Abstract: A method and system for detecting and/or predicting abnormal solids buildup in a main fractionator bottom of a fluid catalytic cracking system measures one or more process parameters of the fluid catalytic cracking system (such as a differential pressure across a reactor cyclone, a noise after the main fractionator bottom, a heat transfer at the steam generator, and/or a differential pressure across the main fractionator) and determines abnormal solids buildup when the measured process parameter(s) changes significantly from a baseline value. The method and system implements algorithms using computing devices to detect or predict an abnormal condition based on the change in the process parameter.

Abstract: A method and system for monitoring a process in a process plant includes collecting data from a process control system within the process plant, where the data is representative of a normal operation of the process when the process is on-line and operating normally, performing a multivariate statistical analysis to represent the normal operation of the process based on a set of collected on-line process data comprising a measure of the normal operation of the process when the process is on-line and operating normally, and representing a real-time on-line operation of the process using monitored on-line process data comprising a measure of a real-time operation of the process when the process is on-line as an input to the representation of the normal operation of the process.

Abstract: A system and method for detecting abnormal operation of a hydrocracker includes a model to model the hydrocracker. The model may be configurable to include one or more regression models corresponding to different operating regions of the portion of the hydrocracker. The system and method may also determine if a monitored temperature difference variable deviates significantly from the temperature difference variable predicted by the model. If there is a significant deviation, this may indicate an abnormal operation.

Abstract: A system and method for detecting abnormal situations associated with a stirred vessel in a process plant receives statistical data associated with a pressure within a stirred vessel. A pressure signal associated with the pressure in the vessel is filtered by a digital filter to isolate a frequency component corresponding to pressure changes caused by the movement of a blade of an agitator through a fluid. For example, a pressure sensor device disposed at least partially within the stirred vessel may generate the statistical data based on a pressure signal. The statistical data is analyzed to detect whether one or more abnormal situations associated with an agitator of the stirred vessel exist. For example, the statistical data may be analyzed to detect whether the agitator is broken/unbalanced, corroded, missing a blade or multiple blades, etc. If an abnormal situation is detected, an indicator of the abnormal situation may be generated.

Abstract: A system and method to facilitate the monitoring and diagnosis of a process control system and any elements thereof is disclosed with a specific premise of abnormal situation prevention in a heat exchanger. Monitoring and diagnosis of faults in a heat exchanger includes statistical analysis techniques, such as regression and load following. In particular, on-line process data is collected from an operating heat exchanger. A statistical analysis is used to develop a regression model of the process. The output may use a variety of parameters from the model and may include normalized process variables based on the training data, and process variable limits or model components. Each of the outputs may be used to generate visualizations for process monitoring and diagnostics and perform alarm diagnostics to detect abnormal situations in the heat exchanger.

Abstract: A system and method of monitoring and diagnosing on-line multivariate process variable data in a process plant, where the multivariate process data comprises a plurality of process variables each having a plurality of observations, includes collecting on-line process data from a process control system within the process plant when the process is on-line, where the collected on-line process data comprises a plurality of observations of a plurality of process variables and where the plurality of observations of the set of collected process data comprises a first data space having a plurality of dimensions, performing a multivariate statistical analysis to represent the operation of the process based on a set of collected on-line process data comprising a measure of the operation of the process when the process is on-line within a second data space having fewer dimensions than the first data space, performing a univariate analysis to represent the operation of the process as a multivariate projection of the on-l

Abstract: A system and method of monitoring and diagnosing on-line multivariate process variable data in a process plant, where the multivariate process data comprises a plurality of process variables each having a plurality of observations, includes collecting on-line process data from a process control system within the process plant when the process is on-line, where the collected on-line process data comprises a plurality of observations of a plurality of process variables, performing a multivariate statistical analysis to represent the operation of the process based on a set of collected on-line process data comprising a measure of the operation of the process when the process is on-line, where the representation of the operation of the process is adapted to be executed to generate a result, storing the representation of the operation of the process and the set of collected on-line process data, and generating an output based on a parameter of the representation of the operation of the process, where the parameter

Abstract: A number of techniques are disclosed to facilitate process data collection and monitoring. The techniques may involve and support the selection of process parameters to be monitored, including scanning techniques for automated identification of such parameters. The techniques may also involve the management of data storage and archiving operations to facilitate continued process data collection arising from an on-line process. In these and other ways, the disclosed techniques are well-suited for process data collection and monitoring in connection with diagnostic elements of a process control system and other contexts involving process status indicators and the underlying process variables.

Abstract: A number of techniques are disclosed to facilitate process data collection and monitoring. The techniques may involve and support the selection of process parameters to be monitored, including scanning techniques for automated identification of such parameters. The techniques may also involve the management of data storage and archiving operations to facilitate continued process data collection arising from an on-line process. In these and other ways, the disclosed techniques are well-suited for process data collection and monitoring in connection with diagnostic elements of a process control system and other contexts involving process status indicators and the underlying process variables.

Abstract: In methods and systems that may facilitate detecting abnormal operation in a process plant, values of a process variable are analyzed to determine whether they significantly deviate from expected values. If there is a significant deviation, an indicator may be generated. Analyzing the process variable may include, for example, utilizing a plurality of thresholds determined based on statistics of the process variable. Analyzing the process variable may also include, for example, determining whether a first number of values of the process variable are in a first region, and whether a second number of values are in a second region.

