P1-B IPA Overview and Data Collection
1 Overview
Located in Boston, Massachusetts USA, and Toronto Canada, Ctrl Designer LLC (CDL) is a data mining and process control software company. We provide Excel add-ins software solutions for data analysis, project planning, process control implementation as well as the conversion of big data from the web to Excel and then to RStudio and Quarto.
Our mission is to empower our clients with competitive edge software to convert their data to results to improve their productivity.
The company provides the following products:
- P1-Industrial-Plant-Assessment (IPA)
- P2-Level-Of-Automation (LOA)
- P3-Operational-Trend-Builder (OTB)
- P4-Standard-Operating-Procedure-Converter (SOP)
- P5-User-Requirement-Specification (URS)
- P6-Functional-Requirement-Specification (FRS)
- P7-Detail-Design-Specification (DDS)
The Industrial Plant Assessment (IPA) has been developed for the continuous processes such as refineries or chemical plants. It consist of the following phases
A- Selecting and collecting the Plant Analog Inputs (AI), Analog Outputs (AO) Data
B- Partial Component Analysis of AI, AO and Both
C- Oscillation Analysis
D- Controller Performance Analysis
The IPA is using the following tools:
| N | Tool | Engine |
|---|---|---|
| 1 | A-CDL-Plant-Assessment-File-Builder-v100a.xlsm | Excel |
| 2 | B-CDL-PCA-Builder-v100a.qmd | R, RStudio and Quarto |
| 3 | C-CDL-Oscillation-Builder-v100a.qmd | R, RStudio and Quarto |
| 4 | D-CDL-Control-Analysis-v100a.qmd | R, RStudio and Quarto |
| 5 | E-CDL-Control-Loops-Performance-v100a.xlsm | Excel |
| 6 | F-CDL-Build-Reports-v100a.xlsm | Excel |
This document provide step by step instruction on how to install Selecting and collecting the Plant Analog Inputs (AI), Analog Outputs (AO) Data
1.1 Tasks
The RACI matrix is a project management tool that defines the roles, responsibilities, and involvement levels of every team member working on specific project tasks. Also known as the Responsibility Assignment Matrix, RACI stands for the roles attributed to various stakeholders in a project :
Responsible (R): The person (or a group) who does the actual work
Accountable (A): The task owner who ensures the task is completed successfully
Consulted (C): The experts who provide insights and guide the person doing the task
Informed (I): The people who are part of the project but don’t contribute directly to specific tasks.
The following table represents the tasks with responsibility and hours required by the Ctrl Designer Engineer:
| N | Task | Customer Control Engineer | Ctrl Designer Engineer | Case A | Case B |
|---|---|---|---|---|---|
| 1 | Meeting - Initial Definition | ||||
| 1.1 | Review Plant and Divide into Plant Area (ISA-106) | C | R | 1 | 1 |
| 1.2 | Select a Case-Study Plant Area or Unit | C | R | 1 | 1 |
| 2 | Select the Unit and its associated Units | ||||
| 2.1 | Collect data for selected Plant Area or Unit | ||||
| 2.2 | Develop Tag List | R | C | ||
| 2.3 | Collect 1 Hour Data | R | C | ||
| 2.4 | Select 7 days (normal and Abnormal) dates | R | R | 1 | 1 |
| 2.5 | Collect Data 7 Days - 1 minutes | R | C | ||
| 3 | Analyze | ||||
| 3.1 | Data Reconciliation | C | R | 4 | 6 |
| 3.2 | Generate report and Review | C | R | 1 | 1.5 |
| 3.3 | Operability Performance | C | R | 2 | 3 |
| 3.4 | Generate report | C | R | 1 | 1.5 |
| 3.5 | Controllability Performance | C | R | 2 | 3 |
| 3.6 | Generate report | C | R | 1 | 1 |
| 3.7 | Control Loop Performance | C | R | 2 | 4 |
| 3.8 | Generate report | C | R | 1 | 1 |
| 3.9 | How to Tuning Selected Loops | C | R | 2 | 2 |
| 3.10 | Generate report | C | R | 1 | 1 |
Case A: Less than 501 AI + AO Tags (1 Minutes Data for 3 to 7 days) total of 20 Hours.
