process profiling: investigation and prediction of process upsets with advanced diagnostics
DESCRIPTION
2009 HART Plant of the Year Award winner Mitsubishi Chemical Corporation Uses HART Technology to Detect Abnormal Situations and Failures before they Affect the Processhttp://hartcomm.org/protocol/realworld/realworld_success_mitsubishi09.htmlTRANSCRIPT
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Process Profiling: Investigation and Prediction of Process Upsets with Advanced
Diagnostics
Process Profiling: Investigation and Prediction of Process Upsets with Advanced
Diagnostics Bill Zhou – Marketing Engineer
Takayuki Aoyama – Instrument Group Leader
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PresentersPresenters
Bill Zhou
Takayuki Aoyama
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AgendaAgenda
Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics
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Customer ChallengesCustomer Challenges
I hate dealing with re-work or
scrapping of product.
“
I am tired of always reacting to issues and
want a proactive plan.
“
I’m having trouble identifying sources
of process variability.
“
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Recap of SPM Case Studies in 2008Recap of SPM Case Studies in 2008
SPM helped determined root-cause Verified issue was fixed with SPM
1. Inadequate straight pipe length in DP flow measurement
2. Partial impulse line plugging caused by dirt
3. Fully plugged manifold
4. Compressor vibration issues
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AgendaAgenda
Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics
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See the Process NoiseSee the Process Noise
Update Rate: 1-2 times / second
Update Rate: 22 times / second
Higher sampling rate leads to high resolution of process profile
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Statistical Process Monitoring (SPM)Statistical Process Monitoring (SPM)
Tracks changingprocess noiselevels
Tracks changesin PV (i.e. whatthe operator sees)
SPM Turns Process Noise Into Valuable Information
2nd variable
3rd variable
PV
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The SPMTM ModelThe SPMTM Model
“Vision without action is a daydream.
Action without vision is a nightmare.”
Japanese proverb
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AgendaAgenda
Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics
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Introduction of Mitsubishi ChemicalIntroduction of Mitsubishi Chemical
Unit FY2007 FY2008
Net sales Billions of yen 2930 2909
Operating income Billions of yen 125 8
Recurring profit Billions of yen 217 -4
Net income Billions of yen 164 -67
1 billion Yen = US$ 10.8 million
Mitsubishi Chemical Corp.Found in June 1950New operation started in 1994 by merging Mitsubishi Kasei and Mitsubishi PetrochemicalBusiness: Petrochemical, Function Products, Health Care etcEmployees: 4,963 (non-consolidated)
URLhttp://www.mitsubishichem-hd.co.jphttp://www.m-kagaku.co.jp
39,305 (MCHC)
Mitsubishi Chemical Holdings Corporation (consolidated)
Our company is the largest Chemical company in JapanWe provide petrochemical, functional chemical, medical, and information electronics
products. Mitsubishi Chemical was founded in 1950 and now we have about 40 thousand
employees. Net sales is approximately 30 billion US dollars.
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JapanJapan
Japan
Japan is the small country just next to China. As you can see, it’s the small-small land on this slide.
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Impression of JapanImpression of Japan
Some people believe that NINJA or CHONMAGE people are walking around in Japan.But this is not true.You would not see the NINJA and the CHONMAGE people in Japan except for sumo
wrestlers and comedians.
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Mizushima Kashima
KawasakiMatsuyama
Yokkaichi
Sakaide
Naoetsu
Kurosaki
Plant MapPlant Map
Tsukuba
Petrochemical, Plastic products,
Pharmaceutical, Health care,
Information electronics products
Mitsubishi Chem.
Mitsubishi Chemical has 4 large petrochemical plants in Japan.I work at the Kashima plant which is indicated with the red box in this slide. I am responsible for the ethylene process in the plant.
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SPM Case Studies for 2009SPM Case Studies for 2009
SPM enabled Predictive Maintenance1. Entrained air of pump inlet suction line
2. Partial plugging in one of two impulse lines New findings with SPM
3. SPM as indicator of strong winds
4. Pressure pulsation of switching feed line
5. Dryer Switching Key findings and requests for Emerson
I have divided my 5 case studies into 3 sections.First section is useful for the maintenance practice.Second section is new findings using SPM.The last section is about requests for the future development SPM function.
