Analyzer Diagnostics for confident operationsSIVAKUMARSENIOR MANAGER – ANALYTICAL BUSINESSYOKOGAWA SINGAPORE

FCG Singapore Seminar | 10 June 2016

What is an Analyzer ?

• Instruments for determining the qualitative and quantitative composition of gas/ Liquid mixtures.

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The Status of instrumentation engineers is they are not aware what the analyzer is for ? There is lack of knowledgeable people in Analytical field !

The measuring component, its range       & the reading severity is mostly determined by the plant licensors    

Challenges for Refineries ?

The challenge of modern refineries in the ever growing global competition is to increase their refining margin and by that their profit. Nowadays, global competition, forces refineries to maximize process intensification and process optimization, which are required key stones to increase the refining margins and by that the profit of the entire refinery.

It all starts from the crude oil and ends with final distillates and blends. Optimization of the entire refinery production chain is a major task and starts with enhancing the efficiency of each of the following interdependent processes:

How importance an Analyzer is in a plant & why ?

FCG Singapore Seminar | 10 June 2016

Different Analyzer MeasurementsLiquid

pHConductivityDissolved OxygenOxygen demandDensityChlorineTurbidity

GasOxygenCO, NOX, SO2, CO2, THCDensityPMHydrogen & H2SPhysical properties like

cloud point, pour point, Flash Point, Simulated distillation

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FCG Singapore Seminar | 10 June 2016 5

The three R's of analyzer selection: • Reliability - The analyzer must be highly reliable so it will

maintain a service factor in excess of 95%.

• Repeatability - The output of the equipment must be repeatable for a given input. It need not be accurate (though of course this is desirable) but it must always give the same numeric output for a given calibration or process sample.

• Return - Every analyzer system installation must have an economic return or justification. If it is not used for some form of continuous monitoring or control the unit will not get the attention it receives to remain in operation at the required service factors to be considered reliable.

What is Diagnostics & its relation to Analyzers ?

• To determine an Analyzer is working OK or not depends on how accurately it is calibrated & how accurate is the calibration solution or gas ?

• There should be a way to inform the technician that the calibration result is out of tolerance limits

•• Most of the analyzers working principle depends

on sample flow/ pressure / temperature & so it needs to be continuously monitored

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What happens if there are no Diagnostics ?

• The technician will not be aware whether the reading the analyzer displays is correct

• The frequency of calibration/ validation depends on whether the analyzer functioning is within the tolerance limit which can be ascertained only by diagnostics features

• Wastage of buffer solutions or calibration gases

• Proper closed loop control will not be possible

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pH Response Check with Chemical Cleaning

0

4.5

7

pH

tH

Good Sensor

Aged Sensor

tRtW

Time

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Meas Wash Meas

pH electrode broken, reading always 7 +/‐ 1 unit (ASPOT/SLOPE)

Short circuit in wiring. 

Moisture in cable, connector, connection box or electronics.

Wrong wiring

Customer complaints

My sensor does not respond to changes

Most of these problems will be recognized by sensor diagnostic functions.

SMART SENSORS

Et

E1 E3 E2E5 E4

Input 2

Input 1

LiquidEarth

Et

E1 E3 E2E5 E4

Input 2

Input 1

LiquidEarth

No Flow

Increase in Impedance

Polluted / Dirty Reference JunctionEt

E1 E3 E2E5 E4

Input 2

Input 1

LiquidEarth

Et

E1 E3 E2E5 E4

Input 2

Input 1

LiquidEarth

ImpedancDecreases

Glass Sensor Broken / CrackedHigh Impedance 

Liquid Earth Not Connected 

Diagnostics – ImpedanceWash cycle can be started automatically

E5.2

E4.1E5.1

E5.2

Why customer specification ask for digital sensor technology ?

• Customer trends – Easy maintenance and service– cost reduction of cable distribution– Reliability– Less Knowledge of maintenance staff to interpret Analog signals

• Functionality point of view– Optimizing process control, simplifying maintenance

– Reducing configuration time by decreasing manual data entry

– Laboratory calibration is automatically uploaded in Field instrumentation

Proprietary info goes here…Page.12

Dissolved oxygen sensor diagnostics

Example - SENCOM PC Software SPS24

Simple Calibration and Process Setup

Same Easy Calibration Procedure

Sensor Diagnostics– Use calibration results to perform in‐depth analysis 

of each sensor

Comprehensive Database

Information Protection

various data export possibilities – to guarantee protection of sensor history information

Nowadays nobody wants display at the field, Sensors are directly connected , Configurable using RS485 thru PC or MODBUS RTU thru process control systems

FCG Singapore Seminar | 10 June 2016

Virtual Tech Diagnostics Software

Peak DataRetention TimePeak HeightPeak SeparationTailing CoefficientBase Level at Gate OnNoise Level at Gate OnS/N at Gate On

Valve DataNumber of operations

Detector DataOperation Time

Oven Performance DataMax Temp in each analysisMin Temp in each analysis

Monitor & Analyze

• Parameters Over Thresholds• Data For Analysis

Pack & Report

Redundant Ethernet

Maint. Shop PC

PCAS GC Workstation

• To Maintenance Shop PC• Corporate GC Support Center

Email Notification Option

HART Features for Analyzers

“Device description (DD)” has parameter information of device.Describe parameter name, relation between parameters, menu tree structure and method by using “Device Description Language (DDL)”.The source code of DDL complied to binary file and distribute to host venders and also to users.

FeaturesNo need to upload menu and parameter information from device.DD supported host can treat multiple venders and devices.

DDsDDs

DDs

HART, Profibus or Foundation Fieldbus?Which bus system is best for my analyser?

Basically the answer is a known fact and depends on chosen DCS system architecture. Analyser have to follow these decision

• Where is HART best?In brownfield plants based on 4‐ 20 mA technology

• PROs    ‐ Configuration in workshop via HART‐Tool ‐ Remote access via HART‐Tool for maintenance purpose

• CONs    ‐ No use two way communication for process control

• Where are Fieldbuses best?In greenfield plants, because here it is easier to set up infrastructure of two way communication. This allows to  use all device data process control and maintenance purpose

• Profibus PA is stronger in Europe and first designed for Factory Automation

• FF is stronger in America and Asia and especially designed for Process Automation 

The diversity of these three protocols, gave customer to find best opportunity for his process, because most of  analysers support all three.