Plant Data Integrity How to leverage PI data with Intelligent Validation and Reconstruction Pieter Theron, Consulting Manager Keops Isis, South Africa

Honeywell DCS 32 LCN SSF Facts Various SCADA 40 Raw Gas 4.5 Gm 3 n/h Coal 70ktDAF/d Oxygen 950km 3 n/h Power 780 MWh Steam 7,850t/h Fuels 13,000t/d 100,000bbl/d Chemicals 7,000t/d PI Historian 75k tags, 45krt 8k calcs Sigmafine Data recon APC 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 Project PI Gas Circuit Oil Workup Chemical Workup Gas production Excel/VB Detail models Boundary models Global model Daily totals from.PV

 Data pre-processing required (2% balance)  Investment not leveraged due to data problems  Missing data  Wrong data  PI data cannot be trusted  Need Data Integrity  validation  configuration control  accountability/ownership Issues on PI-Sigmafine project

Data Integrity Requirements 20-FT-1001 P,V,T DCS 20F1001 PI 20F1001.PV X Y Z Z=X+Y

Data Integrity Concept TDCSCADAMIMSPI IN Tools Network Presentation layerInterface layer Configuration Control Data Validation Data Reconciliation Network

Data Validation/Reconstruction Corrected data Reports Graphs KPI’s Configuration PI  Periodic data validation  Configurable criterion  Reconstruction  Auto Model retrain  User interaction screens  Reporting, graphs  validation process  validation model  KPI Adaptive Techniques

Data Validation Business Process Collect data from PI GEDGED Recon struct ion Write values to PI Notify IG + jobcard Generate reports Auto Ad Hoc

Data Configuration Management  Maintain baseline  Event/time driven  Manage change process  detect  initiate  audit trail  Workflow screens  Reporting, graphs  configuration  validation  history  KPI Configuration DB PI TDC MIMS

Configuration Management Business Process Receive request and 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, printing sign-off and notification Jobcard request, status feedback, configuration database update, request completion and notification to IG Manual Auto Emergency

Mirroring Business Process Collect configuration data from relevant systems Compare config with baseline Open jobcard? All fields? No changes Change management process & reporting

Integration  Two parts  Server side  Client side  Common functions  configuration  Specific functions  real-time  relational  Benefits  Ease of maintenance  Application specific  Customisable TDCSCADAMIMSPI DIS interface layer

DIS Server System Integration Architecture 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 model Data Reconciliation Data Validation and Reconstruction Data Archive Raw Real time Data Data Configuration Management Instrumentation Optimization models

Benefits  Controlled changes to configuration  Automatic synchronization  Electronic workflow using Outlook  Valid data for decision making  Reconstructed data for modeling  Unlock value of reconciliation  Accountability $$$$

Conclusion  Accountability for plant data required  Configuration control ensures time value of measurements  Data validation ensures reliability  Data Integrity unlock value of  Plant Data  Value added applications Reconciliation Reconciliation Modeling Modeling APC APC

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