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Plant Performance Monitoring
KPS has developed an on-line performance monitoring solution specifically
targeted at the process industries sector to support engineers and operators
in achieving best practice plant operation. The application monitors a wide
range of measurements and key performance indicators from plant and equipment
at a production site and provides the guidance of required values of variables
to meet operating objectives such as maximum yield, maximum efficiency or
minimum emissions.
Key Elements of Solution
- Current unit operating data is read directly from the production information
system and the value of each variable compared to a best practice operating
template under similar operating conditions e.g. same product grade, throughput
etc
- Selected groups of variables such as control setpoints, KPI’s,
product quality etc can be compared vs. the template with easy to use visual
displays
- Plant operating data is automatically screened for invalid or inconsistent
measurements to aid rapid diagnosis of plant operating conditions
- Summary display shows the status of all plant operating variables in
one table e.g. measurements falling within and outside an expected range
of best practice operation
- Best practice operating periods are identified from historical plant
operation. The required operating objective is defined according to a set
of user defined criteria e.g. maximise throughput and minimise out of emissions.
- The average values and ranges of all relevant unit operating variables
such as temperatures, pressures and control setpoints are stored for each
operating period to form a library of best practice operating templates
for a range of operating conditions.
Benefits
- Easy to understand visual displays
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- Identify and repeat best operating practices
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- Reduced energy use and emissions
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- Optimise unit operation and control settings
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- Maximise yield and throughput
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- Quickly identify poor or abnormal operations
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- Rapidly troubleshoot unit performance problems
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- Specify optimum plant operating envelope
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Technical Advantages
- Automatically detects unreliable or inconsistent values e.g. values out
of range or invalid combinations of values
- Rapidly troubleshoots hundreds of operating variables – can easily
include all the significant measurements on a processing plant
- Identifies optimum or best practice ranges for all variables i.e. KPI’s,
control variables and plant measurements
- Results are presented in a transparent and easy to understand format – providing
insight and a ‘birds eye view’ of plant conditions
- Definition of optimum plant operation can be specified in terms of multiple
plant operating constraints or objectives e.g. maximum yield and minimum
energy use
- Automatic import of new data and set up of template library – supports
rapid monitoring of conditions and updates to best practice templates
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