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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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Predictive IntelligencePredictive IntelligencePredictive Intelligence
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
What is an Abnormal Situation?What is an Abnormal Situation?
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Smart Business DevicesSmart Business Devices
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Smart Business DevicesSmart Business Devices
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Smart Business DevicesSmart Business Devices
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Traditional SystemTraditional System
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Traditional SystemTraditional System
Device Problem manifests as
process problem
PIC -101
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Smart System with PI capabilitySmart System with PI capability
FY -1
FY-1
No Low Pressure yet!
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Plugged Impulse LinesPlugged Impulse LinesPlugged Impulse Lines
OK
OK
plugged
plugged
Both OK 1 plugged both plugged
HighSide
LowSide
SUM
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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
SPM Variable Logging Advanced Process Alerts
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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
SPM Variable Logging Advanced Process Alerts
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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
SPM Variable Logging Advanced Process Alerts
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Temperature Sensor Drift AlertTemperature Sensor Drift Alert
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
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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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event
Themocouple Degeneration AlertThemocouple Degeneration Alert
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© 2008 Fieldbus Foundation
2008 FFIMC-ISA Vadodara Event