GasWorks Process Analysis Software

Transcription

1 GasWorks Process Analysis Software The Thermo Scientific GasWorks software suite provides an intuitive, information-rich and flexible window into the operation of our process gas analyzers. Produced in a certified ISO 9001 environment, GasWorks software is designed for rapid installation and to facilitate ongoing operation while providing a secure, stable platform for process analytics. Product Specifications Features and Benefits Supports stand-alone analyzer operation Sets no limits to the number of sample streams or analytical methods Includes a rigorous mathematical engine to deconvolute complex mixtures Remote software upgrades by modem Multi-layered security with expiring passwords and audit trail Industry best diagnostics and equipment support package Supports the integration of third-party analytical equipment Thermo Scientific GasWorks software has been designed to ensure that the process analyzer is simple to configure, operate and maintain without the need for specialist mass spectrometry knowledge. The suite includes a wide range of functions and features, allowing it to be matched exactly to the needs of the user. Whether the requirement is for simple alarm indication in the event of a manufacturing process failure, or for complex data presentation for process understanding and control, GasWorks is well equipped to offer an effective solution. Regular updates ensure that the software takes advantage of the latest technology as it becomes available. GasWorks Applications Multi-point, multi-component process gas analysis Environmental air monitoring General purpose laboratory gas analysis Process research and development Gravimetric gas analysis Ultra-pure gas validation Residual gas analysis

2 Analysis Configuration Analysis Configuration Mass spectrometer analysis configuration is completed using a single form. The operator starts at the left most tab and works to the right. New sample streams are added using the Streams tab. This allows the sample stream to be named and its connection port to be defined. Stream settling times can be set on a per-stream basis. For difficult applications where memory effects are possible, a settling time management routine can be defined. The next step is to select the Analysis tab where any number of analysis recipes can be named and defined. The gases are selected from an appropriate subset of the global library by simply picking them from the application gas list and copying them across to the selected gas list. Once the list is complete, the operator selects the Advanced form which presents the fragmentation matrix in such a way as to make peak selection a point-and-click procedure. The individual spectrum for each gas is loaded from the library, without limit to the number of peaks, and the selected masses are checked, column-bycolumn. If the expected maximum and minimum gas concentrations are edited, the software will warn the operator in the event that the defined analysis is beyond the capability of the system due to the degree of overlap or the expected signal/noise ratio at the selected mass. The operator is also provided with a degree of control over the speed and precision for each of the defined analysis methods. Sample Stream Configuration Analysis Configuration Advanced Matrix Configuration Method Configuration Analytical Schedule Configuration Method Development and Scheduling The next step in defining the analytics is to use the Derived Value form (not shown) in order to specify any mathematical relationships that might be required. Examples of commonly used online calculations include Respiratory Quotient, Calorific Value and Carbon Balance. Once these have been defined, they become available on the Method tab. This is where the method recipes are named and assembled using the list of previously defined analyses, derived values and device readings. Each method can be set to run for a fixed number of measurement cycles or it can be given a predetermined duration. The Alarm Editor can be used to define alarm set points and trigger conditions for measured values of any of the analytes in the method recipe. Each of these individual alarms can be associated with 1 of 10 configurable alarm responses. More can be added if necessary. Once all the required methods have been defined, the next step is to organize the analytical procedures using the Schedule tab. Each entry is assembled by selecting the Stream, Sequence and Method from the available lists. If a required sequence isn t available in the default list, the Sequences editor (not shown) can be used to define custom sequence intervals such as every third cycle, every 4 minutes or every Monday morning at 8:00 a.m. The final step is to define any reports that might be required before uploading the new schedule to the mass spectrometer using the Synchronize button.

