Introduction

1

System Overview

2

Analyzer Monitoring

3

Analyzer Validation / Calibration

4

Analyzer Maintenance

5

Analyzer KPI’s / Reporting

6

System Engineering

7

Advanced Functionality and Services

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Siemens ASM Analyzer System Manager

System Description V1.7 Release 04/2013

ASM - Analyser System Manager

System Description

1. Introduction The challenge Today’s analyzer specialists are responsible for a wide range of devices. From a world class refinery, dealing with more then two hundred analyzers of different types to a small plant with a handful of various analyzer types. Analyzers are heterogeneous. Different communication standards, operation philosophies and maintenance procedures are in use. As this is a very widespread situation, a common look and feel is vital for at least some basic functions. Analyzers are delivering results and status information to the control system at any time. High quality is a must for this data. Siemens ASM is the tool to prove and document this performance and reliability. Not only the control system requires the measured values. Also other systems, like Enterprise Resource Planning Systems (ERP) or Manufacturing Execution Systems (MES) are using analyzer data, too. The access to this data through a standardized interface is a significant advantage. ASM is the tool to fulfill all these requirements! The functionality The Siemens ASM is a SIMATIC based software system, which is designed to monitor, check and trend all kinds of analytical equipment. Such equipment ranges from a simple transmitter type analyzer up to a complex analyzer system, being capable of measuring multiple components in various streams. Core functions of the Siemens ASM are:  Monitoring the operational state of the equipment  Validating analyzers and instruments, manual, semi-automatic and fully automatic, according proven Industry Standards like ASTM D 3764-09  Statistical Evaluation and Reporting of validation results  Performing time-rated statistics to gain Key Performance Indicators (KPIs) like availability, failure rates, etc.  Management of all analyzer maintenance related activities  Interfacing to DCS systems to provide analyzer related data and interlock validation and/or maintenance activities The complete functionality of an ASM System is based on an analyzer network and may also include Programmable Logic Controller (PLC) functionality together with specific engineering works.

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System Description

The Siemens ASM offering key points are: 

Siemens as analyzer vendor has extensive know-how in Analyzer technology and the related validation, calibration and maintenance activities. Many years of experience are the foundation of the ASM software.

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The system uses proven industry standards and standard practices such as ASTM 3764, D6299 and E178

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The Siemens ASM is a state-of-the art system with latest technology and built-in flexibility for adaption to current project requirements or future needs : -

the integrated “Graphics Designer” can be used for screen customization.

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the integrated “Report Designer” can be used for report customization.

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if required, additional logic may be added via SIMATIC S7 controllers (optional)

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The system is scalable from small single-user applications for a few analyzers up to fully redundant client/server systems for a large number of analyzers.

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Siemens as a global company with worldwide local presence is able to provide -

- Long term service contracts for system maintenance

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- Local and/or remote support concepts

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- Investment security by continuous enhancement of the system

Siemens Global Support The Siemens ASM is based upon the SIMATIC platform - for which service & support is available in more than 100 countries worldwide. For the ASM specific functionality our 3 system integration centers in Karlsruhe, Germany and Singapore provide 3rd level support.

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System Description

2. System Overview The Siemens ASM is a modular and cost efficient solution based on proven SIMATIC components: 

One central server collects and stores all data. The server provides information to the connected clients (workstations, notebooks…).

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Client workstations (PC or notebooks) allow visualization and monitoring of the complete system.

The client workstations can be connected to the server as required, e.g. in the central control room or directly at the shelters. They provide an overview over the complete system. Typical ASM system layout:

This concept allows a very flexible local interaction and monitoring, the operators and the maintenance personnel can see the current status of the complete system from the shelter or from the control room. For analyzer validation and benchmarking historical data are required. The central server provides the complete history of data for the required calculations and also for review to all users at each supervision station.

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2.1

System Description

System architecture

The system is based on field proven SIMATIC components. The combination guarantees high performance, reliability and a secure investment. 

For the supervision system the industry standard SCADA software SIMATIC WinCC is used. The predefined screens can be customized as required.

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The analyzer validation, maintenance and report modules are included in the field proven Siemens ASM (Analyzer System Manager) software package.

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For specific interfacing or project specific application logic (e.g. valve control for the sampling system) the industry standard SIMATIC S7 can be integrated - as rack-mounted controller with central I/O’s or as soft-PLC within the ASMServer and remote I/O modules.

