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Introduction 1

Safety notes 2

Description 3
Analyzer System Manager
Access authorization 4
Software Solutions
System Manual 5
Interfaces

Graphical User Interface 6


System Manual

Functions 7

System Configuration 8

Modes and action states 9

Alarm list 10

Service and maintenance 11

ASM calculations A

Appendix B B

List of abbreviations C

09/2018
A5E45502866-01
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.

Siemens AG Document order number: A5E45502866 Copyright © Siemens AG 2018.


Division Process Industries and Drives Ⓟ 12/2018 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents

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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6.3.5 Analyzer views ....................................................................................................................... 33


6.3.5.1 Process view .......................................................................................................................... 33
6.3.5.2 Validation view (analyzers only)............................................................................................. 35
6.3.5.3 Calibration view (analyzers only) ........................................................................................... 38
6.3.5.4 Diagnostics view .................................................................................................................... 39
6.3.5.5 Maintenance view .................................................................................................................. 41
6.3.5.6 Report view ............................................................................................................................ 43
6.3.6 Alarm list screen..................................................................................................................... 44
6.3.7 Reference bottle screen ......................................................................................................... 45
7 Functions .............................................................................................................................................. 47
7.1 ASM system start-up and shutdown ...................................................................................... 47
7.1.1 General .................................................................................................................................. 47
7.1.2 System start-up procedure ..................................................................................................... 47
7.1.2.1 Automatic system start-up ..................................................................................................... 47
7.1.2.2 Configuration of automatic logon ........................................................................................... 48
7.1.2.3 Configuration of automatic start-up ........................................................................................ 48
7.1.2.4 Configuration of WinCC start-up list....................................................................................... 49
7.1.3 Manual system shutdown ...................................................................................................... 50
7.1.4 Automatic system shutdown .................................................................................................. 50
7.2 Monitoring functions ............................................................................................................... 50
7.2.1 Process data .......................................................................................................................... 50
7.2.2 Validation data ....................................................................................................................... 50
7.2.3 Calibration data ...................................................................................................................... 51
7.2.4 Diagnostics data..................................................................................................................... 51
7.2.5 Maintenance data .................................................................................................................. 51
7.2.6 Alarms .................................................................................................................................... 51
7.2.7 Equipment modes and actions............................................................................................... 51
7.3 Analyzer validation ................................................................................................................. 52
7.3.1 General .................................................................................................................................. 52
7.3.2 Single/multi cycle validation ................................................................................................... 54
7.3.3 Validation procedures ............................................................................................................ 54
7.3.3.1 Manual validation ................................................................................................................... 54
7.3.3.2 Semi-automatic validation ...................................................................................................... 55
7.3.3.3 Automatic validation ............................................................................................................... 55
7.3.4 Evaluation of deviations ......................................................................................................... 55
7.3.4.1 ASTM rules ............................................................................................................................ 56
7.3.4.2 Deviation rules ....................................................................................................................... 56
7.3.5 Validation methods ................................................................................................................ 58
7.3.5.1 Reference sample method ..................................................................................................... 58
7.3.5.2 Line sample method ............................................................................................................... 64
7.3.6 Validation Warning ................................................................................................................. 67
7.4 Analyzer calibration ................................................................................................................ 67
7.5 Diagnostics ............................................................................................................................. 70
7.6 Maintenance operations ......................................................................................................... 71
7.6.1 Planning maintenance operations.......................................................................................... 71
7.6.2 Creating and scheduling new maintenance activities ............................................................ 72
7.6.3 Start maintenance activities ................................................................................................... 73
7.6.4 Documentation of maintenance requests .............................................................................. 74
7.6.5 Electronic documentation ....................................................................................................... 80

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7.6.6 Key performance indicators ....................................................................................................81


7.6.6.1 Detailed description ................................................................................................................82
7.6.6.2 Evaluating KPIs.......................................................................................................................83
7.7 Analyzer reporting functions ...................................................................................................83
7.7.1 Analyzer reporting ...................................................................................................................83
7.7.2 Standard reports .....................................................................................................................84
7.7.3 Predefined reports ..................................................................................................................86
7.7.3.1 ASM_AlarmList .......................................................................................................................87
7.7.3.2 ASM_AnalyzerConfiguration ...................................................................................................87
7.7.3.3 ASM_AnalyzerMaintenance ....................................................................................................87
7.7.3.4 ASM_AnalyzerPerformance ....................................................................................................88
7.7.3.5 ASM_AuditTrail .......................................................................................................................88
7.7.3.6 ASM_PlannedActivities ...........................................................................................................89
7.7.3.7 ASM_ValidationDetails............................................................................................................89
7.7.3.8 ASM_ValidationHistory ...........................................................................................................89
7.8 Bottle management system ....................................................................................................90
7.9 Alarm logging system..............................................................................................................90
8 System Configuration ............................................................................................................................ 91
8.1 General ...................................................................................................................................91
8.1.1 Start-up ...................................................................................................................................91
8.1.2 'About...' ..................................................................................................................................91
8.2 System configuration using the ASM manager ......................................................................91
8.2.1 Equipment hierarchy ...............................................................................................................92
8.2.2 Tabs ........................................................................................................................................92
8.2.3 Globals tab ..............................................................................................................................93
8.2.4 Database setup tab .................................................................................................................98
8.2.5 Element types tab ...................................................................................................................99
8.2.6 Elements tab .........................................................................................................................102
8.2.6.1 Add element ..........................................................................................................................104
8.2.6.2 Site settings ..........................................................................................................................106
8.2.6.3 Plant settings ........................................................................................................................107
8.2.6.4 Shelter settings .....................................................................................................................108
8.2.6.5 Analyzer settings ...................................................................................................................109
8.2.6.6 Process stream settings........................................................................................................118
8.2.6.7 Component settings ..............................................................................................................118
8.2.6.8 Validation stream settings .....................................................................................................119
8.2.6.9 Validation component settings ..............................................................................................121
8.2.6.10 Reference bottle/Reference bottle certificate .......................................................................122
8.3 Maintenance configuration ....................................................................................................123
8.3.1 Configure maintenance activity .............................................................................................123
8.3.2 Activate/deactivate a maintenance activity ...........................................................................124
8.3.3 Maintenance schedule ..........................................................................................................124
8.4 Reference gas bottle management.......................................................................................125
8.4.1 General .................................................................................................................................125
8.4.2 Reference bottle attributes ....................................................................................................127
8.4.3 Adding a new bottle ..............................................................................................................128
8.4.4 Modifying a bottle ..................................................................................................................128
8.4.5 Assigning a bottle to an analyzer ..........................................................................................130

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8.4.6 Electronic documentation ..................................................................................................... 131


8.4.7 Reminder functions .............................................................................................................. 131
8.4.8 Using the ASM importer ....................................................................................................... 132
8.5 Diagnostic components ........................................................................................................ 132
8.5.1 Limit settings ........................................................................................................................ 132
8.5.2 Rule settings ........................................................................................................................ 133
8.6 Process capability ................................................................................................................ 134
8.6.1 Deviation calculation 'absolute' ............................................................................................ 135
8.6.2 Deviation calculation 'relative to reference' .......................................................................... 136
8.6.3 Deviation calculation 'relative to span' ................................................................................. 138
9 Modes and action states ......................................................................................................................141
9.1 Analyzer modes ................................................................................................................... 141
9.2 Analyzer house modes ........................................................................................................ 143
9.3 Maintenance action states ................................................................................................... 144
9.4 Validation states and results ................................................................................................ 145
9.5 Quality Codes....................................................................................................................... 146
10 Alarm list ..............................................................................................................................................149
11 Service and maintenance .....................................................................................................................151
11.1 Service and support ............................................................................................................. 151
A ASM calculations .................................................................................................................................153
A.1 General functions ................................................................................................................. 153
A.1.1 Arithmetic average ............................................................................................................... 153
A.1.2 Variance ............................................................................................................................... 153
A.1.3 Standard deviation (stdev) ................................................................................................... 154
A.2 Calculations for deviation validation procedures ................................................................. 154
A.3 Calculations for ASTM validation procedures ...................................................................... 157
A.4 KPI calculations.................................................................................................................... 161
A.4.1 Absolute values .................................................................................................................... 161
A.4.2 Relative values ..................................................................................................................... 162
A.4.3 KPI recalculation .................................................................................................................. 163
A.5 Validation limit conversions .................................................................................................. 164
B Appendix B ..........................................................................................................................................165
B.1 Audit trail .............................................................................................................................. 165
C List of abbreviations .............................................................................................................................167
C.1 List of abbreviations ............................................................................................................. 167
Index ...................................................................................................................................................169

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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:

Edition Features, Remarks


09/2018 First edition

1.3 ASM software version


The installed ASM software version can be found found in the "About box" on each ASM
view or under Globals tab in the ASM Manager.