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FC
3051S
3051STransmitter
Pumps
Control Valve
Case #1: The Problematic PumpCase #1: The Problematic Pump
First case study is based on one of our normal pump systems.We installed the 3051S pressure transmitter for this flow measurement.There are three pumps and one control valve to maintain the discharge flow.
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0.0
0.5
1.0
1.5
2.02.5
3.0
3.5
4.0
4.5
5.0
31
-Oct
-08
02
-No
v-0
8
04
-No
v-0
8
06
-No
v-0
8
08
-No
v-0
8
10
-No
v-0
8
12
-No
v-0
8
14
-No
v-0
8
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Stdev [kPa]
Flow rate [t/h]Setpoint [kPa]Valve position [%] Abnormal situation
Trend of stdev, valve position, flow rateTrend of stdev, valve position, flow rate
Stdev value jumped when flow measurement decreased.
This trend chart shows the information collected from the pump process.Light blue line shows the DCS output, green shows setpoint, and red is the standard
deviation.During normal operation, I noticed a sudden drop in flow rate.When this happened, the standard deviation spiked.This is when I started my investigation into what happened.
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0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
07
-No
v-0
80
6:2
8
07
-No
v-0
80
7:4
0
07
-No
v-0
80
8:5
2
07
-No
v-0
81
0:0
4
07
-No
v-0
81
1:1
6
07
-No
v-0
81
2:2
8
07
-No
v-0
81
3:4
0
0.00
0.05
0.10
0.15
0.200.25
0.30
0.35
0.40
0.45
0.50Stdev [kPa]
Flow rate [t/h]Setpoint [kPa]Valve position [%]Motor ampere [A]
stdev
DCS output
Flow rate
Is it the Valve or is it the Pump??Is it the Valve or is it the Pump??
We suspected either improper valve position or insufficient motor performance
(Flow should↑ when
DCS output ↓)
This is a detailed view of the previous trend chart.The drop in flow rate caused the DCS output to decrease because this loop was on auto.I suspected this was due to valve malfunction so I monitored the actual valve position.
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0
1
2
3
4
5
6
7
12:0
0 A
M
3:00
AM
6:00
AM
9:00
AM
12:0
0 P
M
3:00
PM
6:00
PM
9:00
PM
12:0
0 A
M
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Stdev
Motor ampere
Valve Position (no issue)
Flow rate
No issue found on valve positionNo issue found on valve position
What we observed was:
Stdev ↑ when flow rate ↓, pump motor amp ↓
From this data, I determined there is no issue with the valve.This means that the control valve is not guilty.This leads us back to the pump.
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Is Pump the Culprit?Is Pump the Culprit?
Entrained air through pump inlet
Flow direction
CASE CLOSED
Benefit from SPM information・ Future detection of entrained air・ Indicator of when to release air from the lines
Stdev ↑ & pump motor amp ↓ prompted investigation on the pumps
When the process operator checked the filter of the pump,they found that gas existed inside the pipes. Therefore, we have found that the root cause is entrained air.In the future, we will use the standard deviation as a future indicator of entrained air.
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Case #2: The Common Plugged LineCase #2: The Common Plugged Line
Flow rate
DCS output
This line often has plugging issues. Thus we installed 3051S with SPM.
The second case study is detecting plugged impulse lines.This measurement has had plugging issues in the past.Thus we installed the 3051S to detect the abnormal situation.
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0
1
2
3
4
5
6
7
8
9
1020
09-0
8-21
04:4
8
2009
-08-
2107
:12
2009
-08-
2109
:36
2009
-08-
2112
:00
2009
-08-
2114
:24
2009
-08-
2116
:48
2009
-08-
2119
:12
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
Trend of Plugged Line DetectionTrend of Plugged Line Detection
Flow rate
Dropped down
Stdev
Valve position
Expected
StdevBehavior of this abnormal situation (aka process criminal) was unexpected
This is the trend chart we collected for this application. We expected the standard deviation to decrease due to the plugged impulse line.But what I observed was totally unexpected, the standard deviation increased.
