New DeltaV Module Templates to Easily Configure, View, and Trend Advanced Pressure Diagnostics

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


AI Block for CV

DA1: Calculated in DeltaV

DA2: Assigned to HART_FV

Pre-engineered


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


Simulation Capability

used for Testing and

Operator Training


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)

Education

New DeltaV Module Templates to Easily Configure, View, and Trend Advanced Pressure Diagnostics