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ABB 800xA Operation

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System 800xA Asset Optimization
Operation
System Version 6.0
Power and productivity
for a better world
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Summary of Contents for ABB 800xA

  • Page 1 System 800xA Asset Optimization Operation System Version 6.0 Power and productivity for a better world...
  • Page 3 System 800xA Asset Optimization Operation System Version 6.0...
  • Page 4 In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hard- ware described in this document.

  • Page 5: Table Of Contents

    Table of Contents About This User Manual General ..........................9 User Manual Conventions ....................9 Feature Pack ......................9 Warning, Caution, Information, and Tip Icons ............10 Documentation of Third Party Software .................11 Terminology........................11 Released User Manuals and Release Notes..............11 Section 1 - Introduction Product Overview ......................13 Product Scope.......................13 Section 2 - Maintenance Workplace and Asset Structure...
  • Page 6 Table of Contents Introduction ........................27 Asset Viewer........................27 Asset Reporter ......................... 34 Condition Details, Asset Monitor Status, and Diagnostics Link ........37 Fault Report Viewer ......................38 Asset Monitor Properties....................40 Section 4 - AO Server Operation Introduction ........................43 Asset Optimization Event Log ..................
  • Page 7 Table of Contents Preventive Maintenance Schedule View ..............72 Section 6 - Web-Enabled Views Operation .........................73 Section 7 - Faceplates Introduction ........................75 Runtime Faceplate ......................75 Generic Counter Check Faceplate ...................78 Section 8 - Control Loop Asset Monitor (CLAM) Introduction ........................81 Running the Control Loop Asset Monitor...............82 Basic Loop Monitoring Mode (Unlicensed) ............82 Enhanced Control Loop Monitoring Mode (Licensed mode)......88 Operation .........................93...
  • Page 8 Table of Contents HXAM_G_Faceplate ..................121 Trends and Logs....................138 History Source ....................138 Log Template ..................... 138 Log Configuration....................138 Trend Template ....................139 Trend Display..................... 140 Asset Monitor Properties ................... 140 Log File Description (.csv file) ................140 Shell and Tube Heat Exchanger Asset Monitor (HXAM-ST) ........

  • Page 9: About This User Manual

    Any security measures described in this User Manual, for example, for user access, password security, network security, firewalls, virus protection, etc., represent possible steps that a user of an 800xA System may want to consider based on a risk assessment for a particular application and installation. This risk...

  • Page 10: Warning, Caution, Information, And Tip Icons

    Feature Pack functionality included in an existing table is indicated using a table footnote (*) : * Feature Pack Functionality Unless noted, all other information in this User Manual applies to 800xA Systems with or without a Feature Pack installed. Warning, Caution, Information, and Tip Icons This User Manual includes Warning, Caution, and Information where appropriate to point out safety related or other important information.

  • Page 11: Documentation Of Third Party Software

    Webster’s Dictionary of Computer Terms. Released User Manuals and Release Notes A complete list of all User Manuals and Release Notes applicable to System 800xA is provided in System 800xA Released User Manuals and Release Notes (3BUA000263*).
  • Page 12 Released User Manuals and Release Notes About This User Manual 3BUA000150-600...

  • Page 13: Section 1 Introduction

    Section 1 Introduction Product Overview System 800xA - Asset Optimization consists of system extensions to the 800xA Base System. Asset Optimization functionality includes Asset Condition Reporting, Asset Monitoring, CMMS (Computerized Maintenance Management System) Integration, and a separate engineered solution for calibration integration to the 800xA System.
  • Page 14 Product Scope Section 1 Introduction – Process Asset Monitors (includes Control Loop Asset Monitor (CLAM), Heat Exchanger Asset Monitor - Shell and Tube (HXAM - ST), and Heat Exchanger Asset Monitor - Generic (HXAM - G). The Control Loop Asset Monitor (CLAM) has two licensing modes: Enhanced Control Loop Monitoring mode (licensed) and Basic Control Loop Monitoring mode (unlicensed).
  • Page 15 Section 1 Introduction Product Scope Figure 1 shows the interaction between the various functional components of Asset Optimization. A S S E T O P T IM IZ A T IO N A S S E T M O N IT O R IN G A S S E T O P T IM IZ A T IO N S E R V E R (L O G IC E X E C U T IO N ) D A T A B A S IC A S S E T M O N IT O R S...
  • Page 16 Product Scope Section 1 Introduction 3BUA000150-600...

  • Page 17: Introduction

    Section 2 Maintenance Workplace and Asset Structure Introduction Asset Optimization information can be accessed from any workplace in the 800xA System. The Maintenance Workplace is a default workplace for maintenance personnel. It is a Plant Explorer Workplace with an Alarm Band that shows Asset Monitoring Alarms for default Asset groups.
  • Page 18 Maintenance Workplace Section 2 Maintenance Workplace and Asset Structure TC07772A Figure 2. Maintenance Workplace The Maintenance Workplace exposes an Alarm Band (top) and three splitter windows. The splitter windows show: • The selected structure in a tree view (left). • All aspects of any selected object (middle right).
  • Page 19 Figure 3. Asset Structure The user is able to change the structure at any time by adding, renaming, rearranging, or deleting Asset Groups or subgroups. Refer to System 800xA Operations Operator Workplace Configuration (3BSE030322*) for details. The five primary Asset Groups have Alarm List aspects that report the Asset Alarms from all objects beneath them.

  • Page 20: Maintenance Workplace 2

    Maintenance Workplace 2 Section 2 Maintenance Workplace and Asset Structure Maintenance Workplace 2 The new workplace provides an easy, enhanced and efficient way for the user to view the Asset status and condition details in few clicks. The Maintenance Workplace 2 is based on the Asset Structure. All the assets that are engineered in the system has to be inserted into the Asset Structure.
  • Page 21 Section 2 Maintenance Workplace and Asset Structure Maintenance Workplace 2 Figure 5. Maintenance Workplace 2 User Interface The layout consists of four views: Alarm Band in the Top Horizontal Panel. Asset Viewer view in the Top Left Panel. Aspect List view in the Bottom Left Panel. 3BUA000150-600...

  • Page 22: Navigation Flow

    Navigation Flow Section 2 Maintenance Workplace and Asset Structure Asset Reporter View in the Top Right Panel. Asset Condition Details View in the Bottom Right Panel. The Maintenance Workplace 2 uses the Asset viewer aspect to navigate to the Objects in the Asset Structure. The root object shows the overall status. It is possible for users to find the affected Object by expanding the tree structure.

  • Page 23: Asset Viewer View

    Section 2 Maintenance Workplace and Asset Structure Asset Viewer View After all the operations are performed, the User Interface is seen as shown in the Figure Figure 6. Maintenance Workplace 2 User Interface Asset Viewer View This part of the UI displays the preview of the Asset Viewer Aspect present under Plant Assets object of the Asset Structure in Process Portal A (PPA).

  • Page 24: Aspect List

    Servers for Configurations. Maintenance Workplace 2 stops responding if the Asset Tree Service is down on the Asset Optimization Server. To know more on how to Add/Modify buttons, refer to System 800xA Operations Operator Workplace Configuration manual (3BSE030322*). 3BUA000150-600...

  • Page 25: Maintenance Filter

    Section 2 Maintenance Workplace and Asset Structure Maintenance Filter Maintenance Filter The Maintenance Workplace comes with four default filters that are designed to expose only those aspects that are needed for the typical maintenance workflow. Figure 7 highlights the Alarm Band with the Maintenance - Technician filter selected.
  • Page 26 Maintenance Filter Section 2 Maintenance Workplace and Asset Structure 3BUA000150-600...

