Você está na página 1de 35

Process Engineering Group

Soft Sensors & Aspen IQ


7th Apr 2012
Swetha Nair

February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

Scope
What are Soft Sensors
What is ASPEN IQ
How to build Soft Sensors
How to update soft sensors
Work flow sheet for Soft sensor updation

February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

What are Soft Sensors?


Mathematical relation that calculates or predicts a controlled property
using other available process data
It is different from simple regression because it captures dynamics, align
data & update it self while running
Why use an soft sensor
It is either impossible or extremely costly to measure on-line
May be used as a backup to an existing analyzer to:
Reduce or eliminate dead time, both from the process and the analyzer
cycle
Provide redundancy for a limited time in case the analyzer is unavailable
February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

Refining Example

PI

TI
TI

TI

Steam

FC

FC
TI
FC

FI

TI

TI

Steam
TI
TI

Aspen IQ Introduction

FI
95% Pt.

FI

Freeze
Pt.

FC

FI

TI

FI

Steam
FC

FC

Flash Pt.
Freeze Pt.

TI
95% Pt.

Examples of Soft Sensors


Refinery petroleum fractionators
Petroleum fraction boiling points (IBP, 90%, 95%, EP)
Petroleum fraction cold properties (flash, freeze, cloud)

Light ends distillation (refining or petrochemical)


Product impurity (C5+, C4-, etc.)

Polymer processes
Melt index (MI) or melt/flow ratio (MFR)
Density

Emissions Monitoring
NOX, CO, particulates
February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

What is Aspen IQ?


Aspen IQ is an AspenTech product which provides all of the tools to
build and implement inferential sensors in industrial processes. The
package contains of
IQModel to develop linear PLS, Non Linear PLS, Hybrid Neural Net or Monotonic
Neural net Models

IQConfig -

to configure the input and output connections and setting the initial

updates and tuning parameters in an IQF file

IQManage for loading and managing an IQF Online.


IQExtract for gathering data for use in developing models or for general reporting.
IQView for viewing and changing values online

February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

What is Aspen IQ: Key Features


Online
Provides both Lab and Analyzer value updating
Wide range of DCS in Informative system interface available
No code generation or programming required

Offline
Broad suits of power tools: PLS, Fuzzy PLS, NN etc.
Graphical Analysis tools available: evaluation & validation
Tools such as: variable selection, dead time estimation & dynamic
analysis
February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

What is Aspen IQ: techniques


Aspen IQ supports several different model types:
Algebraic equation-based inferential sensors
(PCT, RFPCT, PFPCT; must be a steady state model)

Finite Impulse Response (FIR) models ( We do not use )


Regression-based models
(Frequently used, ASPEN IQMODEL & POWERTOOL required)

Non-linear models
( ASPEN IQPowertools to be used, Hybrid Neural net & Monotonic Neural Net to
be used)

First-principle based models ( Linear rigorous equation ;RT-OPT)

February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

How to Build Soft Sensors: ASPEN IQ


Includes six steps
Specify Data (Available process variable, lab/analyzer value)
Condition Data (spikes, flat line detection, etc.)
Align Data (Finding out related data by estimating dead time)
Select Variables (Selecting right variables from initial list)
Analyze Dynamics (Correcting dynamics)
Build Inferential Sensor (Building & deploying)

February 21, 2016

Reliance Technology Group APC / RTO

For Internal Circulation

IQmodel - Navigation
Grayed-out: step that is done in future not currently an option

Black - step
that
can be done
now

February 21, 2016

Reliance Technology Group APC / RTO

10

For Internal Circulation

IQmodel: Specify Data


There are two ways in which you can import data into Aspen
IQmodel
Directly via starting IQmodel and invoking the Specify Data step
By opening an Excel worksheet containing your data and invoking the Excel
IQmodel Add-In

The choice of data entry method influences what type of working file
you use
If you import directly through IQmodel, your working file is an IQM file
If you use the Excel Add-In, your working file is the Excel spreadsheet with an
imbedded IQmodel Project File object