3 System Wizard Online Electronic Manual System Wizard Most Thermo Scientific process analyzers that employ GasWorks also come equipped with a System Wizard that is specifically configured to fully document the analyzer hardware. The main body of this electronic manual provides command buttons that allow the operator to drill down to a component of interest and then to interrogate a series of views on the selected subassembly. The view options typically include an Overview accompanied by a brief explanation of the selected item, one or more Tutorial views that provide a more in-depth explanation of the underlying principles, and a Parts Manual that identifies the parts along with their part numbers. Additional views might include Animations to augment the tutorials, Wiring Diagrams, and individual PDF documents that detail Test Specifications or Maintenance Procedures. A navigator panel indicates the location of the selected component and will illustrate multiple layers when the software is viewed in a wide-screen format. The Wizard also includes a Maintenance Log for storing engineering reports which can be quickly located using a color-coded calendar interface. Wizard Builder The Wizard Builder is the tool that is used to define the operation and scope of the System Wizard. It does this by identifying all the individual drawings, photographs, rich text files and documents that make up the completed System Wizard. The builder determines where command buttons are placed on the screen, how they are labeled and what forms are loaded when they are clicked. The builder is also used to define what headings appear in the Views menu for each form and which forms are loaded when the menu item is selected. The builder has an intuitive editor that follows the style of the other GasWorks edit forms, allowing the operator to easily edit the flow and function of the manual. This design permits individual users to extend the range of the software to cover any ancillary equipment that might be added locally. Examples might include sample conditioning systems, sensors, logic devices or communication equipment. Online Tutorial and Parts Manual

4 Data Presentation Numerical Data View by Stream System Status Monitor Message Log Data Presentation When the analyzer is working through one of its many possible activities, GasWorks is available to present the data in a variety of formats. The numeric screen is available to present scrollable columns of data for each of the selected sample streams. The operator can also configure an unlimited number of trend forms, each of which supports multiple Y axes having log or linear scales, and can color code each to match the individual trace it represents. The time axis can be changed on-the-fly to represent days, hours, minutes or seconds, and a cursor can be dragged to a point of interest in order to get a numeric reading for each trace. Support for multiple trend displays is particularly important when the analyzer is monitoring a number of independent processes such as mini-reactors or fermentors. These are commonly used for process development in a variety of industries. In order to simplify the process of configuring multiple trend displays, a Trace Wizard is provided that takes the operator step-by-step through the process of defining the parameters to be tracked. Each trend display definition is saved and becomes available from a pick-list for subsequent use. The Wizard presents all the current active sample streams and all the available raw peak intensities, calculated concentrations, derived values, device readings and analog inputs for selection. The operator is given a choice of color-code for each trace and can select from auto-scale or manual. The virtual desktop can be used to display many concurrent forms. Trend Wizard

5 Numerical Spreadsheet Histogram Scan Trend Display Start Schedule Start Calibrate Start Single Stream Analysis Start Multiple Ion Monitoring Start Histogram Scan Start Analog Scan Start Leak Detect Activity Modes In addition to performing complex gas analysis, the analyzer can be set to provide Analog or Histogram Scans. The analog scan is used to verify the performance of the instrument since it illustrates peak shape, mass alignment and sensitivity. The histogram scan is used to diagnose the composition of a selected sample stream. In both cases, the mass range and dynamic range can be adjusted. In the case of the histogram, a pre-recorded background scan can be subtracted and the resulting spectra can be used in a library search for the identification of the various components in the mixture. The histogram configuration can be named and saved so that it can be included in the analytical schedule. Additional activities include a comprehensive Multiple Ion Monitoring mode that is based on selected ions rather than selected gases. There is also a Leak Detect mode that can be used to help localize a vacuum leak. The Control Center is used to manually set temperatures and tuning parameters. Tools are included that plot the amplifier outputs as a selected lens voltage is scanned. The user is then able to drag a cursor to the optimum tuning point on the graph in order to set the value for each lens in turn. Dual detector calibration can also be controlled from within the control center.