Abstract: In methods and systems that may facilitate detecting abnormal operation in a process plant, values of a process variable are analyzed to determine whether they significantly deviate from expected values. If there is a significant deviation, an indicator may be generated. Analyzing the process variable may include, for example, determining whether a number of values of the process variable are increasingly deviating from expected values, or determining whether the process variable is cycling. Analyzing the process variable may also include, for example, processing and analyzing the process variable to determine whether the process is in a normal state, one or more abnormal states, or an indeterminate state.

Abstract: A system for detecting abnormal operation of at least a portion of a process plant includes a model to model at least the portion of the process plant. The model may be configurable to include multiple regression models corresponding to multiple different operating regions of the portion of the process plant. The system may also include a deviation detector configured to determine if the actual operation of the portion of the process plant deviates significantly from the operation predicted by the model. If there is a significant deviation, this may indicate an abnormal operation.

Abstract: A method of modeling a heat exchanger is disclosed and comprises assigning input temperatures, assumed output temperatures, and a set of flow rates, inputting the parameters into a set of equations arranged to calculate a heat transfer coefficient, inputting parameters into a second set of equations arranged to calculate output temperatures, substituting actual output temperatures for the assumed output temperatures, and again calculating the heat transfer cooefficient. The new heat transfer coefficient is then used to obtain revised actual output temperatures, and the initial actual output temperatures and the revised actual output temperatures are compared to determine whether they differ by less than a desired variance. If not, a new iteration is performed until the output temperatures converge.

Abstract: A weight estimating system for estimating the weight of a mailpiece and a postage metering system including such a weight estimating system. The weight estimating system includes a measuring system, a diverter mechanism and a microprocessor system. The measuring system includes a transport, a first plurality of detectors for measuring the dimensions of the mailpiece and a second plurality of detectors for measuring values of other characteristics of the mailpiece which are indicative of the presence of non-paper materials in the mailpiece as the mailpiece is transported. The microprocessor is responsive to the second detectors to determine if non-paper materials are included in the mailpiece and, if not, determines the volume from the dimensional measurements and estimates the weight as the product of the volume and a density for paper output an appropriate postage amount to the meter and the mailpiece to the printer.

Abstract: An internal combustion engine's start-up torsional disturbances are reduced by drawing down intake manifold pressure prior to engine cranking. In a preferred arrangement, a secondary air injection reaction pump is adapted for evacuating the intake manifold to effect the desired draw down of the intake manifold pressure.

Abstract: A system detects abnormal conditions associated with a process plant. The system receives signal processing data generated by signal processing data collection blocks implemented by a plurality of devices. The signal processing data collection blocks may generate data such as statistical data, frequency analysis data, auto regression data, wavelets data, etc. The system includes an analysis engine configured to detect at least one abnormal condition associated with the process plant. The signal processing data is provided to the analysis engine, and the analysis engine determines if an action should be taken.

Abstract: A printing apparatus and method to for use in a continuous high velocity mail production system, preferably for printing postal indicia. A transport path conveys a series of mail pieces at a print velocity. At least two ink jet print heads are available to perform printing operations. During normal operation, only one print head is operating at a time. To allow continuous uninterrupted operation, when a first print head is removed from service for a maintenance operation, a second print head is automatically brought into service. Adjustments to the triggering of the print cycle are made to account for the different print heads at different locations.

Abstract: A dynamic registration device for a mailing system that reduces the problems of dust generation, ink smearing, and print head contact is provided. The biasing force normally applied to the back panel of a mail piece, such that the front panel maintains contact with a registration plate, is controlled by an actuator such that the force can be removed when the printing module is not performing the actual printing process. Thus, the biasing force can be applied only when the print head is actually printing and the biasing force can be removed once printing has been completed. In other embodiments utilizing multiple printing modules, when one of the printing modules is inactivated, the biasing force can be removed, and the mail pieces pass through the inactive printing module without being registered against the top registration plate.

Abstract: A top registration transport mechanism and method for a mailing machine is provided. The transport mechanism includes one or more displaceable rollers that have a diameter larger than the drive/idler rollers. A semi-elastic belt is looped around the drive/idler rollers and displaceable rollers. The larger diameter of the displaceable rollers causes a portion of the transport belt in the area of the displaceable rollers to be slightly raised. The registration plate can contact the raised portion of the belt to displace the belt and displaceable rollers, thereby ensuring that very thin mail pieces can be effectively processed by the transport. As thicker mail pieces traverse the transport, the displaceable rollers can be further displaced before the entire transport mechanism must be displaced to maintain registration of the mail piece against the bottom of the registration plate.

Abstract: A device for moistening an envelope flap includes a mechanism which defines an envelope feed path and a plate disposed adjacent the envelope feed path. The plate passes between the envelope body and the envelope flap. A plurality of orifices formed in the plate discharge moistening fluid received from a reservoir onto the envelope flap. The moistening device also includes a valve mechanism to selectively supply each of the orifices with moistening fluid from the reservoir. A flap sensing mechanism is disposed adjacent the envelope feed path for sensing an edge portion of the envelope flap and operatively connected to the valve mechanism to supply signals to the valve mechanism to selectively actuate the valve mechanism to selectively supply moistening fluid to the orifices in response to the sensing of the edge portion of the envelope flap.