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Process Analysis Using 3D Plots Dr. Frank Seibert, University of Texas

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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Page 1: Emerson Exchange 3D plots Process Analysis

Process Analysis Using 3D Plots

Process Analysis Using 3D Plots

Dr. Frank Seibert, University of Texas

Page 2: Emerson Exchange 3D plots Process Analysis

PresentersPresenters

Frank Seibert, University of Texas

Terry Blevins, Principal Technologist

Julian Post,

Paul Muston,

Mark Nixon

Page 3: Emerson Exchange 3D plots Process Analysis

IntroductionIntroduction 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:– Target applications – Analysis of high speed processes, distributed

processes and data from spectral analyzers.

– Historian modifications/design for support of arrays data.

– Web enabled 3-D plotting, how array support was used to improve update performance.

– Field Trial at University of Texas, Pickle Research Center where absorber temperatures were analyzed during startup 3-D plotting and .

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.

Page 4: Emerson Exchange 3D plots Process Analysis

Analysis of High Speed Data AnalysisAnalysis of High Speed Data Analysis DeltaV supports measurement and

control execution at speed as fast as100 msec.

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.

Values are saved in historian and accessed as though they had been reported at the module execution rate.

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.

Controller

Historian

Application station

Analysis Tools e.g.

Entech Toolkit

Var 10 PI4735A.PV - Ind. DO1204AA.dat

Primary Cleaner Feed Pressure 05/29/2001 14:15:14

Time Series

0.00 102.40 204.80 307.20 409.60Sec

35.75

37.16

38.57

39.98

41.39psig

Mean=38.1345 2Sig=1.671 (4.38% )

Var 10 PI4735A.PV - Ind. DO1204AA.dat

Primary Cleaner Feed Pressure 05/29/2001 14:15:14

Power Spectrum (FFT)

0.00 6.00 12.00 18.00 24.00Cycle/Sec

0.0000

1.9535

3.9069

5.8604

7.8138Variance (E-3)

0

25

50

75

100% Variance

De-Trend=No, Win=None, Seg=0

Var 10 PI4735A.PV - Ind. DO1204AA.dat

Primary Cleaner Feed Pressure 05/29/2001 14:15:14

Auto Correlation (FFT)

0.0 3.2 6.4 9.6 12.8Sec

-1.0

-0.5

0.0

0.5

1.0

Var 10 PI4735A.PV - Ind. DO1204AA.dat

Primary Cleaner Feed Pressure 05/29/2001 14:15:14

Power Spectrum PeaksDe-Trend=No, Win=None, Seg=0

Lower Threshold: 1.703E-3, Change Threshold: 2.044E-3

Total Variance: 0.69770% Total P-P 2 Sigma

Peak Freq. Period Shape Variance Amplit. Remain.1 0.018785 53.234 4 3.557 0.44559 1.64062 0.039546 25.287 2 1.246 0.26373 1.66013 0.38086 2.6256 1 0.8886 0.22271 1.66314 0.70557 1.4173 1 0.8553 0.21849 1.66345 0.062533 15.992 2 1.294 0.26870 1.65976 0.19043 5.2513 1 0.7231 0.20090 1.66457 0.36664 2.7275 4 1.797 0.31669 1.6555

**Truncated**

Profession /Operator

Station

Standard Trend – 100msec

Resolution

Array/Data Set

Page 5: Emerson Exchange 3D plots Process Analysis

Distributed ProcessDistributed Process

Temperature and/or pressure distribution across a process unit is often important from an operation perspective.

Univariate plots are ineffective in finding problems

3-D plots show relationship of measurements and how this relationship changes with time

TTTT TTTT

TTTT TTTT

TT

TT

TT

TT

TT

TT

TTTT TTTT

TTTTTT TT

Page 6: Emerson Exchange 3D plots Process Analysis

Spectral AnalyzersSpectral Analyzers

Spectral analyzers may be used at critical points throughout the process.

– Pharmaceutical - inspection of feedstock, blend uniformity, granulation, drying and coating and particle size analysis. Online QA/QC tool for production.

– Chemical - acid value, adhesive content, cure, melt index, and polymer processes -reaction monitoring

– Refinery, petrochemical - fuel production monitoring

A wide variety of commercial on-line, at-line, and laboratory spectral analyzers are available.

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.

