Digitalization and Analytics for Smart Plant Performance

Frank (Xin X.) Zhu, PhD, is Senior Engineering Fellow and Leader of Engineering Innovations at Honeywell UOP. He has made significant contributions to the theoretical framework, the computational tools, and applications in the fields of data analytics, production planning, operation scheduling, process modeling, design and optimization. He has published seminal journal articles and widely used books especially in the areas of process operations, process design and energy systems. He holds 68 US patents, is the co-founder and chair of ECI International Conference: CO2 Summit, and the recipient of prestigious AICHE Energy Sustainability Award.

Preface xiii

Acknowledgments xvii

Part 1 Challenges and Opportunities For Digitalization 1

1 Challenges for Operation Excellence 3

1.1 Introduction 3

1.2 Operation Activities in a Process Plant 4

1.3 The Major Challenges Facing the Industries 5

1.4 The Methodology of Connected Plant 11

1.5 Digitalization Enabling Connected Plant 12

1.6 What is the Digitalization Journey? 18

1.7 Overview of the Book Structure 19

References 21

2 Mission of Connected Plant 23

2.1 What is Connected Plant? 23

2.2 Major Functions of Connected Plant 24

2.3 Digital Twins: The Core of Connected Plant 27

2.4 Conclusions 32

References 33

3 Data Analytics for Operation Excellence 35

3.1 Introduction 35

3.2 Process Data Overview: Characteristics and Attributes 37

3.3 Unique Attributes of Process Data Analytics 39

3.4 Model Types and Characteristics 40

3.5 First Principle Modeling and its Characteristics 42

3.6 Statistic Modeling and its Characteristics 45

3.7 Optimization Models 47

3.8 Artificial Intelligence (AI) and Machine Learning (ML) Models 50

3.9 Put All Together: Digital Twin as a Data Science Platform 55

References 59

Part 2 Model Thinking For Smart Operations 63

4 Statistics Basics 65

4.1 Introduction 65

4.2 Normal Distribution 65

4.3 Conditional Probability 72

4.4 Bayes’ Probability 73

4.5 Statistic Tests 75

References 84

5 Advanced Statistic Modeling 85

5.1 Introduction 85

5.2 Distribution Models 85

5.3 Correlation Models 94

5.4 Advanced Modeling Techniques 101

5.5 Data Mining 106

5.6 Summary 107

References 107

6 Rigorous Process Modeling 109

6.1 Introduction 109

6.2 Reaction Kinetic Modeling 110

6.3 Reactor Types and Modeling 126

6.4 Integrated Kinetics and Reactor Modeling 131

6.5 Catalyst Deactivation Root Causes and Modeling 135

6.6 Distillation Modeling 136

6.7 Process System Modeling and Simulation 138

6.8 Separation Technology Overview 142

References 144

7 Linear Optimization Modeling 147

7.1 Introduction 147

7.2 Linear Optimization for Planning 148

7.3 How to Deal with Nonlinear Terms? 151

7.4 Delta Vector as Linear Approximation of Nonlinear Yield Models 154

7.5 Successive Linear Programing (SLP) Approach 159

References 160

8 Nonlinear Optimization Modeling 161

8.1 Introduction 161

8.2 Successive Quadratic Programming (SQP) Approach 162

8.3 Local Versus Global Optimum 162

8.4 Optimality Conditions 166

8.5 Nonlinear Process Optimization Model 167

8.6 Stochastic Programming 171

8.7 Simulation-Based Optimization 178

8.8 A Case Study for Process Optimization 180

8.9 Concluding Remarks 188

References 190

9 Process Control and APC Modeling 193

9.1 Introduction 193

9.2 Process Modeling in Control 194

9.3 Regulatory Control: Managing Individual Variables 207

9.4 PID Controller Modeling 211

9.5 Advanced Process Control (APC) 221

References 233

10 AI and Machine Learning Modeling 235

Amit Gupta and Frank (Xin X.) Zhu

10.1 Introduction 235

10.2 Artificial Neural Networks 235

