Solutions

for

Industrial Agility
BP Exploration
Operating Company
Ltd.
D2D Productisation
D2D Pump Module
FAT
2005Apr05

PME-BPE4770

_________________________________________________________________________________________

PME-BPE4770 D2D Pump Module

FAT
File Name: 342162182.doc

Prepared By:
Matrikon Europe Ltd.
Bruce Cordiner
60 Carden Place
Aberdeen
UK
Phone:
Fax:

+44 (0) 1224 659835

+44 (0) 1224 659801

Revision History:
Date

Versi
on

Description

Created by

1.0

New Document

Bruce Cordiner

2005Apr0
5

Reviewed by

Sign-off:
Approved By

Date

Signature

CONFIDENTIAL
The information contained herein is confidential and proprietary as defined by the BP Matrikon iSurveilance Pilot
Project Contract #103338

_________________________________________________________________________________________

Document Terminology
Term/Abbreviati
on
HEX
DAS
FAT
LAN
Matrikon
Matrikon OPC
OPC
OPC Server
PLC
SAT
ProcessDoctor
ProcessMonitor
ProcessNet
WAN

D2D Pump Module FAT Rev 1

Terminology

Description
Heat Exchanger
Data Acquisition System
Factory Acceptance Test
Local Area Network
Matrikon Inc.
Matrikons OPC-Compliant servers and
clients
The communication standards published
by the OPC Foundation
A software package that makes data
from a system such as RTP available
using the OPC-DA standard.
Programmable Logic Controller
Site Acceptance Test
Matrikons web-based performance
diagnosis and monitoring tool
Matrikons tool that lets operators
monitor process variables
Matrikons suite of web-based products
for gathering and manipulating process
control data
Wide Area Network

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PME-BPE4770

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Table of Contents
1 Overview
1
1.1 Introduction
1
1.2 Testing
1
1.3 Test
2
1.4 Test
2
1.5 Test
3
2 Test
4
2.1 Data
4
2.2 Normal
4
2.3 Pressure
4
2.4 Temperature
5
2.5 Valve
5
2.6 All
6
3 Configuring
7
3.1 NetObjects
7
3.2 HEX
9

Philosophy
Data

Generation
System
Methodology.
Cases
Loading
Conditions
Cycling
Cycling
Cycling
Cycling

the

Heat

Exchanger

object
Overview

Object

Configuration

3.2.1 Constants
11
3.2.2 HEX
12
3.2.3 HEX
12

Inputs
Outputs

List of Appendices
D2D Pump Module FAT Rev 1
Table of Contents

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D2D Pump Module FAT Rev 1

Table of Contents

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Table of Tables
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D2D Pump Module FAT Rev 1

Table of Contents

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OVERVIEW

1.1 Introduction
This project will consist of creation of a standard application framework,
with specific module development, which can be distributed for multiple
usage. This application will leverage from existing ISIS architecture using
Matrikons ProcessSuite of software tools, including ProcessNet,
NetObjects, and ProcessMonitor.
Matrikon have been asked by the BP D2D team to develop a heat
exchanger tracker application that calculates and measures efficiency
levels of various pieces of critical equipment. The HEX application will be
a pilot version of the final application, for BP to take into operate to
allow a field trial.
For details on the design of the HEX object, see the Heat Exchanger Object
DDS.

1.2 Testing Philosophy

The D2D HEX module has two main components:
1. The ProcessMonitor analyses
2. The ProcessNet reports
Each of these components takes their configuration from NetObjects, which
has its own configuration interface.
In the future, a configuration interface could be built specifically for the heat
exchanger. This would allow wizards to be created, which would simplify the
configuration, and lead a user through the necessary tasks to monitor a new
heat exchanger.
Testing will be performed in the Matrikon Europe office in Aberdeen.

D2D Pump Module FAT Rev 1

Configuring a new object

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1.3 Test Data Generation

Test data will be in the form of .csv files. These .csv files will be generated by
a Hysys testing model developed by Drew Dewil (BP) (see below).

Figure 1 - Hysys pump / Heat exchanger model

This model combines the two D2D modules, allowing us to generate test data for
each of the modules.

