Control Performance Analytics - CPA

Control Performance Analytics - CPA

Control Performance Analytics - CPA


As the complexity of industrial process applications grows, so do production management requirements for process safety, adaptability, and product quality. More openness is required to recognize the possibility for process improvement and fine-tuning.

Control performance is critical in process industries for meeting production objectives. Each process application begins with a single control loop. According to studies, around 50% of all control loops are not well-tuned, whether owing to non-optimal settings, manual operation, oscillating controlled systems, or mechanical faults with control valves.

Furthermore, process engineers are generally in charge of hundreds of control loops in large-scale process facilities. Evaluating control performance across several process stages for alarms takes a significant amount of effort and knowledge. Due to continuous process changes and equipment wear and tear, detecting potential areas for improvement and modifying control loops is not a one-time activity.

Automated Control Loop Analysis for Efficient Plant Optimization


CPA is a cloud-based managed service that improves the transparency of process data and the optimization of control loops. The collection and analysis of plant-wide data provide the client with comprehensive product control. Automatic KPI (key performance indicators) computation identifies control loop states, which can recognize setpoint tracking, steady-state difficulties, and even static or sliding friction in-process valves. The tool also enables automated testing of new parameter sets to test control loops without interfering with plant operations.

CPA - What Is It?


CPA takes data from SIMATIC PCS 7 or any other process control system, for example, in CSV format, and sends it to Siemens' cloud-based IoT operating system, such as MindSphere, through a secure connection. CPA creates reports and recommendations for the customer's support teams or Siemens' process consulting specialists to analyze based on the data. Finally, optimization ideas help to enhance the process.

Benefits of Control Loop Optimization Through CPA

  • Increased product quality due to lower fluctuation in process variables
  • Maximized equipment lifetime due to reduced variability in actors
  • Improved set points raise throughput by going closer to the limits
  • Resource savings thanks to improved set point tracking behavior (e.g., energy, raw material)
  • Reduced manual mode of control loops allows overlaying control optimizations such as Advanced Process Control
  • Fewer alarms and fewer operator interactions reduce operators‘ workload

Siemens CPA User Advantages

  • PLANT-WIDE TRANSPARENCY
    • Includes hierarchical plant overview, from management view to single control details for Siemens SIMATIC PCS 7 and other DCS.
  • IMPROVED PLANT ASSET PERFORMANCE
    • Identification of optimization potential as a result of correlating process data automatically with possible asset problems.
  • FAST SETUP
    • Intuitive interface enabling customer to use the application without extensive training.
  • AUTOMATIC STATE DETECTION AND KPI CALCULATIONS
    • Messaging behavior, service factor, steady state accuracy, set point tracking and static friction probability for various control states.
  • COST BENEFITS
    • Long-term process optimization and flexible managed service approach – pay only when you use the application.
  • OPEN, CLOUD-BASED IOT OPERATING SYSTEM
    • CPA is part of Siemen's Asset and Process Performance Suite for industrial applications and advanced analytics.
Contact Process Technology for all your Siemens Process Control products. Call them at 801-264-1114 or visit them at https://process-tech.com.

Compact Portable Samplers: The Foundation for Your COVID-19 Wastewater Surveillance Program

COVID-19 Wastewater Surveillance

An effective COVID wastewater monitoring program relies on representative samples. 


Water samplers are critical components in developing and deploying a community-based underground sewage surveillance program for COVID-19 outbreak detection, including best practices for wastewater sampling, lab analysis, and the immediate delivery of actionable information to local public health officials and administrators.


Wastewater testing refers to numerous water quality procedures examining wastewater's physical, chemical, and biological qualities. 


Officials in certain areas are analyzing wastewater to see whether it contains Covid-19. The test looks for ribonucleic acid (RNA), Covid-19's genetic material, in feces found in sewage and wastewater. 


SARS-CoV-2 causes Covid-19. According to studies, people with SARS-CoV-2 start spilling the virus in their feces shortly after infection. The virus's DNA enters the huge wastewater collecting network. The viral content of a community's wastewater may reflect the prevalence of Covid-19. Modern sampling and analysis methods can identify and quantify it up to a week before people test positive in clinics. Individual testing, contract tracking, and quarantine are possible mitigation and reaction methods. It also enables population sampling and monitoring of large-scale public health initiatives. 


