hemal desai emerson process management - … desai emerson process management mumbai fieldbus...

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© 2008 Fieldbus Foundation

2008 FFIMC-ISA Vadodara Event

Hemal DesaiEmerson Process ManagementMumbai

Fieldbus Foundation – India Marketing Committee

Technology Event

Predictive Intelligence in Devices & Systems

Date : 21st June, 2008 (Saturday)Venue : TROPICANA Conference Room. Hotel : Taj Residency,

Akota Gardens, Vadodara - 390 020 INDIA

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Predictive intelligence is property of device to senses process and equipment abnormalities that may go unnoticed...until they caused a process problem, shutdown or a quality problem.ABNORMAL SITUATION PREVENTION

Predictive IntelligencePredictive IntelligencePredictive Intelligence

DCS-Predictive Intelligence-Detect Anomaly-Generate Alert -Route Actionable Alert to

Right person at Right Time-Take action to prevent ASP

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Predictive IntelligencePredictive IntelligencePredictive Intelligence

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What is an Abnormal Situation?What is an Abnormal Situation?A disturbance or series of disturbances in a process that cause plant operations to deviate from their normal operating state resulting in Operator intervention with potential impacts:

Product qualityThroughputEquipment damagePersonnel injuryProductionEnvironmental

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What is an Abnormal Situation?What is an Abnormal Situation?

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Smart Business DevicesSmart Business Devices

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Traditional SystemTraditional System

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Traditional SystemTraditional System

Device Problem manifests as

process problem

PIC -101

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Smart System with PI capabilitySmart System with PI capability

FY -1

FY-1

No Low Pressure yet!

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Catch to problem before they occurCatch to problem before they occur

advanced warning = time to respond

Protection

Equ

ipm

ent H

ealth

0%

100%

Time

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Statistical Process MonitoringStatistical Process Monitoring

Analyze parameters like Std Dev, Mean, RMS, ROC, etcUses Pattern Recognition & Statistical MethodsApplicable to sensors measuring Pressure, Temperature, Flow & Level instrumentsProcess anomalies generally cause one of the five distinct patternsTransmitters & Valves are able to detect

– Drift: Sensor/Process output changes gradually;– Bias: Sensor/Process output shows a level change;– Noise: Dynamic variation in the sensor/process output is

increased;– Spike: Sensor/Process output is momentarily very high or

low;– Stuck: Dynamic variation in the sensor/process output is

decreased.

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Statistical Process MonitoringStatistical Process MonitoringStatistical Process Monitoring

DP Tx SPM Data

6/4 6/6 6/8 6/10 6/120.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

Source: ExxonMobil Baytown, TX Refinery

SPM data coming from

DP Tx helped predict catalyst

problem 30 min

in advance

23:30

23:00

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ChallengeImpulse lines can fill with solid material or freeze in cold environments due to heat trace failuresPlugging in one or both lines cause on scale failure (DP/AP/GP)Transmitter output appears normal

SolutionMonitor for changes in standard deviationPlugging in one or both lines cause significant change in standard deviation

SPM Variable Logging Advanced Process Alerts

Plugged Impulse LinesPlugged Impulse LinesPlugged Impulse Lines

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Plugged Impulse LinesPlugged Impulse LinesPlugged Impulse Lines

OK

OK

plugged

plugged

Both OK 1 plugged both plugged

HighSide

LowSide

SUM

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Fluid Composition Change Aerated LiquidFluid Composition Change Aerated LiquidFluid Composition Change Aerated LiquidChallenge

Undesired air bubbles are introduced into liquid flowMeasurement errors which may reduce product quality and equipment life

SolutionStandard deviation increases while mean decreasesSPM monitors for standard deviation value and triggers alert when value is reached


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Furnace Flame InstabilityFurnace Flame InstabilityFurnace Flame InstabilityChallenge

Feed is waste gases with varying BTU content; can cause flameoutFlameout is a dangerous condition -shutdown required, resulting in outage, restart and lost production time

SolutionSharp increases in standard deviation is an indicator of flame instability and a precursor to flameoutMonitor for significant increase in standard deviation with no mean change

Unstable Flame


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Rotary Equipment Wear Turbine BladesRotary Equipment Wear Turbine BladesRotary Equipment Wear Turbine BladesChallenge

Turbine blades wear out from liquids or solids in steamCostly repair and maintenanceReduces efficiency of plant

SolutionInstall an inline device to monitor line pressure noise to signal ratio of low pressure turbine bladesLook for changes in noise characteristics (standard deviation) and correlate to blade condition and ongoing wear

AP/GP DiagnosticTransmitter Location


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Application List using SPM in DPTApplication List using SPM in DPTApplication List using SPM in DPTPlugged impulse lines

Fluid composition changeAerated liquidWet gasWet steam

Furnace flame instability

DP LevelAgitation lossPlugged impulse lines (DP Level)

Accurate process alerts with variable logging

Pulsation induced measurement error

Orifice plate wear, reversed orifice plate

Pump or valve cavitation

Rotary equipment wearTurbine bladesCoal pulverizer primary fan

Pressure transient detection

Well problems in oil & gas production

Process leak detection

Catalyst circulation in FCCTesting Completed

Field Trial Under Progress

Proven

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Typical Drift Alert ScenarioSensor Drift Alert Activated

Typical Drift Over Time

+

0

_

Time

InitialMinimalDifference

User Definable

Drift Limits

DT

Temperature Sensor Drift AlertTemperature Sensor Drift Alert

Factory default:3.0 °C (5.4°F)

Digital AlertCommunicated

when ΔT exceedsuser defined limit.

ΔT measured betweentwo sensors measuring

same process temp.

ΔT changes whensensors drift apart.

What does Sensor Drift Indicate??• Temperature measurement no

longer reliable

What causes a sensor to Drift?• Extreme temperature swings• High vibration• Moisture attacks sensing

element due to poor mechanicalsensor construction

• Platinum element contamination

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Temperature Sensor Drift AlertTemperature Sensor Drift Alert

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Typical ScenarioAlert Activated

Time

InitialBaseline Resistence

Resis

Themocouple Degeneration AlertThemocouple Degeneration Alert

Monitors the HealthOf Thermocouple Loop

Key Applications• Wire runs are long (>50 meters)• There are multiple wiring terminations in the loop• The measurement is mission critical• High Temp Thermocouples• Loops with corrosive gases

DCS

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Themocouple Degeneration AlertThemocouple Degeneration Alert

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hemal desai emerson process management - … desai emerson process management mumbai fieldbus...

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