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Further Investigation into Behavior of PLDFurther Investigation into Behavior of PLD
HiLow
Delta-P
Hi
Low
Delta-P
Expected ↓
However, if there are bubbles in the impulse line, the stdev
can increase instead of expected decrease.
This is an illustration of what happens when there is a plug.When there is a plug in one line, the process noise will decrease. However, if there are bubbles in the line, the process noise will actually increase.The previous trend chart shows this happening.
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Simulation of plugging verified expected behavior – Decrease in stdevSimulation of plugging verified expected behavior – Decrease in stdev
0
2
4
6
8
10
12
14
14:3
1:38
14:3
4:31
14:3
7:24
14:4
0:16
14:4
3:09
14:4
6:02
14:4
8:55
14:5
1:48
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
Normal Operation
Low side closedHigh side closed
Normal Operation
Stdev
Flow rate
Plugged line detected
okok
CASE CLOSED
In order to confirm this behavior in our application,we tested plugging by purging the bubbles and closing the lines leading to the
transmitter.This trend is the result of the test.
From this test, we can see that plugging in both low or high side resulted in decreased standard deviation.
Based on this data, we can say that there was bubble trapped inside the impulse line.Key point here is that SPM detected something wrong in the processeven though standard deviation behaved unexpectedly.
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Case #3: The Windy CityCase #3: The Windy City
M
PDC
Furnace AirHeater
Fresh air inletHeat exchange
Emergency Exhaust
3051S
Feed
Charge gas
To the next
furnaceHeated
air
The third case study is based on the furnace air heater.We have many furnaces and each furnace has the air heater system with it.Fresh air is fed into the heater and heated air is supplied to the furnace.The pressure inside of the heater is controlled by the pressure controller in DCS.We installed Rosemount 3051S transmitter to look for any abnormal situations.
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0.0000
0.0500
0.1000
0.1500
0.2000
0.2500
0.3000
0.3500
0.4000
25
-Se
p-0
8
15
-Oct
-08
4-N
ov-
08
24
-No
v-0
8
14
-De
c-0
8
3-J
an
-09
23
-Ja
n-0
9
12
-Fe
b-0
9
4-M
ar-
09
24
-Ma
r-0
9
13
-Ap
r-0
9
0.0000
0.0002
0.0004
0.0006
0.0008
0.0010
0.0012
0.0014
0.0016
0.0018
0.0020
Stdev [kPa]Pressure [kPa]
Spiking of Stdev Prompted InvestigationSpiking of Stdev Prompted Investigation
Stdev spikes
pressure
Stdev spiked while pressure measurement did not
After installing the 3051S, I analyzed the trend data of the furnace operation.This chart shows that although the operation is normal,sometimes the standard deviation spikes.
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3051S transmitter
Sampling nozzle
Emergency exhaust
Picture of Furnace HeaterPicture of Furnace Heater
Heated air
This is the air heater.Fresh air comes from the top vent of the heater and heated air is sent into the furnace.Red circle in the picture here indicates the location of the 3051S transmitter.Sampling nozzle is connected to the bottom of the heater near the emergency exhaust.
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Picture of Furnace HeaterPicture of Furnace Heater
3051S
The pod is connected to the other sampling line to be less affected by wind
We installed the pod to avoid measurement distribution change due to the strong winds.But it is difficult to remove the influence from the wind completely.
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0.0000
0.0500
0.1000
0.1500
0.2000
0.2500
0.3000
17-J
an-0
9
22-J
an-0
9
27-J
an-0
9
1-F
eb-0
9
6-F
eb-0
9
11-F
eb-0
9
16-F
eb-0
9
0.0000
0.0002
0.0004
0.0006
0.0008
0.0010
0.0012
0.0014
Stdev for furnacesPressure inside of furnace
Wind velocity
The Effects of Strong WindThe Effects of Strong Wind
Stdev affected when strong wind blew into the pod
Pressure is also slightly affected
With the 3051S, we measured standard deviation and compared it to wind velocity.When the wind became strong, the standard deviation increased.During this time, the pressure measurement is also slightly affected.