Case B: Less than 1001 AI + AO Tags (1 Minutes Data for 3 to 7 days) total of 27 Hours.
1.2 Initial Setup
Please do the following tasks and add Y or N in the status column
| Task | What | Status (Y/N) |
|---|---|---|
| 1 | Install the program folder in a shared drive | |
| 2 | Un-zip the attached file and rename it | |
| Project-[Plant-Name]-YYYY-MM-DD | ||
| Where : | ||
| - Project: Project name like Dow or CDL | ||
| - [PlantName] is the name of the plant-like Freeport | ||
| - YYYY-MM-DD is the year, month two-digit, and day two digit | ||
| - Dow-Freeport-2019-06-17 or CDL-T123-2024-08-15 | ||
| 3 | Fill in the following information | |
Customer Control Engineer name: Customer Control Engineer email |
||
Control Designer Engineer name: Control Designer Engineer email: |
||
| 4 | Provide Read/Write access to - Customer Control Engineer - Control Designer Engineer |
|
| 5 | Confirm the access |
1.3 Select the Unit and its Associated Units
Please do the following tasks and add Y or N in the status column These tasks are performed by a customer control engineer
| N | Task | Status Y/N |
| 1 | Using the Plant M&EB or equivalent representation to identify the Units| | |
| 2 | Open PA-Project.xlsx in The B-Raw-Data folder and then select sheet Units | |
| 2 | List all Major Units is an Excel workbook sheet Definition A- Index 1, 2 etc. B- Plant Area Name C- Unit Name D- Unit Description E- Number of Tags (AI+AO) F- IP(1,2,30 or NONE |
|
| 3 | Select the Unit or Units to be analyzed IPA Phase | |
| 4 | Save workbook as IPA-Project.xlsx in the B-Raw Data folder |
1.4 Collect Data for the Selected Units
This process is divided into the following steps
1- Extract List of Instrument in the plant (Tag)
2- Extract List of Tags being stored in the Historian (History-Tag)
3- Cross Reference Tags vs History-Tags
4- Select Tags to collect Data
5- Collect Long Term Data (Hourly Data)
6- Collect Short Term Data (7 days / 1 minute) Data
1.4.1 Extract List of Instrument in the Plant (Tag)
Please do the following tasks and add Y or N in the status column These tasks are performed by a customer control engineer
| N | Task | Status Y/N |
| 1 | Extract the list of Tags from the Instrument Database | |
| 2 | Store results in a workbook called PA-Project.xlsx in the B-Raw-Data folder sheet Instrument-Database | |
| 3 | From this list generate the Tag-Database sheet with following columns A- Index B- Tag Name C- Tag Type AI or AO D- Tag Description E- Engineering Unit F- Unit Name |
1.4.3 Review
Please review the above workbook with Ctrl Designer Engineer, these are the tasks that should be performed by Ctrl Designer Engineer and customer control engineer.
Cross Reference Tag vs History Tags
Select Tag to collect data
Collect long term data (normally hourly)
Select short term data collection time frame
Collect (3 to 7 days of 1 minute snap )
1.4.6 Collect Long Term Data (Hourly Data)
Please do the following tasks and add Y or N in the status column These tasks are performed by the Historian Engineer
| N | Task | Status Y/N |
| 1 | Review the Tag list | |
| 2 | Review the duration - Begin Time - End Time and sample rate | |
| 3 | Collect data only for one set | |
| 4 | Review with team | |
| 5 | Collect the data |
1.4.7 Collect Long Term Data (Minute Data)
Please do the following tasks and add Y or N in the status column These tasks are performed by the Historian Engineer
| N | Task | Status Y/N |
| 1 | Review the Tag list | |
| 2 | Review the duration - Begin Time - End Time and sample rate | |
| 3 | Collect data only for one set | |
| 4 | Review with team | |
| 5 | Collect the data |
Please contact us if you need more information.
