04 | 07 | 2018

Analyzer Management

Dynamic Quality Measurement

Hans van Nuenen

AIS-ISA

04 July 2018

04 | 07 | 2018

ANALYZER MANAGEMENT

AND

DATA ACQUISITION SYSTEM

(AMADAS)

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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

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History

Flow Metering

Instrument Validation (CALSYS®)

Analyzer Management (AMADAS)

Dynamic Quality Measurement (DQM/QRM)

Quantity Quality

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Functional Decomposition

Analyzer Management System

Corrective Preventive

Predictive

MAINTAINABILITY

Statistical

Process

Control

Significance

Testing

QMI

Validation

PERFORMANCE

Availability

Calculation

QMI Status

Monitoring

AVAILABILITY

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Analyzer Validation ASTM 3764

QMI

Validation Methods of Validation (Analyzers)

Reference Sample Method

Line Sample Method

Reference Measurement Method

Methods of Validation (Detectors)

Time Response Method

1. The sample reference material is

directly introduced at the sample port of

the analyser.

2. The recorded analyser result is

compared with the accepted reference

value of the reference sample.

1. During normal operation of the

analyser a sample is drawn at the

analyser sample port and the

corresponding analyser result is

recorded.

2. The sample is analysed by the

laboratory.

3. The analyser result is then compared

with the accepted reference value

produced by the laboratory.

1. With this method a portable analyser is

temporarily lined-up in series with the

on-line analyser.

2. The reading of the on-line analyser is

compared with the reading of the

portable analyser.

Response that is reached within a

predetermined period of time

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Offset check

To distinguish between:

• Controlled variation

Stable and stays within process limits

• Uncontrolled variation

Pattern changes over time and/or breaches control limits

Control Chart

1. When to take action

2. When to leave the process

alone

6.4

6.5

6.6

6.7

6.8

6.9

7

7.1

7.2

7.3

7.4

1 2 3 4 5 6 7 8 9

Chara

cte

ristic v

alu

e

Sample number

UWL

UCL

LCL

LWL

Trend check

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Functional Decomposition

Analyzer Management System

Corrective Preventive

Predictive

MAINTAINABILITY

Statistical

Process

Control

Significance

Testing

QMI

Validation

PERFORMANCE

Availability

Calculation

QMI Status

Monitoring

AVAILABILITY

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Functional Decomposition

Analyzer Management System

Availability

Calculation

QMI Status

Monitoring

AVAILABILITY

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Status Monitoring

Operational states

NOT IN OPERATION

Not required by operations

UTILISED

Operating normally

PREVENTIVE MAINTENANCE

Scheduled maintenance

Scheduled validation

CORRECTIVE MAINTENANCE

Repair

Ad-hoc validation/calibration

FAULT

In error, waiting for maintenance

QMI Status

Monitoring

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Availability Calculations

Availability

Calculations

Performance Indicators

Operational State calculations

OFFLINE

ONLINE

VALIDATION

MAINTENANCE

Mean Time calculations

Check Rate

Mean Time To Repair (MTTR)

Mean Time Between Checks (MTBC)

Mean Time To Check (MTTC)

Availability Calculations

Operational Availability

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Corrective

Predictive

MAINTAINABILITY

Preventive

Statistical

Process

Control

Significance

Testing

QMI

Validation

PERFORMANCE

Validation

References

Availability

Calculation

QMI Status

Monitoring

AVAILABILITY

Interfacing

LIMS ERP

DCS

LIMS = Laboratory Information Management System

ERP = Enterprise Resource Planning

DCS = Distributed Control System

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Operator

Interface

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Operator

Interface

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DYNAMIC QUALITY MEASUREMENT

&

QUALITY RELEASE

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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.

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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

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Conventional Method

Sampling

Conditioning

System

PRESSURE

TEMPERATURE

FLOW

DCS

DCS

INT

ER

FA

CE

DATA

FILTER

DATA

AGGREGATION

LIMS

OSI-PI

OFF-LINE ANALYSIS

# of Measurements:

2 – 6 / Shipload

LOSS IN

DATA RESOLUTION

LNG LOADING LINE

LNG SAMPLER

CERTIFICATE

OF QUALITY

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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

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Automated Method

Sampling

Conditioning

System

PRESSURE

TEMPERATURE

FLOW

DCS

DCS

LIMS

OFF-LINE ANALYSIS

# of Measurements:

2 – 6 / Shipload

LNG LOADING LINE

LNG SAMPLER

AMADAS

IN

ST

RU

ME

NT

VA

LID

AT

ION

CERTIFICATE OF QUALITY

VALIDATION REPORTS

BILL OF LADING

MAINTENANCE RECORDS

PERFORMANCE DATA

DATA TREATMENT

Quality

Release

Module

SUPERVISORY COMPUTER SHIP DETAILS

SAMPLE CYLINDER DETAILS

LAB DATA

ON-LINE ANALYSIS

# of Measurements:

120 – 140 / Shipload

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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

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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

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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.

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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

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Vessel Data

Certificate

of Quality

Validation

Reports

Alarm Tracking

Instrument

Validation

Reference Gas

Management

DatabaseKey Performance

Indicators

Control Charts

Certification

ISO-8943

Calculations

Bill of Lading

Snapshot

Cooling

Mass Balance

Cargo

Cool Down

HP LP2045W

inputauto

HP LP2045W

inputauto

Operator Interface

Quality Release

Module

GIIGNL

RecommendationsDistributed Control System (DCS)

Plant Information (OSI-PI)

Laboratory Information Management System (LIMS)

Quality Measurement Instruments (QMI)

LNG Samplers

Vaporizers

Impurity

Measurements

(laboratory)

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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.

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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

UIDSID

3

4

1

2

5

6 7 8

ProLiant

DL360e

Gen8

UIDSID

3

4

1

2

5

6 7 8

ProLiant

DL360e

Gen8

04 | 07 | 2018

04 | 07 | 2018

Thank you for your attention!