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What is available
Many measurements are collected in plants and
labs, and are systematically archived
Are they fully exploited ?
Some important variables cannot be measured
Fvrier 2009

"

3
(
+)

'

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&

'4

'
5
2%

$
Fvrier 2009

&

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6

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%
%
%

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Some techniques have been proposed for a long

time
Initially only known and applied by experts
Now generic tools available for on-line and offline applications
Fvrier 2009

#
.
)
/

$
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%

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&

%
8

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778

Fvrier 2009

&

IN
OUT1
OUT2
Redondance

Fvrier 2009

100 100 100

?
50 50
?
?
40
-1
0
+1

10

Redundancy : detailed assessment - 1

To better know a population variable
repeat measurement
calculate the average
the standard deviation of the estimate is reduced by
a factor of 2 if the number of measurements is
multiplied by 4

Temporal Redundancy
Fvrier 2009

11

Redundancy : detailed assessment - 2

To better know a process variable
instal several sensors
take the measurement average
the standard deviation of the estimate is
reduced by a factor of 2 if the number of
measurements is multiplied by 4

Spacial Redundancy
Fvrier 2009

12

Redundancy : detailed assessment - 3

Indirect estimation of
a non-measured
variable

W1

W2

W = W1 + W2
2W = 2W1 + 2W2

Fvrier 2009

13

Redundancy : detailed assessment - 4

*
W1

W2

W = W1 + W2 - W3
2W = 2W1 + 2W2 + 2W3
W3

Fvrier 2009

14

Redundancy : detailed assessment - 5

Even more complex
Reaction force: R = W+W3
W1 = 2 (W+W3)

W1

W = 0,5 W1 - W3
2W = 0,25 2W1 + 2W3

We use a model of the

process in order to estimate
unmeasured variables

W3

Fvrier 2009

15

Redundancy : detailed assessment - 6

Combine several related measurements with
information on the process structure to obtain
several independent estimations of a same
variable

Structural redundancy

F1

T1

T2

F2 = f(P)
F3 = Q / Cp (T2-T1)
Fvrier 2009

16

F1

'

F2

Multiple measurements

F1A

F1

Associate several
measurements of the same
type

F1B

F1

T1

T2

Associate measurements of
different types

F = Q / Cp (T2-T1)

Fvrier 2009

17

,
(
%
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--

%
% %
&

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9

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Fvrier 2009

%
18

'

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Correct each measurement as little as possible

in order to satisfy all constraints and balance
equations
Min

yi* yi

subject to

) 2 where

yi*

validated value

yi

F( yi* , x j ) = 0

measured value
i standard deviation

G( yi* , x j ) > 0

xj

unmeasured value

Fvrier 2009

19

*"
"

& '5
%
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7 ,*"
&

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=&>

%
"

Fvrier 2009

%
'5
"

min ( y x ) W ( y x )
T

min eT We 2 T ( A( y e) d )
e,

20

10

min eT We 2 T ( A( y e) d )
e ,
e = W 1 AT
L
T
= 0 = 2 We + 2 A
e
L
= 0 = A ( y e) d

= ( AW 1 AT )

Ae = Ay d

= ( AW 1 AT )

( Ay d )

e = W 1 AT ( AW 1 AT )

( Ay d )

x = y e = y W 1 AT ( AW 1 AT )

( Ay d )

Fvrier 2009

21

x = y e = y W 1 AT ( AW 1 AT )

.
1

( Ay d )

x = My + b
M = I W 1 AT ( AW 1 AT ) A
1

b = W 1 AT ( AW 1 AT ) d
1

The reconciled values are linear

combinations of the measured values
E ( x ) = ME ( y ) = x
Cov ( x ) = E ( My )( My )

= MCM T

where W -1 = C (measurement covariance)

Fvrier 2009

22

11

)
6

Sigma

Stream

8
7

10

10

9.0

18.0

6.0

4.0

23.0

1.0

30.0

0.50

0.50

28.00

1.00

1.00

1.00

0.50

1.00

1.00

1.00

0.50

0.50

1.00

What if increases ?
Fvrier 2009

23

Fvrier 2009

24

12

'

$ &
) '

%1
6?
/*
%
%

Water

&

30 kg/s
20 C

"
&
Air

40 C

7.5 kg/s

130 C
25 C

%
%
Fvrier 2009

25

0 ' '
kg/s
T in
C
T out
C
Q water kW
Air flow kg/s
T in
C
T out
C
Q air kW
T LM
C
U
W/m2/K

Fvrier 2009

!
30.00
20.00
25.00
627.
7.50
130.
40.00
689.2
51.3
122

32.95
20.00
25.00
689.
7.50
130.
40.00
689.2
51.3
134

30.00
19.51
25.00
689.
7.50
130.
40.00
689.2
51.7
133

30.00
20.00
25.49
689.
7.50
130.
40.00
689.2
51.1
135

30.00
20.00
25.00
627.
6.83
130.
40.00
627.4
51.3
122

30.00
20.00
25.00
627.
7.50
121.9
40.00
627.4
48.7
129

"