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0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0
0.0001
0.0002
0.0003
0.0004
0.0005
0.0006
0.0007
0.0008
0.0009
0.00
0.10
0.20
0.30
0.40
0.50
22-N
ov-0
8
23-N
ov-0
8
24-N
ov-0
8
25-N
ov-0
8
26-N
ov-0
8
27-N
ov-0
8
28-N
ov-0
8
29-N
ov-0
8 0
0.0002
0.0004
0.0006
0.0008
0.001Pre
ssu
re [
kPa]
Two adjacent furnacesTwo adjacent furnaces
Affected by wind
Std
ev [
kPa]
0
2
4
6
8
10
12
22
-No
v
23
-No
v
24
-No
v
25
-No
v
26
-No
v
27
-No
v
28
-No
v
29
-No
vWin
d v
elo
city
[m
/s]
Stdev only affected when strong wind blew directly into the pod.
This trend is the other data set.When the wind velocity increased, the standard deviation changed at the same time.Strong winds affect the reliability of the PV measurement.We have found that standard deviation from SPM can detect this phenomenon.Thus when this happens, we can change the operation from auto to manual to avoid
process upset.
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0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
22
-No
v-0
8
23
-No
v-0
8
24
-No
v-0
8
25
-No
v-0
8
26
-No
v-0
8
27
-No
v-0
8
0
2
4
6
810
12
14
16
18
20
Wind velocitywind direction
Velocity [m/s]Direction [-]
Pressure [kPa]Setpoint [kPa]
Perturbed by wind
Benefit from SPM information・ Indicator of when to change to “Manual” operation due to unreliable dP measurement.・ Prevent unexpected process fluctuation by unstable measurement caused by the wind
Case #3 SummaryCase #3 Summary
Strong winds affect reliable PV
CASE CLOSED
When it is typhoon season in Kashima, our operators can predict the strong winds.However, I believe that SPM is more reliable in prediction than listening to the weather
man.
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T
Turbine
FC
Other plant
Open either valve
Normally manual mode and fully opened
User plant
Case #4: Changing Feed LinesCase #4: Changing Feed Lines
3051S(with Dryer)
(w/o Dryer)
The fourth case study is about switching feed lines.The operator occasionally has to switch the feed lines manually based on production
rate.This happens about 3 to 4 times a year.
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Influence on Stdev by changing the lineInfluence on Stdev by changing the line
0.00
0.05
0.10
0.15
0.20
0.25
0.302
8-A
ug
-08
11
-Se
p-0
8
25
-Se
p-0
8
09
-Oct
-08
23
-Oct
-08
06
-No
v-0
8
20
-No
v-0
8
04
-De
c-0
8
18
-De
c-0
8
01
-Ja
n-0
9
15
-Ja
n-0
9
29
-Ja
n-0
9
12
-Fe
b-0
9
2.00
2.20
2.40
2.60
2.80
3.00
3.20
3.40
Flow rate [km3/h]Stdev [kPa] Line pressure [MPa]
Flow rate
After switching the lines
About 0.8
About 0.1
(with Dryer) (w/o Dryer)
Difficult to verify
switching of the line
by looking at flow
rate.
SPM provides better indication of process
profile change.
After switching the feed lines, there is no quick indication that it was successful.However, when I observed the standard deviation, it was clear the value changed.The standard deviation changes quickly and provides a nice indication that the switch
was successful.
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0
20
40
60
80
100
120
140
160
180
200
12:00 PM 3:00 PM 6:00 PM 9:00 PM 12:00 AM 3:00 AM 6:00 AM 9:00 AM 12:00 PM
0
100
200
300
400
500
600
700
-20 -18 -16 -14 -12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20
Flow rate was also profiledFlow rate was also profiled
[df/dt t/h]
Freq.
