Académique Documents
Professionnel Documents
Culture Documents
Safety notes 2
Description 3
Analyzer System Manager
Access authorization 4
Software Solutions
System Manual 5
Interfaces
Functions 7
System Configuration 8
Alarm list 10
ASM calculations A
Appendix B B
List of abbreviations C
09/2018
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Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
1 Introduction ............................................................................................................................................. 7
1.1 Purpose of this documentation ................................................................................................. 7
1.2 History ....................................................................................................................................... 7
1.3 ASM software version ............................................................................................................... 7
1.4 General information .................................................................................................................. 7
1.5 Warranty conditions .................................................................................................................. 8
1.6 Delivery Information .................................................................................................................. 8
1.7 Standards and regulations ........................................................................................................ 8
2 Safety notes ............................................................................................................................................ 9
2.1 General safety notes ................................................................................................................. 9
2.2 Warranty and liability for application examples ........................................................................ 9
2.3 Industrial security ....................................................................................................................10
3 Description ............................................................................................................................................ 11
3.1 Scope ......................................................................................................................................11
3.2 Features ..................................................................................................................................12
3.3 System architecture and design considerations .....................................................................13
4 Access authorization ............................................................................................................................. 17
4.1 General ...................................................................................................................................17
4.2 Configuring access authorizations ..........................................................................................17
5 Interfaces .............................................................................................................................................. 21
5.1 Analyzer Interface ...................................................................................................................21
5.1.1 Analyzer interface via external OPC client .............................................................................21
5.1.2 Analyzer interface via field bus or hard-wired signals ............................................................22
5.1.3 Analyzer interface via MAXUM OPC server ...........................................................................23
5.2 Interfacing a DCS for validation/calibration handshake operations ........................................24
6 Graphical User Interface ....................................................................................................................... 25
6.1 General screen layout .............................................................................................................26
6.2 Work area screen hierarchy ....................................................................................................28
6.3 Screen layouts ........................................................................................................................29
6.3.1 Overview screen .....................................................................................................................29
6.3.2 Analyzer house screen ...........................................................................................................30
6.3.3 Analyzer sample system screen .............................................................................................32
6.3.4 Analyzer house mimic panel screen (optional) .......................................................................33
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Table of contents
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Table of contents
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Table of contents
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Introduction 1
1.1 Purpose of this documentation
This documentation informs you about the ASM software features, areas of application,
setup options and commissioning of the ASM solution.
1.2 History
The following table shows the most important changes in the documentation compared to
each previous edition:
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Introduction
1.5 Warranty conditions
Due to the variety of technical details, it is not possible to consider every single detail for all
versions of the described system and for every conceivable case in the set-up, operation,
maintenance and use in systems. For further information, or in the case of problems which
are not covered in enough detail in this document, please request the required information
from your local or responsible Siemens regional office.
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Safety notes 2
2.1 General safety notes
WARNING
Danger to life if the safety instructions and residual risks are not observed
If the safety instructions and residual risks in the associated hardware documentation are
not observed, accidents involving severe injuries or death can occur.
• Observe the safety instructions given in the hardware documentation.
• Consider the residual risks for the risk evaluation
WARNING
Malfunctions of the machine as a result of incorrect or changed parameter settings
As a result of incorrect or changed parameterization, machines can malfunction, which in
turn can lead to injuries or death.
• Protect the parameterization (parameter assignments) against unauthorized access.
• Handle possible malfunctions by taking suitable measures, e.g. emergency stop or
emergency off.
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Safety notes
2.3 Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products and solutions only represent one component of such a
concept.
The customer is responsible for preventing unauthorized access to its plants, systems,
machines and networks. Systems, machines and components should only be connected to
the enterprise network or the internet if and to the extent necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, please visit: Industrial security
(http://www.siemens.com/industrialsecurity)
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends to apply product updates as soon as available and to
always use the latest product versions. Use of product versions that are no longer supported,
and failure to apply latest updates may increase customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at: Industrial security (http://www.siemens.com/industrialsecurity)
WARNING
Unsafe operating states resulting from software manipulation
Software manipulations (e g. Trojans, viruses, malware or worms) can cause unsafe
operating states in your system that may lead to death, serious injury, and property
damage.
Keep the software up to date.
• Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
• Make sure that you include all installed products into the holistic industrial security
concept.
• Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
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Description 3
3.1 Scope
In the present time process industries are more and more depending on accurate data e. g.
on the composition of the material flows and quality, incoming and sourcing materials,
monitoring of process conditions and values/results to achieve an efficient and effective
operation and maintenance. Analyzers and their systems 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.
By integrating different data pools from analyzer systems, DCS, data historians, LIMS and
more into the Siemens Analyzer System Manager (ASM), data become more transparent for
the efficiency in saving operating and maintenance costs.
Increasing the data quality in a small scale can leads into an additional revenue per year,
depending on the process.
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Description
3.2 Features
3.2 Features
Siemens ASM is a PC-based HMI system for monitoring, testing and managing analyzers in
subsystems or in a complete plant. The relevant information of the different analyzers is
collected via various communication protocols and saved in a central database. Using the
PC's user-friendly operator interface, it is possible to access measured value trends, device
states and statistical evaluations, among others, or to start test routines for validation of the
results. A comprehensive reporting module with predefined reports is available to document
the results.
Core Functions
● Integration of a wide spectrum of analyzers
● Central monitoring of analytical systems
● Validation/calibration of gas analyzers
● Logging and statistical evaluation of validation results based on ASTM
● Evaluation of diagnostic values
● Automatically calculation of Key Performance Indicators (KPIs)
● Management of all maintenance relevant activities of entire analytical systems
● The system is scalable from small single-user applications for a few analyzers up to plant
systems with a large number of analyzers
Customer benefits using ASM
● Increasing reliability and safety
● Reduction of unplanned maintenance activities due to predictive plannings
● Reducing operating costs due to higher data quality and transparency
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.
Customer benefits
Siemens as an analyzer manufacturer has an extensive know-how in analyzer technology
and the associated validation, calibration and maintenance activities. Many years of
experience are the foundation of the ASM software.
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.
If required, additional logic may be added via SIMATIC S7 controllers.
Siemens as a global company with worldwide local presence is able to provide
● Long term service contracts for system maintenance
● Local and/or remote support concepts
● Investment security due to continuous enhancement of the system
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Description
3.3 System architecture and design considerations
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Description
3.3 System architecture and design considerations
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Description
3.3 System architecture and design considerations
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Description
3.3 System architecture and design considerations
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Access authorization 4
4.1 General
The ASM software provides access authorization for the access-protected system
functionalities. The ASM access authorization system is based on the WinCC User
Administration and optionally on Windows user management when using SIMATIC Logon.
User roles
The following default user roless are predefined:
● Administrators: administrator
● Supervisors: supervisor
● Super user: superuser
● Process operators: operator
● Analyzer technician: technician
● Analyzer reliability SME: expert
● Data quality specialist: specialist
● Visitors: visitor
The predefined users can be modified or deleted as required and new users can be created
by the ASM administrator via the Windows user manager. Passwords must be defined
before first use.
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Access authorization
4.2 Configuring access authorizations
Figure 4-1 WinCC access rights including WinCC default rights marked with *
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Access authorization
4.2 Configuring access authorizations
Access-protected actions
The following ASM access-protected actions exist:
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Access authorization
4.2 Configuring access authorizations
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Interfaces 5
5.1 Analyzer Interface
The ASM server connects the analyzers via a dedicated analyzer network or via the plant
automation network. For analyzers outside this network serial links are provided. The ASM
server is able to automatically input the analyzer data
● for Siemens GC analyzers via the MAXUM OPC server
● for analyzers that support OPC DA directly via the Ethernet network
● for analyzers that support Modbus, Profibus DP, Profinet or hardwired analyzers via a
DAU
For manual data collection there are also entry forms provided, e.g. to store information
about conducted maintenance or validation data.
There are different main communication structures possible. All these possibilities can be
used in combination within one ASM server if required.
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Interfaces
5.1 Analyzer Interface
For this solution the interface PLC is used. 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 according to the cabling requirements,
e. g. close to the analyzers or at the central control room. This feature allows flexible
concepts.