  • Page 27: Section 3 Condition Reporting And Monitoring

    Workplace, and Maintenance Workplace on 800xA System nodes. It is also accessible as a web-enabled view on non-800xA systems. When the Asset Viewer is active in the 800xA client nodes, the status of the assets in the view update 3BUA000150-600...
  • Page 28 Namur icons, should make configuration changes to revert to the existing icons. To know more on how to change, refer to Restore Existing Icons and Colors in System 800xA Asset Optimization Configuration (3BUA000118*). Table 1 shows and describes the Asset Tree severity indicator icons, their related severities, and Maintenance Alarm definitions Table 1.
  • Page 29 Section 3 Condition Reporting and Monitoring Asset Viewer Table 1. Asset Tree Severity Indicator Icons (Old Icons) (Continued) Icon Severity Maintenance Alarm Definition High: Function check: Asset functionality might be temporarily restricted, due 501 to 750 to ongoing work on the asset, e.g. as local operation, maintenance, simulation, or a function check.
  • Page 30 Asset Viewer Section 3 Condition Reporting and Monitoring Table 2. Asset Tree Severity Indicator Icons (Namur Icons) (Continued) Icon Severity Maintenance Alarm Definition High: Function check: Asset functionality might be temporarily restricted, due 501 to 750 to ongoing work on the asset, e.g. as local operation, maintenance, simulation, or a function check.
  • Page 31 Section 3 Condition Reporting and Monitoring Asset Viewer TC08208A Figure 9. Expanded Asset Tree 3BUA000150-600...
  • Page 32 Asset Viewer Section 3 Condition Reporting and Monitoring A colored frame (Table 3) may appear around the Asset Viewer to indicate its current status. No frame indicates that the current status is accurate. Table 3. Asset Viewer/Asset Reporter Status Frame Status None All AO Servers running fine.
  • Page 33 Section 3 Condition Reporting and Monitoring Asset Viewer Refer to Table Table 4, and Table 3, and Figure 8 Figure 9, and their related descriptions to read the Asset Tree. Right-click on the desired object in the Asset Tree to produce a context menu in a view such as the one shown in Figure TC04692E...

  • Page 34: Asset Reporter

    Workplace, and Maintenance Workplace on 800xA System nodes. It is also accessible as a web-enabled view on non-800xA systems. When the Asset Reporter is active in the 800xA clients, the status of the assets in the view update automatically when values change. Web-enabled views require a manual refresh to update the view.
  • Page 35 Section 3 Condition Reporting and Monitoring Asset Reporter Right-click on that item and select Asset Reporter from the context menu to produce a view such as the one shown in Figure TC04725E Figure 11. Asset Reporter From left to right, the columns in the Asset Reporter show: –...
  • Page 36 Asset Reporter Section 3 Condition Reporting and Monitoring Table 6. Asset Reporter Color Scheme for NAMUR NE 107 Subcondition Severity Color Level Gray Normal Blue 1 to 250 Yellow 251 to 500 Orange 501 to 750 751 to 1000 – Description: a description of the current subcondition.

  • Page 37: Condition Details, Asset Monitor Status, And Diagnostics Link

    Section 3 Condition Reporting and Monitoring Condition Details, Asset Monitor Status, and Condition Details, Asset Monitor Status, and Diagnostics Link The Condition Details view provides more information about the selected condition in the Asset Reporter. This view also provides the overall Asset Monitor Status text. Select Condition Details:...

  • Page 38: Fault Report Viewer

    Fault Report Viewer Section 3 Condition Reporting and Monitoring Figure 13. Condition Details View (Maintenance Workplace 2) TC07803B Figure 14. Input Records Tab The Diagnostics menu will open a web page containing additional information about the monitored asset. To access this view, right-click on the desired Asset Monitor (Figure 15) and select Diagnostics from the context menu.
  • Page 39 Section 3 Condition Reporting and Monitoring Fault Report Viewer TC07804B Figure 15. Accessing the Diagnostics Menu To access the Fault Report Viewer through a context menu selection within the Operator Workplace: Navigate to the asset of interest in the Object Browser. Select Fault Report Submitter from the context menu.

  • Page 40: Asset Monitor Properties

    Asset Monitor Properties Section 3 Condition Reporting and Monitoring – FR State: The state of the Fault Report at any instance in time. It can either be the current condition, or the Most Severe Unacknowledged (MSU) condition of the asset. If the alarm line corresponding to the condition is not acknowledged, the Fault Report Viewer keeps the MSU even when the condition goes back to normal, in which case the FR State column reads Most Severe Unacknowledged.
  • Page 41 Section 3 Condition Reporting and Monitoring Asset Monitor Properties Each Item provides the runtime data in the form of a Value, Quality, and Timestamp. Figure 17 provides an example. If the Value field reads , that indicates the Data Source Key AddItem Error (System tab) does not match the correct Asset Monitor Server Data Source Definition.
  • Page 42 Asset Monitor Properties Section 3 Condition Reporting and Monitoring 3BUA000150-600...

  • Page 43: Section 4 Ao Server Operation

    Section 4 AO Server Operation Introduction This section describes operation of the AO Server. It includes: • Asset Optimization Event Log. • All Asset Condition Alarms List. • All Asset Monitoring Status Alarms List. • All Asset Optimization Alarms List. •...

  • Page 44: All Asset Condition Alarms List

    All Asset Condition Alarms List Section 4 AO Server Operation Select in the Aspect List Area to Asset Optimization Event Log produce the Asset Optimization Event Log Aspect view in the Preview Area as shown in Figure Logged messages are color coded: –...

  • Page 45: All Asset Monitoring Status Alarms List

    Section 4 AO Server Operation All Asset Monitoring Status Alarms List All Asset Monitoring Status Alarms List The All Asset Monitoring Status Alarms List provides a list of all Asset Monitoring Alarms reported by all running Asset Monitors in the system. While Asset Condition Alarms provide information about the monitored Asset Conditions, Asset Monitoring Alarms are used to report issues with the Asset Monitoring system and related data sources.

  • Page 46: Asset Optimization Server

    Asset Optimization Server Section 4 AO Server Operation Asset Optimization Server The Asset Optimization Server Aspect provides the main management and diagnostic interface for an AO Server node. To access the Asset Optimization Server Aspect: Open a Plant Explorer Workplace. Navigate to Root, Domain, Asset Optimization, Asset in the Control Structure.

  • Page 47: Asset Monitors Tab

    Section 4 AO Server Operation Asset Monitors Tab To start/stop the AssetMonitoring Service associated with an AO Server, enable/disable the Enable check box in the AO Server tab and click Apply. Starting/stopping the AssetMonitoring Service will also start/stop the AssetMonitoring Engine. Asset Monitors Tab The Asset Monitors tab (Figure...

  • Page 48: Runtime Statistics Tab

    Asset Monitors assigned to this AO Server. For licensing proposes the Objects with Asset Monitors number is reported. This is the number of unique 800xA Objects containing at least one Asset Monitor that will run in AO AssetMonitoring Engines.
  • Page 49 Section 4 AO Server Operation Runtime Statistics Tab TC07809B Figure 22. Asset Monitoring Server Runtime Statistics: Monitoring Server Page – Total number of Asset Monitor conditions (the maximum supported is 30,000). The Asset Monitoring Runtime Statistics: Data Servers page (Figure shows the status of each AssetMonitoring Engine connection to an OPC/DA Server (as defined by the Asset Monitor Data Source Aspect).
  • Page 50 Runtime Statistics Tab Section 4 AO Server Operation information about these properties, navigate to running Asset Monitors that are not in good status and check the Input Records tab in the Asset Monitor Status page (refer to Figure 14 under Condition Details, Asset Monitor Status, and Diagnostics Link on page 37).
  • Page 51 (Figure 26) shows the status of the Asset Monitoring Engine connection to the 800xA Alarm and Event Server, the Active Subscription Status, and a list of the Categories and Attributes supported by the Alarm and Event Server. TC08215A Figure 26. Asset Monitoring Server Runtime Statistics: Alarm and Event Server...
  • Page 52 Runtime Statistics Tab Section 4 AO Server Operation 3BUA000150-600...

