Plant Data in Aspen Plus

Products: Aspen Plus

Last Updated: 19-Jun-2024
Versions: V11.0, V10.0
Article ID: 000050206
Primary Subject:

Solution

This document summarizes an 8 part video series. Attachments are reproduced below for easy downloading.
Find used files in the video series attached to this document below.

View Plant Data in Aspen Plus how-to video series

In this module, we will explain and demonstrate how to incorporate plant data into the Aspen Plus
simulation environment. This allows mapping of the plant measurement tags to simulation
variables. We will begin by describing installation of the plant data feature. Then, we will describe
and demonstrate how to prepare, import, condition, and use plant data to validate your simulation
from within the feature. A similar module can be found describing the plant data feature for Aspen
HYSYS.

(1.) Installation of MES Components

Describes what programs are required to access the plant data feature.
Discusses some solutions to common installation problems.

Script

The Plant Data Feature within Aspen Plus and Aspen HYSYS uses real plant measurements to create
accurate simulations of your plant within the Aspen Engineering Suite. Aspen OnLine must be
installed in conjunction with Aspen Plus or Aspen HYSYS in order to access Plant Data
functionalities. Otherwise, the Plant Data ribbon will not be available in Aspen Plus or Aspen HYSYS
menus.

Aspen OnLine is installed alongside the Aspen Plus, Aspen HYSYS, or Aspen Exchanger Design and
Rating programs. Otherwise, it can be installed by selecting a custom installation within the
AspenONE installer. When prompted which programs to install, under Server Products and Tools,
select Aspen Online in addition to any other AspenTech programs you will be using.

To import plant data from a data historian to Aspen Plus and Aspen HYSYS, the user must configure
an ADSA Data Source using ADSA Client Config Tool. If ADSA Client Config Tool is not available
on the client machine, it can be installed from AspenTech Manufacturing and Supply Chain (MSC)
installation media by selecting the Aspen Desktop Application.

(2.) Understanding Process Workflow

 Describes the general workflow for using the plant data feature.

Script

Though the Plant Data feature has slight variations between Aspen Plus and Aspen HYSYS, the general
workflow remains the same within the feature. We begin by collecting and importing plant data. This can be
done from either Excel or a data historian. We condition the data to address outliers and differences in
sampling times, and map the model variables to plant tags to estimate the model parameters. This allows us
to execute the model using the plant data, validate the model results against plant measurements, and
investigate relationships between variables. Snapshots can facilitate in troubleshooting model convergence
issues, or act as restorative files.

The plant data feature is contained within the ribbon of Aspen Plus and Aspen HYSYS. Between these two
programs, the plant ribbon has nearly identical features. In addition to the ribbon, it is also possible to access
the data from the Navigation Tree.

(3.) Preparing Plant Data

Demonstrates how to access the plant data templates.
Demonstrates how to modify the templates to add data, constraints and other information.
Demonstrates preparing data for use in further demonstrations.

Script

The template for the Excel files can be found within the Plant Data ribbon, and can be saved and
amended as necessary. Faulty readings can be addressed, and supplementary measurements can be
added to the data set. For the demo, a data historian and supporting files are supplied.

In Aspen Plus, open the plant data example file "C2SEO". This file simulates a distillation column
separating ethane, ethylene, and trace methane. We will use it to investigate fouling within the column
reboiler. The template for measurements can be found in the Plant Data tab, under Tools. Let's edit a
file with Tag Names as the Row Labels. Here, we can add the start and end date, notes, and tag
information. The edits needed for this example have been completed, and saved as a file named
"C2S_PlantData_Task4_Completed". From the explorer, find the "C2S_PlantData_Task5" Excel file.
Changes made to this file include the introduction of bounds for the top tray temperature, an override
tag for a faulty bottom temperature reading, an override value for the bottom temperature secondary
sensor, and a formula tag that can be used to estimate the reboiler vapor flow. These changes can be
seen in the file "C2S_PlantData_Task5_Completed".

(4.) Importing Plant Data

Demonstrates how to import data into Aspen Plus.
Demonstrates how to set units of measurement for the data.

Script

Plant data can be imported from a data historian or from Excel files. We need to ensure that the units of
measurement are cohesive between the measured tags and the model.

Run the file in order to build the EO model. Navigate to the Plant Data tab, and from Get Plant Data,
upload the data historian. Select every data set and import them. Do this again for the
"Task4_Completed" and "Task5_Completed" Excel worksheets. Scan through the data to see warnings
for the values of F2000, T1204, and T2304. Before we condition the data, we need to ensure that the
 units are cohesive between the measured tags and the model. Select Tag Unit of Measurement, and
select the correct units. If the wrong unit has already been assigned by mistake, uncheck the "only
update dimensionless" checkbox before applying your changes.

(5.) Conditioning Imported Plant Data

Demonstrates how to average data over a specified time frame.
Demonstrates how to address bad data points by clamping or replacement.
Demonstrates how to determine if parameters are at steady state.

