
HRSG Utilities North Steam Boilers
Steam
Generation
South Steam BoilersHRSG NGL
Oil Plants
Pump Stations
M
NGL Plants
M
ST
• Energy KPIs Management
• Energy Optimization
• Condition based monitoring
AL Stabs AXL Stabs GC Stabs
DC2
Sensor data Power Steam
ST
KNet Analytics KNet online

KNet Analytics KnowledgeNet (KNet)
Online
KNet Web HMI
Designer
Monitor the
entire plant
energy
consumption
from site wide
down to the
equipment level
Automatically
detect the plant
states and
operating modes
and accordingly
adjust targets
Early identify the
energy
performance
gaps and
pinpoint the
equipment
responsible
Isolate the root
cause behind the
performance
gaps. Provide
corrective
actions in line
with best
practices
Provide optimal
settings to
minimize the
cost of the
energy
consumption
Minimize the cost of the energy
consumption
Keys to Success

Intelligent Energy KPIs
Dashboard

Minimize the
Cost of Energy
Consumption
across Abqaiq
Plants
7 Inter-
related
Models
NGL Plant
AL
Stabilizers
AXL
Stabilizer
South
Steam
Boilers
North
Steam
Boilers
Power Plant
Steam
Network
NLP: Nonlinear programming
MINLP: Mixed integer nonlinear programming
MINLP
NLP
Realistic Plant-wide
Optimization Models

Energy savings were estimated to be in the tens of millions of dollars.
Increased visibility of the operations performance from the operator
level to senior management for faster and informed decisions.
The problem-to-resolution cycle time was significantly reduced.
Best values and set points of key parameters for optimal distribution and
increased profitability.
Operations knowledge was retained and shared.
In few words…

Thank you for your attention
Integrationobjects.comExperts in Smart Manufacturing & Industry 4.0

IIOT - Analyse des données et intelligence artificielle pour l'operation optimale de l'usine par Samy Achour, Integration Objects

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IIOT - Analyse des données et intelligence artificielle pour l'operation optimale de l'usine par Samy Achour, Integration Objects