Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve...

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Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical Company

Transcript of Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve...

Page 1: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Process Analytics: Improving Measurement Capability in your Plant

AIChE Meeting: Nov. 17, 2009

Steve WrightProcess & Environmental Analytics

Eastman Chemical Company

Page 2: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Overview of Presentation

Introduction Sampling Theory – Why Analyzers? Process Analyzers and Sensors Sampling Systems Ownership and Maintenance Summary and Q&A

Page 3: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Introduction

Process Analytics is the

• Analytical Measurement of Chemical Composition Chemical Properties

of a Chemical Production Stream

• Using one, or more, of four approaches In-Situ / In-Line Extractive At-Line Ambient Detection

100ppm

100ppm

Page 4: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Eastman Process Analytics: Kingsport

Almost 2000 Process Analyzers and Chemical Sensors Personnel: 41 chemists, engineers, techs and analysts. Support: 24x7 where needed. Responsibilities include:

• Analyzer consultation/ specification

• Analyzer system design/purchase

• Sample system construction

• Installation/checkout

• Preventative maintenance

• Reactive maintenance

• Analyzer succession planning

Page 5: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Why Analyzers?

Page 7: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Majority of Process Measurement Tasks Can be Done Using Simple Sensors or Lab Analyses

Pressure, Temperature, Flow, Mass Lab measurements – slow and steady processes..

For the exceptions – process analytics..

Page 8: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Traditional Reactor Sampling Path

Insert Break

LabQueue

EnterSampleOrder

Ye Olde Bucket/SpigotWait for Truck

Wait for Truck II

GC Results

Sample Point

Create Report

Results!

InsertLunch

Page 9: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

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Under-Sampling (Aliasing)

Page 10: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Comfort Zone – >4F to “over-sampling”

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Meeting Nyquist.. Just barely

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GARBAGE ZONE

Sampling Okay – but it’s breaking the bank..

LAB $$$$$$$$$$$$$$$$$$$

Page 11: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Transitioning from Product A to Product B

How long can we continue making “Good A”And when can we call “Good B”?

Good Measurement canLead to Great Processes

100%

0%

?Good A Good B

??

Time

Page 12: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Target Time

Late

EarlyEarly Error Lead

Late ErrorLag

Time

Pro

cess

Var

iabl

e

“While we’re here, let’s savetime & take the next sample”

“Just trying to keep up”

Input Lead/Lag Control Complexities….

Variability Complicates it even More…

Crew 1 is timely..Crew 2 isn’t..

Processtrend

Sample Time-Stamping Errors

Early Late

Page 13: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Good Measurement canLead to Great Processes

A B at 70 deg C 0-100% in 20 minutesA B at 20 deg C 0-100% in 640 minutes

While waiting 2 hours for analysis 20% change!!!

TwoHours

70 deg C20 deg C

% Completion

60% 80%

The Reaction Continues…

Page 14: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Models

Ultimate process understanding “victory” Control process with lean measurements, T, P, flow, etc. “As good as their input data” Model response surface must be well-defined Models tend to perform best in “known territory”

• Prediction weakness can occur during critical times: Upsets Start-Ups/Shut-Downs Product transitions

Direct measurement benefits• Often easier to set up and maintain than complex models

• Full process interaction / understanding is not required to measure

• Output can help build better models!

Page 15: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

“The Wall” “The Wall”

Loose measurement& control – broad processperformance

Tight measurement& control

“Wall” = > Impurities, lower value product, permits, safety issues, etc.

Run Closer…

Value Proposition

Page 16: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Process Analyzers & Sensors

Page 19: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Area / Point Monitoring Combustible Gases

oNormally report values in terms of % of lower explosive limit (LEL)

oNot specific to gas – detect hydrocarbonsoCatalytic sensor

• Combust the sample

• Require oxygeno Infrared sensor

• Can be used in oxygen deficient or inert environments

• Where “poisoning” of catalytic sensor is of concern

Alan Hensley, 2009

Page 20: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Liquid Analytical pH & Conductivity

oSumps / Pure Water / Condensate & Discharges

• Material release

• Quality

• ContaminationoProcess

• Inferential composition measurement

• pH control for reactions / batch processes Dissolved Oxygen

oWastewater Treatment

Page 21: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Oxygen

Fuel Cell % and ppm level measurements

Paramagnetico% level measurementsoOxygen level in nitrogen convey systems

Zirconium OxideoStack monitoringoHandle dirty environmentsoHigh temperature operation

Alan Hensley, 2009

Page 22: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Physical Property Density (not just for mass flow)

o Inferential Composition MeasurementoDepends on process stream

TurbidityoContamination

ViscosityoProcess Control

Alan Hensley, 2009

Page 23: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Fixed or Dedicated Systems

