Tuning system and method for improving operation of a chemical plant with a furnace

A tuning system for improving operation of a chemical plant, the tuning system comprising:

• a furnace comprising a tube inside the furnace;
• a fractionation column;
• a reboiler associated with the fractionation column;
• a receiver associated with the fractionation column;
• a feed exchanger associated with the fractionation column;
• a server coupled to the tuning system for communicating with the plant via a communication network;
• a computer system having a web-based platform for receiving and sending plant data related to the operation of the plant over the network;
• an interface module comprising:
• one or more processors disposed for receiving signals from the sensor;
• a memory storing executable instructions that, when executed by the one or more processors of the interface module, cause the interface module to:
• receive measured surface temperature data for the tube;
• and
• providing the measured surface temperature data to a database configured to store the measured surface temperature data;
• an optimization unit comprising:
• one or more processors of the optimization unit;
• a memory storing executable instructions that, when executed by the one or more processors of the optimization unit, cause the optimization unit to:
• receive, via the interface unit, the measured surface temperature data;
• correct the measured surface temperature data for overall mass balance closure;
• a reconciliation unit configured for reconciling actual measured data from the plant in comparison with a performance process model result from a simulation engine based on a set of predetermined reference or set points, the reconciliation unit comprising:
• one or more processors of the reconciliation unit;
• a memory storing executable instructions that, when executed by the one or more processors of the reconciliation unit, cause the reconciliation unit to:
• generate reconciled surface temperature data;
• wherein the memory of the optimization unit further stores executable instructions that, when executed by the one or more processors of the optimization unit, further cause the optimization unit to:
• use the measured surface temperature data to determine whether an upset occurred;
• determine a model fitting parameter for a process model for the chemical plant based on the reconciled surface temperature data;
• adjust a cut point of the chemical plant or a tray efficiency of the chemical plant to minimize differences between measured performance of the chemical plant and predicted performance of the chemical plant;
• optimize the process model using the model fitting parameter for the process model for the chemical plant;
• determine a maximum capacity of the furnace based on the measured surface temperature data for the tube inside the furnace;
• and
• an analysis unit comprising:
• one or more processors of the analysis platform;
• a memory storing executable instructions that, when executed by the one or more processors of the analysis unit, cause the analysis unit to:
• receive historical performance data for the chemical plant;
• establish relationships between operational parameters related to a process of the chemical plant;
• analyze the historical performance data for the chemical plant as trends over time to identify indicators of process problems for the process of the chemical plant;
• determine target operational parameters of a final product of the chemical plant based on the historical performance data for the chemical plant;
• and
• predict a limit of the process of the chemical plant based on the target operational parameters of the final product of the chemical plant;
• and
• an output interface comprising:
• a display device;
• one or more processors of the output interface;
• a memory storing executable instructions that, when executed by the one or more processors of the output interface, cause the output interface to:
• generate, for interactive display to an operator of the chemical plant, one or more detailed screens relating performance of the chemical plant to operating variables of the chemical plant;
• generate and deliver a report showing actual performance of the chemical plant compared to predicted performance of the chemical plant;
• provide, to the operator of the chemical plant, alternatives for improving or modifying future operations of the chemical plant, the alternatives comprising operational changes and revamp modifications to generate improved performance of the chemical plant;
• and
• recommend, to the operator of the chemical plant, the target operational parameters of the final product of the chemical plant;
• wherein the reconciliation unit performs a heuristic analysis against the measured surface temperature data and a process model result using a set of predetermined threshold values.