1.4 General information


The system described in this manual has left our premises in a high quality and tested
condition. In order to preserve this condition and to operate this product correctly and safely,
it may only be used in the manner described by the manufacturer. Furthermore, proper
transportation, storage, installation, operation and maintenance of the device is vital for
ensuring correct and safe operation.
This manual contains the information required for the intended use of the described system.
It is addressed to technically qualified personnel who are specially trained or who have the
relevant knowledge of automation technology (measuring and control systems).
Knowledge and technically correct implementation of the safety notes and warnings
contained in this manual are required for safe installation and commissioning, as well as for
safety during the operation and maintenance of the described product. Only qualified
personnel have the required professional knowledge for correctly interpreting the generally
valid safety notes and warnings in this manual in each specific case and to act accordingly.
This manual is an inherent part of the scope of delivery, despite the fact that it can be
ordered separately for logistic reasons.

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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.

1.5 Warranty conditions


We expressly point out that the system quality is exclusively and conclusively described in
the sales contract. The content of this system documentation is neither a part of a previous
or existing agreement, promise or legal relationship, nor is it intended to modify these. All
obligations on the part of Siemens AG are contained in the respective sales contract, which
also contains the complete and solely applicable liability provisions. The provisions defined
in the sales contract for the responsibility for defects are neither extended nor limited by the
remarks in this document.

1.6 Delivery Information


The respective scope of delivery is listed on the shipping documents – enclosed with the
delivery – in accordance with the valid sales contract.

1.7 Standards and regulations


As far as possible, the harmonized European standards were the basis for the specification
and production of this product. If no harmonized European standards have been applied, the
standards and regulations for the Federal Republic of Germany are valid. When this solution
is used beyond the scope of these standards and regulations, the valid standards and
regulations of the country of the operating company apply.

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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.

2.2 Warranty and liability for application examples


The application examples are not binding and do not claim to be complete regarding
configuration, equipment or any eventuality which may arise. The application examples do
not represent specific customer solutions, but are only intended to provide support for typical
tasks. You are responsible for the proper operation of the described products. These
application examples do not relieve you of your responsibility for safe handling when using,
installing, operating and maintaining the equipment.

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Safety notes
2.3 Industrial security

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.

Figure 3-1 ASM structure

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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

3.3 System architecture and design considerations


The overall system consists of the ASM Server and additional PCs for visualization and
monitoring of the complete system as shown in the following figure.
The Siemens ASM Server is configurable: each analyzer has its specific set of parameters
and properties. An authorized user can modify those settings by means of a configuration
tool.

Figure 3-2 Typical ASM project scope

The system components have the following functions:


● ASM Server
The ASM server is collecting and storing all ASM data, the ASM application is installed
there.
● ASM Client
An ASM Client is the user interface to the ASM application. It is used to display the
application; ASM data are not stored there.
● ASM Engineering Station
An ASM engineering station provides all required engineering tools to configure, update
and extend the ASM system. The engineering features can be installed on an ASM client,
on a separate PC (recommendation) or on the ASM server.
● ASM Data Acquisition Unit
The ASM DAU is a SIMATIC PLC that provides all required communication interfaces for
data acquisition. Depending on the ASM setup the PLC can be a software PLC, which is
installed on the ASM server or on an external unit.

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Description
3.3 System architecture and design considerations

Internal structure of the ASM Server


The following figure shows the internal structure of the Siemens ASM server. All data are
stored using a Microsoft SQL server database located on the ASM server.

Figure 3-3 Internal layout of an ASM server system

The ASM server consists of the following modules:


● Analyzer Monitoring
The Analyzer Monitoring module collects and monitors status information of the entire
plant, analyzer houses, analyzer equipment, and analyzer.
– Plant Overview
Analyzer house location marked by interactive colored spots
Colored overall status info
Name tags of the individual houses
– Analyzer houses/shelters
Status of entire house
Status of analyzer installed
Status of sample conditioning system indicators
– Analyzer house overview – analyzer details
Quick & comprehensive overview
Colored status & essential information
One-click-access to the analyzer for details

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Description
3.3 System architecture and design considerations

– Analyzer house overview – optional


Shelter infrastructure
Auxiliary gas cylinders
Analyzers
– Monitoring of the sample handling system
Values, trend chart and status of sensors e. g. flows, pressures, temperatures
– Live analyzer values and trending for each individual analyzer
Planned maintenance activities
Current measurement results
Result trend graph over selectable periods of time
Measured components configuration
For detailed information about the analyzer monitoring functions refer to section
Monitoring functions (Page 50).
● Validation/Calibration
The validation/calibration module provides validation functions to check the analyzers for
reliability of the measured values. Different methods of measurement are available for
recording e. g. reference sample method or line sample method. For the evaluation of the
resulting values different evaluation methods can be selected (ASTM D3764 or deviation
monitoring). Different views are available to analyze the validation results (e .g. control
charts, run charts).
For detailed information about the validation functions refer to section Analyzer validation
(Page 52).
In addition the Validation / Calibration module provides functions to perform an analyzer
calibration.
For detailed information about the calibration functions refer to section Analyzer
calibration (Page 67).
● Reporting Module
The reporting module provides functions for reports and for data analyses of the analyzer
system. Several predefined reports are available.
For detailed information about the reporting functions refer to section Analyzer reporting
functions (Page 83).
● Maintenance Module
The maintenance module provides functions to an operator in order to schedule
maintenance activities and to document the details of a maintenance work (e. g. root
cause history, replace parts, efforts in time).
For detailed information about the maintenance functions refer to section Maintenance
operations (Page 71).
● Bottle Management System
The ASM bottle management system provides functions to an operator to maintain and to
monitor the connected reference gas bottle.
For detailed information about the bottle management system functions refer to section
Bottle management system (Page 90).

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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.

4.2 Configuring access authorizations


For the configuration of access authorization within the ASM software preconfigured access
rights exist. Any combination of access rights can be assigned for each user by the ASM
administrator.
In addition to the ASM-specific access rights the PCS 7 standard access rights will be used.
For more information refer to Industry Online Support
(https://w3.siemens.com/aspa_app/?nodekey=key_9177773&cntryid=DE&comptcid=o&lang=
en&contactid=783).

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

Configuration of ASM access authorizations


The users need to login with name and password to work with the system. Depending on the
configured access rights, a user is granted access or is blocked for using the protected
system functions. The following table shows the preconfigured 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:

Access right Action(s) concerned


Analyzer configuration Start ASM Manager from WinCC
Set analyzer status to 'Not required'/'Required'
Modify diagnostic rule settings (if no results exist)
Add certificate to bottle
Change bottle without changing the certificate
Start software Start the workstation software
Start validation Manual start of the analyzer validation procedure
Specify schedule
Set validation as calibrated
Start calibration Manual start of the analyzer calibration procedure
Specify schedule
Set analyzer state Activate internal analyzer maintenance state
Enter maintenance action Create a new maintenance history entry
Set analyzer state and enter Start, finish and document a maintenance request
maintenance action
Maintenance supervision Configure maintenance activities
Modify pick lists (symptom, component, effect, cause)
Edit lab values Insert values/reference values for validations of type <> refer-
ence sample validation
Edit reference bottles Add or modify reference bottles and data
Delete maintenance action Delete performed maintenance actions
Process Controlling Enter validation comment
Open start validation dialog
Higher Process Controlling Create diagnostic default rule settings
Define/modify diagnostic rule settings
Cancel/modify maintenance request
Edit diagnostic screen settings

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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.

5.1.1 Analyzer interface via external OPC client


This interface is suitable for analyzers with an integrated OPC client or using a central DCS
OPC client. The analyzer data are transferred via OPC to the integrated ASM OPC server.

