Asset Optimization for the Process Industries: From

Data to Insights to Actions

June 2017

Willie Chan, Ashok Rao, Bill Mock

Aspen Technology, Inc.

1 © 2017 Aspen Technology, Inc. All rights reserved.

AspenTech Disclaimer

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new products, product features, product interfaces, integration, design, architecture, etc. that may be
represented as “product roadmaps or product visions”.

Any such information is for discussion purposes only and does not constitute a commitment by Aspen
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Any such commitment must be explicitly set forth in a written contract between the customer and Aspen
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2 © 2017 Aspen Technology, Inc. All rights reserved.

AspenTech recognizes George Stephanopoulos

Founding Chair, AspenTech Academy

Established in 2012 to
 Accelerate application of research innovations in Process Engineering software
 Promote the use of Process Systems Engineering software in universities

3 © 2017 Aspen Technology, Inc. All rights reserved.

Evolution of Process Systems Engineering

Unit Process Plant & Sites

70’s 80’s & 90’s 00’s to Today

ENGINEERING - DESIGN & OPTIMIZE THE ASSET MAINTENANCE - MAINTAIN THE ASSET

MANUFACTURING - OPERATE THE ASSET SUPPLY CHAIN - OPTIMIZE THE SUPPLY CHAIN

4 © 2017 Aspen Technology, Inc. All rights reserved.

Technology Trends
The Industrial Internet of Things (IIOT) is changing the world as we kno w it!

By 2020 - over 7 billion Internet-connected Cloud

industrial devices
* Gartner 2015

Embeddable
Market Trends HW/SW
Analytics
Connected industrial devices will proliferate
worldwide

Sensors and equipment will become

increasingly “smarter”
Cybersecurity

Industrial information systems will move to the

cloud Networking
Connected devices will generate massive amounts
of condition data

Manufacturers will look to analytics to provide deep

process insight

http://www.gartner.com/newsroom/id/3165317
5 © 2017 Aspen Technology, Inc. All rights reserved.
Example: Wealth of Sensor Data in Plant Historians

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Example: P&IDs and Equipment Datasheets

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Example: 3D Plant Model

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Example : Maintenance Data

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Example: Textual / Unstructured data

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Asset Optimization
A comprehensive, holistic approach to driving the highest possible financial return over the entire asset lifecycle

What if you could leverage the rich wealth of asset data to ……

Operate
Run to the limits
of performance

Maintain
Asset
Lifecycle Maximize uptime with
actionable insights

Push the boundaries of

what’s possible

Design
11 © 2017 Aspen Technology, Inc. All rights reserved.
Asset Optimization
A comprehensive, holistic approach to driving the highest possible financial return over the entire asset lifecycle

What if you could leverage the rich wealth of asset data to ……

Operate
Run to the limits
of performance

Smart Sensors
Big Data Maintain
Mobile Connectivity
Cloud Computing Maximize uptime with
High Fidelity Modeling actionable insights
AI & Machine Learning
Advanced Visualization
Push the boundaries of
what’s possible

Design
12 © 2017 Aspen Technology, Inc. All rights reserved.
Solution Vision

Data Sources Aggregate / Clean Insights Messaging and Actions • Data sources that span
/ Consolidate
Asset Optimization Engine time series, maintenance
Operational Data
Time Series Data records and textual
Models Operations
Guidance
content like operating
manuals
Events • Insights by bringing
Maintenance Data
together design,
Workflows operations and
Maintenance maintenance domains,
Asset / Material Info Guidance
Design Data
and automation of
complex analyses and
workflows
Rules
Textual • Guidance with an
Other sources Context Design objective to minimize
Guidance
plant lifecycle costs
subject to the level of
risk the organization can
Capture Organize Implement
tolerate
Predict and Prescribe

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Enabling Technologies
Data Sources Aggregate / Clean Insights Messaging and Actions
/ Consolidate
Operational Data
Closed Loop Control

Data Historian LIMS Sensors

Sensor Needs
Maintenance Data

Analytics Engine
Enterprise Asset Asset Operator Spare Parts
Management Breakdown Data Records
Cognitive Computing Process Modeling

Machine Learning Molecular Modeling

Design Data
Knowledge Graphs Ensemble Modeling
Work Orders
Natural Language Prescriptive Guidance
Processing
Datasheets P&IDs 3D Modeling Big Data Ecosystem
Visualization
Design
Other Sources improvements

literature
PC / Mobile
VR AR

Capture Organize Predict and Prescribe Implement

14 © 2017 Aspen Technology, Inc. All rights reserved.