Traditional StyleoAnalyzer is remote from areaoExtractive sampling with sample systemoHigher costoHigher complexityoRequire more care and feedingoStream ComplexityoAccuracyoSpecific

Page 24: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Photometric MethodsPhotometers UV/NIR/Non-dispersive IR Use specific wavelengths = 1 or 2 components Solids: non-contact

o% moisture Gases

oCO, CO2, NOx, SO2 Liquids

o% water, % organic acids

Alan Hensley, 2009

1100 1300 1500 1700 1900 2100 2300

0

0.2

0.4

0.6

0.8

1

1.2

Nanometers

Page 25: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Process Analyzer Availability

If it can be done in the lab, it can installed on-line.• Up-Front cost issues / ROI

• Sample handling issues

Our group will build it if we cannot buy it.• Integration tasks, sample handling systems

• Panel Shop in B-359A

FRONT VIEW

Page 26: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Sampling Systems

Maintenance

Page 27: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Goals

Representative Sampling / Minimal Handling• Want sample to mirror process content

• Minimal interaction with sample

• Minimal sampling delays

Sample Compatibility with Analyzer Specifications• Temperature

• Pressure

• Flow

• Viscosity

• Particulates / Bubbles

• Materials Compatibility

Page 28: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

In-situ Measurement

No sampling system• Pipeline/tank/line insertion

• No delay – real time results

Probe design Probe can be removed for cleaning – usually.

• Exceptions would be high pressure / temperature applications

Representative! Passive? Yes.

Page 29: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Extractive Sampling Systems

0-10gpm 0-0.5

gpm

RapidBypassLoop

Filter

DP

Flow Integrity Monitor

Analyzer

SampleLoop

Page 30: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Extractive Sampling Systems

Sample stream removed from main process line Advantages

• Allows isolation from process (cleaning/calibration)

• Filtration, dilution, P/T manipulation

• Improved safety – block/bleed

Difficulties• Must have dP across sample loop - or

• Sample pumping

• Delays

• Returning altered material to process or waste

• Filtration maintenance – when needed

Page 31: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Process Analyzer Maintenance

Ownership Cycle..

Page 32: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Development

Purchase

Installation

Start-UpMaintenance

Improvement

Replacement

70-90%Cost of Ownership

Maintenance is major cost of analyzer installation – process GC example

Page 33: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Reliability Maintenance Approach

Reliability – in degrees..• Ideal

Lasts forever, accurate and precise – cheap to own too.

• Reality (March to Entropy) Machine components wear out Unusual, unexpected events happen

• Goal Want capable function whenever machine is needed

• High Availability Uptime.

Want ownership at lowest possible cost. Reliability-Centered Maintenance Approach

Page 34: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Maintenance Categories

Reactive (RTF)• Appropriate for ultra-high reliability, low criticality systems

• Cheapest / Most Expensive approach – feeling lucky?

Preventative (PrM)• Process analytics use PrM

• Shewhart control charts (+/- 3 sigma, run of eight)

• Scheduled benchmarking visits

Predictive (PdM)• Maximum system availability at minimum cost.

• Relies on obtaining detailed history at component levels.

• We now have tools in-place to transition to PdM where needed.

Page 35: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

pH 4pH 4

pH X.XXpH 3.95pH 4.15

Analyzer Benchmarking

Apply standard of known concentration to analyzer

Read analyzer response Compare response to standard response

Within control limits:• Note response, add to control chart

• Walk away, just walk away…..

Outside of control limits, or eight either side of average:

• Note response, add to control chart

• Calibrate analyzer / determine cause / log

Avoids human tendency to over-control, chasing system noise. Much better for process stability.

pH 4.0

pH 3.9

pH 4.1 +3s

-3s

Target

pH 4.00

pH 4 StandardBuffer Solution

Page 36: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Process Analyzer Maintenance

Effective PrM has greatly improved reliability of our analyzers• High availability up-times

• Analyzer data can be trusted for monitoring & control

Productivity (analyzers/analyst) has greatly improved over the last 20 years• Better analyzer technology

• Better diagnostics

• Scheduled PrM

• Improved tools such as OSI PI

Page 37: Process Analytics: Improving Measurement Capability in your Plant AIChE Meeting: Nov. 17, 2009 Steve Wright Process & Environmental Analytics Eastman Chemical.

Questions & Answers

Thanks!

• Steve Wright

• Senior Development Associate

• Process and Environmental Analytics

• Bldg 359A

• Eastman Chemical Company

• Phone: 423-229-4060

• Email: [email protected]