Figure 5-1 Analyzer interface via external OPC client

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Interfaces
5.1 Analyzer Interface

5.1.2 Analyzer interface via field bus or hard-wired signals


This function is useful for analyzers connected via field buses like Profibus, Profinet or
Modbus, or for simple analyzers providing only hardwired 4…20 mA outputs.

Figure 5-2 Analyzer interface via fieldbus or hardwired signals

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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5.1 Analyzer Interface

5.1.3 Analyzer interface via MAXUM OPC server


This is the most suitable option for interfacing Siemens GC analyzers, because it provides
the deepest integration and the full range of functionality (e.g. remote validation with
response information).

Figure 5-3 Analyzer interface via Maxum OPC server

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Interfaces
5.2 Interfacing a DCS for validation/calibration handshake operations

5.2 Interfacing a DCS for validation/calibration handshake operations


The ASM can be interfaced to the DCS to setup a validation/calibration permission
handshake. This is usually done via OPC DA (DA 1.01), where ASM is the OPC server and
the DCS the OPC client.
The following signals are used for the validation/calibration permission handshake with the
DCS for every analyzer concerned:
● ASM Permission-Request (BOOL, true if request is present; QPERM_REQ)
● DCS Permission-Granted Response (BOOL, true if permission granted; PERM_GRA)
● DCS Permission-Denied Response (BOOL, true if permission denied; PERM_DEN)
The DCS must permit a "write" access for the Permission Request signal (see following
figure). In case of a validation or calibration the ASM server asks the DCS system for
permission. The same tags will be used for validation and calibration. For every analyzer
concerned you can configure if the DCS permission handshake is required or not.
If the permission will not be granted within the configured time a timeout will occur. The value
for the "Permission Timeout" in minutes is a centrally configured parameter which is valid for
all analyzers. The DCS system can deny the permission. Once a validation was initiated,
denied or after a timeout occurred, the tags must be reset by the ASM.

Figure 5-4 DCS permission request

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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

6.1 General screen layout


Via the graphical user interface of each ASM workstation a user can interact with the ASM
Server and has access to the required information. The user interface provides as fixed
elements that are always visible
● a navigation area on the upper part of the screen
● a toolbar on the lower part of the screen.
● a work area in the center which displays the currently selected screen, e.g. the ‘Analyzer
Overview Screen’.

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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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.

● start of the reference gas bottle management


● start of the configuration tool "ASM Manager"
The toolbar area is independent from the selected work area except of the alarm list. There it
is possible to switch to new, old, gone, system and historical alarm lists. The toolbar also
permits the shutdown of the workstation, if the currently logged-on user is provided with the
appropriated access rights.

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Graphical User Interface
6.2 Work area screen hierarchy

6.2 Work area screen hierarchy


The overview screen displays a graphical overview of all analyzer houses. From there a
specific analyzer house can be selected. The analyzer house screens display the current
status of the corresponding analyzers. From there a specific analyzer can be selected.
The toolbar permits access to a number of special screens, if the currently logged-on user is
provided with the appropriate access right.

Figure 6-1 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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6.3 Screen layouts

6.3 Screen layouts

6.3.1 Overview screen


The following figure shows the general layout of the overview screen.

Figure 6-2 Overview screen (example)

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

6.3.2 Analyzer house screen


The following figure shows the general layout of an analyzer house.

Figure 6-3 Analyzer house screen (example)

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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6.3 Screen layouts

Optional layout of an analyzer house screen


The following figure shows an optional layout of an analyzer house.

Figure 6-4 Analyzer house screen (optional layout)

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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6.3 Screen layouts

6.3.3 Analyzer sample system screen


The following figure shows the general layout of an analyzer sample system. This screen is
optional.

Figure 6-5 Analyzer sample system screen (example)

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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6.3 Screen layouts

6.3.4 Analyzer house mimic panel screen (optional)


The “Analyzer house mimic panel” screen visualizes alarms which have influence to the
modes of the analyzer house. The analyzer house status will change to 'Breakdown' mode
and generate an alarm message.
The general symbol summarizes all connected alarms to the mimic panel. When one of the
alarms is active the main symbol will change to red. To see all detailed signals which are
currently active a click on the general symbol (in the 'analyzer house screen') will open a
detailed view.

6.3.5 Analyzer views

6.3.5.1 Process view


The following screenshot shows the general layout of the process view of an analyzer or
analyzer house screen.

Figure 6-6 Process view of an analyzer screen (example)

On top of the work area are displayed:


● Mode: Analyzer/analyzer house mode represented by color and name
● Action: Analyzer/analyzer house action represented by color and name
For details about different modes and actions refer to Modes and action states (Page 141)

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6.3 Screen layouts

● Navigation buttons to navigate to other analyzer views


● Quick access buttons:
– Analyzer software: button to open analyzer-specific software directly from WinCC
runtime
– External software: button to open additional external software directly from WinCC
runtime
– Not Required: Changes analyzer states between 'not required' and 'required' ('not
required' means: all alarms coming from the analyzer will be ignored)
In the center part of the work area are displayed:
● Activities tab:
– Analyzer/shelter maintenance requirements are displayed.
– The date of the next scheduled automatic validation (if applicable) or required manual
validation is displayed.
● Configuration data tab (viewing only). Display of:
– The analyzer /shelter configuration data
– Stream configuration data
– Component configuration data
– Analyzer/shelter mode tab:
List of analyzer/shelter operation states is displayed
– KPIs tab (for analyzers only):
Presents various KPIs of the analyzer
● Current readings tab:
The current analyzer/shelter output and readings are displayed.
● Trending chart tab:
The current chart for the analyzer/shelter is displayed. The chart contains
analyzer/shelter sample values of the selected component. The chart can be switched
between the available components of the analyzer/shelter. The default time range for the
chart is set to the last 24 hour period. It is possible to switch to a more detailed view with
samples over the last 4 hour period. Any other filter time range for the chart is selectable.
The Chart is printable. A table of sample values can be displayed.
At the bottom of the process view, the current alarm list for the analyzer/shelter is displayed.
The navigation area, the toolbar and the analyzer view buttons are as visible as in all other
analyzer screens.

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6.3 Screen layouts

6.3.5.2 Validation view (analyzers only)


The following screenshot shows the general layout of the validation view of an analyzer
screen with selected validation history view and run chart tab.

Figure 6-7 Validation view (history view with run chart tab)

On top of the work area are displayed:


● Mode: Analyzer/analyzer house mode represented by color and name
● Action: Analyzer/analyzer house action represented by color and name
For details about different modes and actions refer to Modes and action states (Page 141)
● Status: Validation status/last validation result. This field shows the last validation result or
the current validation status.
● Quick access buttons:
– Scheduled time of the next validation
– Start validation:
If the currently logged-on user is provided with the appropriated access rights he can
use the "Start validation" button to open a dialog where it is possible to configure the
validation method (‘Analyzer configuration’, 'permission’), to configure the schedule
and to start the validation.

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Graphical User Interface
6.3 Screen layouts

● Validation history tab:


The historical list of conducted validations of the analyzer and their results is displayed.
The list is ordered by the validation date and time in descending order, i. e. the latest
validation is displayed on top of the list. By default, the list is limited to the validations that
have been executed within the last 31 days. Any other filter time range is selectable.
– Any validation result can be declared as ‘excluded’ if the currently logged-in user is
provided with the appropriate access rights.
– The last validation result can be declared as ‘calibrated’. If the last validation is set to
‘calibrated’ and the flag ‘ValidationCalibratedStartsNewCycle’ in the ASM manager is
true for this analyzer, then the next validation will be calculated with the current and
the last validation results.
– Summary tab: the validation result for each component is displayed.
– Details tab: the result of each validation method for each component is displayed.
– Sample tab: sample data for each component is displayed. Reference values can be
modified if the currently logged-on user is provided with the appropriated access right.
– Chart tab: data of the relevant validations for each component is displayed in a chart.
– Control chart tab: deviation of the relevant validations for each component is displayed
in a chart.
– Comments tab: By selecting the validation result the user can enter online comments
concerning the validations. An online comment is a text of up to 200 characters.
– CpK value, based on a time frame
Comments are stored with the corresponding date/time and logged-on user.
Any validation result can be declared as ‘excluded’ if the currently logged-on user is provided
with the appropriated access right. The last validation result can be declared as ‘calibrated’.
If the last validation is set to 'calibrated' and the flag ‘ValidationCalibratedStartsNewCycle’ in
the ASM Manager is true for this analyzer, then the next validation will be calculated with the
current and the last validation results.
At the bottom of the validation history view, the current alarm list for the analyzer is
displayed.
The navigation area, the toolbar and the analyzer view buttons are visible as for all other
analyzer screens

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6.3 Screen layouts

The following screenshot shows the general layout of a validation view of an analyzer screen
from the analyzer components perspective.

