Domain : Manufacturing-Oils and Gases Context : In Air separation unit High Capacity compressor and High Capacity turbine are very sensitive equipment which operates at very high pressure and high speed, temperatures and expansion ratios, here the key is how this high precision process to be operated stable absorbing all the noises external and with in process noise and deliver a consistent parameters output values so that requirement of process is met, unless these this condition is met the process control always unpredictable and with quality variations. Intent : The intent was to build a Artificial Intelligence Predictive and control Model even from start of the process and then maintaining the End to End stable process parameters which leads to better temperature and flow distribution and pressure ratios to attain the desired cryogenic product out put. It was clear decision and direction of business to deploy a BB Project to achieve the first level of consistent Sigma value of grater than or Equal to 3.0 and later to review on improving further. HOW and what considerations are made to build the below AI Model : AI has emerged has assistant, guide and consultant to review the present process conditions been operated based on real online data and analyse that in real time in few seconds and make the suitable decision to the bring the process bias, to reflect the process output the intended output. To build the trust on AI Model by the operator, process operation team we have involved then in the design, considered all technical details, design conditions of the Air compressor and Turbine and communication flow to End to End stake holders and taken all suggestions that would call a need for inclusion in the AI Model as Operators and Process Owners being the face of the process and close to reality they know the process very well. When Should People ''Trust'' an AI’s Recommendation : I will give a real example : The operators and shop floor people are the owners of the process, they believe only when the AI model delivers a result which is as expected by them for their process objectives and centre line management KPI given for each parameters. First Confidence with Simulation : So considering this point we have engaged the shop-floor team and operators in design and development to assure that how its build to take them in trust first, with their suggestions and then the same Operators and process owners were participated in simulation of the AI model, They run by themselves seen the output and given the feedback for corrections and fine-tune, many times they accepted the results also. the expected results in the same. ''First Trust'' after 2nd-Simulation & Dry Run : The logics and model were corrected based on End to End review and asked the Operators and process owners re-perform the simulation once again in presence of technical experts, The results to operators and process owners found to be favourable. ''Evident proof of trust'' on AI Model during Commissioning and Go-Live & Post Go-Live : The plant, Air compressor and Multiple turbines were started and taken in line with AI Model predictive & Control system, Found to be favourable with expected desirable result and stable process parameters with in control limits, observed the simulation nodes and possible deviation would lead to failure and the bais, taken control to verify the observed deviation optimized further for the consistent stability of parameters. Positive Business outcome : For Air Compressor : Achieved the Process capability of 1.25 and with a sigma Value of 3.75 For Turbine : Achieved Process capability of 1.42 and with a sigma Value of 4.26. Customer satisfaction due to improved product quality, due to consistency in Online supply to customer. Savings in Power consumption Savings idle running of equipment and deterioration. Realization of product soon after few hours of Factory start up. Measures taken to sustain the developed Trust : Regular Audits & AI performance review Documentation until complete sustenance System alarm tracking/decision lists of shifts MOC, Management of Change method implementation Clear accountability (list of monitors, approver, in charges, especially on Logical changes) Review for bias, fairness, and Legal & regulatory compliance Maintain deviation logbooks for each parameter, failures against the target values AI Model performance review, correction, maintenance and development : Review the performance of the AI system on continuous basis with team and adapt the necessary change to be brought in to the model new dynamics. Take all the learnings from the feedback given by the alarms of system and people. Training and communication Ensure each and every change in the model is communicated to the end to end team members and provide full necessary training on the actions to take. Example, if AI Model is to be over rided by Manual control or visa versa from manual control to AI Model, Ensure to provide hands on experience. 2nd part of the Question : When Should the operator and process Owners should Override AI Model. AI Model doesn’t provide a Permanent Fix, it’s not a solution or application which is not affected by any External or Internal Factor, so considering this we have designed ‘’alarm’’ system which AI predicts the deviation which is out of it’s control and informs the user to take necessary action either online with AI or by taking AI in OFF Mode and override manually to control the process until the External or Internal factors are nullified and then take back the AI Model in line once the noise factor really disappeared. One of the example of External Noise factor for which AI Model has to be taken off and Manual Human Override has to happen. AI Model can’t accommodate the dynamic process variation of downstream or upstream caused due to sudden Pressure fluctuation by control valve malfunction, power frequency variation. This surge in Power frequency or Power factor leads sudden dip in Compressor pressure, RPM and Turbine RPM and expansion ratio. During the above situation if the process is not taken in control sure it leads to destable the whole plant , plant will shutdown different out of control settings, so It’s necessary to take the process out of AI Predictive control and operate manually to bring the process under control and then after manual stabilisation give back the control to AI Model. Conclusion : AI has emerged has assistant, guide and consultant to review the present process conditions been operated based on real online data and analyse that in real time in few seconds and make the suitable decision to the bring the process bias, to reflect the process output the intended output. But AI Model doesn’t provide a Permanent Fix, it’s not a solution or application which is not affected by any External or Internal Factor and it’s not one time installed or invested and forgotten, it’s to be tracked and treated as element of evolution and a process of Continuous improvement and evolution really holds good for this to assure system should not fall behind when the AI solution keeps merging with new horizons. As additional details : How above AI enabled Model was developed and the major steps followed as below : Risk & Bias : The whole process was studied for Severity of failure Air compressor and Multiple Turbines, occurrence and detection, especially on detection failure at each step of the process and instruments while incorporating the logics for predictive model, bias limits were identified, precision modelling were used to arrive at the accuracy of the flow meters and control valves, power and power factor tuning for ramp up and ramp down. Model definition : AI predictive Model was developed by considering historical manual operations data, Risk thresholds, keeping continuous sustainable focus with Model metrics, logical validation, establishing stability and calibration of all instruments and analysers. Simulation & Dry Run : The developed model was tested on dry run simulation for Air compressor and Multiple Turbines to see the model is a best fit and need of correction and fine tuning for desired output, simulation run was executed to identify all the predictive proposal based on assumption for the defined out put of each process parameters, power settings, pressure out outs, temperature, speed of turbines, inlet and out let pressures, temperatures, Valves, pressure relief valves, sensors with the reduced bias. Process conditions of Air compressor and multistage turbines and instrumentation output was measured and noted, temperature and pressure requirements at each process/instrument outputs, logics were corrected, replaced, fine tuned for desired output. Commissioning and Go-Live & Intended sustenance overtime : The plant was taken in line with AI Model predictive & Control system, observed the simulation nodes and possible deviation would lead to failure and the bais, taken control to verify the observed deviation optimized further for the consistent stability of parameters of Air compressor and Multiple Turbines and achieved the Process capability of 1.25 and with a sigma Value of 3.75 and for turbine parameters achieved Process capability of 1.42 and with a sigma Value of 4.26.