6 Utilities Data Review The GasWorks suite includes extensive data review tools that provide various ways of presenting and labeling process data. The data is easily located and rapidly loaded either in its entirety or by use of a configurable filter. The trend review form is augmented with a statistical report generator that can work with selected segments of data. The annotation tool allows multiple copies of an edit field to be dragged into place in order to add comments to significant events. A Microsoft Access TM database search engine is also included. Stored Data File Structure Stored Data File Detail Stored Data Presentation Instrument Log Book GasWorks includes an Instrument Log that can be used to record the instrument hardware configuration details, service history, and fault records. The information is stored in a searchable database format. GasWorks Zip This utility is provided to assist the manufacturer when the operator requests technical support. The program automatically gathers useful information about the system from configuration files, status locations and calibration reports. The collected data are compiled into a compressed ZIP file that can be ed to the help desk where the customer s exact setup can be recreated. This compilation is completed with a single click. GasWorks Install Report The installation report utility performs a comprehensive check of all the configuration files used by the software suite and produces a validation report once the tests are complete. The program checks for version incompatibilities and for missing or damaged files. GasWorks Security This program is used by the system administrator to first define a number of different user groups. Each group can then be provided with a configurable set of access permissions. Finally, individual users are identified with an appropriate group and allocated a user name and password. The administrator is given the option of limiting the number of password retries, assigning an expiration date for passwords, enabling an audit trail and setting automatic log out. GasWorks Doctor GasWorks Doctor This is a powerful troubleshooting tool that is launched by a Diagnose command button on the Instrument Status Panel. The graphical display charts the progress of the automatic tests and pauses for user input when necessary. Once the root cause of the problem has been located, the display indicates where the problem lies, using video clips, photographs or drawings. The text area describes the necessary procedures for clearing the fault. The flowcharts can be modified locally in the event that the factory configuration is changed or if the scope of the test needs to be extended to include customer supplied ancillary equipment.

7 Calibration Configuration Calibration configuration is very similar to analysis configuration in that it can be completed using a single form. The operation is again completed by working from left to right using the tabs located at the top of the form. The first tab is labeled Cal Mixtures. This tab is used to name all the cylinders that will be connected to the analyzer and to edit the gas concentrations for each one. When a new cylinder is added, the gases are selected from the application gas list. One of these can be defined as the balance gas. The concentration of the balance gas is calculated automatically as the other constituent concentrations are edited by the operator. Once all the calibration mixtures have been configured to match the details on the certificate of analysis, the Cal Method can be selected. This reveals a sub-form with a second series of tabs. Each of these includes a check box. These are used to control the progression of the procedure each time a calibration is requested (either manually or by the calibration schedule). The first tab provides for the designation of a Pre-Check mixture. Any of the constituents can be assigned a tolerance that will be used to check the accuracy of the measurements of the gas blend. If the reported concentrations fall within the error bounds defined by the tolerance, then a pre-check pass condition will be reported and the analyzer will return to its previous task, without completing the full procedure. If, on the other hand, any of the reported concentrations fall outside the specified range, the calibration will proceed to make the selected measurements. The primary purpose of the calibration procedure is to modify the gas specification as defined in the gas database. In order to do this, the calibration procedure will direct the measurement of the peak ratios (the fragmentation pattern) and the relative sensitivities for each gas. When highly dynamic processes are being monitored, the calibration scheme can also generate linearity curves, although these are not typically found to be necessary. The Gases form allows the operator to pick each gas from an appropriate cylinder and to specify which of these three measurements will be made for that selected gas. In this way, a procedure can be defined that will modify all the relevant default gas database entries. The calibrated database is used by both the scheduled analysis and by the library search routines, which are available when using the Histogram Scan function. Communication Port Configuration Modbus Register Map Calibration Cylinder Configuration Calibration Background Configuration Calibration Method Configuration Data Communication The next step in configuring the analyzer is to define the channels and protocols that will be used to communicate the analysis data to the DCS, SCADA system or computer host. Individual analyzer serial ports can be independently matched to an individual recipient. The baud rate and format are easily defined. The protocol and style are selected from the drop-down list provided on the Serial I/O tab of the hardware configuration form. In a typical installation, two or three ports might be required to provide redundant communication through a high-level gateway, and additional serial communications might be required to connect to analog and digital modules for hard-wired control purposes. Each measurement, alarm event or component status can be assigned to an individual module using the Analog/Digital and I/O Assignment tabs. The Modbus register map is first built with the assistance of the Modbus Register Mapping Wizard, which requires the operator to simply respond to a series of questions regarding the data to be communicated and the address area to be reserved. Once this very brief procedure has been completed, the register map is presented in an easily edited table of values. This tool is provided to permit intuitive editing of the register map in case the analytical requirements change. The same tools can also be used to configure an embedded OPC Server for two-way communication using the latest technology. DDE and Net DDE protocols are also available for the distribution of analyzer data around the local area network. Data can also be posted in the form of HTML files for publication on a company Intranet. Calibration Data Communtication