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Interfaces
5.1 Analyzer Interface
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Interfaces
5.2 Interfacing a DCS for validation/calibration handshake operations
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Graphical User Interface 6
The Graphical user interface is based on the user-friendly SIMATIC SCADA system. Using
the GUI of each ASM workstation, the user can interact with the system and has access to
the required information, including:
● Display of current process values and historical data
● Display of current validation values and results of the statistical tests
● Execution of a validation or calibration procedure
● Display of work procedures for the validation
● Display of historical data
● Input of lab values
● Settings of the analyzer state (not required, start maintenance)
● Planning of maintenance actions
● Input of maintenance action comments
● Display of the alarms list
● Display of a set of predefined reports
● Display of current diagnostic readings from the analyzers or a connected smart sample
system (optional)
The language of the user interface is English. The following sections describe the user
interface in more detail.
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Graphical User Interface
6.1 General screen layout
Navigation area
The navigation area permits the selection of the following screens:
"Overview" screen with status information of each analyzer
"Analyzer house" screens with more detailed status information of the analyzers in the
corresponding shelter or cabinet.
The selection of the screens is only possible, if the currently logged-on user is provided with
the appropriated access rights. The navigation area shows
● the latest unacknowledged alarm message
● the current date and time
● the ASM Logo or a customer company logo (optional)
● the currently logged-on user.
After selection of the field that displays the current user, the logon dialog box is displayed.
The navigation area is independent from the selected work area.
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Graphical User Interface
6.1 General screen layout
Toolbar area
The toolbar permits access to the following features:
● selection of the alarm list, if the currently logged-on user is provided with the appropriated
access rights
● navigation within the work area screen hierarchy
● printout of the current screen content as hardcopy on the default printer if the currently
logged-on user is provided with the appropriated access rights
● start of the MAXUM Gas Chromatograph Portal Software in an independent window, if
the currently logged-on user is provided with the appropriated access rights
Note
The 'MAXUM Gas Chromatograph Portal Software' is the standard tool for operating and
maintaining the Siemens MAXUM and MicroSAM GCs.
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Graphical User Interface
6.2 Work area screen hierarchy
To navigate within the hierarchy use the navigation area. In addition, navigation from the
overview screen to the analyzer houses screens and further to the analyzer process view
screens is possible by clicking at that part of the screen where the information is provided
within the work area.
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Graphical User Interface
6.3 Screen layouts
In this screen the mode and action of the analyzer houses and analyzers are displayed by
color and name.
When clicking onto an analyzer house field, the work area changes to an analyzer house
screen with the data of the selected analyzer house. When clicking onto an analyzer house
row, the work area changes to an analyzer house process view screen with the data of the
selected analyzer. When clicking onto an analyzer row, the work area changes to an
analyzer process view screen with the data of the selected analyzer. The navigation area
and the toolbar are always visible.
Optionally are available (no standard feature):
● Network status displayed by color and name
● Status of analyzer sample cabinets displayed by color and name
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Graphical User Interface
6.3 Screen layouts
There is an overview of all analyzers within an analyzer house with the current readings and
units. Mode and action of the analyzer houses and analyzers are displayed by color and
name. When clicking onto an analyzer house row, the work area changes to the analyzer
house process view screen with the data of the selected analyzer. When clicking onto an
analyzer row, the work area changes to the analyzer process view screen with the data of
the selected analyzer. The navigation area and the toolbar are always visible.
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Graphical User Interface
6.3 Screen layouts
Mode and action of the analyzer houses and analyzers are displayed by color and name as
well as status of analyzer sample cabinets. When clicking onto an analyzer house row, the
work area changes to the analyzer house process view screen with the data of the selected
analyzer. When clicking onto an analyzer row, the work area changes to the analyzer
process view screen with the data of the selected analyzer.
The display also shows
● An analyzer house with the location of all elements (e. g. analyzers, analyzer sample
cabinets, etc.)
● Analyzer house components (e. g. diagnostic values)
● Network status displayed by color and name
● Navigation elements to:
– open Windows explorer
– open WinCC online trend control window
– return to ASM overview screen
The navigation area and the toolbar are always visible.
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Graphical User Interface
6.3 Screen layouts
The analyzer sample system graphic shows a simplified line representation of the sample
handling system, which includes:
● Location of the analyzer
When clicking an analyzer symbol, the work area changes to the analyzer process view
with the data of the selected analyzer.
● Location of sample system measuring components
● Sample system values
Also displayed are:
● Modes of the analyzers inside the house are represented by their color
● The statuses of the analyzer sample system measuring components are represented by
their color
● The current diagnostic value readings and units of the analyzer sample system
● Navigation elements to:
– open Windows explorer
– open WinCC online trend control window
– return to the ASM overview screen
– return to the analyzer house screen.
The navigation area and the toolbar are always visible.
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
Figure 6-7 Validation view (history view with run chart tab)
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
The following screenshot shows the general layout of a validation view of an analyzer screen
from the analyzer components perspective.
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
● Components tab:
The actual list of controlled diagnostic values and their results are displayed. This could
be an individual value, a response factor or sample system values. Values like flow,
pressure and temperature can be combined as one sample system value.
– Summary tab:
active diagnostic rules for selected component or sample system are displayed.
– Details tab:
the result of each active diagnostic rule for selected component or sample system is
displayed.
– Chart tab:
data of the selected component is displayed in a chart. The data is filtered by a user
selectable time span.
– Control chart tab:
deviation of selected component is displayed in a chart, visualization of configured
limits, a time span is selectable.
– Documents tab:
The 'documents' tab can save several links to documents or folders which are relevant
for the specific analyzer or sample system, e. g. an analyzer manual or a sample
system manual.
– Rule settings tab: configuration and activation of rules for an diagnostic component.
– Limit settings tab: parameterization of limit values used within the rules.
● Events tab:
The list of diagnostic events, filtered by a user-selectable timespan, and the
corresponding data is displayed. An event will be created for each rule violation of a
diagnostic component value. Depending on the rule settings, additional WinCC messages
(alarm/warning) and ASM maintenance requests are possible.
● Details tab:
the results which are triggering an event are displayed.
● Chart tab:
data of the selected event is displayed in the chart. The data is filtered by a user-
selectable time span.
● Control chart tab:
deviation of selected event is displayed in the control chart. The time span is selectable.
● Documents tab: see documents tab of components tab.
Please refer to section Diagnostic components (Page 132) for further information on the
different rules and settings.
At the bottom of the process view, the current alarm list for the analyzer/shelter is displayed.
The navigation area and the toolbar are as visible as in all other analyzer screens.
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
● Completed tab:
A list of completed maintenance actions is displayed. By default a time filter of the last 7
days is selected. The list is ordered by maintenance action date and time in descending
order.
● Schedules tab:
A calendar view with all planned maintenance activities is displayed. Via the context
menu (right mouse click) it is possible to change the view between ‘Day View’, ‘Week
View’ and ‘Month View’.
● Manage Activities tab:
The right side of the manage activities tab shows all defined maintenance activities. New
maintenance activities can be entered at the end of the right table in which all defined
activities are listed by a user who is provided with one of the access rights ‘Enter
maintenance action’ or ‘Maintenance supervision’.
By pressing the two buttons in the middle of the tab, the maintenance activities can be
moved from the ‘All defined activities’ table to the ‘Effective activities’ table.
At the left side of the 'Manage activities' tab all maintenance activities, relevant for this
particular analyzer, are listed.
By pressing the button ‘schedule’ it is possible to schedule maintenance actions. After
scheduling an action, the action is visible in the 'planned' and 'schedules' tab. It is
possible to set a reminder. By the time the reminder becomes effective a maintenance
warning ("maintenance demanded by ASM") will be generated. If the maintenance action
is not started at the scheduled time the status of the analyzer will change to ‘overdue’ and
a maintenance alarm ("maintenance required by ASM") will be generated.
● KPIs tab:
The current key performance indicators for the selected analyzer are displayed. Weak
points that require special attention or immediate intervention can easily be spotted.
● Documents tab:
The 'documents' tab can save several links to documents or folders which are relevant for
the specific analyzer or sample system, e. g. an analyzer manual or a sample system
manual.
