Advanced pressure diagnostics use statistical process monitoring to characterize process variation and detect abnormal conditions such as plugged impulse lines, furnace flame instability, or distillation column flooding. New DeltaV diagnostics module templates, including control modules, operator faceplates, and process history view ease configuration and use of advanced diagnostics. Presented by Emerson's Tom Wallace and Erik Mathiason at 2011 Emerson Exchange in Nashville.

1. New DeltaV Module
Templates to Easily
Configure, View, and
Trend Advanced
Pressure Diagnostics

2. Presenters
 Tom Wallace
 Erik Mathiason

3. Introduction: Easier implementation and
use of SPM in DeltaV
 Any of this sound familiar?
 Brief review of Statistical Process Monitoring (SPM)
 Requirements
 Typical obstacles to implementing SPM
 The Engineering solution
 The Operator solution
 How to get started (topics working together)
 Summary & Resources

4. The Challenges:
Any of this sound familiar?
 I don’t need you to tell me something bad just happened.
I needed you to tell me 20 minutes ago so I could have
prevented it.
 We used to have a guy who could do that.
 I keep fixing the same problem over and over and over….
 I’d love to be proactive, I’m just too busy reacting to get to
it.
 If it takes more time or requires additional training, we
don’t do it.

5. Brief review of Statistical
Process Monitoring (SPM)

6. Why use Device Based SPM?
Higher Frequency Noise

7. Statistical Process Monitoring (SPM) turns
process noise into valuable information

8. The 3051S Analyses High Frequency
Noise (High Pass Filter)
The
Process
The Host
Low Frequency
The 3051S
High Frequency
Host SPM and 3051S SPM are complementary

9. What is actually detected?
SD 1 plugged line SD SD SD
SD 2 plugged lines CV CV
These are general patterns. Actual M, SD, and CV are very different from
process to process. SPM can’t identify the specific cause without the user.
Key
SD = Standard Deviation
M = Mean
CV = Coefficient of Variation
SD SD SD
CV
Frequency specific Frequency specific

10. Process the data in the transmitter, display, record,
display, annunciate, and analyze in the host
Better in the transmitter Better in the host
 Capture data & calculate  Operator optimized
SPM variables displays
– Transmitter gives higher – Replace traditional
frequency information (22 monitoring point displays
Hz)  Fingerprint the process
– Detects conditions not
– Use device generated SPM
visible at host sampling
data
frequencies
 Data historian with time
 Individual variable SPM
synched alarms
 Adaptive limits and alert
 Alarm management
values calculated
 Multi-loop SPM and
optimization

11. Typical Engineering Obstacles to
Implementing SPM Diagnostics
 User design tasks
– Learn enough about SPM to design and implement appropriate
monitoring strategies
– Determine protocol and diagnostics version requirements
– Design and document monitoring strategy by protocol and version
– Design and document configuration module templates
– Design and document operator faceplates
– Design alarm management strategy
– Design data historian configuration
 User configuration tasks
– Configure linked variables to control blocks
– Configure alarm management logic
– Determine and set alarm limits
– Configure Process History View
– Configure operator faceplates

12. The Engineer Solution

13. The Requirements
 Configuration Engineer requirements
– Eliminate up-front design time and minimize configuration
– Pre-engineer Process History View chart (with Alarms)
– Work with HART or FF devices
– Provide meaningful User Help
 Operating requirements
– Provide consistent but customizable operator faceplates
• Buttons launch Detail picture, PHV Trend, or Field Device View
– Provide alarm management to automatically Enable /
Disable SPM alarms
 Process Engineer requirements
– Provide ability to fingerprint the process
– Capture fast sample based time synchronized SPM data and
alarms

14. The Engineering Solution DeltaV 11+
 Use Pre-Configured Control Module Templates
– Separate Module Templates for HART and Foundation
Fieldbus
– Named Set for SPM Variable Selection
 Use Pre-Configured Process History View Charts
– 4 Charts for HART Module Template
– 4 Charts for Foundation Fieldbus Module Template
 Use Pre-Configured Operator Faceplates
– Faceplate and Detail pictures
– Same pictures apply to both HART and Foundation Fieldbus
 Use Provided User Help
– Context-sensitive help within Control Studio
– DeltaV Books On-line

15. The DeltaV and Rosemount 3051S Solution
to Implementing SPM Diagnostics
 User design tasks
– Learn enough about SPM to design and implement appropriate
monitoring strategies
– Determine protocol and diagnostics version requirements
– Design and document monitoring strategy by protocol and version
– Design and document configuration module templates
– Design and document operator faceplates
– Design alarm management strategy
– Design data historian configuration
 User configuration tasks
– Configure linked variables to control blocks (Link 2 to 4 parameters)
– Configure alarm management logic (0 to 2 parameters)
– Determine and set alarm limits (2 to 11 parameters)
– Configure Process History View
– Configure operator faceplates (Specify three parameters)

16. SPM Data: Linking Variables
AI Blocks for PV (AI1),
Mean, and StDev
Pre-engineered

17. SPM Data: Linking Variables
AI Block for CV
DA1: Calculated in DeltaV
DA2: Assigned to
HART_FV
Pre-engineered

18. SPM Data: Linking Variables
Calc Block Calculates
CV and SPM variable
alarm limits
Pre-engineered

19. Configure SPM Alarm Management Logic
ALARMS_ENABLED
Dynamically
enable/disable alarms
using external logic
Prevent “flood of alarms”
Pre-configured

