Emerson Exchange 3D plots Process Analysis


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This presentation on Process Analysis using 3D plots was given at Emerson Exchange, 2010. Details are provided on a field trail in which the DeltaV historian was modified to support array parameters and a web enabled interfaces was used to provide a 3D plot of array data. Information is provided on how this was used to look at absorber column and stripper column temperature profiles.

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Emerson Exchange 3D plots Process Analysis

  1. 1. Process Analysis Using 3D Plots Dr. Frank Seibert, University of Texas
  2. 2. Presenters <ul><li>Frank Seibert, University of Texas </li></ul><ul><li>Terry Blevins, Principal Technologist </li></ul><ul><li>Julian Post, </li></ul><ul><li>Paul Muston, </li></ul><ul><li>Mark Nixon </li></ul>
  3. 3. Introduction <ul><li>The benefits of 3-D plots in data analysis and history collection of array parameters have been demonstrated in a field trial. In this presentation we addressed: </li></ul><ul><ul><li>Target applications – Analysis of high speed processes, distributed processes and data from spectral analyzers. </li></ul></ul><ul><ul><li>Historian modifications/design for support of arrays data. </li></ul></ul><ul><ul><li>Web enabled 3-D plotting, how array support was used to improve update performance. </li></ul></ul><ul><ul><li>Field Trial at University of Texas, Pickle Research Center where absorber temperatures were analyzed during startup 3-D plotting and . </li></ul></ul><ul><li>The technical feasibility of providing 3-D plotting and historian collection of array data has been explore and the value of such a capability proven in two of the target application. </li></ul>
  4. 4. Analysis of High Speed Data Analysis <ul><li>DeltaV supports measurement and control execution at speed as fast as100 msec. </li></ul><ul><li>To enable samples as fast as 100msec to be trended and analyzed, samples may be collected at the controller as an data set/ array and communicated to the historian. </li></ul><ul><li>Values are saved in historian and accessed as though they had been reported at the module execution rate. </li></ul><ul><li>Module executing at 100msec was created to place high speed data into an array parameter. Arrays communicated at a much slower rate e.g. once per 2 sec. </li></ul>Controlle r Historian Application station Analysis Tools e.g. Entech Toolkit Profession /Operator Station Standard Trend – 100msec Resolution Array/Data Set
  5. 5. Distributed Process <ul><li>Temperature and/or pressure distribution across a process unit is often important from an operation perspective. </li></ul><ul><li>Univariate plots are ineffective in finding problems </li></ul><ul><li>3-D plots show relationship of measurements and how this relationship changes with time </li></ul>TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT TT
  6. 6. Spectral Analyzers <ul><li>Spectral analyzers may be used at critical points throughout the process. </li></ul><ul><ul><li>Pharmaceutical - inspection of feedstock, blend uniformity, granulation, drying and coating and particle size analysis . Online QA/QC tool for production. </li></ul></ul><ul><ul><li>Chemical - acid value, adhesive content, cure, melt index, and polymer processes -reaction monitoring </li></ul></ul><ul><ul><li>Refinery, petrochemical - fuel production monitoring </li></ul></ul><ul><li>A wide variety of commercial on-line, at-line, and laboratory spectral analyzers are available. </li></ul><ul><li>Calibration of an NIR analyzer is based on use of spectral data to develop principal component analysis(PCA) and projection of latent structures (PLS) models. </li></ul>
  7. 7. Example: NIR Analyzers <ul><li>Careful development of a set of calibration samples and their use in PCA/PLS model development is the basis for near-infrared analytical methods. </li></ul><ul><li>For purposes of analysis, the spectral data for a sample should be saved and accessed as one set of data e.g. an array . </li></ul><ul><li>3-D plotting of spectral data can be helpful in screening samples and in analyzing on-line use of spectral data. </li></ul>Off-line PCA/ PLS Model Development On-line Quality Parameter Prediction Historian Array/Data Set Application station NIR Analyzer Controller VIM Interface 3-D Plot of Spectral Data
  8. 8. Field Trial - DvCH Array Handling Enhancement <ul><li>All samples for an array are held in the database under a single tag, to enable high access speed (minimization of seek times) or logical grouping of data (e.g. spectral analysis) </li></ul><ul><li>Implementation caters for use of successive elements of array for different measured variables or of the same measured variable (high speed trending) </li></ul><ul><li>Designed also for use of 2-D array to hold several successive scans of several different measured variables </li></ul>2-D array, variable per column Variable per row entry Single Variable Time Time
  9. 9. Time tagging in Controller <ul><li>Array time tagging at Controller – high resolution, improving time-stamp accuracy </li></ul><ul><li>Faster sampling rates possible (scan periods down to 100ms) </li></ul>PHV display of array tag
