Control & Alarms · Intermediate · 1 day

Process Monitoring, Soft Sensors and Early-Warning Limits

Turning historian data into inferentials, monitoring limits and alerts that fire before the alarm does

Duration1 day
LevelIntermediate
FormatOn-site · virtual
CodeTR-E05
SP PV 4.9SP 5.0 Kc · Ti · Td Alarm
Course flyer

Process Monitoring, Soft Sensors and Early-Warning Limits — one-page catalogue.

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Process Monitoring, Soft Sensors and Early-Warning Limits — one-page course flyer
Click the flyer to open the printable PDF.
Request this courseDownload the Training Request Form, quote course code TR-E05, sign and e-mail it to sales@cerasus.ai — or use the consultation form below.
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At a glance

What you will be able to do.

Process, control and operations engineers responsible for unit monitoring; APC support engineers; anyone setting operating envelopes and daily-report limits

Every plant historian holds years of data that nobody looks at until something has already tripped. This course teaches practical monitoring: which variables actually indicate unit health, how to build and validate a regression or first-principles soft sensor for a lab-measured property, and how to set early-warning limits that catch drift in fouling, catalyst activity or column loading days before the alarm. Participants work on their own tags in CeraTrace.

  • Select and clean historian data: sampling, compression, outliers and steady-state detection
  • Build a linear or PLS inferential for a lab property and validate it against lab samples with bias update
  • Distinguish operating envelopes, safe operating limits and early-warning limits and set each correctly
  • Apply statistical limits, trend-based and multivariate (PCA) methods to detect abnormal drift
  • Design monitoring displays and daily reports that operations will actually use
  • Maintain soft sensors and limits under management of change
Course outline

Day by day

Morning

What to monitor: key performance variables, constraints and degradation indicators · historian data quality: compression, sampling, time alignment with lab data · steady-state detection and data reconciliation basics · building an inferential: variable selection, regression, PLS, first-principles · validation, bias update and lab-sample handling

Afternoon

Operating envelope vs safe operating limits vs early-warning limits · statistical and trend-based limits · multivariate monitoring with PCA and contribution plots · early-warning alerts and their relationship to ISA-18.2 alarms · dashboards and daily reports in ProcessVision · workshop on participants' own unit data · maintenance and MOC

Standards referenced
ISA-18.2
ISA-101
ISO 13374
ISO 17359
API RP 554
Request a consultation

Tell us about the unit and the problem.

Send a short brief — plant, service of interest and what you need to achieve — and a Cerasus engineer will respond with a proposed scope and next steps.

Prefer email or phone? sales@cerasus.ai · +974 5506 2743