  • Page 53: Section 5 Condition Event Handling

    The functions described in this section are accessible from the Operator Workplace through context menus from process graphics, etc. Refer to System 800xA Operations (3BSE036904*) for more information on accessing views through context menus. Some or all of these functions are also accessible from...
  • Page 54 Submitting Fault Reports Section 5 Condition Event Handling The Submit Fault Report View shown in Figure 27 is an example of one of five possible Submit Fault Report Views TC05365C Figure 27. Submit Fault Report View for Maximo Integration 3BUA000150-600...
  • Page 55 The Dismiss after successful submittal check box is a local override for the default setting (selected or cleared) chosen during Fault Report Submitter Setup (refer to System 800xA Asset Optimization Configuration (3BUA000118*) for more information). Selecting it deletes the current condition from the system when it is successfully submitted.
  • Page 56 . In that case, a valid Username and Password for the Maximo True system must be entered or the submission will be rejected. Refer to System 800xA Asset Optimization Configuration (3BUA000118*) for more information. Click the arrow next to the Failure Date: field to open a calendar that can be used to set the time and date stamp in the Fault Report.

  • Page 57: Creating And Submitting Fault Reports

    Report for the selected asset without an asset condition being generated by an Asset Monitor. These functions are made possible by the Fault Report Submitter. Refer to System 800xA Asset Optimization Configuration (3BUA000118*) to set up the Fault Report Submitter.
  • Page 58 True Maximo or SAP/PM system must be entered or the submission will be rejected. Refer to System 800xA Asset Optimization Configuration (3BUA000118*) for more information. For Maximo Integration, click the arrow next to the Failure Date: field to open a calendar that can be used to set the time and date stamp on the Fault Report.

  • Page 59: Alarm And Event List Operation

    Individual Alarm and Event lists can be configured to filter on these categories. Refer to System 800xA Asset Optimization Configuration (3BUA000118*) for more detailed information. Some preconfigured Alarm and Event lists that filter on these categories are automatically loaded with the Asset Optimization system extension.
  • Page 60 Section 5 Condition Event Handling The All Asset Condition Alarms List Aspect (Figure 29) displays all Asset Condition Alarms in the 800xA System. TC08221A Figure 29. All Asset Condition Alarms List The All Asset Monitoring Status Alarms List Aspect (Figure 30) displays all Asset Monitoring Status Alarms in the system.

  • Page 61: Cmms Views For Maximo Integration

    System 800xA documentation. CMMS Views For Maximo Integration The CMMS views consist of 800xA System views and Maximo portal views. The CMMS views are similar except for the information that can be accessed or viewed; therefore, only a few representative views will be shown.

  • Page 62: Active Work Orders View

    The Active Work Orders view lists all active Work Orders in the CMMS for a particular asset or group of assets. Select View Active Work Orders from a context menu to open an 800xA System Active Work Orders view such as the one shown in...
  • Page 63 Section 5 Condition Event Handling Active Work Orders View Selecting All Structures will produce Work Order list for the selected asset and all of its children in all structures in which the current asset is contained. To sort the list with respect to a column header topic, click that column header.

  • Page 64: Work Order History View

    The Work Order History view lists the history of all Work Orders in the CMMS for a particular asset or group of assets. Select View Work Order History from a context menu to open an 800xA System Work Order History view.

  • Page 65: Equipment Status View

    The Equipment Status view shows data returned from a status assessment of an asset or group of assets. Select View Equipment Status from a context menu to open an 800xA System Equipment Status view. The CMMS Objects: drop-down list box contains choices of which set of equipment status to view.

  • Page 66: Spare Parts/Availability Of Spare Parts Views

    Parts view that shows the location, quantity available, measurement unit, and cost of the selected spare part. Select View Spare Parts from a context menu to open an 800xA System Spare Parts view. The CMMS Objects: drop-down list box contains choices of which set of spare parts to view.

  • Page 67: Cmms Views For Sap/Pm Integration

    The Active Work Orders view lists all active Work Orders in the CMMS for a particular asset or group of assets. Select View Active Work Orders from a context menu to open an 800xA System Active Work Orders view such as the one shown in...
  • Page 68 Active Work Orders View Section 5 Condition Event Handling TC06086B Figure 34. 800xA System Active Work Orders View (SAP/PM Integration) The CMMS Objects: drop-down list box contains choices of which set of active Work Orders to view. Selecting the current asset shows the Work Orders only for that asset.
  • Page 69 Section 5 Condition Event Handling Active Work Orders View TC08219A Figure 35. SAP/PM Notification Portal View window is open, immediate history is available and accessible using the back and forward buttons. 3BUA000150-600...

  • Page 70: Work Order History View

    The Work Order History view lists the history of all Work Orders in the CMMS for a particular asset or group of assets. Select View Work Order History from a context menu to open an 800xA System Work Order History view.

  • Page 71: Equipment Status View

    The Equipment Status view shows data returned from a status assessment of an asset or group of assets. Select View Equipment Status from a context menu to open an 800xA System Equipment Status view. The CMMS Objects: drop-down list box contains choices of which set of equipment status to view.

  • Page 72: Preventive Maintenance Schedule View

    The Preventive Maintenance Schedule view lists the preventive maintenance schedule for an asset or group of assets. Select View Prev Maint Schedule from a context menu to open an 800xA System Preventive Maintenance Schedule view. The CMMS Objects: drop-down list box contains choices of which set of preventive maintenance schedules to view.

  • Page 73: Section 6 Web-Enabled Views

    Section 6 Web-Enabled Views Operation This procedure describes how to access web-enabled views of the Asset Tree from a Windows-based, non-800xA computer running Microsoft Internet Explorer. Open a Microsoft Internet Explorer window. Navigate to the following address: http://AoServer/ABBAO Where AoServer is the AO Main Server node.
  • Page 74 Operation Section 6 Web-Enabled Views The functionality of the Asset Tree is the same as the one described under Asset Viewer on page 27, and all of the functionality described in this User Manual is accessible through the web-enabled views. The difference is that a web-enabled view is not dynamically updated when a condition changes.

