1. The Application of Process Monitoring and Key Performance Index in Polyethylene Plant International Innotech, Inc. Ricky Hsu Inspiration System, Inc. Jialin Liu, M. F. Yau

2. 1 How to Make Your Data Valuable? DataData InformationInformation KnowledgeKnowledge BenefitBenefit

3. 2 Introduction l Implement Process Data Infrastructure n Integrated HW TDC2000 、 Fisher Provox and DeltaV n Link Lab QC data n Compile the process simulator l Process Monitoring System n Statistical Process Control n Multivariate Statistical Process Control n Computerize Operator Experience l Key Performance Index n Production Performance Index n Operation Performance Index n Equipment Performance Index

4. 3 Platform Backbone (Before) Plant #1 Data Source Plant #2 Data Source Process Simulator HW TDC2000 Lab Data ProvoxDeltaV

5. 4 WinNT Process Simulator Platform Backbone (Now) HW TDC2000 Provox DeltaV Plant Information System Lab Data

6. 5 Process Monitoring System l Statistical Process Control n Why Do We Need SPC n Cause Effect Diagram, Fishbone Diagram n Set up XB/Range control limit n On line monitoring n Off line analysis l Multivariate Statistical Process Control n Why Do We Need MSPC n Set up PCA control limit n On line monitoring n Contribution plot l Computerize Operator Experience n If - Then architecture n Recording symptom and trigger time n Display predefined SOP

7. 6 Process Variation  Uncontrolled Variation  Controlled Variation Predictable Process Time

8. 7 Overview - Cause Effect Diagram

9. 8 Set Up Control Limit

10. 9 Control Limit Management

11. 10 On Line Monitoring (XB/Range)

12. 11 Offline Analysis

13. 12 SPC Summary

14. 13 Why Do We Need MSPC?

15. 14 Principal Component Analysis PC2 PC1

16. 15 Set Up MSPC Control Limit

17. 16 Real Time MSPC

18. 17 Contribution Plot

19. 18 Computerize Operator Experience Trigger Time Symptom Possible Cause Standard Operated Procedure For Example: If (cooling water outlet temperature less than 55 degC) Then (step 1… step 2… :)

20. 19 Key Performance Index l Production Performance Index n Productivity Index n Raw Material Index n Utility Index n Production Rate Analysis l Operation Performance Index n Real Time ISO Spec Monitoring n ISO Daily Report n Integrated ISO & SPC l Equipment Performance Index n Critical Equipment Operated Time n Compressor Performance n Heat Exchanger Performance

21. 20 Productivity Index USIFE’s Data

22. 21 Raw Material Index / Standard Consumption USIFE’s Data

23. 22 Raw Material Index / Unit Cost USIFE’s Data

24. 23 KPI Daily Report USIFE’s Data

25. 24 Production Rate Analysis Tool

26. 25 Calculated and Standard Production Rate

27. 26 Selected Time Range for Analyzing

28. 27 First Level Effect

29. 28 Second Level Effect

30. 29 Key Performance Index l Production Performance Index n Productivity Index n Raw Material Index n Utility Index n Production Rate Analysis l Operation Performance Index n Real Time ISO Spec Monitoring n ISO Daily Report n Integrated ISO & SPC l Equipment Performance Index n Critical Equipment Operated Time n Compressor Performance n Heat Exchanger Performance

31. 30 Real Time ISO Spec Monitoring USIFE’s Data

32. 31 Real-Time SPC for Operator

33. 32 ISO Daily Report USIFE’s Data

34. 33 Integrated ISO & SPC

35. 34 Analyzing Process Capacity

36. 35 Analyzing Process Capacity

37. 36 Key Performance Index l Production Performance Index n Productivity Index n Raw Material Index n Utility Index n Production Rate Analysis l Operation Performance Index n Real Time ISO Spec Monitoring n ISO Daily Report n Integrated ISO & SPC l Equipment Performance Index n Critical Equipment Operated Time n Compressor Performance n Heat Exchanger Performance

38. 37 Critical Equipment Operated Time USIFE’s Data

39. 38 Adiabatic & Reversible Process S T P suc P dis T suc T* P suc P1P1 P2P2 T1T1 T2T2 T3T3 T4T4 T suc P3P3 P4P4 S1S1 S2S2 S3S3 S4S4 S suc P dis

40. 39 Compressor Performance Display

41. 40 Calibrating Bias USIFE’s Data

42. 41 Heat Transfer Coefficient Reactant Stream Temperature Known Cooling Water Temperature Known

43. 42 Heat Exchanger Performance USIFE’s Data

44. 43 Summary l Data infrastructure provide the powerful management tool for supervisor. l Operator have to concern not only “Safety Alarm”, but also “Quality Alarm”. l When the performance can be defined and evaluated, there is some way to control it.

45. 44 Any Question ?