848T High Density Temperature Measurement Validation Diagnostic.

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Presentation transcript:

848T High Density Temperature Measurement Validation Diagnostic

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 2 Emerson Confidential Slide 2 Why On-Line Validation? “Occasionally, a thermocouple may fail in a manner that gives randomly high temperature readings.” “..the temperature alarm and shutdown systems should reliably distinguish between these false readings and an actual runaway. Otherwise needless risk and expense are introduced by unnecessary reactor shutdowns.” “Perhaps even more important is the loss of confidence in the shutdown systems by operations personnel – the shutdown interlock might be bypassed at a time it is most needed” From an article by Arthur Smart, Jr., Celanese Chemical Co. (1981)

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 3 Emerson Confidential Slide 3 Measurement Validation: What is it? Industry First Diagnostic Provides online validation of data during measurement Approximates standard deviation of the input error in relation to a measurement trend Allows the user to understand abnormal deviations in the measurement Also calculates PV rate of change – to detect abnormally fast process changes Provided in 848T Fieldbus

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 4 Emerson Confidential Slide 4 Measurement Validation: Why use it? Measurement qualification before control –Only use valid measurements in the process control strategy Allows for validation of data to detect degraded conditions –Provides alerts to the user of the abnormal temperature behavior –Online Sensor failure can be detected before the sensor actually fails. Proactively change-out sensors before failure. Avoid Shutdowns Know process rate of change –Detect abnormally fast process increases or decreases, and be alerted before they become unsafe –Alerts allow unsafe condition detection BEFORE upper or lower limits are reached

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Emerson Confidential Slide 5 Measurement Validation Diagnostic -Industry First on the 848T Fieldbus- Industry first diagnostic provides validation of measurement data which can help identify the following issues: –On-scale Errors- when the output of a transmitter is within process alarm limits yet does not accurately indicate actual process information. –Invalid measurement readings that lay outside of alarm limits when actual process variable is within acceptable range –Abnormally fast process rates of change. Issues are usually due to failing sensors (most common), electronic interference, corroded termination points, loose electrical connections and runaway reactions

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 6 Emerson Confidential Slide 6 Prevent Unnecessary Shutdowns, Optimize Processes And Increase Safety Avoid unnecessary process shutdowns –Detect measurement abnormalities and take preventative action before shutdown is necessary Avoid loss of revenue and safety concerns associated with shutdown process –Determine validity of measurement points that are outside of alarm limits Avoid on-scale failure related issues –Identify on-scale failures and take action before process efficiency and safety is compromised Improve Energy Efficiency Increase Product Quality Improve Product Yield and Throughput –On-scale failure can lead to process shutdown Avoid unsafe process conditions –Detect abnormally fast process rates of change before alarm state is reached –The earlier unsafe conditions are identified the more manageable they are

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 7 Emerson Confidential Slide 7 A Closer Look: How Measurement Validation Works By evaluating sample to sample deviations over an averaged trend, Measurement Validation can detect abnormal deviations in measurements which in turn can be related to a specific issue Sample to sample deviation is calculated as follows: –A rolling average of raw process measurements is taken to create a trend line –the difference of the most current measurement to the average is calculated, generating a pseudo rate of change value –This value is then compared to a rolling average of pseudo rate of change values- the difference of the two values resulting in the deviation output which is then compared to customer selected alert limit –The deviation output is then compared a customer selected limit which, depending on severity setting, will generate a status that the user can use to take action. Process Rate of Change is calculated by measuring the time and difference between samples and applying a moving filter to eliminate high frequency noise.

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 8 Emerson Confidential Slide 8 Case Study Amoco made these calculations for a particular Hydrocracker unit During study, 78 “incidents” occurred The measurement validation analysis helped the operators differentiate between –12 valid high temperature excursions and 66 malfunctions One malfunction due to multiplexor failure 2 were due to radio interference 63 were due to the failure of 63 Thermocouples. –Operators were able to perform preventative maintenance instead of process shutdowns

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 9 Emerson Confidential Slide 9 Measurement Validation: Configuration Alert Limits –Deviation and Rate of change Increasing and Decreasing limits Alert Severity –Failure, warning, advisory, or not used Deadband –Decide how sensitive your alerts are, i.e. how much they have to go down before the alarm is surpressed.

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 10 Emerson Confidential Slide 10 Measurement Validation: Status Handling Advisory Plant Web Alerts available –Excessive Deviation and Excessive Rate of Change Four levels of validation severity for both Rate of Change and Deviation –Failure – Sets PV to fail status, triggers Failed plant web alert (sensor failure) –Warning – Sets PV to uncertain status, triggers Maintenance plant web alert (sensor degraded) –Advise – No change to PV status, triggers Advisory plant web alert –Not Used – Provides Rate of Change or Deviation output with no status handling

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 11 Emerson Confidential Slide 11 Measurement Validation: Dashboard DD

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 14 Emerson Confidential Slide T New Model Option Codes New Option Codes 848T D04Measurement Validation Diagnostic

[File Name or Event] Emerson Confidential 27-Jun-01, Slide 15 Emerson Confidential Slide 15 Key Takeaways High Density transmitters provide a cost effective method of measuring moderate to large numbers of measurement points New input options allow the 848T to be used in more applications Appropriate installation practices allow the 848T to be used in critical applications Measurement validation provides a new level of integrity for a highly reliable measurement.