Figure 6-8 Validation component view (example)

● Component/run chart tab:


Components for the analyzer and Cpk value for the selected time frame are displayed.
– Run chart: component values for each validation found in the time range are
displayed.
– Control chart: difference between analyzer and reference value of each validation
found in the time range, is displayed for the selected component.
– Distribution chart: displays the deviation results in a distribution chart.
– Calculation results: the results of a selectable validation method for each validation
found in the time range are displayed for the selected component.
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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6.3 Screen layouts

6.3.5.3 Calibration view (analyzers only)


The following screenshot shows the general layout of the calibration view of an analyzer
screen.

Figure 6-9 Calibration view (example)

On top of the work area are displayed:


● Mode: Analyzer/analyzer house mode represented by color and name
● Action: Analyzer/analyzer house action represented by color and name
For details about different modes and actions refer to Modes and action states (Page 141)
● Status: Calibration status/last calibration result. This field shows the last calibration result
or the current calibration status.
● Quick access buttons:
– Scheduled time of the next calibration
– Start calibration:
If the currently logged-on user is provided with the appropriate access rights and the
calibration is not active yet he can use the "Start calibration" button to start a
calibration procedure.

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6.3 Screen layouts

● Calibration history tab:


The historical list of conducted calibrations of an analyzer and their results is displayed.
This list is ordered by the calibration date and time in descending order, i. e. the latest
calibration is displayed on top of the list. By default, the list is limited to the calibrations
that have been executed within the last 31 day period. Any other filter time range is
selectable.
– A control chart showing the change of the calibration response factor over number of
calibrations for the selected component is displayed. The chart can be switched
between the components of the analyzer.
After executing a calibration, the new calibration response factors for the components
are displayed and stored. The new factor is added to the control chart.
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.

6.3.5.4 Diagnostics view


The following screenshot shows the general layout of the diagnostic view of an analyzer
screen.

Figure 6-10 Diagnostic view (example)

On top of the work area are displayed:


● Mode: Analyzer/analyzer house mode represented by color and name
● Action: Analyzer/analyzer house action represented by color and name
For details about different modes and actions refer to Modes and action states (Page 141)

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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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6.3 Screen layouts

6.3.5.5 Maintenance view


The following screenshot shows the general layout of the maintenance view of an analyzer
screen.

Figure 6-11 Maintenance view with tab ‘completed’ (example)

On top of the work area are displayed:


● Mode: Analyzer/analyzer house mode represented by color and name
● Action: Analyzer/analyzer house action represented by color and name
For details about different modes and actions refer to Modes and action states (Page 141)
● Time filter: For time relevant data a time filter can be applied. This time filter is not visible
on all tabs. By default, the time span is set to the last 7 days period. Any other time range
can be selected.
● Quick access buttons:
– Button ‘put in maint.’: This button allows you to directly start a maintenance activity.
The new activity will be displayed at the ‘open’ tab.
– Button ‘history maint.’: This button allows you to enter data and comments to an older
(not planned) activity.
Information about the ASM maintenance view can be displayed via the ‘about…' button
● Planned tab:
A list of planned maintenance actions is displayed. The list is ordered by maintenance
action date and time in descending order.
● Open tab:
A list of currently open maintenance actions is displayed. The list is ordered by
maintenance action date and time in descending order.

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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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6.3.5.6 Report view


The following screenshot shows the general layout of the maintenance view of an analyzer
screen.

Figure 6-12 Report view (example)

On top of the work area are displayed:


● Mode: Analyzer/analyzer house mode represented by color and name
● Action: Analyzer/analyzer house action represented by color and name
For details about different modes and actions refer to Modes and action states (Page 141)
The available reports are displayed.
For time-relevant reports a time filter will be applied. By default, the time span is set to the
last 24h period. Any other time range can be selected.
In case of a detailed validation report the user can select one of the conducted validations to
get detailed information of the selected validation.
Information about the ASM reports view can be displayed via the ‘about…’ button.
It is possible to open pdf reports out of a shared folder. It is also possible to preview reports
(right side of the window).
At the bottom of the process view, the current alarm list for the analyzer / shelter is
displayed.
The navigation area, the toolbar and the toolbar analyzer view buttons are always visible.

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6.3 Screen layouts

6.3.6 Alarm list screen


The system acquires events, stores them in archives and makes them available to the users.
The following figure shows an example of an alarm list.

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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6.3.7 Reference bottle screen


The following screenshot shows the general layout of a reference bottle screen.

Figure 6-13 Bottle config

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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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.

7.1.2 System start-up procedure

7.1.2.1 Automatic system start-up


After start-up of the operating system, a pre-configurated user will be logged-in and the ASM
Software should start-up automatically due to an automatic start-up of WinCC.

Note
In case of manual login of another user the ASM Software can be started manually.

→ Start the WinCC-Application and activate the project if necessary.

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Functions
7.1 ASM system start-up and shutdown

7.1.2.2 Configuration of automatic logon


To activate an automatic logon procedure to the operating system refer to the corresponding
operating system manual.
1. "START → Run…" and enter control user passwords
→ Click on "OK" (e.g. Win Server 2003)
2. "START → Run…" and enter netplwiz
→ Click on "OK" (e.g. Windows 7)
3. In the following dialog deactivate the option "User must enter a user name and password
to use this computer."
→ Click on "OK"
4. In the following dialog enter the username and the password for the user which should be
logged-in at start
→ Click on "OK" If you restart the system the entered user name will be logged in.

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.

7.1.2.3 Configuration of automatic start-up


To enable the automatic start-up of WinCC proceed as follows:
‘START → SIMATIC → WinCC → AutoStart’.
The following dialog will open:

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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7.1.2.4 Configuration of WinCC start-up list


Use WinCC Explorer to open the computer properties and add the following tools to the
additional task/application start-up list:
● SiData4SQL_OPCDaC.exe from the program installation subfolder Siemens\ASM\bin
● SiData4SQL_WinCCMsg.exe from the program installation subfolder Siemens\ASM\bin
● MessageServer.exe from the program installation subfolder Siemens\ASM\bin
● SiDataController.exe from the program installation subfolder Siemens\ASM\bin (as start-
up parameter for this application use /start)
Ensure that these entries are at the end of the list.

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Having done these configuration steps, WinCC runtime and the ASM software will start
automatically after the start-up of the operating system.

7.1.3 Manual system shutdown


ASM Server:
Select "deactivate" in the WinCC Control Center. The WinCC runtime will be deactivated.
After deactivation the WinCC project can be closed and the server can be shut down.
ASM client:
Close the WinCC Runtime by clicking on the <exit> button in the toolbar. Then select
"deactivate" in the following dialog. The WinCC Runtime will be deactivated. After
deactivation the WinCC project can be closed. If desired, the client can be shut down.

7.1.4 Automatic system shutdown


If connected to an UPS the ASM server will be shut down automatically after a power failure
of the UPS.

7.2 Monitoring functions


One of the main functions of the ASM system is the monitoring and reporting of the system
analyzers. The different types of data that are monitored and recorded using the ASM
system are explained in the following sections.

7.2.1 Process data


This function monitors process values and stores these values in the database memory with
measuring units and time stamp. The stored process values can be visualized in tables as
well as in a trend graph on the ASM screen. For more details refer to Section Process view
(Page 33).

7.2.2 Validation data


This function monitors measured values during a validation and stores these values in the
database memory with measuring units and time stamp. The stored validation values can be
visualized in the ASM regarding each individual validation result. For more details refer to
Section Validation view (analyzers only) (Page 35).

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7.2.3 Calibration data


This function monitors measured values during a calibration and stores these values in the
database memory with measuring units and time stamp. The stored calibration values can
be visualized in the ASM regarding each individual calibration result. For more details refer
to Section Calibration view (analyzers only) (Page 38).