At the bottom of the process view the current alarm list for the analyzer/shelter is displayed.
The navigation area and the toolbar are as visible as in all other analyzer screens.
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Graphical User Interface
6.3 Screen layouts
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Graphical User Interface
6.3 Screen layouts
Alarms collected via the I/Os will be signaled via the message system. An operator can
acknowledge each message, so that new alarms can be easily detected. The system
provides a complete message history. The alarm list screen displays the currently active and
unacknowledged alarms. Each alarm consists of the following columns:
● Date/time stamp
● Source
● Message text
● Origin (e. g. analyzer)
● Type (Alarm, System)
● Status of the Message (come, gone, … )
For every analyzer only the highest priority alarm message (if present) is displayed.
Unacknowledged alarms are displayed with a flashing text. Using a button all visible alarms
can be acknowledged. The alarm list can be switched to a screen that displays the complete
alarm history (history screen). The alarm list can be switched to a screen that displays
operator messages, e.g. acknowledging a message and audit trail messages. For details
about the available alarms refer to Alarm list (Page 149).
Note
The Alarm system is a WinCC standard feature. For detailed information refer to Chapter
Industry support (https://support.industry.siemens.com/cs/ww/en/view/90682677)
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Graphical User Interface
6.3 Screen layouts
This screen allows the configuration of the reference bottles and its components as
described in the following sections. The screen can be opened using the toolbar button.
At the left side of the screen a tree view of the plant with all analyzers are displayed. The
purpose of this tree is to filter the reference bottles which are listed in the middle of the view.
The tree view is organized within a hierarchy as follows:
● Plant: All bottles from the entire plant will be shown in the bottle list.
● Shelter: The bottles which are assigned to the analyzers in the shelter will be shown.
● Analyzer: Only the bottles which are assigned to the analyzer will be shown.
● Stream: Only available for multi-stream analyzers. The bottles for this stream will be
shown in the bottle list.
The list of configured reference bottles is displayed in the middle of the view. As described
above the content of this list can be filtered by the selection of the tree view. The list shows
the bottles together with the certificate number and the expiration date of the bottle.
At the top of the right side all information of the bottle are displayed. That covers bottle
properties, includes components and additional documents.
At the lower right side, bottles and certificates can be assigned to or removed from a bottle. It
is possible to assign multiple bottles for one analyzer/stream, but only one bottle can be
active (If the checkbox is marked, the bottle is active otherwise it is not).
For further information refer to Reference gas bottle management (Page 125).
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Graphical User Interface
6.3 Screen layouts
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Functions 7
7.1 ASM system start-up and shutdown
7.1.1 General
SIMATIC WinCC is the platform and framework for the ASM software application.
The ASM Software is embedded in the SIMATIC WinCC application, installed on the ASM
server and on each of the workstations. The ASM software is started and stopped together
with WinCC.
WinCC consists of the "Control Center" and the WinCC Runtime. Activating the Control
Center starts the Runtime. Deactivating the Control Center stops the Runtime.
Note
In case of manual login of another user the ASM Software can be started manually.
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Functions
7.1 ASM system start-up and shutdown
Note
To bypass the automatic logon process and to log on as a different user, hold down the
SHIFT key during logon or Windows restart.
Select the correct WinCC project (file of type .mcp) and leave the settings as shown above.
The usual path is: D:\ASMData\WinCCProj\ASMServer\ASMServer.MCP. Then click "OK".
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Functions
7.1 ASM system start-up and shutdown
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Functions
7.2 Monitoring functions
Having done these configuration steps, WinCC runtime and the ASM software will start
automatically after the start-up of the operating system.
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Functions
7.2 Monitoring functions
7.2.6 Alarms
This function monitors all the available alarms related to an analyzer and its sample system
(optional) and stores these values in the database memory with measuring units and time
stamp. These alarms can be visualized in the different alarm windows. For more details refer
to Section Alarm list screen (Page 44)
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Functions
7.3 Analyzer validation
7.3.1 General
One of the core functions of the ASM is checking the analyzers for reliability of the measured
values. Two different methods of measurement are available for recording the values,
namely the reference sample method and the line sample method. The resulting values can
be checked using different evaluation methods (based on ASTM D3764 or deviation
monitoring). The objective of the validation is to recognize fluctuations and deviations with
respect to a reference value and to thus to enable a statement about the reliability and drift
of a measurement.
The data involved are shown in the following figure.
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NOTICE
Malfunctions due to improper modifications
Users which are trained adequately and authorized for these tasks may modify the
statistical formulas. However, Siemens declines any responsibility for malfunctions due to
improper modifications.
If there are multiple values for one component during a validation, it depends on the ASM
configuration of the analyzer, which value is used for the calculations. If it is set to "Last
value" and former validations only had a different value, the latter is not included in new
validations.
DCS permission
If a DCS is available, ASM is able to request permission to the DCS system. For more
information refer to Section Interfacing a DCS for validation/calibration handshake operations
(Page 24).
Note
This function is only possible if the analyzer is able to handle this feature!
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Manual mode
The following workflow describes the sequence of actions.
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Semi-automatic mode
The following workflow describes the sequence of actions.
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Automatic mode
The following workflow describes the sequence of actions.
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Input
● n reference samples
● n analyzer (stream) samples
Output
● Evaluation of the measured component values of the validation stream
The analyzer switches to the reference stream. The displayed operation mode changes
to "Validation". The system then collects sample values using the reference stream.
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According to the selected analysis method "Deviation monitoring" or "ASTM 3764" the
system will evaluate the samples as follows:
ASTM 3764
After having collected the samples the system performs a test on outliers using the ‚Dixons’
method as described in ASTM D 3764. Any outliers that are recognized are removed. If after
having executed this test the minimum number of required samples is not obtained any
more, the procedure is aborted and an error message is issued.
If there remains a sufficient number of samples, the system calculates the arithmetic average
value and the variance of the valid samples.
The system then performs a test on the variability of the samples using the ‘F-test’ method
as described in ASTM D 3764. As soon as a significant difference in variance is detected the
procedure is aborted.
Finally a bias test (Student T-test) is performed for every component with the following
results:
● Number of outliers
● Average of the samples
● Variance of the samples
● Result from F-test
● Bias in level present yes/no (result from T-test)
● Overall validation result
– Passed - the analyzer produced measured quantities that met the compliance limits of
the validation settings.
– Failed - the system issues a warning or alarm message.
For details about ASTM D 3764 calculations refer to Calculations for ASTM validation
procedures (Page 157)
Deviation monitoring
After having collected the samples are collected the system checks if there is a sufficient
number of samples. If so the system calculates the arithmetic average value, the absolute
and relative deviation of the valid samples. According to the configured deviation rules the
system then performs a test on the
● Number of sequenced points outside the control limit
● Number of sequenced points outside the spec limit
For every tested component the following test results are issued:
● Average of the samples
● Result of the deviation rules
● Overall validation result
– Passed - the analyzer produced measured quantities that met the compliance limits of
the validation settings.
– Failed - the system issues a warning or alarm message.
For details about deviation monitoring calculations refer to Calculations for deviation
validation procedures (Page 154)
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Manual mode
The following workflow describes the sequence of actions.
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Input
● n lab samples (Li)
● n analyzer (stream) samples (Ai)
Output
● Evaluation of the lab component values compared to the recorded sample values.
The operator must enter the sampling time range. The lab samples should be taken
during this time span. The system then checks if enough samples are present in the
system during the selected sampling time span. Then the analyzer samples are checked
for stability. If not enough samples are present or if the readings are not stable, a
corresponding message ("limit exceeded") is issued. In this case the system will not
continue the validation process and the validation is rejected.
Otherwise the system calculates the predicted value for each sample and displays it in
the components list in the analyzer value column.
From now on the operator may enter the lab values in the components list in the
reference value column. It is also possible to enter the lab values at a later time.
After all lab values are entered the system calculates the delta between the lab values
and the analyzer values to the formula:
Δi = Ai – Li.