  • Page 75: Section 7 Faceplates

    The Running Time Check Asset Monitor has a user interface (the Runtime Faceplate), that displays runtime data and allows the user to reset the runtime. Refer to System 800xA Asset Optimization Configuration (3BUA000118*) to set up, configure, and become familiar with the Asset Parameters, Input Records, and Output Records of the Running Time Check Asset Monitor.
  • Page 76 Runtime Faceplate Section 7 Faceplates Figure 38 shows an example Runtime Faceplate where the Runtime Limit is 24 hours. TC05034C Figure 38. Runtime Faceplate (Example) Table 7 lists and describes the elements in the Runtime Faceplate. Table 7. Runtime Faceplate Elements Element Description Status...
  • Page 77 Section 7 Faceplates Runtime Faceplate Table 7. Runtime Faceplate Elements (Continued) Element Description Limit Reached Indicates whether or not the running time limit has been reached. Adj Run Time Hrs. An adjusted running time hours estimate based on the percentage of (adjusted running unaccounted runtime hours (for instance, when the Monitoring Server is shut time hours)

  • Page 78: Generic Counter Check Faceplate

    Generic Counter Check Faceplate Section 7 Faceplates Generic Counter Check Faceplate The Generic Counter Check Asset Monitor Faceplate is provided in the Generic Counter Check Asset Monitor object type. It is a sample that can be customized in the Object Type using the Counter Check Asset Monitor. Figure 39 shows an example Generic Counter Check Faceplate.
  • Page 79 Section 7 Faceplates Generic Counter Check Faceplate Table 8. Generic Counter Check Faceplate Elements (Continued) Element Description Counter Condition Reports the counter condition label and its current subcondition text. The text Indication is color coded based on the condition severity. Count The current transition count of the monitored asset.
  • Page 80 Generic Counter Check Faceplate Section 7 Faceplates 3BUA000150-600...

  • Page 81: Section 8 Control Loop Asset Monitor (Clam)

    (PV), set point (SP), and control output (CO) data. This data is captured by the 800xA System as OPC data. The Control Loop Asset Monitor is configured to receive PV, SP, and CO data from its control loop into its Asset Monitor Input Parameters.

  • Page 82: Running The Control Loop Asset Monitor

    Basic Loop Monitoring mode (Unlicensed). • Enhanced Control Loop Monitoring mode (Licensed). Basic Loop Monitoring Mode (Unlicensed) The CLAM logic uses history services of 800xA System to read PV, SP and CO inputs from log configuration continuously. The Log configuration is necessary for 3BUA000150-600...
  • Page 83 Section 8 Control Loop Asset Monitor (CLAM) Basic Loop Monitoring Mode (Unlicensed) running a successful CLAM. Refer to System 800xA Asset Optimization Configuration (3BUA000118*) - Control Loop Asset Monitor Input Data Storage and Display Configuration for details about log template. After the specified Data Set size is collected, it sends these values to the Loop Performance Monitoring audit for loop diagnosis information.
  • Page 84 Basic Loop Monitoring Mode (Unlicensed) Section 8 Control Loop Asset Monitor (CLAM) clicking Asset Monitor Status. Click Conditions for Condition details of CLAM as shown in Figure Figure 41. Condition details of Control Loop Asset Monitor Faceplate has the following tab views in operator mode (Figure 42): •...
  • Page 85 Section 8 Control Loop Asset Monitor (CLAM) Basic Loop Monitoring Mode (Unlicensed) Figure 42. Typical faceplate view in operator’s role (Unlicensed) In addition to the above tabs, an application engineer sees two more tabs. They are: • Controller configuration • Loop configuration 3BUA000150-600...
  • Page 86 Basic Loop Monitoring Mode (Unlicensed) Section 8 Control Loop Asset Monitor (CLAM) These tabs are useful in configuring CLAM for various parameters specific to controller and loop. Figure 43 shows the typical configured CLAM faceplate under application engineer's and operator’s role. Figure 43.
  • Page 87 Section 8 Control Loop Asset Monitor (CLAM) Basic Loop Monitoring Mode (Unlicensed) Select CLAM Faceplate in the Aspect List Area to launch CLAM Faceplate in Preview Area. The faceplate has multiple tabs with access to the most important aspects for reviewing results or entering configuration.

  • Page 88: Enhanced Control Loop Monitoring Mode (Licensed Mode)

    Enhanced Control Loop Monitoring Mode (Licensed mode) Section 8 Control Loop Asset Monitor • Loop Performance Details (Figure 45): Used to view Control Loop Asset Monitor summary results. Diagnosis information does not appear in the figure as it is under unlicensed mode. Figure 45.
  • Page 89 Section 8 Control Loop Asset Monitor (CLAM) Enhanced Control Loop Monitoring Mode (Licensed The Asset Monitor status continuously displays and evaluates Condition details of FCE and Loop Performance Summary. View the asset monitor status by right- clicking Asset Monitor Status. Click Conditions for Condition details of CLAM as shown in Figure licensed mode, CLAM diagnostics are displayed as Suggested Action.
  • Page 90 Enhanced Control Loop Monitoring Mode (Licensed mode) Section 8 Control Loop Asset Monitor • Loop performance details • Trend In addition to the above tabs, an application engineer sees two more tabs. They are: • Controller configuration • Loop configuration Figure 48.
  • Page 91 Section 8 Control Loop Asset Monitor (CLAM) Enhanced Control Loop Monitoring Mode (Licensed Final Control Element Details (Figure 49): Used to view final control element diagnosis information and indices. It shows various parameter details of FCE as shown in Figure 49 with diagnosis as tool tip text.
  • Page 92 Enhanced Control Loop Monitoring Mode (Licensed mode) Section 8 Control Loop Asset Monitor • Loop Performance Details (Figure 50): Used to view Control Loop Asset Monitor summary results. It shows various parameters details of FCE as shown Figure 50 with diagnosis as tool tip text. Figure 50.

  • Page 93: Operation

    Section 8 Control Loop Asset Monitor (CLAM) Operation After running long enough for loop auditing to execute, if parameters in the FCE and Loop performance read , it indicates that Current Data Not Analyzable the Asset Monitor instance may not be receiving PV, SP, and CO data. Check the Input Records tab of the Asset Monitor and correct the Data Source Items configuration of that Asset Monitor instance for any errors in the entry.

  • Page 94: Final Control Element Summary

    The filtered sum is compared to certain severity levels and is presented in System 800xA alarm list. In order to get reliable diagnoses, it is very important that the CLAM configuration parameters are properly configured.

  • Page 95: Loop Performance Summary

    Section 8 Control Loop Asset Monitor (CLAM) Loop Performance Summary The weights named W1, W2 and W3 corresponds to the asset parameters Weight_H_FCE_Stiction_Backlash, Weight_H_FCE_Leakage and Weight_H_Loop_Non-linearity as shown in Figure The weighted signals are summed that represents a health value for the FCE. This value is compared to predefined alarm thresholds to decide if an alarm is necessary.

  • Page 96: Performance Indices

    Performance indices Section 8 Control Loop Asset Monitor (CLAM) The weighted signals are summed that represents a health value for the loop performance. This value is compared to predefined alarm thresholds to decide if an alarm is necessary. Performance indices The performance indices used in CLAM are described in the list below.
  • Page 97 Section 8 Control Loop Asset Monitor (CLAM) Performance indices Table 9. Indices used in CLAM Sl.No Name Description Index class Standard Deviation Calculates the standard deviation of the Basic statistics Controller Output controller output. The result is a measure of the control effort to keep the loop under automatic control.
  • Page 98 Performance indices Section 8 Control Loop Asset Monitor (CLAM) Table 9. Indices used in CLAM Sl.No Name Description Index class Outlier Index Simple algorithm for detecting outliers by using Data validity a sliding window, checking if single outliers exceed the standard deviation significantly. [0- 1000 ‰].
  • Page 99 Section 8 Control Loop Asset Monitor (CLAM) Performance indices Table 9. Indices used in CLAM Sl.No Name Description Index class Auto-correlation Describes how fast the auto-correlation Performance (ACF) ratio function (ACF) of the data decays over time. A comparison is made between a dead time value for the specific loop category and the value where the ACF decreases below 30 %.
  • Page 100 Performance indices Section 8 Control Loop Asset Monitor (CLAM) Table 9. Indices used in CLAM Sl.No Name Description Index class Oscillation Index Detects and quantifies oscillating signals. The Oscillation on Control Error result is in the interval [-1…1] where a positive value means that an oscillation was found and the closer to one the value is the more regular is the oscillation.
  • Page 101 Section 8 Control Loop Asset Monitor (CLAM) Performance indices Table 9. Indices used in CLAM Sl.No Name Description Index class Shut-off Process Index detecting valve leakage or zero Valve Value Index instrument errors. The index requires the controller output to be zero for a significant amount of time, since it is calculated based on the flow when the output is set to zero.
  • Page 102 Performance indices Section 8 Control Loop Asset Monitor (CLAM) Table 9. Indices used in CLAM Sl.No Name Description Index class Valve sizing Index Quantifies the amount of time that the controller Valve output is within normal operating range (10- 90%). [0…100%] Nominally the controller should be within normal range >...