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The integrated Access Authorization is based on Microsoft Windows. It is easy to manage and provides a high level of security. ASM Workstation

ASM Workstation

...

ASM Server SIMATIC WinCC OPC

OPC-Server

LIMS

DCS

AnalyserMonitoring Validation / Calibration

Reporting Module SQL Database

Maintenance Module

OPC

Modbus TCP

OPC Client

SIMATIC WinAC RTX (Soft PLC) (optional)

Ethernet

Ethernet

Profibus / Profinet

Analysers

DCS connection and validation handshake: The system provides an integrated OPC (DA) server and client. The current value of each SCADA tag can be accessed in read-only mode by the DCS via OPC. A standardized handshake to enable validation is provided. Results of statistical calculations and analyzer performance data are available via OPC.

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System Description

LIMS connection: The system provides connectivity to LIMS-Systems based on OPC via a predefined standard interface. ASM will act as OPC (DA) server. Project specific interfacing can be provided if required. System configuration: The Siemens ASM system is configurable: each analyzer has its specific set of parameters and properties. An authorized user can modify those settings by means of a Windows based configuration tool (see also section 7). Access authorization: The system provides access authorization for the predefined protected system functionalities. Depending on the configured access rights, the user is granted access or he is blocked for the protected system functions. The authorization system is configurable and based on Windows Active Directory (AD). This means that the user/password information resided in Windows. Standard Windows security functionalities like e.g. password policies and password aging can be configured. Data safety / backup: Automatic backup procedures for the collected data within the system database as well as a complete Disaster Recovery set of the server are part of the ASM system setup.  Data Backup cycles and extent is configurable.  Backup data can be transferred to another storage location or media for enhanced data security. Scalability: The system can be scaled from small single user systems up to clientserver systems with multiple users and/or redundant servers. If more than one ASM server is used at site level, each ASM client can be configured to provide access to each of the ASM servers. A maximum number of 300…600 analyzers can be managed and monitored within one ASM server, depending on the number of signals per analyzer). Additional servers can be added as required to extend the system capacity. Tracability is provided for Operation and Configuration:    

All relevant operator actions (e.g. start of a validation, enter lab data) are logged with timestamp / user / action performed Modification of analyzer settings are logged with timestamp / user / action performed Bulk import actions are logged with reduced level of detail These events can be displayed, filtered, printed, used in reports, …

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2.2

System Description

Interface to Analyzers

The ASM server connects to the analyzers via a dedicated analyzer network or via the plant automation network. For non-networked analyzers serial links are supported. The ASM server is able to automatically gather the analyzer data 

for Siemens analyzers via the Maxum OPC server

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for analyzers that support OPC or Modbus/TCP directly via the Ethernet network

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for analyzers that support Modbus RTU or Profibus DP via serial links / fieldbus

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for hardwired analyzers via the integrated Soft-PLC and corresponding I/O’s

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In addition there are also entry forms provided for manual data collection, e.g. to store information about conducted maintenance or operating conditions of the analyzer and/or sampling system.

There are three different main communication structures possible. All these three possibilities can be used in combination within one ASM server if required. 1. Analyzer interface via external OPC Server: For analyzers with an integrated OPC Server or if a central system, e.g. the DCS, is providing the analyzer data via OPC.

With this approach no additional hardware is required with in the ASM.

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System Description

2. Analyzer interface via fieldbus or hardwired signals: For analyzers connected via fieldbuses like Profibus, Profinet or Modbus, or for simple analyzers providing only hardwired I/O signals e.g. 4…20 mA. For this solution an SIMATIC PLC controller is provided, The PLC can be extended with local or remote I/O modules as required. The PLC is connected to the ASM server via Ethernet (TCP/IP). The location for the PLC mounting can be selected based on the cabling requirements, e.g. close to the analyzers or at the central control room. Very flexible concepts are feasible. 3. Analyzer interface via Maxum OPC Server: This is the most suitable option for interfacing SIEMENS gas chromatographs like Maxum ed II or MicroSAM. The setup provides the deepest integration and the full range of functionality for these analyzers (e.g. remote calibration with response information).

