Advanced Diagnostics: 4 Steps to Better Decision Making
Advanced DiagnosticsAdvanced Diagnostics: : 4 Steps to Better Decision 4 Steps to Better Decision MakingMaking
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PresentersPresentersPresenters
Bill ZhouProduct Marketing [email protected]
Andrew KlosinskiPrinciple [email protected]
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AgendaAgendaAgendaCustomer ChallengesStatistical Process Monitoring Technology4 Steps to Better Decision MakingCase StudyMore ExamplesSummary
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Customer ChallengesCustomer ChallengesCustomer Challenges
By focus on devices thatactually need maintenance
Reduce Maintenance Costs Improve Product Quality
By identify processoptimization opportunities
Increase Process Uptime
By predicting and preventing abnormal events
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AgendaAgendaAgendaCustomer ChallengesStatistical Process Monitoring Technology4 Steps to Better Decision MakingCase StudyMore ExamplesSummary
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Fast Update Rate Provides Higher Resolution of your ProcessFast Update Rate Provides Higher Fast Update Rate Provides Higher Resolution of your ProcessResolution of your Process
Update Rate: 1-2 times / second
Update Rate: 22 times / second
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SPM Turns Process Noise into Valuable InformationSPM Turns Process Noise into SPM Turns Process Noise into Valuable InformationValuable Information
Tracks changingprocess noiselevels
Tracks changesin PV (i.e. whatthe operator sees)
2nd Variable
3rd Variable
PrimaryVariable
Stat
istic
al V
aria
bles
Statistical Process MonitoringStatistical Process Monitoring
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AgendaAgendaAgendaCustomer ChallengesStatistical Process Monitoring Technology4 Steps to Better Decision MakingCase StudyMore ExamplesSummary
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4 Steps to Better Decision Making4 Steps to Better Decision Making4 Steps to Better Decision Making
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AgendaAgendaAgendaCustomer ChallengesStatistical Process Monitoring Technology4 Steps to Better Decision MakingCase StudyMore ExamplesSummary
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Plugged Impulse Line SituationPlugged Impulse Line SituationPlugged Impulse Line Situation
Flow for ControlFlow for Control
Controller OutputController Output
Flow
rate
Valv
e Po
sitio
n
Recovered without Recovered without maintenancemaintenance
Flow for InterlockFlow for Interlock
Plugging occursPlugging occurs
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Plugged Impulse Line Seen Through Standard DeviationPlugged Impulse Line Seen Through Plugged Impulse Line Seen Through Standard DeviationStandard Deviation
Standard DeviationStandard DeviationFlow for Flow for InterlockInterlock
Flow for ControlFlow for Control
Plugging occursPlugging occurs
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Set Proper Alert Based on Standard DeviationSet Proper Alert Based on Set Proper Alert Based on Standard DeviationStandard Deviation
Flow for ControlFlow for Control
Flow for Flow for InterlockInterlock
Standard DeviationStandard Deviation
Impulse line clearedImpulse line cleared
SET ALERT THRESHOLD
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Actionable Information Help Reduce Maintenance CostsActionable Information Help Reduce Actionable Information Help Reduce Maintenance CostsMaintenance Costs
Inside wall
• Dirt covered all around the inside wall of the pipe before cleaning the pipe
• Tore off dirt sometimes caused plugging the impulse line
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AgendaAgendaAgendaCustomer ChallengesStatistical Process Monitoring Technology4 Steps to Better Decision MakingCase StudyMore ExamplesSummary
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Furnace Flame InstabilityFurnace Flame InstabilityFurnace Flame InstabilityChallenge
– Feed is waste gases with varying BTU content; can cause flameout
– Flameout is a dangerous condition -shutdown required, resulting in outage, restart and lost production time
Solution– Sharp increases in standard deviation
is an indicator of flame instability and a precursor to flameout
– Monitor for significant increase in standard deviation with no mean change
1. Normal furnace operation2. Early detection of flame instability3. Flame-out occurs
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DP LevelAgitation LossDP LevelDP LevelAgitation LossAgitation LossChallenge
– Agitation motors can burn out without detection
– Undetected loss of agitation may result in poor product quality or batch loss
– DP level is subject to impulse line plugging
Solution– Loss of agitation results in significant
reduction in standard deviation– Plugged impulse lines also are
detected through a reduction in standard deviation.