  • Page 103: Input Data Plots

    Section 8 Control Loop Asset Monitor (CLAM) Input Data Plots Table 9. Indices used in CLAM Sl.No Name Description Index class Master Flag Flag documenting whether a loop is the inner or Property outer loop in a cascade (no performance index).
  • Page 104 Input Data Plots Section 8 Control Loop Asset Monitor (CLAM) The duration of the trend display is set to one hour by default. It can be increased to any higher range stored in the CLAM Log Template, which stores four weeks of data by default.

  • Page 105: Alarm List For Loops

    Section 8 Control Loop Asset Monitor (CLAM) Alarm List for Loops Figure 55. Aspect shortcuts Alarm List for Loops The most recent information of all possible alarms triggered by a Control Loop Asset Monitor for the loop it is assigned to, can be viewed from the Alarm List Aspect as shown in Figure 56.

  • Page 106: Clam Diagnostics

    CLAM Diagnostics Section 8 Control Loop Asset Monitor (CLAM) Figure 56. Alarm list CLAM Diagnostics The available CLAM Diagnostics are: Final Control Element Diagnostics. Loop Performance Diagnostics. Final Control Element Diagnostics include the following: FCE Action. FCE Leakage. FCE Size. FCE Stiction/Backlash.

  • Page 107: Final Control Element Diagnostics

    Section 8 Control Loop Asset Monitor (CLAM) Final Control Element Diagnostics Loop Performance Diagnostics include the following: Loop Tuning. SetPoint Oscillation. External Disturbances. Data Reliability. Harris Index. Setpoint Crossing Index. Oscillation Index. Controller Output Saturation. Manual Mode. 10. Cascade Tracking. 11.
  • Page 108 Final Control Element Diagnostics Section 8 Control Loop Asset Monitor (CLAM) corresponding indices dealing with valve movement. An important prerequisite is the handling of noise, which is not related to valve movement. FCE Leakage Gasket leaks can occur when valves are removed or replaced. These leaks are best detected by visual inspection.

  • Page 109: Loop Performance Diagnostics

    Section 8 Control Loop Asset Monitor (CLAM) Loop Performance Diagnostics Loop Nonlinearity Many problems in control loop performance are caused by significant nonlinearity within the control loop. If the controller is in manual mode, a significant oscillation is always externally generated. If the controller is in automatic mode, then a significant external oscillation is identified based on the following characteristics: •...
  • Page 110 Loop Performance Diagnostics Section 8 Control Loop Asset Monitor (CLAM) Set Point Oscillation The detection of setpoint oscillations is important for the detection of external excitation in a control loop. The setpoint is usually much less distorted and noisy than the control error. The setpoint can only oscillate if it is the output of a master controller in a cascade loop.
  • Page 111 Section 8 Control Loop Asset Monitor (CLAM) Loop Performance Diagnostics Harris index is therefore a number between 0 and 1: the higher the number, the higher the controller performance to the theoretical maximum. Setpoint Crossing Index This index identifies the amount of control error zero crossings related to the total number of samples in a data batch.
  • Page 112 Loop Performance Diagnostics Section 8 Control Loop Asset Monitor (CLAM) the control error is often far away (more than 3% of loop range) from the target. A low index value means that the deviation between process variable and target is within acceptable limits.

  • Page 113: Section 9 - Heat Exchanger Asset Monitor (Hxam)

    The Heat Exchanger Asset Monitor application begins with the identification of Heat Exchanger Objects configured in the 800xA System Workplace. At the time of configuration, the user identifies process measurement inputs that allow the Heat Exchanger Asset Monitor to track the performance of the physical device.

  • Page 114: Objective

    Objective Section 9 Heat Exchanger Asset Monitor (HXAM) Objective The objective is to detect drastic drops in heat exchanger efficiency, rather than minute changes. This is accomplished by taking baseline measurements of the critical readable process variables around the heat exchanger and noting any trends indicative of declining performance.

  • Page 115: Terminology

    Section 9 Heat Exchanger Asset Monitor (HXAM) Terminology Terminology Refer to Heat Exchanger Specific Terminology on page 187 for specific heat exchanger terminology used in this document. Generic Heat Exchanger Asset Monitor (HXAM-G) This section describes the salient features of the Generic Heat Exchanger Asset Monitor operation.
  • Page 116 Description Section 9 Heat Exchanger Asset Monitor (HXAM) – Delta P Hot: Alternatively, P In and P Out for the hot side may be used to calculate Delta P. – Delta P Cold: Alternatively, P In and P Out for cold side may be used to calculate Delta P.

  • Page 117: Methodology

    Section 9 Heat Exchanger Asset Monitor (HXAM) Methodology • Mass flow less than 0 Kg/hr. • Mass flow greater than 1000000 Kg/hr. • Pressure less than -10,000 (any units). • Pressure greater than 10,000 (any units). • Volume flow less than 0 M /hr.
  • Page 118 Methodology Section 9 Heat Exchanger Asset Monitor (HXAM) During Monitoring, the Asset Monitor at every analysis phase checks the COPS and compares with the available BOPS. If the COPS data falls within the respective tolerance band values (see, BOPS Info Tab) of any particular BOPS data set, Enew and Unew will be calculated and compared to the BOPS stored Ebaseline.
  • Page 119 Section 9 Heat Exchanger Asset Monitor (HXAM) Methodology ACD will be created. The ACD will inform plant operations personnel that the heat exchanger operational efficacy has fallen significantly and should be investigated further. Conversely, if Enew has gone up by a percentage (E_Improvement_Level) that is configured by the user or more, an ACD will be created indicating that the heat exchanger Performance Factor has improved and similarly, an ACD will be created.

  • Page 120: Generic Heat Exchanger Asset Monitor Operation

    Generic Heat Exchanger Asset Monitor OperationSection 9 Heat Exchanger Asset Monitor (HXAM) • Staleness: If any one or more of the trained BOPS goes stale, an ACD is created. • If Delta Tx has exceeded a high or low limit specified at configuration time. •...