Analysis of viral concentrations in particular institutions such as nursing homes and college dormitories and neighborhoods or whole communities may help restrict the spread and avert additional harm. 


The CDC created the NWSS in September 2020 in response to the COVID-19 pandemic. The CDC's National Watershed Surveillance System (NWSS) coordinates and increases the nation's ability to monitor SARS-CoV-2. 


There may be a way to identify the new Coronavirus in low quantities in wastewater. Many states, including Colorado, Ohio, New York, and Wyoming, have successful Covid-19 wastewater testing programs. Universities and municipalities use this method to identify community hotspots. Multiple success stories have proven early identification and control using dorm wastewater monitoring and individual COVID testing. These universities were among the first to use COVID patterns in wastewater to reduce community spread inside dormitories and across campus. 


Representative samples facilitate COVID wastewater monitoring. For COVID-19 epidemic identification, water samplers are essential for wastewater collection, lab analysis, and quick distribution of actionable information to local public health authorities and administrators. These data disclose the population numbers in a specific geographic region to estimate the virus's prevalence and quantity in wastewater. Combine Hach® small portable samplers with laboratory testing for automated composite wastewater sample collection that may help avoid outbreaks.


VISIT THIS PAGE ON THE PTI WEBSITE FOR MORE INFORMATION ON THIS SUBJECT.


Process Technology, Inc.
801-264-1114

A Superior Method of Measuring Dissolved Oxygen in Pure Water Systems at Power Plants

Measuring Dissolved Oxygen in Pure Water Systems at Power Plants

Approximately half of all unexpected shutdowns in power plants happen because of water cycle chemistry difficulties, which result in expensive repairs and unrecoverable lowered operating income. Dissolved oxygen, or DO, is one of the most critical metrics to monitor to increase the efficiency of power plant water systems. DO induces corrosion in iron and copper-containing components. These particles' transport and deposits may potentially hasten deterioration and destroy vital industrial equipment. 

DO is monitored at numerous points across a water system. DO is traditionally detected using polarographic sensors, which employ a gas permeable membrane to separate the sample from the electrochemical cell within. Polarographic sensors may need monthly electrolyte and membrane changes depending on the working conditions. Because of the required polarization, the sensor cannot generate valuable results for many hours after service. They are also affected by dissolved hydrogen and are sensitive to sample flow rate. 

The Mettler Toledo Thornton online pure water optical DO sensor, unlike typical DO sensors, does not need polarization. It analyzes data quickly and accurately by using optical technologies. It responds to measurements six times quicker than polarographic sensors. Because the optical DO sensor does not require an electrolyte or a membrane, it is not sensitive to flow and is not vulnerable to particle and dissolved hydrogen interference. There is no internal body to repair, and servicing is only necessary once a year to quickly change the one-piece Optocap sensing element, decreasing operating costs and downtime for facilities. 

The Mettler Toledo Thornton pure water optical DO sensor measures dissolved oxygen content in power plant pure water systems quickly, accurately, and with low maintenance.

Process Technology, Inc.
801-264-1114

PTI Salespeople Dan Taylor & Daniel Gibbs at Siemens Process Automation Training


Process Technology, Inc. salespeople Dan Taylor & Daniel Gibbs at Siemens Process Automation training explain PTI vertical markets and territory in this video.

Process Technology, Inc.
801-264-1114

The TriGas X5000 Integrated Gas Detection Solution

The TriGas X5000 Integrated Gas Detection Solution

Methane, hydrogen, sulfide, ammonia, carbon dioxide, carbon monoxide, chlorine, ozone, and other poisonous and explosive gases are produced and used in wastewater and potable water treatment facilities. Furthermore, the increased concentration of toxic chemicals and less oxygen in enclosed spaces make these environments particularly risky for employees.