  10. 10. Field Trial Design Considerations <ul><li>Designed to allow full incorporation in DvCH product </li></ul><ul><li>Existing facilities to be supported for each individual measured variable in scanned array, as if configured individually for history collection </li></ul><ul><li>Existing read of tag for specified interval, applied to tag for first element of array, gives all samples for array within time interval in time-stamp order (including array index part) so </li></ul><ul><ul><li>Samples in time order </li></ul></ul><ul><ul><li>Samples at same time in array-index order </li></ul></ul><ul><li>Hence DvCH clients (e.g. PHV, DeltaV Reporter and OPC HDA) can meaningfully access history without code change. (See PHV display on previous slide). </li></ul><ul><li>Easy to extend client-interface for individual measured variable access etc. e.g. 3-D plotting app </li></ul>
  11. 11. 3D Plotting Technology <ul><li>Various approaches may be taken in visualizing 3D data. Surface Plot, Bar Plot , Series Plot , Line Plot, Scatter Plot, Wirefame Plot, Mesh  Plot </li></ul><ul><li>Limited number of commercially available components for use with a web browser. </li></ul><ul><li>Wire frame plot has may advantages in viewing and analyzing date. </li></ul>3D Bar Plot 3D Wire Frame and Surface Plot
  12. 12. 3D Plot Capability for Field Trial <ul><li>A 3-D wire frame plot component was selected for the field trial. </li></ul><ul><li>Used to visualize absorber temperatures collected by the historian as array data. </li></ul><ul><li>Interface may be accessed using web browser . </li></ul><ul><li>3-D plot interface supports rotation and easy access to individual measurement values </li></ul>
  13. 13. Controls Provided for 3D Plot <ul><li>Selection of Absorber or Stripper </li></ul><ul><li>3D views from different angles </li></ul><ul><li>Selection of time span and resolution </li></ul><ul><li>Move back in forth in time </li></ul><ul><li>Array data used for 3D plots was saved in DeltaV Continuous Historian </li></ul>
  14. 14. 3D Views Supported View1 View2 View3
  15. 15. Time Span Selections 1 Hour 15 Minute 4 Hour
  16. 16. SRP CO2 Capture Pilot Plant <ul><li>Gas Capacity, m 3 /min = 25 </li></ul><ul><li>Solvent Capacity, liter/min = 130 </li></ul><ul><li>Inlet CO2 Composition, mol% =1-20 </li></ul><ul><li>Capabilities: </li></ul><ul><li>- Solvent Screening </li></ul><ul><li>- Packing Performance </li></ul><ul><li>- Effect of Absorber Inter-cooling </li></ul><ul><li>- Solvent Regeneration Variations </li></ul><ul><li>- Evaluate Process Dynamics </li></ul><ul><li>- Evaluate Heat Exchangers </li></ul><ul><li>- Model Validation </li></ul>
  17. 17. Field Trial - UT/SRP CO2 Capture Process
  18. 18. Stripping Column <ul><li>Column Diameter, cm = 42.8 </li></ul><ul><li>Packed Height, cm = 600 </li></ul><ul><li>Pressure, bar = 0.2-4 </li></ul><ul><li>Provides for Flashing Feed </li></ul><ul><li>Windows for Observation </li></ul><ul><li>Kettle Reboiler </li></ul><ul><li>Shell and Tube Condenser </li></ul><ul><li>Plate and Frame Cross Exchanger </li></ul><ul><li>11 bar Saturated Steam </li></ul><ul><li>10 C Chilled Water </li></ul>
  19. 19. Absorption Column <ul><li>Column Diameter, cm = 42.8 </li></ul><ul><li>Packed Height, cm = 600 </li></ul><ul><li>Pressure, bar = 1 </li></ul><ul><li>Windows for Observation </li></ul><ul><li>Inter-cooling Capability </li></ul><ul><li>Extensive Temperature Measurements </li></ul>
  20. 20. Absorber Intercooling Process Flowsheet
  21. 21. Absorber Intercooler Skid
  22. 22. Absorber: No Intercooling
  23. 23. Absorber Intercooling Operation
  24. 24. MEA Absorber Temperature Profile L/G = 4.8 (lb/lb), 415 ACFM, 0.3 Lean Loading No Intercooling 86.5% Removal, Run 1 Intercooling (40 ° C) 93% Removal, Run 2
  25. 25. MEA Absorber Temperature Profile L/G = 2.1 (lb/lb), 500 ACFM, 0.2 Lean Loading No Intercooling 83.2% Removal, Run 11 Intercooling (40 ° C) 82.5% Removal, Run 12
  26. 26. Effect of Absorber Inter-cooling Parameter Without Inter-cooling With Inter-cooling % CO2 Removal 87 93 Stripper Efficiency, kJ/kg CO 2 4,170 4,015
  27. 27. Absorber 8-27-2010 1:27-5:25pm View 1
  28. 28. Absorber 8-27-2010 1:27-5:25pm View 2
  29. 29. Absorber 8-27-2010 1:27-5:25pm View 3
  30. 30. Absorber 8-27-2010 4:27 – 8:25pm View 1
  31. 31. Absorber 8-27-2010 4:27 – 8:25pm View 2
  32. 32. Absorber 8-27-2010 4:27 – 8:25pm View 3
  33. 33. Stripper 8-27-2010 1:28 – 5:28pm View 1
  34. 34. Stripper 8-27-2010 2:28 – 6:28pm View 2
  35. 35. Stripper 8-27-2010 2:28 – 6:28pm View 3
  36. 36. Stripper 8-27-2010 3:28 – 8:26pm View 1
  37. 37. Stripper 8-27-2010 4:28 – 8:26pm View 2
  38. 38. Stripper 8-27-2010 4:28 – 8:26pm View 3
  39. 39. Business Results Achieved <ul><li>3-D plots and historian support of array data is being used to analyze absorber column temperature variation during startup. It is expected that insight gained through the use of 3-D plotting on-line will lead to a reduction in startup time </li></ul><ul><li>Analysis of high speed data associated with liquid pressure/flow loops is planned and should lead to improvements in the process operations. </li></ul>
  40. 40. Summary <ul><li>3-D plotting based on historian collection of array data can be used to analyze distributed process and spectral data. </li></ul><ul><li>Trending of high speed data is possible if data is collected at the controller in an array. </li></ul><ul><li>The benefits of 3-D plotting of absorber temperature and trending of high speed data will be demonstrated at the UT Pickle Research Center. </li></ul><ul><li>Field trial work to demonstrate 3-D plotting and historian collection of array data sets a foundation for future enhancement in DeltaV. </li></ul>
  41. 41. Questionnaire