30.00
20.00
25.00
627.
7.50
130.
48.07
627.4
58.3
108

26

13

1
Water flow
T in
T out
Q water
Air flow
T in
T out
Q air

kg/s
C
C
kW
kg/s
C
C
kW

Cp water
Cp air

Meas.
Vali

30.00
30.30
1.50
20.00
19.81
0.50
25.00
25.19
0.50
627.3
680.6
7.50
0.40
7.41
130.00
129.96
1.00
40.00
40.04
1.00
689.2
680.6
-61.9 balance error
0.0

M1
T1
T2
M2
T3
T4

4.182
1.021

kJ/kg/C
kJ/kg/C

Area
T LM
U

(M-V)/
-0.198
0.372
-0.371

m2
C
W/m2/K

0.215
0.044
-0.044
0.366 =SSQ
100.00
51.40
132.4

Constraint :
M1 Cpw (T2-T1) = M2 Cpa (T3-T4)
Slightly nonlinear (bilinear)
Fvrier 2009

27

2&

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F1=F2
F5=F4
F2=F3+F4

Fvrier 2009

5 variables
3 constraints

28

14

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&

2
&

6,

F1=F2
F5=F4
F2=F3+F4

xA1=xA2
xA5=xA4
F2xA2=F3xA3+F4xA4
xBi=1-xAi

15 variables
11 constraints

Fvrier 2009

29

A"

&
3

QC

4
QB

F1=F2
F5=F4
F2=F3+F4

Fvrier 2009

xA1=xA2
xA5=xA4
F2xA2=F3xA3+F4xA4
xBi=1-xAi

27 variables
18 constraints
H1+H4=H2+H5
H2+QB=H3+H4+QC
Hi=f(Fi,xAi,Ti)
30

15

)
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9 &
3

T3=Tb(P3,xA3)
T4=Tb(P4,xA4)

QC

27 variables
20 constraints

4
QB

F1=F2
F5=F4
F2=F3+F4

xA1=xA2
xA5=xA4
F2xA2=F3xA3+F4xA4
xBi=1-xAi

H1+H4=H2+H5
H2+QB=H3+H4+QC
Hi=f(Fi,xAi,Ti)

Fvrier 2009

31

*
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1
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Fvrier 2009

32

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Fvrier 2009

33

'
Collect measurements
Reconciliation
New
goals

Parameter identification
Simulate performance

Control
actions

Alternatives & Optimization

Revamp /capacity
increase

Fvrier 2009

34

17

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&

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Fvrier 2009

35

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Fvrier 2009

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Fvrier 2009

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45

Fvrier 2009

46

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Weighted sum of squares of measurement errors

30 000

Source: Wacker Chemie GmbH

25 000
20 000

Sept. 93
On line
daily
+ +autom.

15 000
10 000
5 000

0
1992

1994

1993

Fvrier 2009

47

Validation
being tuned

140
120
100
80

Plant 1
Plant 2

60
40
20
0

1989

Fvrier 2009

1991

1993

1995
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Fvrier 2009

49

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HP header
degassing section

S4

S5
MP header

P3
S3

P2
S2

LP header

S1
P1

Fvrier 2009

50

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:0 #
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Fvrier 2009

53

Data
validation

Fvrier 2009

54

27

Implementation in Belsim
VALI Suite

Your Partner in Process Intelligence

USERS

n
t io
ta r
n
se ye
re La

g
in
ss r
e
oc ye
P r La

ValiReport

GUI
ValiModeller

OnlineEngine

License server

Offline Engine

ValiFilter

n
t io
ca
i
un r
m aye
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L
o

ValiLink

PIMS

DCS

SQL

Fvrier 2009

Mastering Production Data For Improved Performance

28

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57

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Fvrier 2009

59

&
-

Operation close
to the limit

$
Mass and
energy balances

Statistical
Process control

Audits
Environment
Protection

Safety

Quality
Fvrier 2009

60

30

&
2 1
&

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Fvrier 2009

61

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$
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)$
(,# ?

Thermodynamics:
assume ideal gas
Air=N2+O2
NG=CH4
Fumes=
O2,N2,CO2,H2O

Fvrier 2009

63

OBJECT
OWNER
VAR.NAME MEA.VAL.
MEA.ACC.
P.U.
===========================================================
STREAM
AIR.1
MFO2
21.000
CST
%
STREAM
AIR.1
MOLF
0.21500E+06 -10.00
Nm3/h
STREAM
AIR.1
P
1.0130
-2.000
bar
STREAM
AIR.1
T
15.000
1.00
C
STREAM
AIR.2
P
20.000
-2.000
bar
STREAM
AIR.2
T
500.00
2.00
C
UNIT
CEFFIC
77.000
-5.000
%
C-1
STREAM
FUME.1
T
OFF
C
STREAM
FUME.2
MFO2
14.000
-2.000
%
STREAM
FUME.2
P
1.0200
-2.000
bar
STREAM
FUME.2
T
600.00
2.00
C
STREAM
NG
MFC1
OFF
%
STREAM
NG
MOLF
6000.0
-2.000
Nm3/h
STREAM
NG
P
20.000
-2.000
bar
STREAM
NG
T
15.000
1.00
C
STREAM
POWER
POWER
16100.
-1.000
kW
UNIT
RDP
0.10000
0.100ER-1
0.100E-01 bar
UNIT
TEFFIC
80.000
-5.000
%
T-1
Fvrier 2009

64

32