  • Page 121: Hxam_G_Faceplate

    Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate Any error in configuration will set the Quality Status to and any other error during execution will set the badConfigurationError Quality Status to . In either case the Asset Monitor will stop executing and will show an error message.
  • Page 122 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) TC08480A Figure 59. HXAM_G_Faceplate - Performance Tab – BadOutOfService: Asset Monitoring Server Engine is shut down. – Good: Asset Monitor is running smoothly. – Bad: Asset Monitor had encountered some error. – BadConfigurationError: Configuration error in Asset Monitor.
  • Page 123 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate – Calculated Date: Shows the time when the Ebaseline was calculated. It shows during Training. Not Available – Best Baseline E: Shows the best Ebaseline among the trained BOPS. It shows if any BOPS gets stale and the Asset Monitor goes back to Training.
  • Page 124 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) • HD Cold: Gives the Heat Duty for the Cold Side. Temperature Tab The Temperature tab (Figure 60) shows the details of the Delta_Tx_Operating_Point, Delta_T_Hot_Operating_Point, and Delta_T_Cold_Operating_Point conditions being assessed. This tab is the view of HXAM_G_Temperature_FE Aspect.
  • Page 125 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate The fields in the Temperature tab are: • Delta Tx Monitor: – Status: Gives the status of the Delta Tx Monitor. The status values are: Enabled: If Delta Tx Monitor is enabled. Not Enabled: If Delta Tx Monitor is not enabled.
  • Page 126 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) – Limit Reached: Gives the subcondition for the Delta_T_Hot_Operating_Point condition. The different subconditions that will be reported during Monitoring are as follows: Normal: Delta T Hot is within the Normal range. Increasing: Delta T Hot has crossed the Delta_T_ Hot _Increasing Limit.
  • Page 127 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate Decreasing: Delta T Cold has crossed the Delta_T_ Cold _Decreasing Limit. Low: Delta T Cold has crossed the Delta_T_ Cold _Low Limit. – Delta T Cold: Gives the value of Delta T Cold for the current OPS. Pressure Tab The Pressure tab (Figure...
  • Page 128 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) the values of Delta P Hot and Delta P Cold will show when the Asset Monitoring Server is not running and otherwise, except when the Status field says Enabled The fields in the Pressure tab are: •...
  • Page 129 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate Not Available: During Training. Data Unavailable: If Delta P Cold Monitor is but Delta P Cold data is not available. – Limit Reached: Gives the subcondition for the Delta_ P_Cold _Operating_Point condition. The different subconditions that will be reported during Monitoring are: Normal: Delta P Cold is within the Normal range.
  • Page 130 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) TC08483A Figure 62. Mass FlowTab Enabled: If Mass Flow Hot Monitor is enabled. Not Enabled: If Mass Flow Hot Monitor is not enabled. Stale Data in Trained Set: If one or more BOPS is stale. Not Available: During Training.
  • Page 131 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate High: Mass Flow Hot has crossed the W_Hot _High Limit. Decreasing: Mass Flow Hot has crossed the W_Hot _Decreasing Limit. Low: Mass Flow Hot has crossed the W_ Hot _Low Limit. – Mass Flow Hot: Gives the value of Mass Flow Hot for the current OPS.
  • Page 132 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) – Mass Flow Cold: Gives the value of Mass Flow Cold for the current OPS. Heat Duty Tab The Heat Duty tab (Figure 63) shows the details of the Delta_HD_Operating_Point, HD_Hot_Operating_Point, and HD_Cold_Operating_Point conditions being assessed.
  • Page 133 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate will show when the Asset Monitoring Server is not running and otherwise except when the Status field says Enabled The fields in the Heat Duty tab are: • Delta HD Monitor: – Status: This field gives the status of the Delta HD Monitor.
  • Page 134 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) – Limit Reached: Gives the subcondition for the HD_Hot_Operating_Point condition. The different subconditions that will be reported during Monitoring are: Normal: HD Hot is within the Normal range. High: HD Hot has crossed the HD_Hot_High Limit.
  • Page 135 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate Trend Display Tab The Trend Display tab shows the plots of the logged properties against time. This tab is the view of Trend Display Aspect. Three properties are logged and the user can configure for which logged property the trend is to be displayed.
  • Page 136 HXAM_G_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) TC08485A Figure 64. BOPS Info Tab training. Some of the tolerance values are used by logic to determine the nearest of all BOPS to the COPS. Last calculated Training period When all the BOPS go stale or when you press the "Clear BOPS and Retrain" button, the Asset Monitor will go to training mode.
  • Page 137 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_G_Faceplate The following formula is used for calculating the training period: Minimum of: 1% of Heat Exchanger Service Interval, or 40 * Monitoring Interval * Number of Expected BOPS sets. General Info Tab The General Info tab (Figure 65) displays general information.

  • Page 138: Trends And Logs

    HXAM_G_Available_Logs_FE. HXAM_G_Available_Logs_FE is not actually used for logging, but displays the values for which logs are configured on the default Heat Exchanger object type Refer to System 800xA Operations Operator Workplace Configuration (3BSE030322*) for more details. History Source The History Source Aspect is used to define the Service Group that handles a subset of logs, i.e.

  • Page 139: Trend Template

    Section 9 Heat Exchanger Asset Monitor (HXAM) Trend Template The data for these properties are read from the AssetMonitorProperties Aspect, which is populated by the Asset Monitoring Engine. The view of the Log Configuration Aspect is shown in Figure 66. The logged data for a property can be viewed by selecting the Status tab and clicking Read.

  • Page 140: Trend Display

    Trend Display Section 9 Heat Exchanger Asset Monitor (HXAM) Trend Display The Trend Display Aspect displays the four logged heat exchanger properties graphically as a function of time. Asset Monitor Properties The Asset Monitor Properties Aspect displays the values of parameters defined within the HXAM-G object.
  • Page 141 Section 9 Heat Exchanger Asset Monitor (HXAM) Log File Description (.csv file) All the Process Data, Calculated Data, and ACDs in the order shown in Table 10 (Heading is also provided). Table 10. Log File Headings and Explanations Heading Explanation Time Stamp The current time in local time standard when the Asset Monitor started execution.
  • Page 142 Log File Description (.csv file) Section 9 Heat Exchanger Asset Monitor (HXAM) Table 10. Log File Headings and Explanations (Continued) Heading Explanation Delta T Cold Cold Side Temperature Difference Delta Tx Temperature Difference Across heat exchanger Is Hot Side Condensing Specifies if Hot Side is Condensing Thc Hot Eff Effective Delta T Hot if Hot Side is Condensing...
  • Page 143 Section 9 Heat Exchanger Asset Monitor (HXAM) Log File Description (.csv file) Table 10. Log File Headings and Explanations (Continued) Heading Explanation HD Hot ACD ACD for HD Hot HD Cold ACD ACD for HD Cold Delta HD ACD ACD for Delta HD Clear BOPS Clear_BOPS: Specifies if the Asset Monitor has to be retrained...

  • Page 144: Shell And Tube Heat Exchanger Asset Monitor (Hxam-St)

    Shell and Tube Heat Exchanger Asset Monitor (HXAM-ST) Section 9 Heat Exchanger Asset Shell and Tube Heat Exchanger Asset Monitor (HXAM-ST) The following topics discuss Shell and Tube Heat Exchanger Asset Monitor operation. Description The Shell and Tube Heat Exchanger Asset Monitor (HXAM-ST) is based upon Delta T measurements made across the heat exchanger, in combination with mass flow information available from the control system, if they are available.
  • Page 145 Section 9 Heat Exchanger Asset Monitor (HXAM) Description – Delta P Cold: Alternatively, P In and P Out for cold side may be used to calculate Delta P. If the data values are well outside of reasonable range, then the Heat Exchanger Asset Monitor will assume that these values are not valid data.