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According to the selected analysis method "Deviation monitoring" or "ASTM 3764" the
system will evaluate the samples as follows:
ASTM 3764
The system performs a test on outliers using the ‚Dixons’ method as described in
ASTM D 3764. Any outliers that are recognized are removed. If after having executed this
test the minimum number of required samples is not obtained, the procedure is aborted and
an error message is issued.
If there remains a sufficient number of samples, the system calculates the arithmetic average
value and the variance of the valid samples. Finally a bias test (Student t-test) is performed
for every component with the following results:.
● Number of outliers
● Average and variance of the latest n analyzer values
● Average and variance of the latest n lab values
● Result from F-test
● Bias in level present yes/no (result from T-test)
● Overall validation result
– Passed - the analyzer produced measured quantities that met the compliance limits of
the validation settings.
– Failed - the system issues a warning or alarm message.
For details about ASTM D 3764 calculations refer to Calculations for ASTM validation
procedures (Page 157)
Deviation monitoring
After having collected the samples the system checks if there is a sufficient number of
samples. If so the system calculates the arithmetic average value, the absolute and relative
deviation of the valid samples. According to the configured deviation rules the system then
performs a test on the
● Number of sequenced points outside the control limit
● Number of sequenced points outside the spec limit
For every tested component the following test results are issued:
● Average of the samples
● Result of the deviation rules
● Overall validation result
– Passed - the analyzer produced measured quantities that met the compliance limits of
the validation settings
– Failed - the system issues a warning or alarm message.
For details about deviation monitoring calculations refer to Calculations for deviation
validation procedures (Page 154)
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7.4 Analyzer calibration
The user can start the calibration process via the graphical user interface (GUI) of the ASM if
the analyzer supports that feature.
During the calibration process the system determines the new calibration response factor for
each component involved. The new response factors are saved after the calibration has
finished.
Note
The analyzer calibration via the ASM calibration view is only available for MAXUM analyzers.
Other analyzers with calibration functions (e. g. Siemens Series 6 and Series 7 analyzers)
will be handled using the validation view or diagnostic view because of more extensive
configuration possibilities.
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7.4 Analyzer calibration
DCS permission
If a DCS is available, ASM is able to request permission to the DCS system. For more
information refer to Section Interfacing a DCS for validation/calibration handshake operations
(Page 24).
The calibration process is handled internally inside the analyzers. The ASM Server only
initiates the calibration, when permission was given from DCS and saves the relevant data.
For more information refer to Section Interfacing a DCS for validation/calibration handshake
operations (Page 24).
Note
To use this function an analyzer must be able to handle this feature!
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Calibration workflow
The following workflow describes the sequence of actions during an analyzer calibration. The
calibration process is handled internally inside the analyzers. The ASM Server only initiates
the calibration after permission was given from DCS, and saves the relevant data.
During the analyzer calibration, the new calibration response factor for each component
involved is determined and saved after the calibration has finished.
If an alarm is issued during the calibration procedure the calibration has failed. No new
values will be available for the analyzer concerned.
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7.5 Diagnostics
7.5 Diagnostics
ASM is capable to monitor additional values out of sample systems and analyzer houses.
These will be displayed as diagnostic values of the analyzer system. These are parameters
which directly affect the analyzer performance such as
● Response factors
● Sample temperature
● Sample pressure
● Sample flow
If these parameters are different from their pre-defined setpoints, this can affect the quality of
the sample input and eventually the final measurement of the analyzer. ASM monitors and
saves these values either cyclically, triggered by an event or on changes.
An operator can also define different limits for every diagnostic value and the reaction of the
system if one of these limits is exceeded such as an alarm or a warning.
According to the configuration of the ASM manager the analyzer mode can also be shown as
alarm in the diagnostic values. For more information about the diagnostic view and the
different tabs available there refer to Diagnostics view (Page 39) .
The Diagnostics function provides following features:
● Monitoring of external sensor data (Diagnostic values)
● Apply / remove a set of limits to the diagnostic values.
Removing is only possible if the limit is not used in a rule.
– Control limits
– Warning limits
– Spec limits
● Apply / remove of rules.
This feature allows an operator to apply the limits to the system. Only in the "limit
settings" section predefined limits can be selected.
● Electronic documentation (Manuals in pdf format).
The system provides the possibility to store electronic documents (pdf files) for each
analyzer concerned. These documents can easily be retrieved and displayed by
authorized personnel, thus providing up-to-date information for data sheets and system
drawings. This feature provides one single location for all maintenance-related
documentation.
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Figure 7-6 Dialog to combine several requests with one “normal” master request
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The following dialog shows an automatically created and finished request as “Master”
request and multiple additionally selected requests. Since the option “combine to one
request” is not activated, each request will be documented individually.
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Any changes performed on the master request before clicking the first time on next, also
have effect on the subsequent requests. Possible modifications in the subsequent requests
do not influence any other requests.
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The following dialog shows a scheduled request as “Master” request and several additionally
selected requests. The start and end times will be transferred to the master request and after
documentation the selected requests will be deleted.
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The following dialog shows a scheduled request as “Master” request and several additionally
selected requests. Since the option “combine to one request” is not activated, each request
will be documented individually except the scheduled request which will be deleted after
documentation.
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Figure 7-7 Document dialog to document each request with scheduled master (first request)
Any changes performed on the master request before clicking the first time on next, also
have effect on the subsequent requests. Possible modifications in the subsequent requests
do not influence any other requests.
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The second way shows the KPIs during a variable timeframe. The operator selects the
desired analyzer and opens the maintenance view. There he selects KPIs.
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7.7 Analyzer reporting functions
Each report has a condensed overview with the most important data on the first sheet. Such
a report can either be displayed on a screen or sent to a printer. It is possible to export a
report to a pdf file, to Microsoft Word or to a Microsoft Excel sheet for further analysis (a
license for MS Excel or Word is not included within the current offer).These exported reports
can then be copied to portable media to become available also outside the system.
Additionally to the predefined reports it is possible to create and open individual pdf reports
out of a shared folder.
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Reports can be saved on individual workstations and can be refreshed with current data
upon request.
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7.7.3.1 ASM_AlarmList
Subject: list of alarms filtered by a user-selectable time range.
The report is not specific to a certain analyzer or shelter. The report is limited to alarms
generated within the selected time span.
7.7.3.2 ASM_AnalyzerConfiguration
Subject: details of analyzer configuration data.
This report can be displayed for a specific analyzer or for all analyzers.
7.7.3.3 ASM_AnalyzerMaintenance
Subject: Details of maintenance actions carried out per analyzer, such as
● Time/date
● User
● Action
● Problem
● Symptom
● Cause
● State
The report can be displayed for a specific analyzer or for all analyzers. The report is limited
to maintenance actions executed within the selected time span.
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7.7.3.4 ASM_AnalyzerPerformance
Subject: Calculated analyzer performance indicators:
● Availability time
● Checking time
● Failure time
● Mean time between failure (MTBF)
● Mean time to repair (MTTR)
● Not required time
● Online time
● Report time
● Availability rate
● Checking rate
● Failure rate
● Reproducibility rate
● Calibrations executed within the selected time span
● Maintenance actions executed within the selected time span
The report can be displayed for a specific analyzer or for all analyzers. The report is limited
to maintenance actions executed within the selected time span.
7.7.3.5 ASM_AuditTrail
Subject: list of user-filtered operations within a user-definable time range. General activities
on ASM manager, shelter activities and analyzer-specific activities will be listed using data of
● Area
● Source
● Operation time
● Operation description
● Computer
● User
The report can be displayed for a specific analyzer or for all analyzers. The report always
includes the shelter and general information. The report is limited to audit trail data
conducted within the selected time span.
For more details refer to Section Audit trail (Page 165).
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7.7.3.6 ASM_PlannedActivities
Subject: list of planned maintenance activities filtered by a user-definable time range.
The report can be displayed for all analyzers. The report is not specific for a certain analyzer
or shelter.
7.7.3.7 ASM_ValidationDetails
Subject: Validation details that have been selected within the relevant time range as follows:
● Date/time
● Type of validation
● Reference material
● Gas bottle used (if applicable)
● Result of the validation (PASS/FAIL)
● Collected samples for the components
● Calculated results of methods for every component
● Component input data used for calculations
The report can be displayed for the validation of a specific analyzer. The validation needs to
be selected before.