1.4 Test System

The physical test system used will be a dell server in the Aberdeen office. This
Dual Xeon 3Ghz server with 4GB of ram will run all of the Virtual Machines
required for the test system. The server will be configured as below:

D2D Pump Module FAT Rev 1

Configuring a new object

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Matrikon Europe Development VMWare Server

ProcessMoni
tor Machine
ProcessMonito
r
SQL Server
NetObjects
DB

ProcessNet
Netobjects
Machine.
ProcessNet
NetObjects
Desktop
Historian

Oracle
Server
ProcessGuard
Oralce 9i

1.5 Test Methodology.

As we will be generating manual data to test the HEX model, we will test the
model in an offline mode, i.e. not scheduled. This will allow us to add a .csv
file to the server, and run data through the model, writing history to the
Desktop Historian server.
The .csv files will be created with distinct time ranges, so that the data can be
analysed in the historian.
We are using Desktop Historian as an example historian, however, in
production any OPC HDA compliant server could be used, or OSI PI.
The original .csv test data will be inserted into Desktop Historian using a
custom, temporary analysis in ProcessMonitor. After confirmation that all the
test-data has been loaded into the historian, we can run the HEX model on the
.csv data, and analyse the results.
The HEX model runs on 5 second data for 15 minutes (interpolated data).

D2D Pump Module FAT Rev 1

Configuring a new object

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2 TEST CASES
2.1 Data Loading
Test
#

DDS
Sect
5

Test
Create a group
in opc explorer
with each of the
D2D test HEX
tags.
Set the values
of each of the
tags to a value
unique to that
tag.

Expected Result
Values in OPC
Explorer match
those on the HEX
schematic page.

BP
Initial

Matrik
on

Commen
ts

2.2 Normal Conditions

For this test, all data will be set to optimal / expected inputs and constants, so
that all traffic light symbols will show a green, safe status. Sample input data
will be used and results should correspond with equivalent sample output
data.
For this test, a sample .csv file (HEX Inputs Normal Conditions.csv) will be
inserted via the HEXImport analysis to the desktop historian. This will
update the display in processnet as well. The HEX module will then be run,
generating output data.

Tes
t#

DDS
Sectio
n

4.3.1

Test
Import .csv data
into Matrikon
Desktop historian
on the processnet
machine
Run
processmonitor
HEX model

Expected Result

BP
Initial

Matrikon
Initial

Commen
ts

Input values change to

match the imported .CSV
file.
Output values change, and
are within expected range.

2.3 Pressure Cycling

During this test, we will enter cyclical pressure data (PA) to the model. The
pressure values will resemble a sin wave in graphical format. Running the
data through our HEX object will show either a red, amber or green status in
the pressure cycling traffic light.

D2D Pump Module FAT Rev 1

Configuring a new object

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PME-BPE4770

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For this test, three sample .csv files (RED pressure cycling (PA).csv,
AMBER pressure cycling (PA).csv, and GREEN pressure cycling (PA).csv)
will be inserted via the HEXImport analysis to the desktop historian. This
will update the displays in processnet as well. From here, we will be able to
check that the traffic light in the processnet display change in relation to the
values entered.
Tes
t#
1

DDS
Sectio
n
--

4.3.1

4.3.1

4.3.1

Test
Import .csv data into Matrikon
Desktop historian on the
processnet machine
Run the process monitor
analysis with RED data.
Run the process monitor
analysis with AMBER data.
Run the process monitor
analysis with GREEN data.

Expected Result

BP
Initial

Matriko
n Initial

Input values change to match the

imported .CSV file.
Traffic light shows red.
Traffic light shows amber.
Traffic light shows green.