20. Configure SPM Alarm Management Logic
PV_LIM_MODE
If PV or Mean exceeds
limits, STDEV and CV
alarms can be disabled
Prevent nuisance alarms
Pre-engineered

21. HART Devices: Pre-configured CALC
Block Logic
Enabling and Disabling
Std Dev Alarms
Determining if Mean (or
PV) Exceeds Limits
Calculating the Coefficient
of Variation (CV)

22. Set Alarm Limits
11 Alarms Pre-Configured
Alarms from AI Module
•PV High (HI_ALM)
•PV Low (LO_ALM)
•PV Hi Hi (HI_HI_ALM)
•PV Lo Lo (LO_LO_ALM)
•PV Bad (PVBAD_ALM)
Additional Alarms for SPM
•Mean High (MEAN_HI)
•Mean Low (MEAN_LO)
•StDev High (STDEV_HI)
•StDev Low (STDEV_LO)
•CV High (CV_HI)
•CV Low (CV_LO)
Default Disabled

23. Configure SPM Operator Faceplate
DEVICE_TAG
Access device
information from
AMS Device Manager
Pre-engineered

24. Configure Operator Faceplate
FP_VAR_#
Specifies SPM
variable(s) to show on
the Faceplate
Pre-engineered

25. Process History View Chart
PV or Mean
with Limits
Abnormal Event
Cleared
StDev or CV Abnormal Event
with Limits Entrained Air
List of
Variables
Alarms and
Events

26. DST’s, FF segment loading, template
modification & reuse
 DST’s
– HART Devices, 1 DST for all parameters
– FF Devices, 1 DST for all parameters
 FF segment loading
– 3 links per FF device if scheduled communications is used
– 0 links per FF device if unscheduled communications is used
 Template Modification
– Template can be user modified as desired
 Template content reuse
– Template content can be used all or in part in other
templates
– Template content can be used, unmodified or modified, by
any licensed DeltaV user running V11 or newer

27. The Operator Solution

28. Pre-configured SPM Faceplate (HART and
FF) Show Maximum of 2 SPM Variables
User enterable
faceplate name
SPM Variable 2:
StDev or CV
SPM Variable 1:
PV or Mean
StDev and Alarm
StDev Alarm Limits
Faceplate
Buttons

29. Pre-configured
SPM Faceplate Buttons
Process History View
Primary Control Control Studio
Detail Picture
Acknowledge All
AMS Device Manager
(Device Dashboard Screen)

30. Pre-configured SPM Detail Picture
(Operator editable W/O Control Studio)
Alarms and
Configuration Priority
Associated with Adjustment and
PV and SPM individual enable
Blocks / disable for
Alarms
Overall Alarm
enable / disable

31. Pre-configured SPM Detail Picture
(Operator editable W/O Control Studio)
Simulation
Capability used for
Testing and
Operator Training

32. Pre-configured SPM Detail Picture
(Operator editable W/O Control Studio)
Displayed
Variable
Selection

33. How to get started, experiment
 Tap operator insight and intuition
 Make an educated guess on points and problems
– Pumps cavitate, agitators stop, columns flood, lines plug
 Paint with a broad or narrow brush, your choice
 Trend, establish what “normal” looks like
– Establish baseline when process is at steady state
– Run with alarms disabled until you understand normal
 Set alarm limits and run with alarms enabled
– The 3051S automatically and adaptively calculates limits. Look at
those limits in AMS and input into DeltaV.
 When abnormal conditions occur, capture, analyze, adjust

34. How to get started, ask and help operators
 Develop an operator reference book
– Document what “normal” looks like (process signature)
• May need several based on plant operating parameters
– Capture abnormal conditions and alerts generated
• Capture process signature of upstream, downstream, or related
parameters that could have cause / effect relationship
– Identify and document earliest reproducible signature of
abnormal condition
• This may be the monitored point, or upstream or related points
– Capture corrective actions and process signature of
corrective actions.
– Document most effective corrective actions as operator
guidelines

35. How to get started, engineer improvements
 Expect the unexpected
– Experiment, we don’t know what we don’t know
– Some points will reveal new insight, some won’t
 Start with unmodified template
– Understand what operators and other stakeholders find useful
– Understand where and how to use it in your process
 Modify the template or use parts in other templates slowly
– Modification and reuse are good, but not required
– Determine needs, modify, and document
– Run trials and verify modifications work and deliver expected value
– Adopt plant standards for use for each modified version
 Stop where you’re comfortable

36. Business Results Achieved Expected
 Implementation
– Reduced learning time
– Eliminate design time
– Reduce configuration time
 Use
– Additional process engineering insight
• Diagnose root causes
• Eliminate root causes
– Additional operator insight
• Anticipate and prevent abnormal situations
• Reduce process upsets
• Operate closer to limits

37. Summary
 SPM parameters are calculated in the 3051S pressure transmitter to
capture higher frequency noise
 Pre-engineered templates reduce cost, time, and required expertise
 Templates are provided for HART and FF devices
 Templates work with DeltaV version 11 and newer
 The Engineering Solution
– Control module templates
 The Operator Solution
– Trending
– Operator faceplates
– Operator detail displays
 Templates can be used as-is, or modified

38. Where To Get More Information
 The 3051S Kiosk at the Technology Exhibit
 DeltaV White Paper (need posting)