7.2.4 Diagnostics data


This function monitors additional diagnostic values like sample system values (e. g. sample
pressure, sample temperature, sample flow) and stores these values in the database
memory with measuring units and time stamp. The stored process values can be visualized
in tables as well as in a trend graph on the ASM screen. For more details refer to Section
Diagnostics view (Page 39).

7.2.5 Maintenance data


This function monitors maintenance data such as calculated key performance indicators,
work procedures and planned maintenance actions for every analyzer concerned and stores
these values in the database memory with measuring units and time stamp. For more details
refer to Section Maintenance view (Page 41).

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)

7.2.7 Equipment modes and actions


This function monitors equipment modes and actions during the operation of the ASM and
stores these values in the database memory with mode or action and time stamp. For more
details refer to Section Modes and action states (Page 141)

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7.3 Analyzer validation

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.

There are different ways to start the validation process:


● Start via ASM GUI
● Scheduled start via ASM GUI
● Start by DCS - ASM is reading change of mode
● Start at analyzer - ASM is reading change of mode
During the validation process the system archives the defined values, executes predefined
statistical calculations (tests) on those values and stores the corresponding calculation
results. For more details on the statistical calculations and procedures refer to ASM
calculations (Page 153).

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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).

Scheduled start of a validation


To reduce the amount of manual work for the user it is possible to schedule automatic
validations after predefined time intervals. The schedule is configured using the "Analyzer
Validation Screen". If a schedule is configured the following tasks will be executed:
● The validation procedure for the analyzer will be started at the scheduled intervals.
● The ASM validation system then executes the configured validation method for the
analyzer.
● The validation result is determined and stored in the database.
● An error message is issued if the validation fails.

Note
This function is only possible if the analyzer is able to handle this feature!

Reference sample method


The analyzer measures a defined reference sample from a reference bottle. The system
compares a predefined number of measured sample values from the process stream with
measurements of the reference bottle.

Line sample method


When using the line sample method, a sample is taken from the process gas stream. This
sample is analyzed at the lab and the results are entered. The system then compares the
measured sample values of the relevant time period with the lab results.
For detailed information about both reference sample method and line sample method refer
to Validation methods (Page 58)

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7.3.2 Single/multi cycle validation


Depending on analyzer configuration, the validation sequence runs through multiple cycles
and consists of multiple samples of reference. To calculate the validation results within ASM,
different procedures can be selected using the ASM Configuration tool.
● Single sample (Single cycle validation)
The analyzer validation sequence runs through only one cycle and consists of a single
reference sample. This sample is recorded in the database and is used for calculations to
determine if the analyzer is valid.
● Multi sample with averaging (multi cycle validation)
The analyzer validation sequence runs through multiple cycles and consists of multiple
reference samples. This produces multiple deviation calculations which are all recorded
in the RAW data table and then are averaged. The average is used for calculations to
determine if the analyzer is valid.
● Multi sample with first (multi cycle validation)
The analyzer validation sequence runs through multiple cycles and consists of multiple
reference samples. Only the first sample is recorded in the RAW data table and will be
used for calculations to determine if the analyzer is valid.
● Multi sample with last (multi cycle validation)
The analyzer validation sequence runs through multiple cycles and consists of multiple
reference samples. Only the final sample is recorded in the RAW data table and will be
used for calculations to determine if the analyzer is valid.

7.3.3 Validation procedures


For every analyzer there are different procedures possible in which a validation can be
performed:
● Manual validation
● Semi-automatic validation
● Automatic validation

7.3.3.1 Manual validation


The validation procedure can only be started manually on the ASM by the user using the
graphical user interface (GUI).
For this type of validation the necessary parameters have to be entered manually such as:
● Start time
● End time
● Analyzer values for each component.
The manual validation can be triggered by both reference sample method and line sample
method.

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7.3.3.2 Semi-automatic validation


Initiating such a validation routine from ASM shall be subject to a maintenance release from
DCS, authorized by an operator. This type of validation most commonly involves introducing
a bottled sample or reference media of a defined composition to the analyzer manually. The
analyzer itself is not changing its current mode but needs to be configured for an unfrozen
measured value available through DCS during validation or maintenance activities.
The validation procedure shall be started manually and is followed by a guided script for a
service technician. The service technician will run through the different steps until completion
by manually entering the actual values as validation results into ASM. The ASM will
automatically collect the validation results and evaluate them against the reference sample
method values. This semi-automatic validation mode can be repeated for several number of
configurable validation points (e. g. zero or span, zero and span, Zero and 2 span, etc.…).
The semi-automatic validation can be triggered by the reference sample method.

7.3.3.3 Automatic validation


For this type of validation, the ASM receives the validation values from the analyzer, which
controls the validation sequence by its own.
The validation can be started as follows:
● The analyzer will receive a trigger signal from the ASM to start an automatic validation
● An operator can start a validation at the analyzer and the analyzer will then send a trigger
signal to the ASM system indicating that a validation is active.
The automatic validation can be triggered by the reference sample method.

7.3.4 Evaluation of deviations


Currently two sets of validation rules are implemented in the system. ASM always calculates
the validation over a definable amount of deviations. It is only possible to use one rule set at
the same time. The ASM generates warnings and alarms depending on the configuration of
the rules. Nevertheless an operator should check the control charts from time to time in
search for anomalies.

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7.3 Analyzer validation

7.3.4.1 ASTM rules


ASTM International (originally American Society for Testing and Materials) is an international
standards organization that defines rules for a wide range of materials, systems and
services. ASM provides the possibility to use the ASTM standard to validate the analyzer
deviations. This ASTM standard is a fixed set of statistical equations (Dixon, Student-T and
Chi-Square) that will be used as a deviation rule by ASM.
The rule set scans for outliners and checks the statistical distribution of the deviations. The
mathematical details can be read in the ASTM standard.
While the used equations are fix, the parameters (the amount of expected deviations) can be
changed in the ASM manager during the engineering phase.
This rule is designed to evaluate the quality of the validations with statistical equations. This
makes the result very reliable. On the other hand this rule is very hard to understand. The
correlation between deviation marks and alarms is based on statistics and, because of that,
not easy to evaluate.

7.3.4.2 Deviation rules


This is a highly adaptable set of rules that can be used to evaluate the deviations. During the
engineering period an engineer has the choice between 12 different, freely combinable
single rules. These rules are easy understandable. On this way an operator can easily find
out the reason why a validation passed or failed. On the other hand that these rules react
(simplified) on patterns in the deviation chart. None of these rules has any statistical
equations.
● Calculate Limits
This parameter defines whether the control and warning limits shall be calculated from
historical data or if the parameters 'Control Limit' and 'Warning Limit' shall be used as
fixed values. This parameter can be set in the ASM Manager.
● Control Limit
The Control Limit can be defined in the ASM Manager. While its detailed interpretation is
dependent on the selected single rule, the limit is used to generate alarms. The number
of points that fi are allowed to exceed the control limit before an alarm will be generated
can be freely defined.
● Warning Limit
The Warning Limit can be defined in the ASM Manager. While its detailed interpretation is
depended on the selected single rule, the limit is used to generate warnings. The number
of points that fi are allowed to exceed the warning limit before a warning gets generated
can be freely defined.
● Specification Limit
The specification limit is mainly used for the CpK calculations. It can also be used for
Deviation Rule 0 which monitors if the specification limits are complied with.
● Aim
The aim is the target deviation of the system. In an optimal state this parameter should be
close to zero.