Agitator
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Pump / Valve CavitationPump / Valve Pump / Valve CavitationCavitationChallenge
– The onset of cavitation results in several negative side effects• Process efficiency• Elevated process noise• Increased vibration• Risk of physical plant damage
Solution– Use Advanced Diagnostics with
SPM enabled to monitor for high variations due to elevated process noise
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Rotary Equipment WearTurbine BladesRotary Equipment WearRotary Equipment WearTurbine BladesTurbine BladesChallenge
– Turbine blades wear out from liquids or solids in steam– Costly repair and maintenance– Reduces efficiency of plant
Solution– Install an inline device to monitor line pressure noise to
signal ratio of low pressure turbine blades– Look for changes in noise characteristics
(standard deviation) and correlate to blade condition and ongoing wear
AP/GP DiagnosticTransmitter Location
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Pressure Transient DetectionPressure Transient DetectionPressure Transient DetectionChallenge
– Sudden changes in pressure and velocity of flow caused by valves, pumps, power failures, or changes in delivery rates
– Insufficient monitoring and lack of detection leads to transients exceeding design pressure of pipe
– May result in reduced delivery efficiency and pipes made vulnerable to leakage or rupture
Solution– Use variable logging to record peak pressure
reading and time stamping to know when the transient occurred
– Use process alerts to provide early warning of pressure transient
1. Pressure transient triggers process alert and time stamp upon exceeding user configured threshold
2. User configured threshold is used to trigger an alert based on high or low pressure values
3. Duration of pressure transient is logged4. Extreme pressure values and time since occurrence are logged
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Distillation Column FloodingDistillation Column FloodingDistillation Column FloodingChallenge
– Common process problem– Column stops efficient
separation– Difficult to diagnose, can take
a long time to correct• Traditional indication (Packing
temperatures) only change after flooding occurs
Solution– Tested at University of Texas– Monitor the DP across the
packing– Increases in standard
deviation previously correlated to flooding serve as a leading indicator of incipient flooding
11:30 11:35 11:40 11:45 11:50 11:55 12:00 12:05 12:10 12:15
0.9
0.95
1
1.05
Reb
oile
r D
uty
(MM
BT
U/h
r)
March 5, 2008 - Reboiler Duty
SP
PV
11:30 11:35 11:40 11:45 11:50 11:55 12:00 12:05 12:10 12:15215
220
225
230
235
240
Col
umn
Tem
pera
ture
s(D
eg F
)
Column Temperatures
Bed Top
Bed MiddleBed Bottom
Vapor Inlet
11:30 11:35 11:40 11:45 11:50 11:55 12:00 12:05 12:10 12:15
0.035
0.04
0.045
0.05
0.055Diagnostics Standard Deviation
Sta
ndar
d D
evia
tion
(in H
2O)
Flooding Observed in Sight Port
Normal Incipient Flooding
RunawayFlooding
Flooding Detected by 3051S
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Application ListApplication ListApplication ListTested Applications:
Plugged Line DetectionFurnace Flame Instability– Gas– Coal
Distillation Column FloodingCatalyst Circulation in FCCFluid Composition Changes– Wet Gas Detection– Entrained Air Detection
Pulsation Induced Measurement ErrorsImpulse Line Leak Detection
Applications in Test:Rotary Equipment Wear– Steam Turbine Blade Wear– Coal Pulverizer Primary Wear
Wet Steam DetectionSteam Trap FailureAgitator Loss (Reactor Tank)Pressure Transient DetectionCavitation Detection– Pump and Valve
DP Level– Plugged Impulse Lines– Wet Leg Drying Out– Dry Leg Getting Wet
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AgendaAgendaAgendaCustomer ChallengesStatistical Process Monitoring Technology4 Steps to Better Decision MakingCase StudyMore ExamplesSummary
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3051S Advanced Diagnostics for HART3051S Advanced Diagnostics for 3051S Advanced Diagnostics for HARTHART
3051S SuperModule®
(All Vintages)ASP™ Diagnostics
Suite3051S with Advanced
HART Diagnostics
Statistical Process Monitoring (SPM)• Detect abnormal process changes
Process Standard Deviation & Mean• Get more insight into the process with
additional variables
+ =
Variable Logging• Improve troubleshooting by tracking
process variables
Advanced Process Alerts• Indicates process and environmental
changes
Time Stamping• Know the timeline to diagnostic events
Enhanced EDDL• Intuitive and user-friendly interface
for a better view into your process
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Rated #1 for 14 years in a row. Flow ControlAwards
Control Engineering
Award
Wireless
Fieldbus
Advanced PlantWebFunctionality
AdvancedDiagnostics
Tuned-Systems™
SanitaryQuick
Connect
DP LevelBest Practices
PressureBest Practices
SafetyCertified
QuickConnect
IntegralManifolds
Remote Displayand Interface
Multivariable
Ultra for Flow
Direct Mounting
Integrated DP Flowmeters
DP FlowBest Practices
ScalableSuperModule®
Platform
0.025% Accuracy10 Yr Stability12 Yr Warranty
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SummaryRosemount 3051S Advanced Diagnostics
SummarySummaryRosemount 3051S Advanced DiagnosticsRosemount 3051S Advanced Diagnostics
Fast updating pressure transmitter provides more insight into the process– Standard Deviation– Mean
Applying best practices with Diagnostics can help detect and prevent abnormal situationsMany applications are possible, where ever there is process noise, we can use Advanced Diagnostics!
On the web: http://www.rosemount.com/3051s
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