7.7.3.8 ASM_ValidationHistory
Subject: list of validations with
● Start and end time
● Used validation procedure
● Result state generated within the selected time span
The report can be displayed for a specific analyzer or for all analyzers. The report is limited
to validations within the selected time span.
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7.8 Bottle management system
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8.1 General
This chapter describes the available system configuration for using the complete functional
range of ASM. This includes the complete configuration of sites, plants, shelters, analyzers
and their components.
8.1.1 Start-up
The tool can be started via the Windows Start Menu (Siemens -> ASM -> ASM Manager)
and by default also over the WinCC Runtime if the currently logged-in user has the
appropriated access right.
8.1.2 'About...'
A mouse right-click inside a free area of the ASM manager displays information about the
ASM Manager.
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Site -> Plant -> Shelter -> Stream -> Component -> Diagnostic Component
Site -> Plant -> Shelter -> Analyzer -> Stream -> Component
Site -> Plant -> Shelter -> Analyzer -> Stream -> Diagnostic Component
Site -> Plant -> Shelter -> Analyzer -> Validation Stream -> Component -> Value
Site -> Plant -> Shelter -> Analyzer -> Validation Stream -> Diagnostic Component
Site -> Plant -> Shelter -> Analyzer -> Calibration Stream -> Component
Site -> Plant -> Shelter -> Analyzer -> Validation Program
Site -> Plant -> Shelter -> Analyzer -> Calibration Program
8.2.2 Tabs
The ASM Manager screen provides different tabs that can be used to configure an ASM
system.
Of these 4 tabs only the 'Elements' tab can be used by an operator. The other three tabs are
accessible only for system administrators.
● Elements tab:
Use this tab to configure the present ASM system elements (e.g. analyzers, streams,
components…)
● Element types tab:
Use this tab to define default elements and properties, which can be used in an elements
tab to configure the present ASM system.
● Globals tab:
Use this tab to define global settings of the ASM system.
● Database Setup tab:
Use this tab to configure database settings of the present ASM system.
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NOTICE
System malfunction
Manual modification of settings could lead to malfunction of the system. To avoid this
• Only authorized personnel may use this function!
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NOTICE
System malfunction
Manual modification of settings could lead to malfunction of the system. To avoid this
• Only authorized personnel may use this function!
This tab is used to configure the basic settings, which are relevant for the ASM database
(ASMDB). These settings can only be modified by a user with windows administrator rights.
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NOTICE
System malfunction
Manual modification of settings, element type names or property names could lead to
malfunction of the system. To avoid this
• Only authorized personnel may use this function!
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● Properties
Property values are filled with default values when a new element was added.
Changing property options will update the value of all existing properties of this type if the
value was not updated before in the "Elements" tab. The user can configure the fields of
the typicals in ‘element types’ which are common in most of the cases.
● Archive Options:
– Trigger:
An action which leads to an update of a value.
– Value:
A value to be updated
– Cycle:
The time defined here serves as cycle time for archiving a value indicated by the value
parameter after a certain action indicated by the trigger type has been triggered
● Report Options:
These are the settings for a report layout.
● Advanced Options:
In this option there are certain settings for the each property.
– Enabling configuration (CONFIGURATION_ENABLE=1) lets an ASM operator set
values at the block input through ASM manager.
– The attribute DISPLAY_POSITION decides the ranking of properties in the property
grid.
– DROPDOWNLIST: This is the name of ‘Enum’ for a list of property values.
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Note
System malfunction
Manual modification of settings could lead to malfunction of the system. To avoid this
• Only authorized personnel may use this function
Changes of settings under the element tab can be performed by an operator. The
configuration tool allows the configuration of the analyzer settings as described in the
following sections. In the elements tab the actual configuration is done, based on the defined
element types. Not all properties, which are defined for element types are configurable.
The configuration tool consists of three parts within the standard view:
● a. Tree view
● b. Properties
● c. Property options (Archive, Report and Advanced Options)
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In the configuration interface (tree view) there are the following options - using right click on
one tree view element:
● Add:
Add new Element type (not recommend, shall be performed only by trained personal)
● Edit:
Change settings of selected element
● Delete:
Delete element and all child elements (not recommend, shall be performed only by
trained personal)
● Copy:
copy element structure in hierarchy (not recommend, shall be performed only by trained
personal)
● Cut:
cut element structure in hierarchy (not recommend, shall be performed only by trained
personal)
● Paste:
paste copied or cut element structure in hierarchy (not recommend, shall be performed
only by trained personal)
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Property options
This area shows further options of the properties. The area can be hidden by a checkbox.
● Each property item has a name, data type, value, unit of measurement (UOM) and
description.
● All editable property options are highlighted with white background.
● Note: Deleting an element will delete the complete structure with all child elements.
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A GC analyzer communicates with ASM via the MAXUM OPC server. If the ASM receives
values from MAXUM OPC server, the ASM must know the address of the hierarchy. Since
the ID saved in an OPC client is transmitted, its proper address info must be entered.
Addresses for separate element type must be different. The analyzer transmit ID is
'AddressInfo1' in the analyzer properties window, as it can be seen in the hierarchy of the
OPC client.
Similarly 'AddressInfo3' is for stream and 'AddressInfo4' is for component. Addresses for
separate element type must be different, e. g. referring to the previous example the
addresses would be as follows:
● AddressInfo1: 001 (Anlz001)
● AddressInfo2: 001 (App001)
● AddressInfo3: 001 (Strm001)
● AddressInfo4: 001 (Comp001)
Once the configuration is done with all correct address info, we have to run the ‘ASM Wizard’
(press start - wizard button). It will show the shelter, analyzer and components with the
correct tag instances, stream IDs, components IDs for which the tags and pictures are to be
created in the tag management.
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The following elements can be added to an analyzer of this type (according to the definition
of this type element):
● Stream
● Validation Stream
The AddressInfo of a validation stream starts with 020
A validation stream contains
– validation components,
– diagnostic components and
– diagnostic components for SSS.
● Calibration Stream
The AddressInfo of a calibration stream starts with 030
A validation stream contains
– Calibration values
● Validation Program
● Calibration Program
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Possible element types that can be added within stream are as shown in the previous
screenshot:
● Component
These are the main analyzer elements which are to be analyzed by the system.
● DeviationValidationSettings
These settings are necessary in case of a line sample validation since it receives
information such as process values. Within the process stream, we have to add ‘deviation
validation settings’. In line sample validation, some additional component settings for
components deviation have to be done as it can be seen in the following screenshot:
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● Deviation validation settings and ASTM validation settings are added for line sample
validation.
● A validation stream is added with two different component values i.e. span and zero,
since there are two separate validation values.
● Two separate bottles are added for zero and span.
● No calibration stream was added since it is not useful here.
● A validation program is added to run the validation when the command is triggered over
the validation screen.
● Since there are no features inside the calibration view to show the calibration values, the
validation view is used for that purpose.
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The following screenshot shows an example of the hierarchy of a CEMS analyzer element:
● Streams and components are added as shown in the screenshot. In this example there is
only one validation component used regardless of zero or span.
● Deviation validation settings and ASTM deviation settings are added for line sample
validation.
● A calibration stream is added but not used in this type of CEMS analyzer.
● Programs are added to start the validation and calibration procedures.
The CEMS structure tags must be imported. To find them search the tag management for
the right CEMS OPC server. Once the ASM configuration is finished you shall run the wizard
to create the tags for a CEMS analyzer. Tags are created according to the set structure.
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● Component PV triggered
Analyzers which do not continuously provide process values, but provide values after a
particular cycle time and/or in some cases to reduce the amount of data a PV trigger is
used to store the PV. For this purpose 'Component PV triggered' is used here.
● Diagnostic component for SSS
is also available for diagnostic values of a smart sampling system. Generally it includes
temperature, pressure or flow values. When the parameter name is written as
temperature, pressure or flow values, the system recognizes that it is an SSS and in case
of alarms it records the corresponding alarms like temperature alarm or warning instead
of diagnostic alarms.