10.3 Key Concept in ML: Perceptron 238

10.4 Machine Learning 242

10.5 Ml Applications in the Process Industry 246

References 248

Part 3 Connected Plant For Smart Operations 251

11 Connected Metering and Measurements 253

Martin Bragg

11.1 Introduction 253

11.2 Review of Metering Devices 254

11.3 Connected Metering 258

11.4 Positive-Unexpected Consequences of the Digital Economy 267

11.5 The Outlook for Connected Metering 269

11.6 Conclusions 273

References 274

12 Connected Asset and Safety Management 275

Frank (Xin X.) Zhu and Tony Downes

12.1 Introduction 275

12.2 Review of Different Maintenance Strategies 276

12.3 The Concept of Operating Windows 280

12.4 The Major Gaps in Current Asset Management 283

12.5 Digitalized Asset Management 284

12.6 Process Safety Management 290

12.7 Case Study: APM Drives Capacity Improvement 299

Reference 301

13 Integrated Production Planning and Process Control 303

13.1 Introduction 303

13.2 Current Practice in Site-Wide Optimization and Control 304

13.3 Simultaneous Approach for Site-Wide Optimization and Control 304

13.4 General Decomposition Strategy 309

13.5 MPC-Based Integration Approach 314

13.6 Rigorous Model-Based Integration Approach 322

13.7 Comparison Between the MPC and Rigorous Model-Based Approaches 324

References 325

14 Digitalizing the Energy Management 327

14.1 Introduction 327

14.2 The Concept of Energy Intensity 328

14.3 Energy Benchmarking for Processes 337

14.4 The Concept of Key Indicators 340

14.5 Set Up Targets for Key Indicators 346

14.6 Economic Evaluation for Key Indicators 350

14.7 Site-Wide Energy Management Strategy 354

14.8 Digital Twin for Energy Management 360

14.9 Establishing Energy Management System 361

References 365

15 Integrating the Workflows 367

Frank (Xin X.) Zhu and Joe Ritchie

15.1 Introduction 367

15.2 Key Elements of Industrial Supply Chain 368

15.3 Little Integration of Supply Chain Work Processes 381

15.4 Gaps Existing in Current Supply Chain Management 382

15.5 Integrated Work Process for Supply Chain Management 383

15.6 Supply Chain Digital Twin: One Platform for Workflow Integration and Automation 385

15.7 Integration of Engineering Models with Supply Chain

Digital Twin 387

References 388

16 Digitalizing the Workforce 389

Rohan McAdam

16.1 Introduction 389

16.2 Enabling the Workforce 390

16.3 Empowering the Workforce 398

16.4 Digitalization Challenges 410

16.5 Summary 416

References 416

Part 4 Digital Solutions For Smart Operations 419

17 Honeywell Forge: The Platform for Connected Plant 421

Matt Burd and Frank (Xin X.) Zhu

17.1 Honeywell Forge: A Digital Platform for Connected Plant 421

17.2 IIoT for Data Infrastructure 421

17.3 How It Works? 423

17.4 Intelligent Models Behind Digital Twins in Honeywell Forge 429

17.5 Cybersecurity 434

Reference 436

18 Digital Reediness Assessment and Six-Step Digitalization Journey 437

18.1 Introduction 437

18.2 Digital Readiness Assessment 438

18.3 The Six-Step Digitalization Journey 449

18.4 Recommendations: A Digital Transformation Management System 454

18.5 Establishing a Digital Transformation Management System 455

References 457

19 Digital Project Evaluation and Development 459

19.1 Introduction 459

19.2 Business Case Evaluation 459

19.3 Digital Project Development Steps 461

19.4 Remarks on Digital Project Development 465

19.5 S-Curve for Project Review and Management 469

19.6 Basics of Economic Analysis 472

Reference 475

20 Application Case Studies 477

20.1 Introduction 477

20.2 Application Cases from Digital Twins 477

20.3 Applications from Other Digital Projects 481

References 506

Index 507