Page 7: Emerson Exchange 3D plots Process Analysis

Example: NIR AnalyzersExample: NIR Analyzers Careful development of a set of

calibration samples and their use in PCA/PLS model development is the basis for near-infrared analytical methods.

For purposes of analysis, the spectral data for a sample should be saved and accessed as one set of data e.g. an array.

3-D plotting of spectral data can be helpful in screening samples and in analyzing on-line use of spectral data.

Off-line PCA/ PLS Model

Development

On-line Quality Parameter Prediction

Historian

Array/Data Set

Application station

NIR AnalyzerController

VIM Interface

3-D Plot of Spectral

Data

Page 8: Emerson Exchange 3D plots Process Analysis

Field Trial - DvCH Array Handling EnhancementField Trial - DvCH Array Handling Enhancement

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)

Implementation caters for use of successive elements of array for different measured variables or of the same measured variable (high speed trending)

Designed also for use of 2-D array to hold several successive scans of several different measured variables

2-D array, variable

per column

Variable per

row entry

Single

Variable

Time

Time

Page 9: Emerson Exchange 3D plots Process Analysis

Time tagging in ControllerTime tagging in Controller

Array time tagging at Controller – high resolution, improving time-stamp accuracy

Faster sampling rates possible (scan periods down to 100ms)

PHV display of array tag

Page 10: Emerson Exchange 3D plots Process Analysis

Field Trial Design ConsiderationsField Trial Design Considerations Designed to allow full incorporation in DvCH product Existing facilities to be supported for each individual measured

variable in scanned array, as if configured individually for history collection

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 – Samples in time order– Samples at same time in array-index order

Hence DvCH clients (e.g. PHV, DeltaV Reporter and OPC HDA) can meaningfully access history without code change. (See PHV display on previous slide).

Easy to extend client-interface for individual measured variable access etc. e.g. 3-D plotting app

Page 11: Emerson Exchange 3D plots Process Analysis

3D Plotting Technology3D Plotting Technology

Various approaches may be taken in visualizing 3D data. Surface Plot, Bar Plot , Series Plot , Line Plot, Scatter Plot, Wirefame Plot, Mesh  Plot

Limited number of commercially available components for use with a web browser.

Wire frame plot has may advantages in viewing and analyzing date.

3D Bar Plot

3D Wire Frame and Surface Plot

Page 12: Emerson Exchange 3D plots Process Analysis

3D Plot Capability for Field Trial3D Plot Capability for Field Trial

A 3-D wire frame plot component was selected for the field trial.

Used to visualize absorber temperatures collected by the historian as array data.

Interface may be accessed using web browser.

3-D plot interface supports rotation and easy access to individual measurement values

Page 13: Emerson Exchange 3D plots Process Analysis

Controls Provided for 3D PlotControls Provided for 3D Plot

Selection of Absorber or Stripper

3D views from different angles

Selection of time span and resolution

Move back in forth in time

Array data used for 3D plots was saved in DeltaV Continuous Historian

Page 14: Emerson Exchange 3D plots Process Analysis

3D Views Supported3D Views Supported

View1 View2 View3

Page 15: Emerson Exchange 3D plots Process Analysis

Time Span SelectionsTime Span Selections

1 Hour15 Minute 4 Hour

Page 16: Emerson Exchange 3D plots Process Analysis

SRP CO2 Capture Pilot PlantSRP CO2 Capture Pilot Plant

16

Gas Capacity, m3/min = 25

Solvent Capacity, liter/min = 130

Inlet CO2 Composition, mol% =1-20 Capabilities: - Solvent Screening - Packing Performance - Effect of Absorber Inter-cooling - Solvent Regeneration

Variations - Evaluate Process Dynamics - Evaluate Heat Exchangers - Model Validation

Page 17: Emerson Exchange 3D plots Process Analysis

Field Trial - UT/SRP CO2 Capture ProcessField Trial - UT/SRP CO2 Capture Process

Page 18: Emerson Exchange 3D plots Process Analysis

Stripping ColumnStripping Column

Column Diameter, cm = 42.8

Packed Height, cm = 600

Pressure, bar = 0.2-4

Provides for Flashing Feed

Windows for Observation

Kettle Reboiler

Shell and Tube Condenser

Plate and Frame Cross Exchanger

11 bar Saturated Steam

10 C Chilled Water

Page 19: Emerson Exchange 3D plots Process Analysis

Absorption ColumnAbsorption Column

Column Diameter, cm = 42.8 Packed Height, cm = 600 Pressure, bar = 1 Windows for Observation Inter-cooling Capability Extensive Temperature

