PLANT PERFORMANCE ANALYSIS

• Plant performance analysis has been define

as the reconciliation, rectification &
interpretation of plant measurements to
develop better understanding of plant
operation.
 TERMINOLOGIES

IDENTIFICATION :
• Procedure for developing hypotheses & determining critical
measurement.
VALIDATION :
• Procedure for screening measurements to determine whether
they are consistent with known unit characteristics.
RECONCILIATION :
• Procedure for the adjustment of the measurement to close the
process constraints.
RECTIFICATION :
• Procedure for the identification of measurement that contain
gross errors.
INTERPRETATION :
• Procedure for using the plant measurement or adjustments to
troubleshoot, detect faults, develop a plant model or estimate
parameters.
TROUBLESHOOTING :
• Procedure for identify & solve a problem in operating unit.
FAULT DETECTION :
• Procedure for identify deteriorating unit operating performance.
PLANT PERFORMANCE TRIANGLE
PLANT ANALYSYS PREPARATION

• The purpose of plant analysis preparation is to provide

guidelines for preparation.
• There are four categories of preparation stage.
1) Analyst preparation.
2) Model preparation.
3) Plant preparation.
4) Laboratory preparation.
 ANALYST PREPARATION

A n a ly s t m u s t h a v e a s t r o n g f o u n d a t io n in p la n t o p e r a t io n & t h e u n it u n d e r s t u d y .

A n a ly s t P r e p a r a t io n

P r o c e s s F a m ilia r iz a t io n D a t a A q u is it io n M a t e r ia l B a la n c e E n e r g y B a la n c e

PFDs O p e r a t in g T im e P & ID s
In s tru m e n t Sequence
D ia g r a m

U n it
I n s t a lla t io n

O t h e r P r o c e s s C o n s t r a in t E q u ip m e n t C o n s t r a in t D a ta B a s e
 PLANT MODEL PREPARATION

A m o d e l is t h e m a t h e m a t ic a l r e p r e s e n t a t io n o f a u n it .
A m o d e l c a n b e u s e d t o t r o u b le s h o o t , f a u lt d e t e c t io n ,
c o n t r o l & d e s ig n .

M odel
R e la t i o n a l M o d e l P h y s ic a l M o d e l

e . g . M o d e l L in e a r in t h e e .g . C S T R &
p a ra m e te r & T r a y E f f ic ie n c y
N e u ra l N e tw o rk
 PLANT PREPARATION

• INTENT
• COMMUNICATION
• SCHEDULE
• PIPING MODIFICATION
• INSTRUMENTATION
• SAMPLE CONTAINER
• FIELD MEASUREMENT CONDITIONS
• PRELIMINARY TEST
 LABORATORY PREPARATION

• INTENT
• CONFIDENCE
• SAMPLING
1) Sampling Locations
2) Sampling Safety
3) Sample Transport, Storage, & Discharge System
4) Sample Container Cleaning
 APPLICATION / SUMMARY

• The goal of plant performance analysis is to develop an

accurate understanding of plant operation, the result of
plant performance analysis ultimately leads to a more
efficient, safe, profitable operation.
• Plant performance analysis used to improve quality &
quantity of product.
• For getting ISO certification one should do the plant
performance analysis.
• Plant performance gives an idea of the whole process.
 REFERENCE

• Robert H. Perry & Don W. Green, “Perry’s Chemical

Engineering Hand Book” VIIth Edition ( Dupont ).
• Verneuil,V. S. Jr., and P.Yang, Frantisek Madron “Banish
Bad Plant Data” Chemical Engineering Progress, October
1992, 45-51. ( Rectification )
• Gans, M. and B. Palmer “Take Charge of Your Plant
Laboratory” Chemical Engineering Progress, September
1993, 26-33 ( Plant Test Preparation )
• Gans, M., Kohan D. and B. Palmer “Systematize Trouble
Shooting Techniques” Chemical Engineering Progress,
April 1991, 25-29 ( Troubleshooting )
• MacDonald, R.J. and Howat, C.S., “Data Reconciliation and
Parameter Estimation in Plant Performance Analysis,” AIchE
Journal, 34(1), January 1988, 1-8.( Interpretation )
• Fan, J.Y.,Nikolaou, M., and R.E.White, “An Approach to Fault
Diagnosis of Chemical Processes via Neural Networks,” AIchE
Journal, 39(1), January 1993, 82-87. ( Interpretation )
• Chiu-Nan Wei, “Diagnose Process Problems,” Chemical
Engineering Progress, September 1991, 70-74. (Interpretation )
• Frey, H. C. and Rubin, E.S., “Evaluate Uncertainties In
Advanced Process Technologies,” Chemical Engineering
Progress, May 1992, 63-70. ( Reconciliation )
• Chiu-Nan Wei, “Diagnose Process Problems,” Chemical
Engineering Progress, September 1991, 70-74. ( Interpretation )
• Verneuil,V.S. Jr., and P. Yang, “Improve Prediction With Data
Reconciliation”, Hydrocarbon Processing, October 1993, 79-80. (
Reconciliation )
• Watababe, K. and Himmelblau, D. M., “Incipient Fault Diagnosis
Of Nonlinear Processes With Multiple Causes Of Faults,”
Chemical Engineering Science, 39(3), 1984, 491-508.
( Interpretation )
• Wallace, B.W., Ting-man, T. and Michael, E. R., “Effect of
Uncertainties in Thermodynamic Data and Model Parameters
Calculated Process Performance,” Indian Engineering Chemical
Research, 32, 1993, 1367-1371.( Interpretation )
• SITES:-
1) www.google.com
2) www.knovel.com
3) www.elseviour.com
4) www.sciencedirect.com
5) www.plantperformance.com
THANK YOU