process profiling: investigation and prediction of process upsets with advanced diagnostics

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

PresentersPresenters

Bill Zhou

Takayuki Aoyama

AgendaAgenda

Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics

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.

“

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

AgendaAgenda

Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics

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

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

The SPMTM ModelThe SPMTM Model

“Vision without action is a daydream.

Action without vision is a nightmare.”

Japanese proverb

AgendaAgenda

Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics

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.

JapanJapan

Japan

Japan is the small country just next to China. As you can see, it’s the small-small land on this slide.

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.

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.

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.

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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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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0.50Stdev [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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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.

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.

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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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.

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.

Simulation of plugging verified expected behavior – Decrease in stdevSimulation of plugging verified expected behavior – Decrease in stdev

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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.

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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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.

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.

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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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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ssu

re [

kPa]

Two adjacent furnacesTwo adjacent furnaces

Affected by wind

Std

ev [

kPa]

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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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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.

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.

Influence on Stdev by changing the lineInfluence on Stdev by changing the line

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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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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.

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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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.

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.

AgendaAgenda

Customer Challenges Process Intelligence Case Studies at Mitsubishi Chemical Summary and Future of Diagnostics

Loop Power & Connectivity

Diagnostic Coverage Beyond the TransmitterDiagnostic Coverage Beyond the Transmitter

Process Intelligence

Safety Certified

Transmitter Health

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

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

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

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

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