2.4 Temperature Cycling

During this test, we will enter cyclical temperature data (ToutA) to the model.
The temperature values will resemble a sine wave in graphical format.
Running the data through our HEX object will show either a red, amber or
green status in the temperature cycling traffic light.
For this test, three sample .csv files (RED temperature cycling (PA).csv,
AMBER temperature cycling (PA).csv, and GREEN temperature cycling
(PA).csv) will be inserted via the HEXImport analysis to the desktop
historian. This will update the displays in processnet as well. From here, we
will be able to check that the traffic light in the processnet display change in
relation to the values entered.
Tes
t#
1

DDS
Sectio
n
--

4.3.1

4.3.1

4.3.1

Test
Import .csv data into Matrikon
Desktop historian on the
processnet machine
Run the process monitor
analysis with RED data.
Run the process monitor
analysis with AMBER data.
Run the process monitor
analysis with GREEN data.

D2D Pump Module FAT Rev 1

Configuring a new object

Expected Result

BP
Initial

Matriko
n Initial

Input values change to match the

imported .CSV file.
Traffic light shows red.
Traffic light shows amber.
Traffic light shows green.

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PME-BPE4770

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2.5 Valve Cycling

During this test, we will enter cyclical valve data (TICop) to the model. The
valve values will resemble a sin wave in graphical format. Running the data
through our HEX object will show either a red, amber or green status in the
valve cycling traffic light.
For this test, three sample .csv files (RED valve cycling (PA).csv, AMBER
valve cycling (PA).csv, and GREEN valve cycling (PA).csv) will be inserted
via the HEXImport analysis to the desktop historian. This will update the
displays in processnet as well. From here, we will be able to check that the
traffic light in the processnet display change in relation to the values entered.
Tes
t#
1

DDS
Sectio
n
--

4.3.1

4.3.1

4.3.1

Test
Import .csv data into Matrikon
Desktop historian on the
processnet machine
Run the process monitor
analysis with RED data.
Run the process monitor
analysis with AMBER data.
Run the process monitor
analysis with GREEN data.

Expected Result

BP
Initial

Matriko
n Initial

Input values change to match the

imported .CSV file.
Traffic light shows red.
Traffic light shows amber.
Traffic light shows green.

2.6 All Cycling

During this test, we will enter cyclical data for pressure, temperature and
valve to the model. The values will resemble a sin wave in graphical format.
Running the data through our HEX object will show either a red, amber or
green status in the cycling traffic lights.
For this test, three sample .csv files (All RED.csv, All AMBER.csv, and All
GREEN.csv) will be inserted via the HEXImport analysis to the desktop
historian. This will update the displays in processnet as well. From here, we
will be able to check that the traffic light in the processnet display change in
relation to the values entered.
Tes
t#
1
2

DDS
Sectio
n
-4.3.1

Test
Import .csv data into Matrikon
Desktop historian on the
processnet machine
Run the process monitor
analysis with RED data.

D2D Pump Module FAT Rev 1

Configuring a new object

Expected Result

BP
Initial

Matriko
n Initial

Input values change to match the

imported .CSV file.
Traffic lights all show red.

Revised on: 2005-Apr-01

PME-BPE4770

_________________________________________________________________________________________

DDS
Sectio
n
4.3.1

4.3.1

Tes
t#

Test
Run the process monitor
analysis with AMBER data.
Run the process monitor
analysis with GREEN data.

D2D Pump Module FAT Rev 1

Configuring a new object

Expected Result

BP
Initial

Matriko
n Initial

Traffic lights all show amber.

Traffic lights all show green.

Revised on: 2005-Apr-01

PME-BPE4770

_________________________________________________________________________________________

3 CONFIGURING THE HEAT EXCHANGER

OBJECT
3.1 NetObjects Overview
For the purposes of configuring the HEX object, the most important
component that we will use is the Object Hierarchy designer.
The Object Hierarchy designer allows you to create new instances of objects,
and relate them.

Figure 2 - Object Hierarchy Designer

Object instances are displayed in the Connection View where relationships

with other objects are shown in the [Object Name] (in this instance HEX
view. The [Object Name] properties view shows the Attribute groups, and
properties for the current object.
Values for each of the attributes can be changed by right-clicking the
property, and selecting Edit. This will display the following form:

D2D Pump Module FAT Rev 1

Configuring a new object

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PME-BPE4770

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CREATING A NEW OBJECT

Figure 3 - Edit attribute value wizard.