  • Page 146: Methodology

    Methodology Section 9 Heat Exchanger Asset Monitor (HXAM) • Mass flow greater than 1,000,000 Kg/hr. • Pressure less than -10,000 (no units). • Pressure greater than 10,000 (no units). • Volume flow less than 0 M /hr. • Volume flow greater than 1,000,000 M /hr.
  • Page 147 Section 9 Heat Exchanger Asset Monitor (HXAM) Methodology • W Cold. • Delta P Hot. • Delta P Cold. Stable will be when the BOPS that is significantly different is recorded, remains within one percent of change for three consecutive executions. If Design Heat Transfer Efficiency (Design U) is configured by the user, the calculated Ubaseline will be compared against the Design U during training.
  • Page 148 Methodology Section 9 Heat Exchanger Asset Monitor (HXAM) will be replaced with the current COPS, if it persists for more than three times the Asset Monitor Sample Interval (AMSI). Similarly, ACDs will be created if Unew has gone down by a percentage that is configured by the user or more of Ubaseline, informing plant operations personnel that the heat exchanger heat transfer efficiency has declined or fallen significantly (based on the drop of Unew from Ubaseline), and should be investigated further.
  • Page 149 Section 9 Heat Exchanger Asset Monitor (HXAM) Methodology • If any of the following variables has exceeded a high or low limit specified at configuration time: – Delta T Hot. – Delta T Cold. – W Hot. – W Cold. –...

  • Page 150: Shell And Tube Heat Exchanger Asset Monitor Operation

    Shell and Tube Heat Exchanger Asset Monitor Operation Section 9 Heat Exchanger Asset Monitor Shell and Tube Heat Exchanger Asset Monitor Operation Once the Asset Monitor is properly configured, one can start the Asset Monitor (Asset Monitor Aspect Name: HXAM_ST) by starting the Asset Monitoring Server. Figure 67 shows the view of the Asset Monitor when the Asset Monitoring Server is not running.

  • Page 151: Hxam_St_Faceplate

    Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate A normal working Asset Monitor without any errors will appear similar to the one shown in Figure TC08463A Figure 68. HXAM_ST Aspect when HXAM-ST Asset Monitor is Working Normally HXAM_ST_Faceplate A detailed view of the Asset Monitor can be seen from the HXAM_ST_Faceplate. The HXAM_ST_Faceplate has 13 tabs, with each tab showing a detailed picture of the condition being assessed.
  • Page 152 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) TC08464A Figure 69. Performance Tab – BadConfigurationError: Configuration error in Asset Monitor. – GoodLocalOverride: Asset Monitor is under Training/Asset Monitor is in Monitoring Phase but there is no BOPS recorded/one or more BOPS has gone stale.
  • Page 153 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate – Best Baseline E: Shows the best Ebaseline among the trained BOPS. It shows if any BOPS gets stale and the Asset Monitor goes back to Training. • Current Performance Factor: – Value of E: Shows the Enew calculated from the current input data.
  • Page 154 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) Heat Transfer Tab The Heat Transfer tab (Figure 70) shows the details of the Heat_Transfer_Performance condition being assessed. This tab is a view of the HXAM_ST_Heat_Transfer_FE Aspect. TC08465A Figure 70. Heat Transfer Tab The fields in the Heat Transfer tab are: •...
  • Page 155 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate The text box in Figure 70 tells the user how many BOPS are received during Training and how many BOPS are received out of the expected number during Monitoring. • Compared Heat Transfer Coefficient: –...
  • Page 156 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) U_Significant_Improvement_Level from Ubaseline). Cannot Compare: Heat Exchanger input data cannot be compared against any trained BOPS. Temperature Tab The Temperature tab (Figure 71) shows the details of the Delta_T_Operating_Point, Delta_T_Hot_Operating_Point, and Delta_T_Cold_Operating_Point conditions being assessed. This tab is the view of HXAM_ST_Temperature_FE Aspect.
  • Page 157 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate The Limit Reached field for all Temperature Monitors will show , when the Normal Asset Monitoring Server is not running or if Status field says Not Available , or . The values of Delta Tx, Delta Stale data in Trained Set Not Enabled T Hot, and Delta T Cold will show...
  • Page 158 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) Not Enabled: If Delta T Hot Monitor is not enabled. Stale Data in Trained Set: If one or more BOPS is stale. Not Available: During Training. – Limit Reached: Gives the subcondition for the Delta_T_Hot_Operating_Point condition.
  • Page 159 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate Increasing: Delta T Cold has crossed the Delta_T_ Cold _Increasing Limit. High: Delta T Cold has crossed the Delta_T_ Cold _High Limit. Decreasing: Delta T Cold has crossed the Delta_T_ Cold _Decreasing Limit. Low: Delta T Cold has crossed the Delta_T_ Cold _Low Limit.
  • Page 160 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) and Delta P Cold will show when the Asset Monitoring Server is not running and otherwise, except when the Status field says Enabled The fields in the Pressure tab are: • Delta P Hot Monitor: –...
  • Page 161 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate Not Available: During Training. Data Unavailable: If Delta P Cold Monitor is but Delta P Cold data is not available. – Limit Reached: Gives the subcondition for the Delta_ P_Cold _Operating_Point condition. The different subconditions that will be reported during Monitoring are: Normal: Delta P Cold is within the Normal range.
  • Page 162 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) TC08468A Figure 73. Mass FlowTab The fields in the Mass Flow tab are: • Mass Flow Hot Monitor: – Status: This field gives the status of the Mass Flow Hot Monitor. The status values are: Enabled: If Mass Flow Hot Monitor is enabled.
  • Page 163 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate High: Mass Flow Hot has crossed the W_Hot _High Limit. Decreasing: Mass Flow Hot has crossed the W_Hot _Decreasing Limit. Low: Mass Flow Hot has crossed the W_ Hot _Low Limit. – Mass Flow Hot: Gives the value of Mass Flow Hot for the current OPS.
  • Page 164 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) Heat Duty Tab The Heat Duty tab (Figure 74) shows the details of the Delta_HD_Operating_Point, HD_Hot_Operating_Point, and HD_Cold_Operating_Point conditions being assessed. This tab is a view of the HXAM_ST_HeatDuty_FE Aspect. TC08469A Figure 74. Heat Duty Tab The Limit Reached field for all Heat Duty Condition Monitors will show Normal when the Asset Monitoring Server is not running or if Status field says...
  • Page 165 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate The fields in the Heat Duty tab are: • Delta HD Monitor: – Status: This field gives the status of the Delta HD Monitor. The different status that one might see here are as follows: Enabled: f Delta HD Monitor is enabled Not Enabled:...
  • Page 166 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) Low: HD Hot has crossed the HD_Hot_Low Limit. – HD Hot: Gives the value of HD Hot for the current OPS. • HD Cold Monitor: – Status: Gives the status of the HD Cold Monitor. The status values are: Enabled: If HD Cold Monitor is enabled.
  • Page 167 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate Tube Velocity Tab The Tube Velocity tab (Figure 75) shows the details of the Tube_Velocity condition being assessed. This tab is the view of HXAM_ST_Tube_Velocity_FE Aspect. TC08470A Figure 75. Tube Velocity Tab The Limit Reached field for Tube Velocity Monitor will show when the Normal...
  • Page 168 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) – Normal: Tube Velocity is within the Normal range. – High: Tube Velocity has crossed the Tube Velocity_High Limit. – Low: Tube Velocity has crossed the Tube Velocity_Low Limit. • Tube Velocity: Gives the value of Tube Velocity for the current OPS. Limit Approach Temperature Tab The Limit Approach Temperature (LAT) tab (Figure...
  • Page 169 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate – Stale Data in Trained Set: If one or more BOPS is stale. – Not Available: During Training. • Limit Reached: Gives the subcondition for the Limit_Approach_Temperature condition. The different subconditions that will be reported during Monitoring are: –...
  • Page 170 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) The fields in the Shell Side Flow tab are: • Status: This field gives the status of the Shell Side Flow Monitor. The different status values are: – Enabled: If Shell Side Flow Monitor is enabled. –...
  • Page 171 Section 9 Heat Exchanger Asset Monitor (HXAM) HXAM_ST_Faceplate TC08473A Figure 78. Temperature Crossover Tab • Limit Reached: Gives the subcondition for the Temperature_Profile condition. The different subconditions that will be reported during Monitoring are: – Normal: The Heat Exchanger is not working on Temperature Crossover. •...
  • Page 172 HXAM_ST_Faceplate Section 9 Heat Exchanger Asset Monitor (HXAM) BOPS Info Tab The BOPS Info tab (Figure 79) gives the user information on the trained BOPS. The first text box in Figure 79 will display the same message as the text box in Figure 69 on page 152.

