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Abstract
Introduction
Abnormal
Situation
Severity Emergency
Abnormal
response
Region of process control
Alarm
Normal Corrected
response situation
Region of Abnormal
Situation Prevention
Alarm
Corrected
situation
Time
Process control in this situation may take the process variable back to a point in
the normal region that is not far from the abnormal situation. The proposed
abnormal situation prevention approach, on the other hand, identifies the
abnormal situation at an earlier time (Figure 1) and identifies the source of the
fault. The abnormal situation is identified as it starts to develop. The whole
diagnostic, detection, and corrective actions take place in the normal operating
region. How is this done? This is done by comparing the actual real time
operating conditions to the ideal base. Ideal base here refers to the normal
process operating conditions without any deviation or abnormal situation. The
proposed approach uses advanced pattern recognition technologies, signal
analysis, statistical process control, as well as expert system based solution with
the smart devices for improved process operation, and early abnormal situation
detection and prevention.
As the stage order increases, the cost severity associated with the abnormal
situation increases and may result in major damaging consequences. Circle (A)
in Figure (2) represents two corrective approaches, preventive maintenance and
knowledge-based diagnostic and fault detection. The preventive maintenance
takes a corrective action with respect to physical entity such as cleaning the
valve or the transfer pipe. The knowledge-based diagnostic uses historian data
to develop a multivariate model to detect the behavior of the process. This
approach can get very complex. It uses low frequency filtered data and relies on
historian data. It does not have the capability to gather data on-line to update
the monitoring models. This approach fails to detect abnormal situations if the
abnormal situation is very fast or with a high frequency unless a damaging
consequence is evolved. Furthermore, this approach fails to predict health of
machinery, devices, and transmitters used in the process. It can, though, give a
good indication of process variable deviation from normal operation condition.
The response time domain for circle A is slow and can be too late.
Circle B represents the use of smart field devices and field instruments.
Eryurek et al. (2005) illustrates that improved process measurements and real
time analysis/detection could have prevented or at least substantially reduced
the damage of approximately 25-40% of reported abnormal situations. With
advances in computing and measurement device technologies and advances in
communication such as the digital Fieldbus technologies, todays smart field
devices and transmitters are capable of providing much more information
regarding the processes and its conditions. Smart field devices and instruments
manufactured by Emerson Process Management have built-in ASPTM blocks
(Figure 3) which captures high frequency process data (22 Hz) and have data
analysis capabilities. Abnormal situation prevention algorithm now can have
access to data that was lost with a low frequency analysis (Figure 4).
Abnormal
Situation Plant shut down
Cost A
Valve malfunction
B
C Loss of production
Pressure changes
Time
Sensor AI PID AO
Readings
ASP Alert
ASPTM Statistical Data
Block Frequency Data
Auto Regression Data
Wavelets Data
Sampling
frequency is
1-60 seconds
Embedded in
Emerson DeltaV (Ovation, ..)
Fieldbus
Device ASP
ASPTM
Block
Equipment/Process
ASP
. Abnormal Situation PlantWeb
Statistical Prevention Module Alerts
.
. Frequency (Data gathering,
Auto Regression analysis,
and monitoring)
Wavelets
TM
ASP
Block Other
Process
Data
Case Studies
Various case studies are presented below to illustrate the effectiveness of the
proposed abnormal situation prevention methodology.
Module Summary
The Coker abnormal situation prevention algorithm monitors each pass in the
furnace of the Delayed Coker to check for high coking. Generally, a decrease in
either the flow or heat transfer rate for a given pass indicates that there is high
coking in that pass. During the learning phase, data is collected for each pass.
At the end of the learning phase, a regression model is developed which can
predict the value of each monitored variable as a function of the load variable.
The value predicted by the model is considered the normal operating condition
for that monitored variable. When the actual value differs from the predicted
value by more than a certain threshold, an abnormal situation (high coking) is
detected. This algorithm is implemented in DeltaV (Figure 6) and is used in
industrial trials.
Module Summary
A lower or higher differential pressure across the slide valve than normal
slide valve opening is a good indication of abnormal situation development in the
catalyst transfer pipe. Catalyst circulation can also be limited by mechanical
problems with the slide/plug valve. The abnormal situation prevention module
consists of two steps:
High Coking
Detected
Pass 1
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Information
Module Summary
The objective of this algorithm is to detect conditions in column operation
that lead to flooding or to predict flooding conditions as early as possible to avoid
entire column or tray flooding. Different algorithms can be developed to identify
flooding conditions depending on existing instrumentations and potential future
instrumentations.
Module Summary
In the learning phase, the method collects data and applies various modeling
techniques to relate input and output data. The models developed in the
learning phase are used in the monitor phase to identify abnormal situations.
Each model is assigned a region of confidence for operation. The region of
confidence is user specified.
Conclusion
References