KPIs for Asset Management: A Pump Case Study

The integration of multiple data sources and the convergence of process control systems and business intelligence layer such as the enterprise resource planning (ERP) are paving the way for important progress in plant operation optimization. Numerous companies offer “Analytics Services” to leverage this newly available mine of data but applications still appear to be limited to certain specific types of large plants. Key Performance Indicators (KPIs) is arguably the most used approach to make sense of large and complex systems in a wide variety of fields and its applicability to industrial operations is more and more common, to the extent that standardization of KPIs has become a major topic for the International Organization for Standardization (ISO). While the KPI standard ISO 22400 focuses on KPIs for manufacturing operations management at the plant level, the scope of this thesis is to bring it to the first layer of the control system: the equipment. In addition to being part of the quest for operational excellence and energy efficiency, bringing KPIs to the asset level is an important step towards integration of the different layers of the automation pyramid, integrating in particular control and scheduling. Developed within the frame of the new generation of Operations Management Software for the process industries, this work presents a case study on the most widely used assets in the field – pumps, based on operational data of different plants in the Oil & Gas and Chemicals industries. (Less)

[1]  Nina F. Thornhill,et al.  Online Performance Monitoring of Industrial Compressors Using Meanline Modelling , 2014 .

[2]  Nina F. Thornhill,et al.  Optimization of a network of compressors in parallel: Operational and maintenance planning – The air separation plant case , 2015 .

[3]  Sebastian Engell,et al.  Optimal operation: Scheduling, advanced control and their integration , 2012, Comput. Chem. Eng..

[4]  Dukki Chung,et al.  Next Generation Pump Systems Enable New Opportunities For Asset Management And Economic Optimization , 2002 .

[5]  J. Ahola,et al.  Pump operation monitoring applying frequency converter , 2008, 2008 International Symposium on Power Electronics, Electrical Drives, Automation and Motion.

[6]  Augusto Nelson Carvalho Viana,et al.  Optimization of parallel variable-speed-driven centrifugal pumps operation , 2008 .

[7]  Ralf Stetter,et al.  Optimization of a pump health monitoring system using fuzzy logic , 2013, 2013 Conference on Control and Fault-Tolerant Systems (SysTol).

[8]  Xiaohua Xia,et al.  Optimal operation scheduling of a pumping station with multiple pumps , 2013 .

[9]  H. Marzi.  Reconfigurable multi-stage neural networks in monitoring industrial machines , 2005, Proceedings of the 2005 IEEE Midnight-Summer Workshop on Soft Computing in Industrial Applications, 2005. SMCia/05..

[10]  Andrew Kusiak,et al.  Data-driven minimization of pump operating and maintenance cost , 2015, Eng. Appl. Artif. Intell..

[11]  Andrew Kusiak,et al.  Modeling and analysis of pumps in a wastewater treatment plant: A data-mining approach , 2013, Eng. Appl. Artif. Intell..

[12]  Xiaoli Li,et al.  Utilization of information maximum for condition monitoring with applications in a Machining Process and a water pump , 2004, IEEE/ASME Transactions on Mechatronics.

[13]  Nina F. Thornhill,et al.  Preprocessing of raw data for developing steady-state data-driven models for optimizing compressor stations , 2014, 2014 UKACC International Conference on Control (CONTROL).

[14]  Andrew Kusiak,et al.  Minimizing pump energy in a wastewater processing plant , 2012 .

[15]  Andrew Kusiak,et al.  Models for optimization of energy consumption of pumps in a wastewater processing plant , 2011 .

[16]  Jacobus Willem de Villiers Groenewald,et al.  A process performance monitoring methodology for mineral processing plants , 2014 .

[17]  Nina F. Thornhill,et al.  Modeling and Optimization of Industrial Centrifugal Compressor Stations Employing Data-Driven Methods , 2014 .

[18]  Filippo Attivissimo,et al.  Model based control and diagnostic system for centrifugal pumps , 2014, 2014 IEEE Workshop on Environmental, Energy, and Structural Monitoring Systems Proceedings.

[19]  Jussi Tamminen,et al.  Estimation of pump operational state with model-based methods , 2010 .

[20]  Margret Bauer,et al.  KPIs as the interface between scheduling and control , 2016 .

[21]  Jero Ahola,et al.  Frequency-Converter-Based Hybrid Estimation Method for the Centrifugal Pump Operational State , 2012, IEEE Transactions on Industrial Electronics.

[22]  Duc-Phuc Vuong,et al.  Pump efficiency instrumentation based on thermodynamic method and traditional technique , 2012, ICCA 2012.