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System Description

3. ASM Monitoring Module (SCADA System) – Full Client The ASM SCADA system provides a client-server based monitoring, supervision, control and data acquisition for the connected analyzers. Via the graphical user interface at each supervision station, the user has access to the required information, including the System Overview, Analyzer Overview, Network Overview and the message system. The ASM SCADA system provides a high flexibility to adapt the graphical user interfaces to the customer needs. The following screens are provided: System Overview: Displays an overview of all shelters and analyzers and the alarm list for the complete system, example:

Shelter Overview: Displays the current analyzer house status and the status of the corresponding analyzers, example:

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System Description

Analyzer Overview: Displays the current analyzer readings, analyzer status, trending chart of the measured value and current alarm list for the analyzer, example:

Network Overview: The network overview displays the network components (switches) and their current state by color, example:

Message system: The system acquires events, stores them in archives and makes them available to the users, example:

Alarms collected via the I/O’s (e.g. flow alarm, pressure alarm) will be signaled via the message system. The operator can acknowledge each message, so that new alarms can be easily detected. The system provides a complete message history.

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System Description

4. Analyzer Validation and Calibration Module The analyzer validation and calibration module provides functionality for the performance benchmarking of the analyzers. It contains tools and methods to determine 

if the analyzers produce repeatable, reliable measures

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if a systematic offset (bias) is present in analyzer results

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if an analyzer calibration is required

The ASM provides two monitoring methods to obtain this information: -

Statistical monitoring based on the industry standard ASTM D 3764-06 issued by the American Society for Testing and Materials

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Deviation monitoring method with checking for drift or unusual patterns within the established warning and control limits

The applied validation method depends on the type of analyzer. For each analyzer one of the predefined methods can be assigned within the configuration tool, available methods are 

Line sample method Compare the analyzer measurement with the result of the laboratory: A sample is taken from the analyzer stream and is analyzed at the laboratory. The lab results are entered in the ASM system. The ASM system compares a predefined number of measured sample values with the lab results.

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Reference sample method Compare the analyzer measurement with a measurement of a known sample: A sample is taken from a reference bottle and the ASM system compares a predefined number of measured sample values with this reference values. Functionality to manage reference bottles and a procedure to establish a reference value are provided within the system.

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System Description

The user can start the validation process via the graphical user interface (GUI) at one of the ASM workstations. In order to reduce the amount of manual work for the user it is possible to schedule automatic validations after predefined time intervals. The system will issue an alarm in case a scheduled validation cannot be executed. During the validation the system archives the defined values, executes the predefined tests on the values and stores the corresponding results. The following tests are provided: ASTM D-3764 procedure  Dixon’s test  Variation tests  F-test, Chi-Square-test  Student’s t- test

- test on outliers - test on unusual patterns and drift - test on variation - test on variation and bias

Deviation monitoring procedure Predefined rules can be configured for monitoring warning and control limits like e.g.  X sequenced point(s) outside the control limit  X sequenced point(s) between the warning and the control limit  X sequenced point(s) on the same side of the aim / zero line The result of the validation procedure will be either PASSED or FAILED. In case of problems, the maintenance personnel can use the system to investigate the cause. A reliable help for this work is the history of previous measurements and validations. They can be used to compare the previous state with the current state. Detailed information is available at the user interface in tabular form and by means of control charts with selectable, predefined time ranges. Via the graphical user interface of each ASM workstation, the user can interact with the ASM system and has access to the required information, including      

display of current and historical trends display of current validation values and results of the statistical tests initiate a validation or calibration display of historical data input of lab values display the list of current system alarms

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System Description

Example for Deviation monitoring control chart:

Upon selection the run chart shows the value behavior in a visual way. Automatic check rules are performing repeatable and measurable tests as scheduled - the maintenance personnel are informed only when required.

Calibration of an analyzer can be done upon request and confirmation of an authorized user. The system keeps a log of all conducted calibrations. Zero and span correction factors as obtained from the analyzer can also be charted.