Script

Conditioning the data will provide the program with a protocol for addressing bad data. Protocols can
include “clamping” a tag to within a certain range, replacing a tag with another value when the current
value is erroneous, or replacing the tag with a secondary tag. This last example proves useful when
redundant sensors are used.

Enter the Tag Manager, check the Averaging checkbox, and set an average period of sixty minutes for
all tags. This will smooth the data to reduce noise by averaging all plant measurements in the last sixty
minutes. Next, check the Data Validation checkbox to allow for tag validity checking and bad quality
value overrides. It is possible to set limits of the plant measurements, such as lower and upper limits of
zero and forty metric tons per hour for F1000, the feed flow into the column. Check off the clamp
checkboxes for F1000 and T1204, the top tray temperature reading. If these plant measurements are
beyond the limits, the values will be clamped to the defined lower or upper limit values. As shown in
the Raw Data form, the reboiler vapor flow measurement F2000.PV is not of good quality. To
override the raw value with a default value, we can either specify a constant overriding value in the
field Override Value (Decimal), or use an alternative tag. The alternative tag could be a secondary
plant measurement, or a formula tag whose value is estimated from other plant measurements. Formula
tag F2000.IV, whose value is estimated from the plant measurement for the bottom product flow, will
be used to replace the plant measurement F2000.PV. Notice that tag T2304 is set to be replaced by tag
T2334, a redundant sensor. Finally, it is possible to ensure that key tags have reached steady state.
Select the steady-state detection checkbox. For F1000.PV, add a tolerance of four, a trend tolerance of
four, and a time span of sixty minutes. This will add steady state detection criteria for the plant data set.
The flow into the column must be at steady state in order to be considered a good data set. Changing
the tolerance and trend tolerance will change the criteria for steady state. Now we can click condition
data to prepare the data for use in the simulation by applying the settings we have entered.

(6.) Mapping Model Variables to Tags

Demonstrates how to map a simulation to the plant measurements.
Demonstrate how to prepare model parameters for plotting and analysis.

Script

In order to use plant data to calibrate the model, we need to map the model variables to the plant
measurements. This will allow for us to execute the model using the plant measurements as
reconciliation inputs. Any output variables that we want to investigate must be added to the
variable/tag mapping form as well; otherwise, we can’t see possible relationships.

Either Sequential Modular or Equation Oriented variables can be mapped in Aspen Plus. Add the
variables to the variable/tag mapping form by copy and paste. In this demo the EO variables of interest
can be found from the Navigation Tree under Flowsheeting Options, Measurement,
C-2-Splitter-Measurement, EO Variables. Here, we copy the model variables from the flowsheet.
 Under the plant data ribbon, we click Select and Map Variables, and paste the copied variables into
the form. We repeat this process to add in the reboiler overall heat transfer coefficient, column
efficiency, and column feed ethane fraction. Now, we map the source tags, matching the tag name to
the source tag. For EO enabled flowsheets, it is possible to automatically map selected EO variables
with plant tags. Click Tools, then Map Tags to Measurements to open the window. This method will
not copy the variables ending in offset or model. If the tag name under the measurement block is
specified, its name will automatically be populated. Select the EO variables to be mapped to tags, and
click the map button.

(7.) Running Model and Analyzing Results

Demonstrates how to run the simulation using plant data.
Demonstrates how to view the results.
Demonstrates how to plot specific tags to investigate relationships between them.

Script

We need to configure the run sequence in order to utilize the conditioned data sets and their mappings.
This will also allow for comparison and graphing of the different trials.

Under Plant Data, click Manage Run Sequence and Add a new run sequence. Check the details of
the sequence, and Add the conditioned data sets. We can Run the model, and the model results will be
analyzed against the plant data. Once the model runs are complete, we can Analyze the results. Simply
select the desired data sets, and Compare. Results can be Plotted by selecting specific variables,
choosing which variable to appear on the X axis, and plotting the data. If it is not necessary to have a
variable on the X axis, time can be used instead.

(8.) Troubleshooting Convergence with Snapshots

Describes what snapshots can be used for.
Demonstrates how to create a snapshot.
Demonstrates how to view and restore snapshots.
Demonstrate how snapshots can help investigate model accuracy.

Script

A snapshot is a collection of the values of selected variables saved in a model solution. The snapshot
can facilitate in troubleshooting model convergence issues, or act as a restorative file. For example, it is
possible to roll back the mapped variables to the values prior to the run execution. For each model
execution against each selected data set, a snapshot is generated right before and after the model
execution. Note that only the values of the variables added to the variable/tag mapping form will be
saved in the snapshot.

Snapshots can be accessed under the Plant Data tab with the button Manage Snapshots. Here, you
can create a new snapshot to preserve the current variable values, view a snapshot to see deviations
from current variable values, or restore the snapshot to set the current variable values to those stored
within the snapshot.