Control asset comparative performance analysis system and methodology

Abstract

A system and method is provided for determining the variability induced on a process output. The method includes the analysis of input variable values to determine the total variability. A series of processes may be analyzed and ranked so that a process owner may gain an understanding of how a target process performs relative to the processes of other process owners. The method includes the generation of graphical process comparisons and advice regarding asset performance. The method also includes the estimation of cost impacts due to changes in induced variability.

We claim: 
     
         1 . A computer-implemented method for generating advice to improve the economic value of an industry target process unit having a control application comprising the steps of:
 selecting a set of same industry process datasets comprising of process unit input and output variable values of units from the same industry as the target unit;   selecting a set of target process datasets comprising input and output variable values for the target unit;   determining the overall induced variability gaps for the set of same industry datasets and the set of target process datasets;   determining the overall output variability gaps for the set of same industry datasets and the set of target process datasets;   determining the overall variability reduction ratio gaps for the set of same industry datasets and the set of target process datasets;   rank ordering the same industry process units based on at least one overall variability category, wherein the categories include overall induced variability gaps, overall output variability gaps, and overall variability reduction ratio gaps; and   generating advice to improve the economic value of the target process based on comparing at least one target unit overall variability category to the same industry overall variability category.   
     
     
         2 . A computer-implemented method for generating advice to improve the economic value of an industry target process unit having one or more control applications, utilizing a variability graph comprising the steps of:
 selecting sets of same industry process units;   separating the process units into at least one category based on at least one overall variability, wherein the categories comprise:
 quartiles based on overall induced variability, and 
 quartiles based on overall output variability; 
   constructing a graph of the process units with at least one category displayed, wherein the graph comprises:
 lines dividing the processes into quartiles by overall induced variability gaps, 
 lines dividing the processes into quartiles by overall output variability gaps, and 
 radial lines extending from the origin dividing the processes into quartiles by overall variability reduction ratio gaps; 
   displaying overall induced variability and overall output variability of the target process on the variability graph; and   generating advice based on comparing the target unit's position on the graph.   
     
     
         3 . The computer-implemented method of  claim 2 , wherein:
 if the target process's overall output variability needs improvement but the target unit's overall variability reduction ratio gap is acceptable, the generated advice comprises reducing the target unit's overall induced variability; and   if the target process's overall output variability needs improvement but the target unit's overall induced variability gap is acceptable, the generated advice comprises improving the target unit's overall variability reduction ratio gap.   
     
     
         4 . The computer-implemented method of  claim 3 , wherein the target unit is a crude unit, wherein reducing the target unit's overall induced variability gap is accomplished by improving the variability of the feed rate, feed temperature, and feed API to the target unit. 
     
     
         5 . The computer-implemented method of  claim 3 , wherein reducing the target unit's overall variability reduction ratio gap is accomplished by improving the target unit's control applications. 
     
     
         6 . A system for generating advice to improve the economic value of an industry target process unit having a control application comprising:
 a server, comprising:
 a processor, and 
 a storage subsystem; 
   a database stored by the storage subsystem comprising:
 same industry process datasets comprising process unit input and output variable values of unites from the same industry as the target unit; and 
 operational performance datasets for the target unit comprising input and output variable values; 
   a computer program stored by the storage subsystem, when executed causing the processor to:
 select a set of same industry process datasets; 
 select a set of target process datasets; 
 determine overall induced variability gaps for the set of same industry datasets and the set of target process datasets; 
 determine the overall output variability gaps for the set of same industry datasets and the set of target process datasets; 
 determine the overall variability reduction ratio gaps for the set of same industry datasets and the set of target process datasets; 
 rank order the same industry process units based on at least one overall variability category, wherein the categories include overall induced variability gaps, overall output variability gaps, and overall variability reduction ratio gaps; and 
 generate advice to improve the economic value of the target process based on comparing at least one target unit overall variability category to the same industry overall variability category. 
   
     
     
         7 . A system for generating advice to improve the economic value of an industry target process unit having one or more control applications, utilizing a variability graph comprising:
 a server, comprising:
 a processor, and 
 a storage subsystem; 
   a database stored by the storage subsystem comprising:
 same industry process datasets; and 
 operational performance datasets for the target unit; 
   a computer program stored by the storage subsystem, when executed causing the processor to:
 select a plurality of same industry process unit datasets; 
 organize the process units into at least one category based on at least one overall variability, wherein the categories comprise:
 quartiles based on overall induced variability, and 
 quartiles based on overall output variability; 
 
 construct a graph of the process units with at least one category displayed, wherein the graph comprises:
 lines dividing the processes into quartiles by overall induced variability gaps, 
 lines dividing the processes into quartiles by overall output variability gaps, and 
 radial lines extending from the origin dividing the processes into quartiles by overall variability reduction ratio gaps; 
 
 display overall induced variability and overall output variability of the target process on the variability graph; and 
 generate advice based on comparing the target unit's position on the graph. 
   
     
     
         8 . The system of  claim 7 , wherein:
 if the target process's overall output variability needs improvement but the target unit's overall variability reduction ratio gap is acceptable, the generated advice comprises reducing the target unit's overall induced variability; and   if the target process's overall output variability needs improvement but the target unit's overall induced variability gap is acceptable, the generated advice comprises improving the target unit's overall variability reduction ratio gap.   
     
     
         9 . The system of  claim 8 , wherein the target unit is a crude unit, wherein reducing the target unit's overall induced variability gap is accomplished by improving the variability of the feed rate, feed temperature, and feed API to the target unit. 
     
     
         10 . The system of  claim 8 , wherein reducing the target unit's overall variability reduction ratio gap is accomplished by improving the target unit's control applications.