Flow rate Flow rate w/ Dryer
Flow rate w/o Dryerw/Dryer
w/o Dryer
Distribution
Flow rate profile can also be observed, but Stdev is a
faster indicator of completed switching
Stdev is reliable indicator
CASE CLOSED
This chart shows a longer trend of the flow profiles.Here we can see that there is a clear indication of successful switching of the feed lines.However, in order to draw this chart, it requires a longer period of time for sampling the
data.
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FC
Case Study #5 Dryer Switching Case Study #5 Dryer Switching
PI
3051S
3051S
dryer
A
B
In this process, we switch the dryer operation every 20 days.We installed 2 units of 3051S to monitor static pressure and flow measurement of this
process.
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0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
24-
Dec
-08
13-
Jan-
09
2-F
eb-0
9
22-
Fe
b-0
9
14-
Mar
-09
3-A
pr-0
9
23-
Ap
r-09
0.0000
0.0001
0.0002
0.0003
0.0004
0.0005
0.0006
0.0007
Switching Dryer Operation Affects StdevSwitching Dryer Operation Affects Stdev
Switch over every 20 days
Stdev of pressure transmitter
Stdev of flow transmitter
Case Open: On-going investigation into WHY
Stdev cycles with switchingCASE OPEN
The process profile of the transmitters showed similar pattern before and after switching dryer operation.
I am not sure why there is such a pattern.Thus, this interesting case is still under investigation.
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Summary of Process ProfilingSummary of Process Profiling
Key findings SPM enables Predictive Maintenance SPM is applicable to many applications
– we will increase installation to broaden the monitoring coverage
Request to Emerson – Expedite to market diagnostic for loop– Detect capillary plugging– Detect Hydrogen penetration of Diaphragm– Detect Leak of seal fluid in Diaphragm– More sensitive detection for single line plugs
In summary, I found that SPM can enable predictive maintenanceand it’s also useful to detect slight changes in the process.I am planning to increase SPM usage to broaden the process coverage and discover
other applications.I would like to share with you some requests to Emerson on future diagnostic
developments.
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AgendaAgenda
Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics
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Loop Power & Connectivity
Diagnostic Coverage Beyond the TransmitterDiagnostic Coverage Beyond the Transmitter
Process Intelligence
Safety Certified
Transmitter Health
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Benefits
Process Intelligence
SIS
Safety Certified
Transmitter Health
Loop Power & Integrity
PluggedImpulseLine(s)
FlameInstability
AgitationLoss
EntrainedAir
2525Applications
Looking Beyond the Device to Deliver More Process IntelligenceLooking Beyond the Device to Deliver More Process Intelligence
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Voice of theCustomer
BenefitsLoop Power & Integrity
Water &Corrosion
Failing power supply
Wiring issues
BAD
+
_
XX
X
SIS
Process Intelligence
Safety Certified
Transmitter Health
Looking Beyond the Device Verifying Loop Power and IntegrityLooking Beyond the Device Verifying Loop Power and Integrity
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BenefitsTransmitter Health
SIS
Process Intelligence
Safety Certified
Output SaturatedHigh Variation AlertTemperature not updatingOutput SaturatedLCD Update errorOutput SaturatedMean Change DetectedTemperature not updatingOutput SaturatedCold Start
00:013:11:01:3700:013:11:31:3700:013:16:01:3300:013:23:05:0000:013:41:11:2300:015:23:32:4700:016:58:16:3700:023:23:54:3800:123:16:24:6700:153:57:14:32
Status Event Time Since Event
Diagnostic Status Log
Loop Power & Integrity
Enhance Transmitter Health and Process Insight with Historical Event LogEnhance Transmitter Health and Process Insight with Historical Event Log
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Benefits
SIS
Process Intelligence
Loop Power & Integrity
Transmitter Health
SIL3 Power &Process Diagnostics
Advanced Diagnostics Enable the Safest Pressure InstallationAdvanced Diagnostics Enable the Safest Pressure Installation
Safety Certified to single use in SIL2 or multiple use in SIL3
10 Year ProofTest Interval
Safety Certified
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Where To Get More InformationWhere To Get More Information
Come see a live demonstration at the technology exhibit!
Rosemount 3051S Advanced Diagnostics on the web– www.Rosemount.com/3051SDiagnostics