Data Science – Pattern Discovery, Pattern Search, and
Process Data Visualization
Pattern Discovery
Process Sensors

Compact Data Visualization

Pattern Search

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 Data Science – Root Cause Analysis (RCA)
KPI exhibits undesirable spikes. RCA to identify precursors/causes
Historian Time series

Bayesian Network RCA Model

(Machine Learning)
Precursors detected by RCA

M03

M01

Precursor
M04 predictive lag: 80 min

M02
Feature Extraction (Data Science)
- Structure learning
- Conditional probabilities
- Causal links connect nodes

Predictive Capabilities (Data Science)

Real-time
Data

Warning! High probability of KPI spike @ time=XXX

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 Empirical Modeling – Multivariate Analysis

Data Conditioning
Anomaly Detection
Key Contributions
Operational Guidance
Optimization of Operation

PLS / PCA Modeling isolates the most

17
important data dimensions
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Molecular Characterization – From Analytical Data to
First-Principle Molecule-based Process Models
Molecular Distributions
Whole Crude Data
~ 20 points

Distilled Cuts Data

~ 100 points MC
Model
GC-MS Data
~ 1000 points

FT-ICR-MS Data
~ 50,00 points

Molecule-based Process Model

18 © 2017 Aspen Technology, Inc. All rights reserved.

 Operations Analytics – Combining Data Science, 1st Principle
& Empirical Modeling for Equipment Analytics
Connect plant measurements Deploy column model and monitor
to simulation model plant operation

Auto tune model with

historical plant data Display measured and calculated
values (predictions)
Connected historian as
historical and real-time
plant data source

Monitor operation using real-time data

Real time dashboard

19 © 2017 Aspen Technology, Inc. All rights reserved.

Maintenance Analytics – Training of Agents from
Maintenance and Historical Data to Monitor Plant Operation

Sensor Data Smart Trained Agents Asset Monitoring and Failure Prediction

Asset Work History

20 © 2017 Aspen Technology, Inc. All rights reserved.

 Areas for Future Research & Development

Data Sourcesand
Data Sourcing Aggregate / Clean ComputingInsights
and Visualization Messaging and Actions
Transmission / Consolidate
Operational Data
Cognitive Reasoning Closed Loop Control

Cloud and Edge Analytics

Data Historian LIMS Sensors Knowledge Graphs
Sensor Needs
Cognitive
Maintenance Data
Natural Language Processing
Cybersecurity Knowledge
Computing Analytics Engine
Software Defined Storage Graphs
Spare Parts
Enterprise Asset Asset Operator Ensemble modeling
Management Breakdown Data Records
Cognitive Computing Process Modeling
Augmented Reality
Model Calibration Machine Learning Molecular Modeling
Design Data
Knowledge Graphs Ensemble Modeling
Virtual Reality Work Orders
Prescriptive Engine Natural Language Prescriptive Guidance
Processing
Datasheets P&IDs 3D Modeling Big Data Ecosystem Mobile Devices
Machine Learning Visualization
Design
Other Sources improvements
Molecular modeling
literature
Prescriptive PC / Mobile
VR AR
Ensemble
Engine Predict and Prescribe
modeling
Implement
Capture Organize
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Empowering the Next Generation of Process Engineers

• Engineering
• Modeling
• Optimization
• Data Science
• Machine Learning
• Analytics

22 © 2017 Aspen Technology, Inc. All rights reserved.