● Diagnostic component
is also available if any other diagnostic values are available. In case of alarms, it
generates diagnostic alarms and diagnostic warnings instead of sampling alarms. If
temperature, pressure or flow signals are defined as diagnostic components and not the
SSS, It would generate diagnostic alarms only.
● A validation stream contains the validation components zero and span, where zero and
span values are checked respectively. Also the standard validation component is added
to check span values only.
● A calibration stream is also added for calibration values.
● Programs are added to start the validation and calibration procedures.
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System Configuration
8.2 System configuration using the ASM manager
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8.2 System configuration using the ASM manager
The properties and property options have to be configured according to the analyzer
component information.
Note
Depending on the analyzer type, it might become necessary to add and configure
validation/calibration levels with their components and also a validation program.
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System Configuration
8.2 System configuration using the ASM manager
Parameter Description
Calculate limits Control and warning limits will be calculated in a validation compo-
nents control chart
DeviationMonito- Activates/deactivates the rule
rungRuleXXEnabled
NumValControlLimitRuleXX Defines the validation number for ALARM
NumValWarningLimitRuleXX Defines the validation number for WARNING
MinimumValidationSample Defines the minimum number of samples needed for a validation
Maximum samples Maximum number of samples used for a calculation
NumLastValidationsRule8 Points out to the last x points outside the warning limit on the same
side of the aim
NumLastValidationsRule9 Points out to the last x points at the last half of the warning limit on
the same side of the aim
Level for stability test (ASTM) ASTM defined configuration
Minimum stability test sample ASTM defined configuration
(ASTM)
Minimum validation interval ASTM defined configuration
(ASTM)
Performace limit control ASTM defined configuration
(ASTM)
Reproducibility (ASTM) ASTM defined configuration
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8.2 System configuration using the ASM manager
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8.2 System configuration using the ASM manager
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System Configuration
8.3 Maintenance configuration
On the left side of the tab are displayed all activities which are effective for a certain
equipment. On the right site of the tab are displayed all defined activities except those, which
are effective for the equipment. The activity details, depending on the last selection, are
displayed in the bottom area.
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8.3 Maintenance configuration
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System Configuration
8.4 Reference gas bottle management
8.4.1 General
This function allows the configuration of the reference gas bottles and its components.
Access to this function is provided via the ASM graphical user interface (GUI). Only users
with the appropriated access right can handle the following functions:
● Add, modify or delete a gas bottle
● Assign gas bottles to an analyzer
● Remove gas bottles from an analyzer
● Save / export a gas bottle list on PC
● Print a gas bottle list as hardcopy
● Copy and paste gas bottles with included information (e.g. to add new bottles)
● Import reference gas bottles and assign them using the ASM importing tool
● Set gas bottles as active/not active via checkbox. If the checkbox is marked, the gas
bottle is active otherwise it is not.
Note: Since only one bottle can be active any previous bottle will be set automatically to
'inactive' as soon as a certain bottle is set to active.
The WinCC view ‘Reference bottles’ allows the configuration of the reference bottles and its
components as described in the following sections. The view can be opened via the toolbar
button.
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System Configuration
8.4 Reference gas bottle management
On the left side, the screen shows a tree view of the plant with all shelters and analyzers.
The purpose of this tree is to filter the reference bottles which are listed in the middle of the
view. The tree view is organized within a hierarchy as follows:
● Plant: All bottles from the entire plant will be shown in the bottle list.
● Shelter: The bottles which are assigned to the analyzers in the shelter will be shown.
● Analyzer: Only the bottles which are assigned to the analyzer will be shown.
● Stream: Only available for multi-stream analyzers. The bottles for the selected stream will
be displayed in this list.
In the middle part, the list of configured reference gas bottles is displayed. As mentioned
before the content of this list can be filtered by the selection of the tree view. The list displays
the bottles together with their certificate numbers and the expiration date of the bottle
certificates.
On the upper right side, the view shows detailed information about the selected bottle, like
bottle properties such as volume or weight, components and additional documents.
On the lower right side, bottles and certificates can be assigned to or removed from a bottle.
It is possible to assign multiple bottles to one analyzer or stream, but only one bottle can be
active. If the representative checkbox is marked, the bottle is active, otherwise it is not.
Note
Since only one bottle can be active, if one bottle will be assigned while another one is active
the latter will then become deactivated.
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System Configuration
8.4 Reference gas bottle management
Component information
The component information usually consist of the following attributes:
● Name of the component
● Value and uom (unit of measurement) of the component
● Variance of the component
● Additional description of the component
Bottle properties
● The Bottle properties usually consist of the following attributes:
● Certificate number
● Expiration date
● Name of the supplier
● Date when the bottle was validated last
● Date when the bottle was validated first
● Bottle pressure (value + uom)
● Bottle volume (value + uom)
● Bottle weight (value + uom)
● Number of days before the expiration day when a maintenance request will be
created (default: 31 days)
● Number of days before the expiration day when the created maintenance request will
generate a reminder warning (default: 14 days)
● Number of days before the expiration day when the created maintenance request will
generate a reminder alarm (default: 7 days)
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System Configuration
8.4 Reference gas bottle management
After entering the bottle name, the bottle can be specified using the 'Modify bottle details'
dialog.
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8.4 Reference gas bottle management
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8.4 Reference gas bottle management
Modifications will only be stored if the user closes the dialog by clicking the save button.
Note
Incorrect mapping
During validation the system maps the components of a validation stream to the components
of an assigned reference bottle. To find the correct mapping it is very important that the
names are identical. Otherwise the validation cannot be finished in regular time and a
timeout will occur.
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8.4 Reference gas bottle management
Note
Unacknowledged WinCC messages are displayed in a flashing text and are shown on the
very top of the WinCC runtime graphics. There is a button to acknowledge each message,
so that new messages can be easily detected.
Any WinCC alarm or warning message will remain until its cause has been eliminated. Any
acknowledged message will also be indicated within the WinCC picture tree (navigation
area).
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8.5 Diagnostic components
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8.5 Diagnostic components
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System Configuration
8.6 Process capability
● Result
The result configuration is essential for the determination of the repective effect in a case
of violation.
Result Effect
Not applicable always success
Info information
Event event and a maintenance request will be created which must be docu-
mented
Warning warning and WinCC message (also maintenance request) will be created
Alarm alarm and WinCC message (also maintenance request) will be created
● Active
This rule will be ignored if it is not active.
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8.6 Process capability
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8.6 Process capability
Further settings:
● Upper and lower control limit:
These entries require absolute values which can be used as additional limits in the
validation control chart.
● Upper and lower warning limit:
These entries require absolute values. If a validation component value exceeds one of
the limits a warning message will occur.
The proper settings in the validation view control chart are:
● Dev. absolute
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8.6 Process capability
Further settings:
● Upper and lower control limit:
These entries require absolute values which can be used as additional limits in validation
control chart.
● Upper and lower warning limit:
These entries require absolute values. If a validation component value exceeds one of
the limits a warning message will occur.
The proper settings in the validation view control chart are:
● Dev. relative to ref.:
The generated plot shows validation component values in terms of percentage of the
reference value.
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8.6 Process capability
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8.6 Process capability
Further settings:
● Upper and lower control limit:
These entries require absolute values which can be used as additional limits in the
validation control chart.
● Upper and lower warning limit:
These entries require absolute values. If a validation component value exceeds one of
the limits a warning message will occur.
The proper settings in the validation view control chart are:
● Dev. relative to span:
The generated plot shows validation component values in terms of percentage of the
configured span.
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8.6 Process capability
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Modes and action states 9
9.1 Analyzer modes
The analyzer modes indicate the current action of an analyzer.
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Modes and action states
9.1 Analyzer modes
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Modes and action states
9.2 Analyzer house modes
The analyzer house mode is based on the status of the analyzer house and the received
messages.
If an analyzer house is disconnected, no messages will be received or other states will be
analyzed. In the state “Failure” or “Maintenance” no messages are analyzed.
Good / Breakdown (Offline) mode is set if previous modes or messages are not active.