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● Deviation Monitoring rule 0 – Points outside specification limits


This rule checks if a consecutive amount of points are outside of the specification limits.
● Deviation Monitoring rule 1 – Points exceed limits
This rule checks if a defined number of points is outside the control or warning limits and,
if so, generates an alarm or a warning.
● Deviation Monitoring rule 2 – Points between the warning and the control limit on one side
of the aim
This rule checks if a defined number of points is between the warning and the control limit
on the same side of the aim.
● Deviation Monitoring rule 3 – Points between the warning and the control limit on different
sides of the aim
This rule checks if a defined number of points is between the warning and the control
Limit on any side of the aim.
● Deviation Monitoring rule 4 – Points between the aim and the warning limit on one side of
the aim
This rule checks if a defined number of points is between the aim and the warning limit on
one side of the aim. If the analyzer has a high calibration frequency, this rule can be used
to notice drifts in the validation.
● Deviation Monitoring rule 5 – Points on one side of the aim
This rule checks if a defined number of points is on one side of the aim. If the analyzer
has a high calibration frequency, this rule can be used to notice drifts in the validation.
● Deviation Monitoring rule 6 – Points exceed the warning limit on one side of the aim
This rule checks if a defined number of points exceeds the warning limit on the same
side.
● Deviation Monitoring rule 7 – Points exceed the half of the warning limit on one side of the
aim
This rule checks if a defined amount of points exceed the half of the warning limit on one
side of the Aim.
● Deviation Monitoring rule 8 – Number of points within a larger number of historical points
outside the warning limit on one side of the aim
This rule checks if a defined number of points, that are not consecutive but within a larger
number of historical points exceed the warning limit on one side of the aim.
● Deviation Monitoring rule 9 – Number of points within a larger number of historical points
exceed the half of the warning limit on one side of the aim
Checks if a defined number of points, that are not consecutive but within a larger number
of historical points, exceed the half of the warning limit on one side of the aim.
● Deviation Monitoring rule 10 – consecutive points are increasing
Issues a warning if a defined number of consecutive deviations increases.
● Deviation Monitoring rule 11 – consecutive points are decreasing
Issues a warning if a defined number of consecutive deviations decreases.
● Deviation Monitoring rule 12 – consecutive points are alternating
Issues a warning if a defined number of consecutive deviations alternates up and down
(always related to the foregoing value).

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7.3.5 Validation methods


For every analyzer a validation method can be configured. The configured method is
executed during the validation procedure of the analyzer. Which validation method is
available depends on global database settings and the analyzer configuration settings of the
ASM manager. The following validation methods can be configured:
● Reference sample method
● Line sample method

7.3.5.1 Reference sample method


When using the Reference sample method, the analyzer measures a defined reference
sample from a reference bottle. The system compares a predefined number of measured
sample values from the process stream with measurements of the reference bottle.
The reference sample method can be triggered by all validation procedures:
● manual
● semi-automatic
● automatic
Since the validation procedures are different the workflows are described in the following
paragraphs.

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Manual mode
The following workflow describes the sequence of actions.

Figure 7-1 Reference sample method in manual mode

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Semi-automatic mode
The following workflow describes the sequence of actions.

Figure 7-2 Reference sample method in semi-automatic mode

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Automatic mode
The following workflow describes the sequence of actions.

Figure 7-3 Reference sample method in semi-automatic mode

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Start of the reference sample validation method


This validation method can be started
● in manual mode
● in semi-automatic mode
● in automatic mode
Starting the procedure is only allowed if
● the analyzer is in one the following operation modes
– “Valid”
– “Warning”
– “Maintenance”
– “Breakdown”
● the DCS permission handshake is disabled
● DCS permits the start

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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7.3.5.2 Line sample method


When using the line sample method, a sample is taken from the process gas stream. This
sample is analyzed at the lab and the results are entered. The system then compares the
measured sample values of the relevant time period with the lab results.
The line sample method can be used in manual validation.

Manual mode
The following workflow describes the sequence of actions.

Figure 7-4 Line sample method in manual mode

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Start of the method


The validation method can be started in manual mode.
Starting the procedure is only allowed if the analyzer is in one of the following operation
modes:
● "Valid”
● “Warning”
● “Maintenance”
● “Breakdown"

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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7.3.6 Validation Warning


After a validation has finished with a warning, the corresponding WinCC message will be
generated. This message is displayed until one of the next validations finishes with another
result (“valid” or “failed”).
An overview of alarms and warnings can be obtaind from section Alarm list (Page 149).

7.4 Analyzer calibration


One of the core functions of the ASM is the calibration of analyzers. The data involved are
shown in the following figure.

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).

Scheduled start of a calibration


To reduce the amount of manual work for the user it is possible to schedule automatic
calibrations after predefined time intervals. The schedule is configured using the "Analyzer
Calibration Screen". If a schedule is configured the following tasks will be executed:
● Having received a permission from the DCS system the ASM Server initiates the
calibration at the scheduled intervals.
● The calibration result is determined and saved in the database.
● If the calibration fails, an error message is issued.

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.

Figure 7-5 Calibration workflow

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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7.6 Maintenance operations

7.6 Maintenance operations

7.6.1 Planning maintenance operations


The ASM assists an operator in scheduling his maintenance activities. To do so he can
evaluate a couple of necessary parameters such as:
● Key performance indicators.
They provide an operator a general idea of how good a device performs so he can
increase or decrease the intervals of maintenance operations.
● Validations/Calibrations:
These functions act as an early warning system for a possible degradation of an
analyzer. For instance a change in the validation/calibration behavior does not
necessarily mean that an analyzer will cease working immediately. But it shows that the
analyzer should be controlled in the near future or at least during the next shutdown to
avoid unexpected maintenance operations.
● Maintenance activities
ASM can also be used to schedule cyclical maintenance activities such as exchanging
wear and tear parts (e. g. filters or fittings). He should find the necessary information in
the corresponding device manual or the shelter documentation.
The ASM maintenance module provides functionality for planning maintenance activities and
maintenance prediction (KPIs).

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7.6 Maintenance operations

7.6.2 Creating and scheduling new maintenance activities


ASM provides a range of functions for planning, monitoring, and supporting the execution of
maintenance activities.
Maintenance activities are work procedures which can be configured as a list of effective
activities for every analyzer. Such an activity can consist of:
● The name of the activity
● A short description of the activity
● The duration time - working time planned for the maintenance
● Special instructions in plain text
● A pdf document (e.g. with detailed instructions on how to change the filter on a certain
analyzer)
Those maintenance activities are a great help for the day-to-day work of the maintenance
personnel since they provide all required information for the ongoing maintenance from one
central point. They render search for paper documentation redundant.
It is possible to use the following maintenance activities:
● Create, edit and delete maintenance activities.
Only unassigned activities can be deleted
● Assign maintenance activities to or remove maintenance activities from analyzers or
analyzer houses
● Schedule maintenance activities
Automatic maintenance requests will be created after predefined time intervals
● Activate or deactivate "non-freezing" mode
In a "non-freezing" mode a maintenance activity is started without changing the analyzer
mode to maintenance. The duration time of such a non-freezing activity will not be taken
into account when calculating the KPIs.

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7.6 Maintenance operations

7.6.3 Start maintenance activities


Before the maintenance personal starts maintenance work in the field, an analyzer must be
set into maintenance state in ASM.
A maintenance action is a predefined task to be performed for a specific analyzer, e.g.
"Change filter". The system provides functions for planning, monitoring and supporting of the
execution of such actions.

Starting a maintenance action


There are three different ways to start a maintenance action:
● Scheduled requests
A maintenance action is started after predefined time intervals
● Manual requests
A maintenance action is started by an operator using the GUI
● Automatically created requests
A maintenance action is started automatically after a warning or alarm was triggered
For further information refer to "Document Maintenance Requests"

Executing a maintenance action


Each maintenance action consists of the following parameters:
● A maintenance action text, which is selectable from a preconfigured maintenance action
list.
● The type of the action, selectable from a preconfigured type list
– predictive maintenance
– preventive maintenance
– corrective maintenance
● The working hours spent on the maintenance action, or working hours planned for the
maintenance action in case of a planned action.
● The replacements (spare parts) required or planned for the action and optional
comment(s).
● The current date/time and the WinCC user name (automatically added by the system).
To execute such a request, new parameters for the action can be entered. To do so, the
currently logged-in user must be authorized to do so. You can use the GUI to terminate a
maintenance action after having been executed. This is also possible without documenting
the action. Nevertheless a document is necessary to complete a maintenance action. Within
the list for complete actions you can search actions for defined characteristics (e. g. longer
time than expected). If there are is a fixed sequence of maintenance actions following a
certain event (e. g. an alarm), you have the possibility to combine requests which belong
together to work procedures.
Once the maintenance is done, the operation will be finished by clicking on 'Finish' in the
open maintenance tab. Then the maintenance activity can be documented.

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7.6.4 Documentation of maintenance requests


There are different ways to trigger maintenance requests. These requests are scheduled and
filed according to their origin as manually or automatically created requests. At the end,
every request has to be documented. Going through the list of finished requests you can pick
requests according to certain features such as a longer time needed. You can also combine
automatically created and finished requests based on alarm or warning messages during a
maintenance work which belong together.
The following dialog shows an automatically created and finished 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 additionally selected requests
will be deleted.