NFPA 820 specifies rules for protecting wastewater treatment plants and their associated collecting systems against fire and explosive risks. New installations, extensions, and upgrades to existing facilities are all subject to the regulations. Owners utilize the requirements in a risk assessment to determine whether portions of a treatment plant are in danger of fire or other loss. Many sites require combustible gas detection, mainly for methane (CH4). Monitoring hydrogen sulfide (H2S) and oxygen (O2) is also common. The installation of a methane gas detecting station near the roof of a structure is typical. Oxygen and hydrogen sulfide detection stations offer safety in the breathing zone for personnel protection. NFPA 820 mandates alarm signaling for flammable gas detectors and ventilation.

These municipal water and wastewater customers’ monitoring safety challenges are addressed with technology from MSA.

The MSA TriGas X5000 Monitoring System is an integrated gas detection solution that assists plant operators in meeting NFPA 820 requirements. The system monitors combustible gases, hydrogen sulfide, and oxygen levels, with onboard alarming and a communication interface to plant and remote control stations. 

The MSA TriGas X5000 Monitoring System assists you in complying with:
  • NFPA 820: Standard for Fire Protection in Wastewater Treatment and Collection Facilities
  • NFPA 497: Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas 
  • NFPA 70®: National Electric Code® when standard practice dictates separation of electronics from sources of gas leaks. 
The TriGas X5000 Monitoring System is specifically designed for optimum performance in high-moisture environments and typically monitors for oxygen, hydrogen sulfide, and combustible gases (methane or petroleum vapors). This sampling system can also be outfitted with the necessary options to meet the wastewater industry's NFPA 820 section 1.8 standards.

The TriGas X5000 Monitoring System builds on the successful Ultima X TriGas design. The system includes combustibles, H2S and O2 gas monitors, sample pump and end-line filter, power supply, and alarming system with buzzer and strobe light.

TriGas X5000 Components:
  • Ultima X5000 sensors for O2, H2S and IR LEL combustible gas
  • Designed for high-moisture environments
  • NEMA 4X Stainless Steel or Fiberglass Enclosure
  • SM5000 Sample Pump
  • Red Strobe
  • Buzzer
  • Hydrophobic End-of-Line Filter
  • Inlet/Outlet Flashback Arrestors

Continuous Total Organic Carbon Measurement For Ultrapure and Pure Water Systems

Continuous Total Organic Carbon Measurement For Ultrapure and Pure Water Systems

Real-time Measurement for Full Visibility of TOC Excursions

The Mettler Toledo 6000TOCi is an ISM-capable continuous measurement Total Organic Carbon sensor designed to measure the concentration of organic substances in pure and ultra-pure water applications. 

Total Organic Carbon monitoring is essential for determining and controlling organic pollution in pure and ultrapure waters. This technology is used in the pharmaceutical, microelectronic, and power generation industries. 

The 6000TOCi sensor is a continuous-flowing, continuous-measurement instrument that detects any TOC change, no matter how long it lasts. The continuous design also enables quick detection, detecting differences 60 seconds after the sample enters the sensor. The sensor uses advanced UV oxidation technology with fast response times to provide continuous, real-time measurements in pure and ultrapure waters. 

To provide continuous, real-time TOC determination, the 6000TOCi sensor measures conductivity before and after oxidation of organic material with ultraviolet light. 

Because of the 6000TOCi's versatility, it can be installed anywhere on a water system, with results displayed at the point of measurement or in a more convenient location for operators. 

The response time of the METTLER TOLEDO Thornton 6000TOCi Total Organic Carbon sensor is less than one minute. It offers continuous monitoring, which is a significant advantage over batch measurement systems, which take six minutes or more to provide only a snapshot of water quality. 

The M800 Transmitter is a multiparameter, multi-channel instrument with a large color touchscreen display that displays measurement and setup data for the 6000TOCi sensor. Up to four 6000TOCi sensors can be controlled and monitored by the M800. When used together, the 6000TOCi sensor and M800 transmitter form a TOC measurement system with design flexibility for full integration into water systems. The separate components allow for close positioning of the sensor to the sample point for the quickest response while also allowing the transmitter to be integrated into the local control system.

Contact Process Technology for all your Mettler Toledo Process Analytics products. Call them at 801-264-1114 or visit them at https://process-tech.com.