The mode "Warning" is triggered by one of the following messages:
● A user-defined warning of an analyzer application
● Diagnostic violation
The mode "Breakdown" is triggered by one of the following messages:
● A user-defined alarm of an analyzer application
● Diagnostic violation
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Modes and action states
9.3 Maintenance action states
The analyzer action is based on maintenance inputs and messages. The action states
“DueSoon” and “Overdue” are based on messages.
The mode "DueSoon" is triggered by one of the following messages (warnings):
● Scheduled validation requested
● Scheduled calibration requested
● Maintenance requested by asm
● Permission request timeout
● Permission request denied
● Analyzer maintenance requested
The mode "Overdue" is triggered by one of the following messages (alarms):
● Scheduled validation timed out
● Scheduled calibration timed out
● Maintenance required by asm
● Reference bottles expired
● Analyzer Maintenance required
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Modes and action states
9.4 Validation states and results
For the last validation result the following states are possible:
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Modes and action states
9.5 Quality Codes
Quality codes 0xA4 and 0xA8 are set to "OK" by the WinCC OPC Server.
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Modes and action states
9.5 Quality Codes
Quality code 0x40 is set to "Reason could be: Initial/simulated value or maintenance
demanded" by the WinCC OPC Server.
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Modes and action states
9.5 Quality Codes
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Alarm list 10
The following table contains an overview of analyzer house related alarms and warnings. For
each alarm there is an information if this alarm has an effect on mode or action and if a
maintenance request is generated. Priority fields range from "1 - very low" to "15 - very high".
The following table contains an overview of analyzer related alarms and warnings. For each
alarm there is an information if this alarm has an effect on mode or action and if a
maintenance request is generated. Priority fields range from "1 - very low" to "15 - very high".
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Alarm list
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Service and maintenance 11
11.1 Service and support
Training center
Siemens offers corresponding courses for newcomers to laser spectroscopy. Please contact
the central Training Center in Karlsruhe.
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Service and maintenance
11.1 Service and support
Technical support
● You can reach the "Technical Support" for all SC products using:
– the Web form for "Support Request" Internet (http://www.sitrain.siemens.com) .
– Phone: +49 (0)180 5050 222
(€ 0.14 /min. from the German landline network, max. € 0.42 /min. from German
mobile communication networks)
– Fax: +49 (0)180 5050 223
(€ 0.14 /min. from the German landline network, deviating mobile communications
prices are possible)
● You can find the latest information concerning your device on the Internet at our
homepage (http://www.siemens.com/processanalytics).
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ASM calculations A
This chapter describes the formulas for the implemented validation evaluation methods
ASTM D3764 and Deviation monitoring as well as for the KPI calculations.
in which
● Xr represents the sample value
and
● Nr represents the number of samples.
A.1.2 Variance
The variance is a way to capture the degree of being spread out for a certain distribution. It
averages the squared deviation of a random variable from the expected value (mean).
The variance of a number of samples is calculated using the following formula:
in which
● represents the average of the samples
● represents the sample value
● represents the number of samples.
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ASM calculations
A.2 Calculations for deviation validation procedures
in which
● S represents the variance of the samples.
Method Formula
Get maximum samples Max Samples = <Maximum samples>
Deviation relative to span = ( (value - refvalue)/span) * 100 % (with span = max range – min range)
Deviation monitoring rule 0 num_validations_out = sequenced point(s) outside the spec limit
numpoints4warning = <NumValWarningLimitRule0>
numpoints4error =<NumValControlLimitRule0>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL’
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Method Formula
Deviation monitoring rule 1 num_validations_out = sequenced point(s) outside the control limit
numpoints4warning = <NumValWarningLimitRule1>
numpoints4error =<NumValControlLimitRule1>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL’
Deviation monitoring rule 2 num_validations_out = sequenced point(s) between the warning and the control
limit on the same side of the aim
numpoints4warning = <NumValWarningLimitRule2>
numpoints4error =<NumValControlLimitRule2>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 3 num_validations_out = sequenced point(s) between the warning and the control
limit on different sides of the aim
numpoints4warning = <NumValWarningLimitRule3>
numpoints4error =<NumValControlLimitRule3>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 4 num_validations_out = sequenced point(s) between the aim and warning limit
on the same side of the aim
numpoints4warning = <NumValWarningLimitRule4>
numpoints4error = <NumValControlLimitRule4>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 5 num_validations_out = sequenced point(s) on the same side of the aim line
numpoints4warning = <NumValWarningLimitRule5>
numpoints4error = <NumValControlLimitRule5>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
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A.2 Calculations for deviation validation procedures
Method Formula
Deviation monitoring rule 6 num_validations_out = sequenced point(s) at least the size of the warning
limit on the same side of the aim
numpoints4warning = <NumValWarningLimitRule6>
numpoints4error =<NumValControlLimitRule6>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 7 num_validations_out = sequenced point(s) at least half the warning limit on
the same side of the aim
numpoints4warning = <NumValWarningLimitRule7>
numpoints4error =<NumValControlLimitRule7>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 8 limit on the same side
num_validations_out = points out of the last Z points outside the warning
of the aim
numpoints4warning = <NumValWarningLimitRule8>
numpoints4error = <NumValControlLimitRule8>
numlastvalidations = <NumLastValidationsRule8>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
state = 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 9 num_validations_out = points out of the last Z points at least half the
warning limit on the same side of the aim
numpoints4warning = <NumValWarningLimitRule9>
numpoints4error =<NumValControlLimitRule9>
numlastvalidations = <NumLastValidationsRule9>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
state = 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL'
Deviation monitoring rule 10 num_validations_out = sequenced points increasing
numpoints4warning = <NumValWarningLimitRule10>
If numpoints4warning = 0 → No warning
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
Deviation monitoring rule 11 numpoints4warning ==<NumValWarningLimitRule11>
num_validations_out sequenced points decreasing
If numpoints4warning = 0 → No warning
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else num_last_samples = num_validations (used for the current validation)
state = 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
Deviation monitoring rule 12 num_validations_out = sequenced points alternating up and down
numpoints4warning = <NumValWarningLimitRule12>
If numpoints4warning = 0 → No warning
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error | numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
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A.3 Calculations for ASTM validation procedures
Method Formula
Deviation from Spec num_validations_out = sequenced point(s) outside the spec limit
numpoints4warning = <NumValWarningLimitRule0>
numpoints4error = <NumValControlLimitRule0>
If numpoints4warning = 0 → No warning
If numpoints4error = 0 → No error
If (Calculate limits = 0
and (numpoints4error > 0 or numpoints4warning > 0))
num_last_samples = numpoints4error / numpoints4warning
else
num_last_samples = num_validations (used for the current validation) state
= 'SUCC'
if (num_validations_out >= numpoints4warning)
state = 'WARN'
if (num_validations_out >= numpoints4error)
state = 'FAIL’
CpK dev_avg = avg(predictedvalue - [value])
StandardDeviation = stdev(predictedvalue - [value])
osg = <Upper specification limit>
usg = <Lower specification limit>
cpu = (osg - dev_avg) / (3 * StandardDeviation)
cpl = (dev_avg - usg) / (3 * StandardDeviation)
if (cpu < cpl)
CpK = cpu
else
CpK = cpl
note: if standard deviation is 0 the CpK is set to 10
Method Formula
Get maximum samples Max Samples = <Maximum samples>
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A.3 Calculations for ASTM validation procedures
Method Formula
Dixon outlier test N outliers under test
For N = X1 Xn
3 to 7
3 to 10
11 to 13
14 to 30
Compare the resulting r value with the corresponding r value of the following
table
The sample value is rejected, if the calculated r is greater than the r found
in the table.
If a sample value has been rejected, repeat the calculation and test for the
new first and last value in the ordered list.
F test Calculate the larger variance (Sa2 or Sr2) = L
and the smaller variance (Sa2 or Sr2) = M
Calculate the F value with F = L/M
Use a 95 % probability F-Distribution table to determine the limiting
F value (Flim)
If F <= Flim → the variances are essentially the same.
If F > Flim → the variances are significantly different.
