What is Diagnostics and Integrity in Process Control?

Diagnostics and Integrity Solution

Diagnostic and Integrity in process systems is a control philosophy that assesses and monitors machine components, cycle time, and instrumentation and refers to the accuracy and reliability of the diagnostic information generated and used in monitoring and controlling a process. The philosophy includes the validity of the sensors, algorithms, and systems that gather and analyze data to identify potential issues and the ability to correctly diagnose and respond to faults in the process to ensure optimal performance and prevent damage or downtime. Diagnostics integrity refers to the trustworthiness of the diagnostic information and systems used in monitoring and controlling industrial processes and the accuracy and reliability of the measurement and diagnostic data generated by the process control instruments. It is an essential aspect of process control as it ensures the safe and efficient operation of the process by detecting and diagnosing issues in real time.

Diagnostics and Integrity ensure that every component in the system is always working correctly.

Diagnostic and Integrity involves several areas of focus:

  • Valid Sensors and Measurements: Sensors used in the process must be accurate and reliable, providing correct and consistent measurements of process variables. Regular calibration of sensors ensures their continued accuracy.
  • Algorithm Accuracy: Algorithms used to analyze process data and detect potential issues must be accurate and reliable, including algorithms for detecting process anomalies, diagnosing faults, and predicting equipment failures.
  • System Robustness: The process control system must be robust and able to handle unexpected conditions and failures, such as sensor or communication failures, without introducing additional errors or causing the process to become unstable.
  • Response to Faults: The process control system must be capable of correctly diagnosing faults and responding appropriately and safely, which may involve shutting down parts of the process, adjusting process variables, or triggering alarms to alert operators.
  • Data Management: The process control system must collect, store, and manage large amounts of diagnostic data, allowing operators to review and analyze the data to identify trends and potential issues.

The value of implementing Diagnostics and Integrity:

  • OEM/End User value add differentiator.
  • A system that is self-diagnostic (Downtime)
  • Compensate for the gap in technical knowledge in the field.
  • Ensure the components in the system are working correctly (Reliability)
  • Alleviate extended downtime through the implementation of monitoring instrumentation.
  • Alignment with quality requirements (Machine data)
  • Ensure a reliable and repeatable process (Quality)
  • Proactive fault indications prompting immediate action from maintenance and engineering (Downtime)
  • Predictive maintenance and planning.
  • Ensure machine and personnel safety.
  • Onboarding new engineers (Monitoring PLC/HMI).
  • Capture data when the device is performing at its best.
  • Extracting and implementing tribal knowledge in the control platform.
  • Increase OEE (Overall Equipment Effectiveness).
  • Maximize the potential of the machine (Productivity and throughput).
  • Increase profit margins through the understanding of machine capabilities.

PTI's RolePresented with diagnostic issues over many years, PTI gained experience and developed an innovative approach to monitoring machine components and processes during normal operations, leading to the development of a program that provides custom solutions specific to your control processes.

  • Through EvaluationPTI assists in identifying the existing machine component monitoring system and relevant data needed to ensure a robust process.
  • Through TrainingPTI provides targeted instruction on the implementation of Diagnostics and Integrity.
  • Through ImplementationPTI provides a custom self-diagnostic synopsis of your system or overall plant based on your operations, staff, and equipment, guiding your engineering staff through the steps to implement Diagnostics and Integrity in your platforms, ensuring process integrity.

Contact Process Technology for more information. Call them at 801-264-1114 or visit them at https://process-tech.com.