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System Description

5. Analyzer Maintenance Module The analyzer maintenance module provides functionality for analyzer maintenance and calculation of the related KPI’s. Manage maintenance interventions A maintenance intervention is a predefined task to be performed for a specific type of analyzer, e.g. “Change filter”. The system provides functions to plan, monitor and support the execution of such intervention. A list with all active or planned maintenance intervention for an analyzer is available. This list permits  to review the maintenance actions that are planned for the analyzer  to review the maintenance actions that have been performed on the analyzer during the selected time range – this allows to detect relations between analyzer performance KPI’s and maintenance actions New interventions for the analyzer can be entered if the currently logged user is provided with the appropriate authorization. Each intervention consists of  a maintenance action text, which is selectable from a preconfigured maintenance action list.  the type of the intervention, selectable from a preconfigured type list (e.g. repair maintenance).  the working hours spent on the maintenance, or working hours planned for the maintenance in case of a planned intervention.  the replacements (parts) required or planned for the work and a comment.  the system automatically adds the current date/time and the user name. Manage Maintenance procedures Maintenance procedures are work procedures to be followed for the analyzer. For each type of analyzer, it is possible to configure a list of procedures. A procedure can consist of plain text and/or a PDF document, e.g. with detailed instructions on how to change the filter on a certain analyzer. The maintenance procedures are a great help for the day-to-day work of the maintenance personnel. They provide all required information for the ongoing maintenance from one central point, without having to search for paper documentation. Analyzer availability KPI’s The system collects and archives the required signals for analyzer availability calculation. Depending on the analyzer type the signals are collected automatically or entered manually by the user. Based on this information the system calculates the analyzer performance indicators:  Analyzer repeatability  TBRK (Time duration of analyzer breakdown)  TCHK (Time duration an analyzer is unavailable due to inspection, maintenance or calibration)  TPRO (Time period that an analyzer is operational) The system provides an overview for comparisons between all analyzers within the plant. Weak points that require special attention or immediate intervention can easily be spotted. © Siemens AG 2012-2013

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System Description

Within the user interface the calculated KPI’s, work procedures and planned interventions are displayed for each analyzer, example:

Electronic documentation (Manuals in PDF format) The system provides the possibility to store electronic documents (PDF files) for each analyzer. These documents can easily be retrieved and displayed by authorized personnel, providing up-to-date information for   

maintenance procedures data sheets system drawings …

This provides one single location for all maintenance related documentation.

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System Description

6. Analyzer Reporting Module The analyzer reporting module provides functionality for reporting and analysis of the analyzer system data. A list of predefined reports is included:  overall analyzer overview and benchmark report  analyzer validation report  historical charts and trending values  detailed analytical report on reference materials  report of manual validations to be carried out within a selected future period and the backlog (outstanding validations)  analyzer performance report with availability, reproducibility and interventions performed  weekly report (automatically / on demand)  monthly report (automatically / on demand)  report on analyzers that require maintenance  maintenance intervention report and working hours spent per analyzer

Each report has a condensed overview with most important data on the first sheet. Each report may be displayed on the screen or sent to a printer. It is possible to export a report to a PDF file or to Microsoft Excel for further analysis. Automatic time based scheduling of reports is supported. For a trained user with the appropriate authorization it is possible to modify the predefined reports or to create new, user specific reports and charts. A powerful Report Designer is provided with the ASM system.

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System Description

Example of a Standard Performance and a Validation Overview report:

The ASM Reporting is based on Microsoft Reporting Services – integrated with ASM. Their characteristics are:    

main purpose is to create predefined reports with current data display the report within the ASM screens or via Browser all ASM Reports can be adapted / modified via “Microsoft Report Builder” (supports tables, charts, filters, calculations …). Training is recommended. all required licenses are included with ASM license.

In addition there are also Excel based Reports available.  

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main purpose is to create ad-hoc reports and to explore data reports can be saved on individual workstations and can be refreshed with current data upon request Excel 2003 and above is required (not included with ASM license).

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System Description

7. ASM Full Client versus ASM Lean Client For the ASM workstations two types of clients are available: • ASM Full Client • ASM Lean Client Each of them provides specific advantages, as outlined in the following sections.

7.1

ASM Full Client

The Full Client is based on the Siemens SCADA system SIMATIC WinCC.

The ASM specific functionalities are integrated within a SCADA system that allows flexible navigation and extension of the predefined screens, e.g. for adding of additional signals and information. The advantages of this type of client are:  

It is very flexible, screens can be added as required and are customizable typical “SCADA” features are available

The ASM Full Client requires the installation of the SIMATIC WinCC software on the PC and is designed for installation close to analyzer e.g. in the analyzer house. It is in general not designed for installation on PCs in the office environment. We recommend this type of ASM workstation for power users that require the provided flexibility.