  • Page 173: Trends And Logs

    Section 9 Heat Exchanger Asset Monitor (HXAM) Trends and Logs General Info Tab The General Info tab (Figure 80) displays general information. For example, it will display the recommended AMSI, if the AMSI configured by the user does not match the recommended value.

  • Page 174: History Source

    HXAM_ST_Available_Logs_FE is not actually used for logging, but displays the values for which logs are configured on the default Heat Exchanger – Shell and Tube object type Refer to System 800xA Operations Operator Workplace Configuration (3BSE030322*) for more details. History Source The History Source Aspect is used to define the Service Group that handles a subset of logs, i.e.
  • Page 175 Section 9 Heat Exchanger Asset Monitor (HXAM) Log Configuration The data for these properties are read from the AssetMonitorProperties Aspect, which is populated by the Asset Monitoring Engine. The view of the Log Configuration Aspect is shown in Figure 81. The logged data for a property can be viewed by selecting the Status tab and clicking Read.

  • Page 176: Trend Template

    Trend Template Section 9 Heat Exchanger Asset Monitor (HXAM) Trend Template A Trend Template is a template for building Trend Displays. Modifying an existing Trend Template will not automatically affect existing trends. Settings that are affected are those that can not be changed in the existing Trend Display such as number of areas and configurable rows, trace colors, and Hide/Show Table.
  • Page 177 Section 9 Heat Exchanger Asset Monitor (HXAM) Log File Description (.csv file) Description of what data the file contains. Date and time when the file was created. Date and time when logging started. All the Asset Parameters (With heading Asset Parameter Name and Parameter Value).
  • Page 178 Log File Description (.csv file) Section 9 Heat Exchanger Asset Monitor (HXAM) Table 11. Log File Headings and Explanations (Continued) Heading Explanation P Hot Out Hot Side Outlet Pressure Delta P Hot Hot Side Pressure Difference P Cold In Cold Side Inlet Pressure P Cold Out Cold Side Outlet Pressure Delta P Cold...
  • Page 179 Section 9 Heat Exchanger Asset Monitor (HXAM) Log File Description (.csv file) Table 11. Log File Headings and Explanations (Continued) Heading Explanation Heat Transfer Performance ACD for Heat Transfer Efficiency Staleness ACD ACD for Staleness Delta Tx ACD ACD for Delta Tx Delta T Hot ACD ACD for Delta T Hot Delta T Cold ACD...
  • Page 180 Log File Description (.csv file) Section 9 Heat Exchanger Asset Monitor (HXAM) 3BUA000150-600...

  • Page 181: Section 10 Asset Optimization Reporting

    Information Management is installed and appropriately configured. The Asset Optimization Report Template implementation requires that the following 800xA System features be installed on the target Aspect System: • Asset Optimization: required as a source for the report data.

  • Page 182: Ao Asset Condition History Report

    RUN NOW in the Scheduler Definition Aspect. Working with Asset Optimization Reports Saved reports can be reviewed at a later time if the Action Aspect is configured to export to an object path (refer to System 800xA Asset Optimization Configuration (3BUA000118*). 3BUA000150-600...
  • Page 183 Section 10 Asset Optimization Reporting Working with Asset Optimization Reports In the example shown in Figure 82, the saved reports are retained as objects under the AO Running Time Report folder found under Reports in the Scheduling Structure. Figure 82. Saved Reports in Scheduling Structure To review a printed report: Select the completed report according to the date timestamp.
  • Page 184 Working with Asset Optimization Reports Section 10 Asset Optimization Reporting Figure 83. AO Running Time Report Detailed View To reprint a completed report, select the Report Printing Aspect to display files that can be printed as shown in Figure TC07784A Figure 84.
  • Page 185 Section 10 Asset Optimization Reporting Working with Asset Optimization Reports Figure 85. AO Running Time Report (Example) 3BUA000150-600...
  • Page 186 Working with Asset Optimization Reports Section 10 Asset Optimization Reporting An example of the AO Asset Condition History Report is shown in Figure TC07789A Figure 86. AO Asset Condition History Report (Example) 3BUA000150-600...

  • Page 187: Appendix A - Heat Exchanger Specific Terminology

    Appendix A Heat Exchanger Specific Terminology Heat Exchanger Specific Terminology Table 12 is a list of terms associated with heat exchangers. Table 12. Heat Exchanger Specific Terminology Term/Acronym Description AMSI Asset Monitor Sample Interval. Time interval used by the Asset Monitor to sample heat exchanger instrumentation values.

  • Page 188: Bua000150

    Heat Exchanger Specific Terminology Appendix A Heat Exchanger Specific Terminology Table 12. Heat Exchanger Specific Terminology (Continued) Term/Acronym Description Performance Factor Heat Duty HD Cold Cold-Side Heat Duty HD Hot Hot-Side Heat Duty HeatX Heat Exchanger HeatX_G Generic Heat Exchanger HeatX_ST Shell and Tube Heat Exchanger HXAM-G...
  • Page 189 Appendix A Heat Exchanger Specific Terminology Heat Exchanger Specific Terminology Table 12. Heat Exchanger Specific Terminology (Continued) Term/Acronym Description Training Period. Time interval in which all operating point sets should be gathered. Typical values NSI/100 or 200 hours, whichever is smaller. Heat Transfer Efficiency Mass Flow W Cold...
  • Page 190 Heat Exchanger Specific Terminology Appendix A Heat Exchanger Specific Terminology 3BUA000150-600...

  • Page 191: Index

    Index AO asset condition history report 182 AO running time report 182 About this book 9 Inputs 182 Active work orders Output 182 Maximo 62 Asset optimization server 46 SAP 67 AO server tab 46 AO asset condition history report 182 Asset monitors tab 47 AO running time report 182 Runtime statistics tab 48...

  • Page 192: Index

    Index Index Log file description HXAM-G 140 DMS fault reports 53 HXAM-ST 176 Document Logs Conventions 9 HXAM-G 138 Related 11 HXAM-ST 173 Equipment status Maintenance filter 25 Maximo 65 Maintenance workplace 17 SAP 71 Launching 17 Maintenance filter 25 Maximo Faceplate Active work orders 62...

  • Page 193: Index

    Index AO asset condition history report 182 AO running time report 182 Inputs 182 Output 182 Runtime statistics tab 48 Active work orders 67 Equipment status 71 Preventive maintenance schedule 72 Work order history 70 Severity indicator icons 28, 29 Spare parts Maximo 66 Submitting fault reports 53...

  • Page 194: Index

    Index Index 3BUA000150-600 3BUA000150-600...
  • Page 196 Contact us www.abb.com/800xA Copyright© 2014 ABB. www.abb.com/controlsystems All rights reserved. Power and productivity for a better world...

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