Figure 7-6 Dialog to combine several requests with one “normal” master request

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After clicking the document button the following dialog appears.

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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7.6.5 Electronic documentation


The system is able to store electronic documents (pdf files) for each analyzer. These
documents can easily be retrieved and displayed by authorized personnel, providing up-to-
date information for
● Maintenance procedures
● Data sheets
● System drawings
This feature provides one single location for all maintenance-related documents.

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7.6.6 Key performance indicators


The Key Performance Indicators (KPI) provide easy comparable information about the
performance of a device.
Information about KPIs can be obtained in two ways. The process view shows the
accumulated KPI parameters of the last calendar year.

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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7.6.6.1 Detailed description


The following parameters make up the KPIs:
● Online Time:
The Total Online Time is the time period in which a device was operating.
● Checking Time:
The Total Checking Time is the time period in which a device was in validation,
calibration, predictive, corrective or preventive maintenance.
● Failure Time:
The Total Failure Time is the time period in which a device was in breakdown.
● Report Time:
The Total Reporting time is the time period in which documentation was open and
required.
● Not Required Time:
The Total Not Required Time is the time period in which the device was set to the 'Not
Required' mode.
● Mean Time Between Failures:
This time period indicates the mean failure-free time between two failures.
● Mean Time To Repair:
This time indicates the mean time that was needed to set the device in a failure-free state
again.
● Availability time:
The Availability Time is the addition of Online Time and Checking Time. It indicates the
whole time period during which the device was in a regular, failure-free state.
● CpK:
The Capability Process Katayori indicates the process capability.
● Reproducibility:
The percentage of all validations that finished successfully, in relation to all executed
validations.
● Number of breakdowns: self-explanatory
● Number of predictive maintenances: self-explanatory
● Validation out of Control:
The percentage of validations out of control in relation to the number of all validations that
have been executed.
● Validation out of Specs:
The percentage of validations that exceeded the specified limits in relation to the number
of all executed validations.
● Completed / Scheduled validations:
The number of all completed validations in relation to all scheduled validations.
● Corrective / Scheduled maintenance:
This indicates the relation between corrective maintenance and scheduled maintenance.
● PPM Completed / Scheduled Maintenance:
This indicates the relation between the number of predictive, corrective and preventive
maintenances in relation to the number of all scheduled maintenance actions.

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7.6.6.2 Evaluating KPIs


The KPIs are designed to provide comparable quality indicators for all gas analyzers. A solid
knowledge about the quality and the failure rate of an analyzer entity is very helpful to plan
future maintenance operations or analyzer retrofits.
The KPIs themselves are self-explaining. A maximum operation time and a minimum failure
time of the analyzers should be achieved.

7.7 Analyzer reporting functions

7.7.1 Analyzer reporting


The reporting module can be accessed from the ASM graphical user interface. It provides
features for reporting and analyzing the data of an analyzer (system).
The reporting module includes a list of predefined reports.

Figure 7-8 Reporting module

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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7.7.2 Standard reports


The standard reports are based on Microsoft Reports which is integrated within ASM.
Their characteristics are:
● to create predefined reports with current data (main purpose)
● to provide a preview of selected reports within the ASM GUI

Figure 7-9 Example of an analyzer performance report

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Figure 7-10 Example of a validation details report

Reports can be saved on individual workstations and can be refreshed with current data
upon request.

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Figure 7-11 Validation History as an example for an Excel report

7.7.3 Predefined reports


Any predefined report consists of header area, subject area, and footer area. The subject is
explained with the respective report type. Headers and footers have a common structure for
all reports as follows:
● Header:
– company logo
– report title
– analyzer and house concerned or all equipment
● Footer:
– current page and total number of pages
– date when the report was created
The following predefined reports are included in the analyzer reporting functions:
● Alarm list report
● Analyzer configuration and benchmark report
● Analyzer maintenance report
● Analyzer performance report with KPIs and actions performed
● Audit trail report
● Planned activities report
● Validation details report
● Analyzer validation history report

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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


ASM provides a bottle management system in order to keep track on all connected reference
gas bottles. The bottle management system allows the configuration of the reference gas
bottles and its components and properties. In addition, the system monitors the expiration
date of the bottle and informs an operator when a bottle is due to become exchanged.
Access to the bottle management system is provided via the toolbar within the ASM
graphical user interface. The system provides the possibility to store electronic documents
for each bottle.
ASM needs the concentration value of the reference bottle for the calculation of the selected
validation deviation method.
The bottle management system provides the following functions:
● Assigns bottles to individual analyzers
● Modifies or replaces an existing bottle
● Manages bottle certificates
● Monitors inventory and expiring dates

7.9 Alarm logging system


The alarm logging system detects events, stores them in archives and makes them available
to users. Alarms collected via I/Os (e. g. flow alarm, pressure alarm) will be signaled using
the message system. Unacknowledged alarms are displayed with a flashing text. Via a
button an operator can acknowledge each message, so that new alarms can be easily
detected. The alarm logging system provides a complete message history.
Access to the alarm logging system is provided via the toolbar of the ASM graphical user
interface.
The alarm logging system is a WinCC standard feature. For detailed information please refer
to chapter 11 “Message system settings” of SIMATIC Process Control System PCS 7
Operator Station documentation.
For detailed description of the ASM standard alarms refer to Chapter Alarm list (Page 149).

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System Configuration 8
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.

8.2 System configuration using the ASM manager


The ASM Manager is the central configuration tool to configure ASM for shelters, analyzers
and theirs components. Every type of equipment in the system needs to be configured. For
this purpose the ASM system provides a tool for the configuration of these equipment
settings. Those configuration data comprise e. g. the validation method to be used (line
sample/reference sample/none) and the parameters and limits for the selected method. The
system will propose default values as per ASTM.
An operator with the appropriate access authorization level will be able to change these
settings. Such a configuration is done via the "ASM Manager" configuration tool.
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, see Chapter 3.2, Figure 3.1.
The ASM Manager is not only a tool for engineering (element instances) but also for
developing element types. These types may depend on the way how the system is
connected to the analyzer, the possible analyzer data and the function(s) of the analyzer.
The application provides export and import of element types stored in XML files.

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8.2.1 Equipment hierarchy


Depending on type and functions of the different elements, these elements are organized
within a certain hierarchy as follows:

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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8.2.3 Globals tab

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 chapter is only informative.


This tab is an user interface to the global settings for the complete ASM setup. After an initial
ASM installation the default configuration will be displayed. These default settings can only
be modified by a user with window’s administrator rights. In case of an user without
administrator access, e.g. an operator, the text fields of the global settings are set to read-
only.

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The functions and settings of this tab are as follows:


● OPC Server settings:
– OPC Server:
This is preconfigured data. Since in this case it is the OPC server of WinCC, we have
to select OPCServer.WinCC
– Redundancy tag:
Any input there will be ignored.
This function is not yet implemented in this product version.
– Num diagnostic files:
Number of diagnostic files. Path for these files: C:\Program
data\Siemens\ASM\Diagnostic
The number of Sidata SQL files and Sidata SQL message files. If 50 are set then 50
Sidata SQL file and 50 Sidata SQL message files would be generated. As soon as this
number is exceeded the system will start overwriting the first files. The number of files
can be modified according to the size and requirements of the system, but 50 serves
as a default.
These files are used for troubleshooting in case of errors since these logs include all
details.
– Num local buffer files:
Number of local buffer files. Path for these files: C:\Program
data\Siemens\ASM\LocalBuffer
When Sidata application cannot save any data in the database, i.e. in case of a
missing online connection with database, then data are saved in the memory buffer. If
the memory buffer is full then it stores SQL files in a local buffer folder. Once the
database connection is reestablished, the data will be restored. This way no data will
be lost. The number of files can be modified according to the size and requirements of
the system, but 2000 serves as a default.
● SiData4SQL settings section:
– Preproc DLL:
The path where the particular SiData4SQL_preproc.DLL is located.
– Message server 1:
Name of message server 1 if used.
– Message server 2:
Name of message server 2 if used.
– Message Language:
Can be selected at the right side of the box ('english' in this example)
– Diagnostic path:
Used to select a path for saving diagnostic files. Default path for these files:
C:\Program data\Siemens\ASM\Diagnostic
– Local buffer path:
Used to select a path for saving local buffer files. Default path for these files:
C:\Program data\Siemens\ASM\LocalBuffer

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● WinCC message settings section:


– Area name block:
– Equipment name block:
– Batch name block:
– Batch ident block:
These parameters can be defined freely.
● Display of installed ASM version (read-only)
● 'License info' button:
This field shows all licenses installed in this database. License information can also be
found in “Microsoft SQL server management studio” using the following path:
ASMDB (Database) –> Tables –> dbo.rs_licenseInfo
Having clicked the 'License info' button the following screen opens (example) showing the
license information.