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System Description

7.2 ASM Lean Client The alternative approach for the ASM workstation is the ASM Lean Client. It provides all ASM core functionalities (status monitoring, alarming, validation, calibration, maintenance functionality, reports) but is limited in terms of screen customization possibilities. A tree view with status indication is used to show the system overview and for navigation purposes. The advantages of this type of client are:    

the Lean Client is a light .Net application that can be installed without any further SIMATIC licenses it is suitable for office PC environment. the installation is possible via copy deployment (requirements: Windows + .NET framework) only limited resources are required on the PC.

We recommend this type of ASM workstation for normal users that 

enter analyzer data, access analyzer data and display/print reports.

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do not need the flexible, customizable screen layouts.

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System Description

System Engineering The ASM system provides a tool for the configuration of analyzer settings and maintenance procedures. All configuration data is stored in the central database. A complete export/import for configuration data backup purposes is supported. It is possible to create a hierarchical structure within the configuration tool for getting a better overview over the whole plant. This structure is Site  Shelter  Analyzer  Component For each analyzer the configuration data needs to be edited. Configuration data comprises e.g. the validation method to be used (line sample / reference sample / variation method / none) and the parameters and limits for the selected method. The system will propose default values as per ASTM. An engineer with the appropriate access authorization level may change these settings. This configuration is done via the “ASM Manager” configuration tool.

To minimize this manual data configuration, the ASM Manger provides an import interface for the configuration data based on a CSV file (for use with e.g. Microsoft Excel).

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System Description

The system automatically creates a predefined set of tags in the WinCC system. These tags are used to interface the analyzer to the outside world (e.g. collect analyzer reading and status) and to provide analyzer data to external systems (e.g. publish data to a DCS via OPC).

ASM SCADA Screens (ASM Full client only) A powerful graphical editor (SIMATIC WinCC Graphics Designer) is provided to edit user-friendly SCADA screens. Each screen is based upon predefined objects that are linked to the analyzer tags. These screens will be displayed at the ASM Full Client. Maintenance procedures The system provides preconfigured maintenance types (e.g. repair maintenance, testing maintenance) and maintenance procedures (e.g. normal maintenance, validation, calibration, operator activities, other) which can be edited by the operators. New maintenance procedures can be created. It is possible to attach a document with the procedure’s documentation in PDF format.

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System Description

8. Advanced Functionality Project specific functionality can be added to an ASM system upon request. Usually such additional functions will be discussed and specified together with the customer before implementation. The following section lists examples for such specific system extensions. Dashboards / Web Portal Dashboards can be used for the display and distribution of analyzer process states and KPI’s (live or historical) from the ASM database. The data can thus be made available to various functional levels in the enterprise via the Web. Also web-based distribution of ASM reports via a portal or periodic distribution of reports in PDF format is possible. For this functionality a web server with access to the ASM database is required. The underlying technology used to set up and configure such a system are the Microsoft Reporting Services. Consolidated ASM Server A consolidated ASM server can periodically collect data from various underlying ASM servers and consolidate the relevant KPI’s in one central place - thus supporting e.g. benchmarks between devices located in different ASM systems. A consolidated server may be set up on site or global level, as required (see also “Scalability” in 2.).

The underlying technology used to set up and configure such a server are the SQL Server Data Integration Services. A network connection between the servers is required. A consolidated ASM server may be combined with a Dashboard / Web Portal to provide e.g. benchmarks via a wide range of analytical equipment.

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System Description

9. Support Services Siemens engages in ongoing support services for the delivered ASM systems. Services can be provided on site or via remote access and include also the maintenance of the system software and provision of updates. 3-monthly ASM server health check Service If allowed by the customer, named SIEMENS employees will connect to the ASM server remotely for service purposes and for server health check every 3 months. The customer will receive a report of the current system status after each health check. Remote Access Service Remote access is provided via the Siemens cRSP Remote Services platform, using secure authentification and state of the art data encryption methods. The platform is based on IPsec infrastructure and is certified according to CERT / ISO 27001.

A dedicated secure end point (router) on customer side will be set up to establish the connectivity. Alternative approaches are also possible can be agreed according to existing customer IT infrastructure. Hotline Support Service The Ongoing System Service Agreement grants the customer free-of-charge access to the support hotline via telephone and/or email. If the hotline service is used the respective support number must be specified. Software Update Service Furthermore the Service Agreement grants the customer the right to request the current ASM data carrier (software update) free of charge. The customer will be informed by email as soon as a new ASM version is available, informing him of any changes, updates and bug fixes available in the new version.

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