8 Specifications GasWorks General Specifications Supported Operating Systems Supported Analytical Methods Supported Ion Sources Supported Detectors Supported Mass Spectral Libraries Display Precision Directly Supported Protocols Maximum Number of Components Maximum Number of Peaks per Component Maximum Number of Derived Values Maximum Number of Methods Maximum Number of Sequences Maximum Number of Analog Inputs & Outputs Maximum Number of Digital Inputs & Outputs Maximum Number of Trend Windows Maximum Number of Sample Streams Maximum Number of Alarm Points Microsoft Windows TM 95, 98, 2000, NT 4.0 SP4, XP Magnetic Sector and Quadrupole Mass Spectrometers Electron Ionization and Atmospheric Pressure Ionization Faraday only, Faraday/Faraday, Faraday/S.E.M. N.I.S.T. Configurable, defaults to three decimal places Modbus (RTU or ASCII, Master or Slave) Siemens 3964, VGCP, PVGCP, DDE, OPC Siemens 3964R Technology A process analyzer equipped with Thermo Scientific GasWorks software consists of an embedded processor that includes a serial link to a host PC. The host is used to configure the analyzer and may also be used for system interrogation, data presentation and archiving. When the analyzer is connected to a Distributed Control System (DCS) or Sequential Control And Data Acquisition (SCADA) system, the analyzer may be disconnected from the host PC for true stand-alone operation. The main embedded processor is a StrongArm 32-bit unit which runs a deterministic, hard real-time operating system with multi-tasking, multi-threaded operation and continuous self-monitoring. Component subsystems are independently managed by 16-bit processors optimized for reliability and consistency. The workstation component of GasWorks is a multi-threaded, fully event-driven, 32-bit application benefitting from 40 man-years of professional, in-house development. From conceptual design to version-controlled production of upgrades, quality control has been implemented via certified ISO 9001 TickIT procedures. The software accommodates FDA 21 CFR Part 11 requirements for electronic data storage and the Modbus connection is certified by Honeywell for compliance with their Multi-Vendor Interface Protocol (MVIP). System Requirements At a minumim, the host PC should include a Pentium III or Celeron 600 MHz processor with 128 MB RAM. However, it is important that the PC provided for GasWorks is sufficiently well-equipped to run the selected Windows environment. The PC should include a 17-in SVGA or XGA monitor, a CD drive, one serial port (high speed 16C550 preferred), a keyboard and a pointing device. 300 MB of disk space is required for a complete installation and 5 MB per day is typically required if the PC will be used for archiving data Thermo Fisher Scientific Inc. All rights reserved. Microsoft and Windows are registered trademarks and Access is a trademark of Microsoft Corporation in the United States and/or other countries. Pentium and Celeron are registered trademarks of Intel Corporation or its subsidiaries in the United States and other countries. All other trademarks are the property of Thermo Fisher Scientific Inc. and its subsidiaries. Results may vary under different operating conditions. Specifications, terms and pricing are subject to change. Not all products are available in all countries. Please consult your local sales representatives for details. Literature Code PI Room Ping an Mansion No. 23 Jinrong Street Xicheng Dist, Beijing CHINA A-101, ICC Trade Tower, Senapati Bapat Road Pune Maharashtra, INDIA Ion Path, Road Three, Winsford Cheshire CW7 3GA UNITED KINGDOM 1410 Gillingham Lane Sugar Land, TX USA +86 (10) (10) fax Process Instruments +91 (20) (20) fax +44 (0) (0) fax +1 (800) (713) (713) fax