Application of abnormal event detection technology to delayed coking unit
First Claim
1. A method for the early notification of an unplanned abnormal event detection (AED) for some process units of a delayed coking unit (DCU) comprising:
- (a) comparing online measurements from an array of sensors for the process units to a set of models including at least two principal component analysis models for normal operation of the corresponding process units, wherein said delayed coking unit has been divided into at least two equipment groups wherein there is minimal interaction between said equipment groups and principal component analysis models correspond to equipment groups, wherein the inputs to the principal component analysis models include measurements from said array of sensors which have been divided into groups corresponding to equipment groups, wherein said equipment groups are defined by including all major material and energy integrations and quick recycles in the same equipment group and said measurements are cross-correlated with each other,(b) determining if the current operation differs from expected normal operations from the cumulative measurements of said array of sensors that are inputs to said set of models so as to detect the presence of an unplanned abnormal event condition in a process unit which has developed on a timescale of minutes to hours, and(c) determining the underlying cause of an abnormal condition in the DCU.
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Abstract
The present invention is a method for detecting an abnormal event for process units of a Delayed Coking Unit. The method compares the operation of the process units to statistical and engineering models. The statistical models are developed by principal components analysis of the normal operation for these units. The engineering models are based statistical and correlation analysis between variables. If the difference between the operation of a process unit and the normal model result indicates an abnormal condition, then the cause of the abnormal condition is determined and corrected.
122 Citations
44 Claims
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1. A method for the early notification of an unplanned abnormal event detection (AED) for some process units of a delayed coking unit (DCU) comprising:
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(a) comparing online measurements from an array of sensors for the process units to a set of models including at least two principal component analysis models for normal operation of the corresponding process units, wherein said delayed coking unit has been divided into at least two equipment groups wherein there is minimal interaction between said equipment groups and principal component analysis models correspond to equipment groups, wherein the inputs to the principal component analysis models include measurements from said array of sensors which have been divided into groups corresponding to equipment groups, wherein said equipment groups are defined by including all major material and energy integrations and quick recycles in the same equipment group and said measurements are cross-correlated with each other, (b) determining if the current operation differs from expected normal operations from the cumulative measurements of said array of sensors that are inputs to said set of models so as to detect the presence of an unplanned abnormal event condition in a process unit which has developed on a timescale of minutes to hours, and (c) determining the underlying cause of an abnormal condition in the DCU. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A system for early notification of unplanned abnormal event detection (AED) for some of the process units of a DCU of a petroleum refinery comprising:
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(a) on-line data acquisition of measurements from an array of sensors, (b) a set of models including at least two principal component analysis models included in the set describing operations of said process units including automatic detection of drum switches and furnace decoking operations wherein said DCU has been divided into at least two equipment groups, wherein a single principal component model corresponding to an equipment group, and wherein the inputs to the principal component analysis models include measurements from said array of sensors, wherein said array of sensors has been divided into groups corresponding to said equipment groups, and wherein said equipment groups are defined by including all major material and energy integrations and quick recycles in the same equipment group and said measurements are cross-correlated with each other, (c) a set of displays which indicates if the current operation differs from expected normal operations from the cumulative measurements of said array of sensors so as to indicate the presence of an abnormal condition in the process unit which has developed on a timescale of minutes to hours so as to detect an unplanned abnormal event, and (d) a set of displays which indicates the underlying cause of an abnormal condition in the DCU. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44)
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Specification