Hans van Nuenen AIS-ISA 04 July Analyzer Management Dynamic Quality Measurement

Transcription

1 Hans van Nuenen AIS-ISA 04 July 2018 Analyzer Management Dynamic Quality Measurement

2 ANALYZER MANAGEMENT AND DATA ACQUISITION SYSTEM (AMADAS)

3 Definition Analyzer Management and Data Acquisition System (AMADAS) Objective: Guidance and automation of analyser validation Deliver diagnostics on performance Produce availability figures (KPI) Predict and detect abnormal behaviour Issue request for maintenance (validation) Goal: High level of availability of analysers High performance of accuracy Reliability of analyser outputs Application Areas Refineries Petro-chemical plants LNG terminals Quality Release Gas processing plants

4 History Flow Metering Instrument Validation (CALSYS ) Analyzer Management (AMADAS) Dynamic Quality Measurement (DQM/QRM) Quantity Quality

5 Functional Decomposition MAINTAINABILITY Corrective Preventive Predictive Statistical Process Control QMI Validation Significance Testing Analyzer Management System PERFORMANCE QMI Status Monitoring Availability Calculation AVAILABILITY

6 Analyzer Validation ASTM 3764 Methods of Validation (Analyzers) QMI Validation Reference Sample Method Line Sample Method Reference Measurement Method Methods of Validation (Detectors) Time Response Method The During sample normal reference operation material of the is directly analyser introduced a sample at is the drawn sample at the port of 1. With this method a portable analyser is the analyser analyser. sample port and the temporarily lined-up in series with the 2. The corresponding recorded analyser analyser result result is is on-line analyser. compared recorded. with the accepted reference 2. The reading of the on-line analyser is 2. value The sample of the reference is analysed sample. by the compared with the reading of the laboratory. portable analyser. 3. The analyser result is then compared Response with the that accepted is reached reference within a value predetermined produced by period the laboratory. of time

7 Characteristic value Control Chart 1. When to take action 2. When to leave the process alone To distinguish between: Controlled variation Stable and stays within process limits Uncontrolled variation UCL UWL LWL LCL Sample number Pattern changes over time and/or breaches control limits Trend check Offset check

8 Functional Decomposition MAINTAINABILITY Corrective Preventive Predictive Statistical Process Control QMI Validation Significance Testing Analyzer Management System PERFORMANCE QMI Status Monitoring Availability Calculation AVAILABILITY

9 Functional Decomposition QMI Status Monitoring Availability Calculation AVAILABILITY Analyzer Management System

10 Status Monitoring Operational states NOT IN OPERATION Not required by operations QMI Status Monitoring UTILISED Operating normally PREVENTIVE MAINTENANCE Scheduled maintenance Scheduled validation CORRECTIVE MAINTENANCE Repair Ad-hoc validation/calibration FAULT In error, waiting for maintenance

11 Availability Calculations Performance Indicators Operational State calculations OFFLINE ONLINE VALIDATION MAINTENANCE Availability Calculations Mean Time calculations Check Rate Mean Time To Repair (MTTR) Mean Time Between Checks (MTBC) Mean Time To Check (MTTC) Availability Calculations Operational Availability

12 Interfacing MAINTAINABILITY LIMS Corrective Predictive Preventive ERP Validation References QMI Validation QMI Status Monitoring Statistical Process Control Significance Testing Availability Calculation PERFORMANCE AVAILABILITY LIMS = Laboratory Information Management System ERP = Enterprise Resource Planning DCS DCS = Distributed Control System

13 Operator Interface

14 Operator Interface

15 DYNAMIC QUALITY MEASUREMENT & QUALITY RELEASE

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17 Dynamic Quality Measurement (DQM) Provides a system that generates a Certificate of Quality and tracking of validations, including: full traceability of data used, audit trials data reconciliation for the purpose of billing and internal plant mass balancing.

18 Dynamic Quality Measurement / Release Functionality: Dynamic LNG Loading Measurement and Quality Release including: Multi point instrument validation Process analyzer validation Control charting Outlier determination Decision rules Quality release Overall reporting System monitoring

19 INTERFACE Conventional Method DCS OSI-PI LNG SAMPLER Sampling Conditioning System LOSS IN DATA RESOLUTION DCS DATA FILTER DATA AGGREGATION LIMS LNG LOADING LINE PRESSURE TEMPERATURE FLOW OFF-LINE ANALYSIS CERTIFICATE OF QUALITY # of Measurements: 2 6 / Shipload