Site Precision res_value = s * 2.77 with s = standard deviation of analyzer values
if num samples < 1
set validation state = ‘FAIL’
else
set validation state = ‘SUCC’
Systematic Error (BIAS) res_value = sum (analyzer samples – ref. samples) / num samples
if num samples < 1
set validation state = ‘FAIL’
else
set validation state = ‘SUCC’
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A.3 Calculations for ASTM validation procedures
Method Formula
Student T test The procedure depends on the relation between the variance of the reference
samples and the variance of the analyzer samples (outcome of the previously
conducted F test).
Both procedures:
Determine the critical t value from a table of t at a 5 % probability level
using (Na + Nr − 2) degrees of freedom
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A.3 Calculations for ASTM validation procedures
Method Formula
Student T test (continued) Results:
Procedure A: variances are essentially the same
t <= tcrit (case A of ASTM 3764)
→ The analyzer can be considered satisfactory and validated (PASS).
t > tcrit (case B of ASTM 3764)
→ FAIL (issue a warning message)
Procedure B: variances are significantly different
t <= tcrit (case C of ASTM 3764)
If analyzer variance is lower than sample variance
→ the analyzer can be considered satisfactory and validated (PASS).
If analyzer variance is higher than sample variance
→ FAIL (issue a warning message)
t > tcrit (case D of ASTM 3764)
If analyzer variance is lower than sample variance
→ FAIL (issue a warning message)
If analyzer variance is higher than sample variance
→ FAIL (issue an alarm message)
Chi square test The chi-square (x2) test is used to compare the estimated site precision of
the analyzer with the configured published reproducibility value of the meth-
od.
Input
R’ = estimated site precision
n = number of samples
Parameter
R = reproducibility of the method (preconfigured value)
Procedure:
1. Calculate the x2-value:
Results:
x2 > x2crit → site precision of the analyzer exceeds the configured reproduci-
bility of the test method with 95 % confidence (PASS) x2 <= x2crit → site preci-
sion is either less than or statistically indistinguishable from the
published reproducibility of the test method (FAIL)
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ASM calculations
A.4 KPI calculations
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A.5 Validation limit conversions
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Appendix B B
B.1 Audit trail
The audit trail system creates messages due to changes within the ASM system. These
messages can be displayed within the operation list of the alarm logging system included in
the GUI.
The audit trail messages will only be generated if the property ‘AuditTrail’ on the ‘ASM Site’
level is set to “enabled” (configured in the ASM Manager Configuration tool).
The following listing shows the different audit trail messages which will be created due to
changes of the corresponding objects:
● Documents (included in maintenance, diagnostic and reference bottle views)
– adding a document
– changing a document
– deleting a document
– opening an explorer window
● Process view
– switching to required
– switching to not required
– starting the analyzer software
– starting external software
● Validation view
– changing of control/warning limits
– changing of stream bottle
– starting a validation
– enabling/disabling the validation scheduler
● Calibration view
– starting a calibration
– enabling/disabling the calibration scheduler
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Appendix B
B.1 Audit trail
● Maintenance view
– deleting a completed maintenance request
– modifying a completed maintenance request (one for each change)
– starting a request
– finishing a request
– documenting a request
– using a historical request
– changing the maintenance activity
– assigning to a maintenance activity
– removing the assignment of a maintenance activity
– deleting a maintenance activity
– scheduling the change of a maintenance activity
● Diagnostic view
– changing a limit setting
– changing a rule setting
– deleting a limit setting
– deleting a rule setting
● Reference bottle view
– adding a bottle
– changing a bottle
– deleting a bottle
– adding a bottle certificate
– changing the certificate number
– changing the expire date
– changing the "Soon will expire reminder"
– changing the "Maintenance requested reminder"
– changing the "Maintenance required reminder"
– changing a component value
– changing a component name
– deleting a component
– assigning an analyzer
– removing an analyzer assignment
– changing an 'Activate bottle certificate'
– changing an active bottle
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List of abbreviations C
C.1 List of abbreviations
Abbreviation/Symbol Description
AR Availability Rate
ASM Analyzer System Manager
ASTM American Society Of The International Association For Testing And Materials
Avg (Arithmetic) average
CEMS Continuous Emission Monitoring System
CGA Continuous Gas Analysis,
Continuous Gas Analyzer
CpK Capability Index
CR Checking Rate
CSV Comma-separated values
DAU Data Acquisition Unit
DB Data base
DCS Distributed Control System
dec, DEC Decimal (number system)
DLL Dynamic Link Library
e. g. for instance (from latin: exempli gratia)
ERP Enterprise Resource Planning (System)
FR Failure Rate
GC Gas Chromatograph
GUI Graphical User Interface
hex, HEX Hexadecimal (number system)
ID Identificator
i. e. this means (from latin: id est)
IEPB link a link between Industrial Ethernet and PROFIBUS
I/O Input/Output
IP Internet Protocol
KPI Key Performance Indicator
LAN Local Area Network
LIMS Laboratory Information Management System
MES Manufacturing Execution System
MTBF Mean Time Between Failure
MTTR Mean Time To Repair
OPC Object Linking And Embedding For Process Control
OPC DA Object Linking And Embedding For Process Control Data Access
OR Online Rate
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List of abbreviations
C.1 List of abbreviations
Abbreviation/Symbol Description
OS Operating System
PC Personal Computer
PCS7 a Process Control System from Siemens
PDF Portable Document Format
PLC Programmable Logic Controller
PPM Predictive (and/or) Preventive Maintenance
Ref. value Reference value
RR Reproduction Rate
SCADA Supervisory Control And Data Acquisition
SIG Signal
SIMATIC Siemens product group for Automation technology
Spec. limit Specification limit
SQL Structured Query Language
SSS Sample Stream System
Stdev Standard deviation
TCP Transmission Control Protocol
TCT (Total) Checking time and rate
TFT (Total) Failure time
TNRT (Total) Not Required time
TOT (Total) Online time
TRT (Total) Report time
UOM, uom Unit Of Measurement
UPS Uninterruptible Power Supply
WinCC Windows Control Center, a scada and human-machine interface from Siemens
XML Extensible Markup Language
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Index
A F
Access authorization, 17 Features, 12
Action states, 145 Functions
Alarm list, 149 Alarm logging system, 90
Alarm list screen, 44 Analyzer calibration, 67
Alarm logging system, 90 Analyzer validation, 52
Analyzer calibration, 67 Audit trail, 165
Analyzer house mimic panel screen, 33 Diagnostics, 70
Analyzer house screen, 30 Maintenance functions, 71
Analyzer interface, 21 Monitoring functions, 50
Analyzer sample system screen, 32
Analyzer states, 145
Analyzer validation, 52 G
ASM
Gas bottle management, 125
shutdown, 50
Grahical user interface
Start-up, 47
Analyzer sample system screen, 32
ASM Client, 13
Graphical user interface, 25
ASM Engineering station, 13
Alarm list screen, 44
ASM Network, 13
Analyzer house mimic panel screen, 33
Analyzer interface, 21
Analyzer house screen, 30
ASM Server, 13
Calibration view, 38
Internal structure, 14
Diagnostics view, 39
Audit trail, 165
Maintenance view, 41
Overview screen, 29
Process view, 33
C
Reference bottle screen, 45
Calculations, 153 Report view, 43
Calibration view, 38 screen hierarchy, 28
Configuration Screen layout, 26
Access authorizations, 17 Validation view, 35
Diagnostic components, 132
System configuration, 91
Contact partner, 151 M
Maintenance functions, 71
Maintenance view, 41
D
Monitoring functions, 50
Data acquisition unit, 13
Description, 12
Diagnostic components, 132 N
Diagnostics, 70
Navigation area, 26
Diagnostics view, 39
O
Overview screen, 29
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Index
P W
Process view, 33 Work area, 26
Product information on the Internet, 151 Screen hierarchy, 28
Q
Quality codes, 146
R
Reference bottle screen, 45
Reference gas bottle management, 125
Report view, 43
S
Screen hierarchy, 28
Screen layout, 26
Navigation area, 26
Toolbar area, 26
Work area, 26
Shutdown, 50
Start-up, 47
System configuration, 91
System layout, 13
System shutdown, 50
System start-up, 47
T
Technical support, 152
Toolbar area, 26
Training center, 151
U
User
access rights, 18
roles, 17
User interface, 25
V
Validation view, 35
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