From here the user is able to edit the property of the object. Clicking Finish
will commit the changes to Net Objects, and return the user to the Hierarchy
Designer.
New objects can be created in the Connection View by right-clicking in
whitespace, and selecting New Object this will show the following display:

Figure 4 - New Object Wizard

This display allows you to Name the object, set its description, and select the
object-type, for our purposes, the HEX object will be used.

D2D Pump Module FAT Rev 1

Configuring a new object

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PME-BPE4770

_________________________________________________________________________________________

The wizard will then prompt us for the user permissions:

Figure 5 - Object Permissions Dialog

We will allow Administrator Read/Write access, and all other users read
access. Clicking Finish creates the new object with default properties for
each of the attributes.

D2D Pump Module FAT Rev 1

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3.2 HEX Object Configuration

In order to configure the HEX object the user is able to directly input values
for tags existing in the [Object Name] Properties window of the Object
Hierarchy Designer. For example to set the analysis name for the HEX object,
the user firstly has to right click on the PmonAnalysis tag, and click Edit.

The following dialog box will be brought up by the wizard:

D2D Pump Module FAT Rev 1

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_________________________________________________________________________________________

Figure 6 - Edit Attribute Dialog

The user is then able to insert the desired value for the chosen tag in this
case the PmonAnalysis tag would be set to D2DHEX.
In the same way all PNDatasource tags, HEXConstants tags, and
HEXInputs tags will be directly configured from NetObjects. These values
will then be transferred to the ProcessMonitor template for calculations to be
performed, and also to ProcessNet for display purposes in the NetDraw
graphics.

D2D Pump Module FAT Rev 1

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_________________________________________________________________________________________

PROPOGATION
Only once an object configuration has been completed would the user want to
propogate the new configuration to the processmonitor analysis.
Propogation is simply executed by editing the propogate attribute of the HEX.
When the Finish button is clicked, the configuration data will be sent to
processmonitor, and the template will be configured to monitor this new heat
exchanger.

Propogation Attribute

Description / purpose

ProcessDoctor Server

This attribute configures the process

doctor server that will perform the
analysis for this piece of equipment

DB Login

The login
database

DB Password

The password for the process doctor

database

DSN

The Data Source name of the process

doctor database

Propogate

This attribute is used to fire the

propogation of an analysis to process
monitor.

for

the

process

doctor

Successful propogation will result in the relevant analysis being updated in

processmonitor

3.2.1

Constants

Constants are entered into the NetObjects attributes directly.

HEX
Constants

Values

114

D2D Pump Module FAT Rev 1

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CpodB

3275

HdmodA

11089

HdmodB

2283

KdA

0.06

KdB

0.37

KodB

0.37

LMTDf

0.98

MdA

133560

MdB

126050

PrdA

1.03

PrdB

47.7

UdA

0.02

UdB

5.5

UodB

5.5

3.2.2

HEX Inputs

Each of the HEX inputs in NetObjects requires a tag-name to be

configured. This is the tag-name that will be used to source data in the
displays, and in the calculations.
HEX Inputs

Value
NetObjects

TinA

TA1004.pv

127

TinB

TB1004.pv

17

ToutA

OT1004.pv

62

PA

PA1004.pv

190

ModA

MA1004.pv

136150

TICop

TO1004.pv

65

TICsp

TS1004.pv

65

3.2.3

in Example
Values

HEX Outputs

HEX
Outputs

Value
NetObjects

Uactual

D2DHEX1005.Uact
ual

2710

Uclean

D2DHEX1005.
Uclean

1525

D2D Pump Module FAT Rev 1

Configuring a new object

in Example
Value

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_________________________________________________________________________________________

Urel

D2DHEX1005. Urel

180

CpodA

D2DHEX1005.
CpodA

3025

UodA

D2DHEX1005.
UodA

0.02

KodA

D2DHEX1005.
KodA

0.06

D2DHEX1005. Q

7445

ModB

D2DHEX1005.
ModB

83720

ToutB

D2DHEX1005.
ToutB

115

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Configuring a new object

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15