20 LNG Quality Release Current Systems and Pitfalls Data is transferred via different systems, gateways and other devices before it reached the final database. Transferring of data is causing loss of resolution, data filtering and aggregation, especially when using aging control systems Gateways and other data conversion tools included in the chain of transferring data to its final database have higher risk of data loss or interruption due to device malfunction Source of data is not traceable and auditable which leaves the operating company exposed to external auditors for regulatory compliance and in the event of contractual disputes Data extraction and calculation is done manually which leaves room for human error Using the laboratory data is labor intensive and subjected to lots of manual handling including preparing and administering cylinders Number of lab chromatograph measurements is typically limited to 2 to 3 measurements and is therefore statistically a less solid data set when comparing to on-line chromatograph data sets which are in the order of 120 ~ 130 measurement per LNG loading batch. Data treatment on outliers as per GIIGNL recommendation is not possible using lab data Lab analysis results are often only available after the loading of the cargo has been completed Data stored in plant management systems are not auditable and traceable to custody transfer standards

21 INSTRUMENT VALIDATION Automated Method SHIP DETAILS SAMPLE CYLINDER DETAILS LAB DATA SUPERVISORY COMPUTER ON-LINE ANALYSIS Quality Release Module CERTIFICATE OF QUALITY VALIDATION REPORTS BILL OF LADING MAINTENANCE RECORDS PERFORMANCE DATA DATA TREATMENT # of Measurements: / Shipload AMADAS DCS LNG SAMPLER Sampling Conditioning System DCS LIMS LNG LOADING LINE PRESSURE TEMPERATURE FLOW OFF-LINE ANALYSIS # of Measurements: 2 6 / Shipload

22 DQM Data Calculation and Treatment Checking on outliers and other data treatment as per contractual requirements or recommendations made in GIIGNL. Evaluate data and provide warning alarms if data sets are statistically incorrect. Calculate LNG properties including density, heating values and amount of energy transferred as per relevant ISO standards or gas lifting agreements. Calculate dynamically sub-cooling conditions and other parameters to demonstrate that the equipment is in compliance to the applicable ISO standards

23 DQM Monitoring Tools Supervise and monitor the overall LNG loading system. Ensure that measurement data is synchronized with composite sampler and LNG loading operations in accordance to relevant ISO standards. Check condition of LNG vaporizers and samplers throughout the LNG loading operation. Ensure that on-line gas chromatographs and vaporizers are automatically validated with all maintenance actions tracked. Ensure that critical instrumentation is checked including tracking of validations and maintenance actions. Monitoring reference gasses and carrier gasses used and alarms when this need to be replaced or certificates are about to expire. Execute automatically chromatograph checking when participating in proficiency testing for internal or external quality audits (Round Robin Testing). The LNG system will be validated for correct functioning before, during and after the LNG loading

24 DQM Management Tools Reference gas cylinder management Sample cylinder management and tracking Managing validation, calibration, maintenance history and performance data for gas chromatographs, LNG vaporizer and other critical instrumentation.

25 DQM Reporting Tools Quality Release Certificate and Bill of Lading reports Plant mass balancing reports (with optional measurement feedback from vapor returns) Cargo Cool down reports including amount of energy and time spent to cool warm ships. Validation / Calibration records complete with statistical control charts for on-line gas chromatograph, LNG vaporizer and all critical instrumentation Maintenance records to maintain full transparency for internal and external auditors. Inventories for sample cylinders and reference cylinders

26 HP LP2045W HP LP2045W auto input auto input Bill of Lading Snapshot Certificate of Quality Validation Reports Cooling Mass Balance Vessel Data Cargo Cool Down Impurity Measurements (laboratory) Instrument Validation Database Operator Interface Key Performance Indicators Certification Quality Release Module Reference Gas Management ISO-8943 Calculations Alarm Tracking Control Charts Quality Measurement Instruments (QMI) LNG Samplers Vaporizers GIIGNL Recommendations Distributed Control System (DCS) Plant Information (OSI-PI) Laboratory Information Management System (LIMS)

27 LNG Quality Release What is required Stand-alone system with interfacing direct to relevant instrumentation Custody transfer Standard with respect to traceability of data including the ability to reconcile where and when required. Calculations validated and certified by an independent bodies. Calculations and data storage to be secure Energy calculations, loading mass balance and billing reports on vapor returns. Dynamic validation of measurement data, using outlier checks Monitor Vaporizer performance (Repeatability, PT/TT monitoring and degree of sub-cooling) Perform manual/automated validations for instrumentation related to LNG loading Monitoring of all critical parameters and storage of maintenance data and alarms for audit purpose Reporting, statistical evaluations and calculation of performances / KPI. Ability to automatically collect data from LIMS systems Management of sample cylinders and calibration gasses System need to be fully auditable and traceable.

28 SID UID SID ProLiant DL360e Gen8 UID ProLiant DL360e Gen8 LOX Supervisory System.. Instrument Management Gas Chromatograph validation (prior to each ship load) Long term evaluation using control charts Gas Chromatograph Calibration and Round Robin testing Pressure- and Temperature transmitter validation Vaporizer system validation (repeatability check) Instrument Availability Monitoring & Availability calculations Instrument Maintainability

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30 Thank you for your attention!