SSE-11 Solving Industrial Problems with Non-traditional Applications of ROMeo Larry S. Balcom Senior Principal Technical Sales Consultant (c) 610-547-8313 (e) Larry.Balcom@invensys.com Title slide [from Title Slide master] The title slide is available as a Title Master and the background and graphic elements are fixed. Text is editable for the slide heading and presentation details but the small compliance text exists in editable form only on the Title Master itself. This type area should be used only for the purposes of compliance text and should not be replaced by other content. Font, type size and colours are fixed for the Title Master style and should not be modified. Footer details Footer detail appear in the bottom-left corner of the slide and appear in fixed positions and order. Editing of the Footer details is done by accessing ‘Header and Footer’ under the ‘View’ menu in PowerPoint®.

What makes ROMeo a unique application development platform? Simple, yet powerful, graphical real-time solution automation using RTS Excellent solution integration into the industrial IT architecture Flexible, extensible model data structures Robust solver and open equation platform for custom properties Easy, open source programming language to extend functional capability

What kinds of Industrial Problems can ROMeo solve? Transaction Processing Compositional Tracking Operational Validation Soft Sensing and Data Preparation Environmental Analysis Process Analytics Real-time Statistical Process Control

Transaction Processing Compositional Tracking Rigorously calculate unmeasured compositions and flows Reconcile data to improve measurement quality, and detect errors Close material balance, and calculate losses Track vapor return for net delivered calculation Accumulate fuel for terminal operation Store shipments from unloading reports Accumulate client’s deemed N2 for Send out Virtual inventory for each client

Transaction Processing Compositional Tracking Unloading Transaction Data Historian Integrate business systems Calculate customer positions Total inventories Client Inventories

Transaction Processing Compositional Tracking Nomination Transaction Data Calculate operating costs Fuel Gas Deemed Nitrogen Lost and Unaccounted For FIFO shipments Historian

Transaction Processing Compositional Tracking Transaction files can be deleted or archived after processing

Transaction Processing Compositional Tracking Transactions Solve Output

Transaction Processing Manual Operations Validator Control System & SCADA Operational Alarms Work Order Interface system Data Historian Work Oder Data Visual representation of future state CSV Raw Process Data CSV Model Data ROMeo Server EDI data interfaces Data Validation Simplified Hydraulic Model

Soft Sensing and Data Preparation Environmental Analysis

Process Analytics Real-time Statistical Process Control Process data, PAT Analyzers, and Batch control information Wonderware InTouch® & QI-Analyst® SimSci-Esscor Connoisseur® Wonderware Historian & System Platform® QbD Visualization SPC charts, Run charts, Process analysis APC (Advanced Process Control) Dynamic Optimization Data Historian Online-SPC (Statistical Process Control) Soft-Sensors Process Analysis Golden Batches Aim, Sigma, Batch synchronization SimSci-Esscor ROMeo/ARPM®

Process Analytics Real-time Statistical Process Control Data Historians Control Systems Intelligent Instruments (OPC, COM, OLE, ODBC) Wonderware InTouch® Expert Advice System Application Batch SPC Data and Alarms SPC Alarms, Aim & Sigma Process Data SPC Chart Application Batch Run Charts Visualization Client Online-SPC Server ROMeo® Platform Data Reconciliation is available Golden Batches Aim’s Sigma’s Batch Synchronization

Process Analytics Real-time Statistical Process Control The typical WECO “out of control rules” are pre-defined: Rule 1: One point outside the 3 Sigma limits Rule 2: Two out of three points outside the 2 Sigma limit Rule 3: Four out of five points outside the 1 Sigma limit Rule 4: Eight consecutive points above or below the Aim Rule 5: Six points in a trend, increasing or decreasing Rule 6: Fourteen points alternating across the Aim

Process Analytics Real-time Statistical Process Control Rules 2 through 4 and 6 require a zone tracking variable that stores the process pattern for future analysis. The digital zone encoding is: Zone 8: > +3σ Zone 7: = or < +3σ Zone 6: = or < +2σ Zone 5: = or < +1σ Zone 4: = or > -1σ Zone 3: = or > -2σ Zone 2: = or > -3σ Zone 1: < -3σ

Process Analytics Real-time Statistical Process Control The tracking variable will be the length required to evaluate the longest rule. Rule 6 requires a 14 digit number, and is generally the longest rule defined. Recognize that this tracking methodology is limited by the numerical precise of ROMeo variables. Each model execution deletes the left digit, appends the current zone to the right, and analyzes the rules. If the sum is > the rule limit, then it’s an alarm state. The first alarm state found stops processing, and sets the alarm and latch flags. This means that the rules must be evaluated in highest to lowest priority order.

Process Analytics Real-time Statistical Process Control Rule 5 requires adaptation from the classical SPC definition. In batch applications, the aim is not constant and trending up or down may be the normal process behavior. Implementing this rule as described will create false alarms. The intent of the rule is to detect when the process is trending in one direction or the other from the process aim. This can be implemented in the batch context by comparing the relative positions of the process values compared to the Aim and control limits. Relative position (RPV) is calculated as: RPV = (( PV – Aim ) / ( 3 * σ ) ) Where: PV is the current process value Aim is the current Aim value from the GBP σ is the current standard deviation from the GBP The RPV’s are now normalized versus the changing Aim and Sigma, and can be compared for trending. Additional storage variables are used for the trend pattern, and storing the last RPV.

Non-traditional Applications of ROMeo Summary There are many unique and valuable ways to apply the ROMeo platform to solve industrial problems. We have see just a few here this morning. Anytime you need real-time information, to integrate process data or transactional information, and need to digest the data into INFORMATION…. It’s a potential ROMeo application. The solutions that we see are limited only by your creativity!

Q & A Larry S. Balcom Senior Principal Technical Sales Consultant (e) Larry.Balcom@invensys.com