new deltav module templates to easily configure, view, and trend advanced pressure diagnostics
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New DeltaV Module Templates to Easily
Configure, View, and Trend Advanced
Pressure Diagnostics
PresentersPresenters
Tom Wallace
Erik Mathiason
Introduction: Easier implementation and use of SPM in DeltaV Introduction: Easier implementation and use of SPM in DeltaV Any of this sound familiar? Brief review of Statistical Process Monitoring (SPM) Requirements Typical obstacles to implementing SPM The Engineering solution The Operator solution How to get started (topics working together) Summary & Resources
The Challenges: Any of this sound familiar?The Challenges: Any of this sound familiar?
I don’t need you to tell me something bad just happened. I needed you to tell me 20 minutes ago so I could have prevented it.
We used to have a guy who could do that. I keep fixing the same problem over and over and over…. I’d love to be proactive, I’m just too busy reacting to get to
it. If it takes more time or requires additional training, we
don’t do it.
Brief review of Statistical Process Monitoring (SPM)
Why use Device Based SPM?Higher Frequency NoiseWhy use Device Based SPM?Higher Frequency Noise
Statistical Process Monitoring (SPM) turns process noise into valuable informationStatistical Process Monitoring (SPM) turns process noise into valuable information
The 3051S Analyses High Frequency Noise (High Pass Filter)The 3051S Analyses High Frequency Noise (High Pass Filter)
The
Process
The Host
Low Frequency
The 3051S
High Frequency
Host SPM and 3051S SPM are complementary
What is actually detected?What is actually detected?
Key
SD = Standard Deviation
M = Mean
CV = Coefficient of Variation
SD 1 plugged line
SD 2 plugged lines
SD SD
CV
SD
Frequency specific
These are general patterns. Actual M, SD, and CV are very different from
process to process. SPM can’t identify the specific cause without the user.
SD
CV
SD
CV
SD
Frequency specific
Process the data in the transmitter, display, record, display, annunciate, and analyze in the hostProcess the data in the transmitter, display, record, display, annunciate, and analyze in the host
Better in the transmitter Capture data & calculate
SPM variables– Transmitter gives higher
frequency information (22 Hz)
– Detects conditions not visible at host sampling frequencies
Individual variable SPM Adaptive limits and alert
values calculated
Better in the host Operator optimized
displays– Replace traditional
monitoring point displays Fingerprint the process
– Use device generated SPM data
Data historian with time synched alarms
Alarm management Multi-loop SPM and
optimization
Typical Engineering Obstacles to Implementing SPM DiagnosticsTypical Engineering Obstacles to Implementing SPM Diagnostics
User design tasks– Learn enough about SPM to design and implement appropriate
monitoring strategies– Determine protocol and diagnostics version requirements– Design and document monitoring strategy by protocol and version– Design and document configuration module templates– Design and document operator faceplates– Design alarm management strategy– Design data historian configuration
User configuration tasks– Configure linked variables to control blocks– Configure alarm management logic– Determine and set alarm limits– Configure Process History View– Configure operator faceplates
The Engineer Solution
The RequirementsThe Requirements Configuration Engineer requirements
– Eliminate up-front design time and minimize configuration– Pre-engineer Process History View chart (with Alarms)– Work with HART or FF devices– Provide meaningful User Help
Operating requirements– Provide consistent but customizable operator faceplates
• Buttons launch Detail picture, PHV Trend, or Field Device View– Provide alarm management to automatically Enable /
Disable SPM alarms Process Engineer requirements
– Provide ability to fingerprint the process– Capture fast sample based time synchronized SPM data
and alarms
The Engineering Solution DeltaV 11+The Engineering Solution DeltaV 11+
Use Pre-Configured Control Module Templates– Separate Module Templates for HART and Foundation
Fieldbus– Named Set for SPM Variable Selection
Use Pre-Configured Process History View Charts– 4 Charts for HART Module Template– 4 Charts for Foundation Fieldbus Module Template
Use Pre-Configured Operator Faceplates– Faceplate and Detail pictures– Same pictures apply to both HART and Foundation Fieldbus
Use Provided User Help– Context-sensitive help within Control Studio– DeltaV Books On-line
The DeltaV and Rosemount 3051S Solution to Implementing SPM DiagnosticsThe DeltaV and Rosemount 3051S Solution to Implementing SPM Diagnostics
User design tasks– Learn enough about SPM to design and implement appropriate
monitoring strategies– Determine protocol and diagnostics version requirements– Design and document monitoring strategy by protocol and version– Design and document configuration module templates– Design and document operator faceplates– Design alarm management strategy– Design data historian configuration
User configuration tasks– Configure linked variables to control blocks (Link 2 to 4 parameters)– Configure alarm management logic (0 to 2 parameters)– Determine and set alarm limits (2 to 11 parameters)– Configure Process History View– Configure operator faceplates (Specify three parameters)
SPM Data: Linking VariablesSPM Data: Linking Variables
AI Blocks for PV (AI1),
Mean, and StDev
Pre-engineered
SPM Data: Linking VariablesSPM Data: Linking Variables
AI Block for CV
DA1: Calculated in DeltaV
DA2: Assigned to HART_FV
Pre-engineered
SPM Data: Linking VariablesSPM Data: Linking Variables
Calc Block Calculates CV
and SPM variable alarm
limits
Pre-engineered
ALARMS_ENABLED
Dynamically enable/disable
alarms using external logic
Prevent “flood of alarms”
Pre-configured
Configure SPM Alarm Management LogicConfigure SPM Alarm Management Logic
PV_LIM_MODE