February 21, 2016

Reliance Technology Group APC / RTO

11

For Internal Circulation

IQmodel: Specify Data

Specifying variable type:


Independent
Dependent

February 21, 2016

Reliance Technology Group APC / RTO

12

For Internal Circulation

IQmodel: Specify Data- View

February 21, 2016

Reliance Technology Group APC / RTO

13

For Internal Circulation

IQmodel: Condition Data

February 21, 2016

Reliance Technology Group APC / RTO

14

For Internal Circulation

IQmodel: Condition Data

February 21, 2016

Reliance Technology Group APC / RTO

15

For Internal Circulation

IQmodel: Condition Data

February 21, 2016

Reliance Technology Group APC / RTO

16

For Internal Circulation

IQmodel: Align Data

February 21, 2016

Reliance Technology Group APC / RTO

17

For Internal Circulation

IQmodel: Align Data


Data Alignment Results

February 21, 2016

Reliance Technology Group APC / RTO

18

For Internal Circulation

IQmodel: Data Alignment Results

February 21, 2016

Reliance Technology Group APC / RTO

19

For Internal Circulation

IQmodel: Select Variables

February 21, 2016

Reliance Technology Group APC / RTO

20

For Internal Circulation

IQmodel: Select Variables


Variable Selection Dialog

February 21, 2016

Reliance Technology Group APC / RTO

21

For Internal Circulation

IQmodel - Select Variables


Forcing a Variable Active from the Main Dialog

February 21, 2016

Reliance Technology Group APC / RTO

22

For Internal Circulation

IQmodel: Analyze Dynamics

February 21, 2016

Reliance Technology Group APC / RTO

23

For Internal Circulation

ASPEN IQModel: Result

February 21, 2016

Reliance Technology Group APC / RTO

24

For Internal Circulation

Aspen IQ Deployment Procedures


Use IQconfig to define inferential type using IQmodel file, FIR
file, or algebraic calculation, and connect DCS inputs and
outputs
Use IQmanage to load and start the inferential sensor applications
Use IQview to monitor and maintain the inferential sensor
applications
Use IQextract to generate CLC or CSV files for model development
or maintenance
Soft sensor will predict the property based on other variables
online
February 21, 2016

Reliance Technology Group APC / RTO

25

For Internal Circulation

How to update Soft sensors

Inferential needs to be updated to overcome drift &


model error

Bias will be calculated online by grabbing the difference b/w actual and
predicted value Example:
Diesel End Point

M1*K1+M2*K2+M3*K3+M4*K4+BIAS
361DSLEP_P
362DSLEP_P

M1
T
P
StdP
WatK
K1
M2
K2
M3
K3
M4
K4
Bias

February 21, 2016

PFPCT
Tag
Tag
Constant
Constant
Constant
Tag
Constant
Tag
Constant
Tag
Constant
Updated
Online

Diesel Inferred End Point

361TI600_P
361PI060_P
32.
13.6
1.17529
361PDI064_P
-168.58
361FC073_P
-1.49235
361FC071_P
.244329
N/A

Reliance Technology Group APC / RTO

26

For Internal Circulation

How to update Soft sensors


LBUNUMVALS represents the number of previous samples to be
used when updating the lab bias. In this case, we are set up to
use only the last lab sample in the update. However, since this
value is LOCAL, it is engineer-tunable.
LBIASFRAC is the fraction of the bias change calculated by the
LBU module to be applied in computing the new bias. In this
case, we are applying 75% of the bias change. This parameter is
also engineer-tunable.

February 21, 2016

Reliance Technology Group APC / RTO

27

For Internal Circulation

How to update Soft sensors

February 21, 2016

Reliance Technology Group APC / RTO

33

For Internal Circulation

Questions

February 21, 2016

Reliance Technology Group APC / RTO

34

For Internal Circulation

February 21, 2016

Reliance Technology Group APC / RTO

35

For Internal Circulation