Measurements

Page 20: Emerson Exchange 3D plots Process Analysis

Absorber Intercooling Process FlowsheetAbsorber Intercooling Process Flowsheet

Page 21: Emerson Exchange 3D plots Process Analysis

Absorber Intercooler SkidAbsorber Intercooler Skid

Page 22: Emerson Exchange 3D plots Process Analysis

Absorber: No IntercoolingAbsorber: No Intercooling

22

Page 23: Emerson Exchange 3D plots Process Analysis

Absorber Intercooling OperationAbsorber Intercooling Operation

Page 24: Emerson Exchange 3D plots Process Analysis

MEA Absorber Temperature ProfileL/G = 4.8 (lb/lb), 415 ACFM, 0.3 Lean LoadingMEA Absorber Temperature ProfileL/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

Page 25: Emerson Exchange 3D plots Process Analysis

MEA Absorber Temperature ProfileL/G = 2.1 (lb/lb), 500 ACFM, 0.2 Lean LoadingMEA Absorber Temperature ProfileL/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

Page 26: Emerson Exchange 3D plots Process Analysis

Effect of Absorber Inter-coolingEffect of Absorber Inter-cooling

26

Parameter Without Inter-

cooling

With Inter-

cooling

% CO2 Removal 87 93

Stripper Efficiency, kJ/kg CO2

4,170 4,015

Page 27: Emerson Exchange 3D plots Process Analysis

Absorber 8-27-2010 1:27-5:25pm View 1Absorber 8-27-2010 1:27-5:25pm View 1

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Absorber 8-27-2010 1:27-5:25pm View 2Absorber 8-27-2010 1:27-5:25pm View 2

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Absorber 8-27-2010 1:27-5:25pm View 3Absorber 8-27-2010 1:27-5:25pm View 3

Page 30: Emerson Exchange 3D plots Process Analysis

Absorber 8-27-2010 4:27 – 8:25pm View 1Absorber 8-27-2010 4:27 – 8:25pm View 1

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Absorber 8-27-2010 4:27 – 8:25pm View 2Absorber 8-27-2010 4:27 – 8:25pm View 2

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Absorber 8-27-2010 4:27 – 8:25pm View 3Absorber 8-27-2010 4:27 – 8:25pm View 3

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Stripper 8-27-2010 1:28 – 5:28pm View 1 Stripper 8-27-2010 1:28 – 5:28pm View 1

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Stripper 8-27-2010 2:28 – 6:28pm View 2 Stripper 8-27-2010 2:28 – 6:28pm View 2

Page 35: Emerson Exchange 3D plots Process Analysis

Stripper 8-27-2010 2:28 – 6:28pm View 3 Stripper 8-27-2010 2:28 – 6:28pm View 3

Page 36: Emerson Exchange 3D plots Process Analysis

Stripper 8-27-2010 3:28 – 8:26pm View 1 Stripper 8-27-2010 3:28 – 8:26pm View 1

Page 37: Emerson Exchange 3D plots Process Analysis

Stripper 8-27-2010 4:28 – 8:26pm View 2 Stripper 8-27-2010 4:28 – 8:26pm View 2

Page 38: Emerson Exchange 3D plots Process Analysis

Stripper 8-27-2010 4:28 – 8:26pm View 3 Stripper 8-27-2010 4:28 – 8:26pm View 3

Page 39: Emerson Exchange 3D plots Process Analysis

Business Results AchievedBusiness Results Achieved

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

Analysis of high speed data associated with liquid pressure/flow loops is planned and should lead to improvements in the process operations.

Page 40: Emerson Exchange 3D plots Process Analysis

SummarySummary

3-D plotting based on historian collection of array data can be used to analyze distributed process and spectral data.

Trending of high speed data is possible if data is collected at the controller in an array.

The benefits of 3-D plotting of absorber temperature and trending of high speed data will be demonstrated at the UT Pickle Research Center.

Field trial work to demonstrate 3-D plotting and historian collection of array data sets a foundation for future enhancement in DeltaV.

Page 41: Emerson Exchange 3D plots Process Analysis

QuestionnaireQuestionnaire