If PV or Mean exceeds limits,
STDEV and CV alarms can be
disabled
Prevent nuisance alarms
Pre-engineered
Configure SPM Alarm Management LogicConfigure SPM Alarm Management Logic
HART Devices: Pre-configured CALC Block LogicHART Devices: Pre-configured CALC Block Logic
Calculating the Coefficient of
Variation (CV)
Determining if Mean (or PV)
Exceeds Limits
Enabling and Disabling Std
Dev Alarms
Set Alarm LimitsSet Alarm Limits11 Alarms Pre-Configured
Alarms from AI Module
• PV High (HI_ALM)
• PV Low (LO_ALM)
• PV Hi Hi (HI_HI_ALM)
• PV Lo Lo (LO_LO_ALM)
• PV Bad (PVBAD_ALM)
Additional Alarms for SPM
• Mean High (MEAN_HI)
• Mean Low (MEAN_LO)
• StDev High (STDEV_HI)
• StDev Low (STDEV_LO)
• CV High (CV_HI)
• CV Low (CV_LO)
Default Disabled
DEVICE_TAG
Access device information
from
AMS Device Manager
Pre-engineered
Configure SPM Operator FaceplateConfigure SPM Operator Faceplate
Configure Operator FaceplateConfigure Operator Faceplate
FP_VAR_#
Specifies SPM variable(s)
to show on the Faceplate
Pre-engineered
Process History View ChartProcess History View Chart
PV or Mean
with Limits
StDev or CV
with Limits
Alarms and
Events
List of
Variables
Abnormal Event
Entrained Air
Abnormal Event
Cleared
DST’s, FF segment loading, template modification & reuseDST’s, FF segment loading, template modification & reuse
DST’s– HART Devices, 1 DST for all parameters– FF Devices, 1 DST for all parameters
FF segment loading– 3 links per FF device if scheduled communications is used– 0 links per FF device if unscheduled communications is
used Template Modification
– Template can be user modified as desired Template content reuse
– Template content can be used all or in part in other templates
– Template content can be used, unmodified or modified, by any licensed DeltaV user running V11 or newer
The Operator Solution
Pre-configured SPM Faceplate (HART and FF) Show Maximum of 2 SPM VariablesPre-configured SPM Faceplate (HART and FF) Show Maximum of 2 SPM Variables
SPM Variable 1:
PV or Mean
SPM Variable 2:
StDev or CV
StDev and Alarm
Limits
StDev and Alarm
Limits
StDev and Alarm
LimitsStDev Alarm
Faceplate Buttons
User enterable
faceplate name
Pre-configuredSPM Faceplate ButtonsPre-configuredSPM Faceplate Buttons
AMS Device Manager
(Device Dashboard Screen)
Detail Picture
Process History View
Acknowledge All
Primary Control Control Studio
Pre-configured SPM Detail Picture(Operator editable W/O Control Studio)Pre-configured SPM Detail Picture(Operator editable W/O Control Studio)
Overall Alarm
enable / disable
Alarms and
Configuration
Associated with PV
and SPM Blocks
Priority Adjustment
and individual
enable / disable for
Alarms
Pre-configured SPM Detail Picture(Operator editable W/O Control Studio)Pre-configured SPM Detail Picture(Operator editable W/O Control Studio)
Simulation Capability
used for Testing and
Operator Training
Pre-configured SPM Detail Picture(Operator editable W/O Control Studio)Pre-configured SPM Detail Picture(Operator editable W/O Control Studio)
Displayed
Variable
Selection
How to get started, experimentHow to get started, experiment Tap operator insight and intuition Make an educated guess on points and problems
– Pumps cavitate, agitators stop, columns flood, lines plug Paint with a broad or narrow brush, your choice Trend, establish what “normal” looks like
– Establish baseline when process is at steady state– Run with alarms disabled until you understand normal
Set alarm limits and run with alarms enabled– The 3051S automatically and adaptively calculates limits. Look at
those limits in AMS and input into DeltaV. When abnormal conditions occur, capture, analyze, adjust
How to get started, ask and help operatorsHow to get started, ask and help operators
Develop an operator reference book– Document what “normal” looks like (process signature)
• May need several based on plant operating parameters– Capture abnormal conditions and alerts generated
• Capture process signature of upstream, downstream, or related parameters that could have cause / effect relationship
– Identify and document earliest reproducible signature of abnormal condition
• This may be the monitored point, or upstream or related points– Capture corrective actions and process signature of
corrective actions.– Document most effective corrective actions as operator
guidelines
How to get started, engineer improvementsHow to get started, engineer improvements
Expect the unexpected– Experiment, we don’t know what we don’t know– Some points will reveal new insight, some won’t
Start with unmodified template– Understand what operators and other stakeholders find useful– Understand where and how to use it in your process
Modify the template or use parts in other templates slowly– Modification and reuse are good, but not required– Determine needs, modify, and document– Run trials and verify modifications work and deliver expected value– Adopt plant standards for use for each modified version
Stop where you’re comfortable
Business Results Achieved ExpectedBusiness Results Achieved Expected
Implementation– Reduced learning time– Eliminate design time– Reduce configuration time
Use– Additional process engineering insight
• Diagnose root causes• Eliminate root causes
– Additional operator insight• Anticipate and prevent abnormal situations• Reduce process upsets• Operate closer to limits
SummarySummary
SPM parameters are calculated in the 3051S pressure transmitter to capture higher frequency noise
Pre-engineered templates reduce cost, time, and required expertise Templates are provided for HART and FF devices Templates work with DeltaV version 11 and newer The Engineering Solution
– Control module templates The Operator Solution
– Trending– Operator faceplates– Operator detail displays
Templates can be used as-is, or modified
Where To Get More InformationWhere To Get More Information
The 3051S Kiosk at the Technology Exhibit DeltaV White Paper (need posting)
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