● UOMs (Units of measurement) section:


This table shows the available units of measurement entries. These units can be chosen
for further configurations wherever until selection is available, e.g. analyzer value of a
component. This function independent from access rights of the current user.

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The following screenshot shows areas where UOM can be selected:


● Enums:
The table within the "Enums" tab allows viewing, creating, deleting and modifying the
selected enumeration. These values can be used to specify property values, if the
attribute of the property is set correctly to the enumeration name. For system
enumerations, only the column "Value" can be modified. This function independent from
access rights of the current user.

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● 'Apply settings' button:


Any modifications executed under the ‘Globals’ tab will only become effective after having
clicked the ‘Apply settings’ button.
● 'Start wizard' button:
Prerequisites:
– WinCC runtime should be open for running the wizard.
– System is connected to WinCC as well as database.
Using 'Start wizard' you can configure OPC analyzers for OPC drivers. You can also
recreate WinCC pictures. If you use this feature you first have to select the analyzers or
shelters involved then to click the 'Create objects' button as shown in the following
screen.

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8.2.4 Database setup tab

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.

The functions and settings of this tab are as follows:


● Server name:
The name of the server on which ASM is running. It is normally an OS server name. If OS
and ES are equals you can use the 'Set local' button to take over the name of the PC.
● SQL Instance:
It’s the SQL instance which is effective. In this case it’s WINCC.
● User and password:
This function is not yet implemented in this product version.
Since the current version provides only trusted communication between databases used
on the WinCC instance an input of these parameters is not possible.
● Database name:
The name of the database which has to be attached to the SQL instance. Default is
ASMDB. This name can be modified according to the requirements of customers.
● 'Test connection' button:
Clicking this button will check the connection of the database mdf file under the path
stated in the ‘Database file’ field.

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● 'Apply settings' button:


Any modifications executed under the ‘Database Setup’ tab will only become effective
after having clicked the ‘Apply settings’ button.
● Database file:
The path of the database file which has to be attached to the SQL instance. Clicking the
'Attach' button will link the database with the SQL instance.
● Database scheme:
This is the version of the database. Versions can be found in "Microsoft SQL server
management studio" on the path given below.
ASMDB (Database) – Tables – dbo.tInfo

8.2.5 Element types tab

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!

This chapter is only informative.


This tab displays the defined types of equipment and their properties, which includes site,
plants, shelters, analyzers, different types of components and reference gas bottles. Only
defined types can be used for further ASM system configuration . For detailed information
about element types refer to section Elements tab (Page 102) and subordinate sections.
It is possible to add properties which are showing additional information of the process view
or within a report. Property values are default values which are set when adding a new
element. Modifying property options will update the values of all existing properties of this
type.
The following screenshot shows the structure of the element types screen:

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Functional range of this tab includes:


● Manually add or modify element types and their properties Note: It is not recommended,
to manually change names or settings by untrained personal.
● Import or export „ASM Typicals", which contains structural information about the different
classes of equipment if form of xlm files.
● Procedure to import the xml files. This procedure will import the complete hierarchy of the
templates. It is also possible to import separate element types instead of complete
hierarchies by selecting the proper hierarchy level and the path of import.
To do so proceed as follows:
– Right click on Site
– Click on import
– Select the path where the templates are located
– Select site folder and then import

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● To backup or export element types proceed the following steps


- Right click on Site
- Click on export
- Select the destination path.

● 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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8.2.6 Elements tab

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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8.2.6.1 Add element

Add [Administrator Level]:


Adds a new element with following parameters:
⇒ Parent Element: view olny, no modifications possible in this dialog
⇒ Element Name: name of added element
⇒ Element Type: available element types (see combo box)
⇒ Tag instance: Name of the Tag in the WinCC-SCADA System

This configuration will be displayed in the header of the properties interface.

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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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8.2.6.2 Site settings


A site is the highest element in the equipment hierarchy and thus contains superordinate
settings. These settings influence all subordinate elements, e. g. plants, shelters and
analyzers.
The name of the site can be defined in the configuration interface in the tree view. The main
configuration of a site is the control of storage time for certain values. Data which exceed the
configured lifetimewill be deleted. The properties concerning the storage times of system
values are:
● DeleteProcessDataAfterDays: process values, analyzer mode info and messages
● DeleteValidationDataAfterDays: analyzer validation data (raw data and results)
● DeleteCalibrationDataAfterDays: analyzer calibration data
● DeleteDiagnosticDataAfterDays: diagnostic data (raw data, results and events)
Additional site properties are:
● Allowed document types (0 or 1)
– 0: only pdf documents are allowed
– 1: all types of documents and folders can be added
● AuditTrail: can be enabled / disabled and defines if specific changes within ASM Views
are traced or not (modification of this property also create an audit trail message)
● Country: country where the site is located
● Site: optional way to configure the name of the site
● Lifebeat: is a system property which is used during runtime to check if data acquisition is
active.
Note: This property is not configurable.
The plants of each site can be added, deleted or modified by right click on the tree view.
Furthermore all child elements of the site are displayed. The next hierarchy level (plant) can
be selected by clicking on the child of site (tree view).

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8.2.6.3 Plant settings


The plant hierarchy level allows the following configurations:
● Name of the plant: → to change the name of the plant, use the configuration interface in
the tree view.
● Plant code
● Business: Purpose of plant
● PlantName: Optional way to define the plant name
The Shelters of each Plant can be added, deleted or modified by right click on the tree view.
Furthermore all linked elements of the plant are displayed. The next hierarchy level (shelter)
can be selected by clicking on the child of site (tree view).

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8.2.6.4 Shelter settings


The shelter hierarchy level allows the following configurations:
● Name of the Shelter can be configured using configuration interface in the tree view.
● Priority for repair (PRIO): Input to set the priority level for maintenance. The possible
selections are:
– 1: Start Immediately
– 2: Start within 24 hours
– 3. Start within 72 hours
– 4: Start within 5 days,
– 5: No maintenance action due to alarm or warning.
● Warning effects mode (WRNEFFMODE): If set to ‚yes‘, the mode changes to warning if a
warning condition is active. It writes data at the input ‚WRNEFFMODE‘ of the block.
● DiagnosticViewEnable: Using this is the input diagnostic view can be made enable or
disable. It writes data at the input ‚.EN_DIAG’ of the block.
● DiagnosticView default time filter: This input is used to set time filter in diagnostic view.
The Analyzers of each Shelter can be added, deleted or modified by right click on tree view.
Furthermore all linked elements of the shelter are displayed. The next hierarchy level
(analyzer) can be selected by clicking on the child of site (tree view).

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8.2.6.5 Analyzer settings


This section describes the analyzer hierarchy level. To import ‚ASM Typicals‘ in the elements
type tab there are several elements types for different analyzers. These element types are
based on the individual functionality of a particular analyzer. They mainly vary in the
communication settings and validation or calibration procedures. The following analyzer
types are possible:
● Analyzer ASM GC
● Analyzer ASM CGA
● Analyzer ASM CEMS
● Analyzer ASM
First common configurations for all analyzer element types are given such as:
● Name of the analyzer: to change the name of the plant, use the configuration interface in
the tree view.
● Tag instance: The field "Tag instance" in the header of property interface connects the
analyzer to a tag in WinCC.
● Model
● Manufacturer
● Analyzer software: The linked application can be started in the ASM process view
Configuration as an example: C:\Program Files (x86)\SIEMENS\Gas Chromatograph
Portal\GasChromPortal.exe <IPAddress>. The text <IPAddress> will be replaced with a
configured property value.
● External software: If there is one it can be started in the ASM Process View.
Configuration as an example: C:\Program Files (x86)\Internet Explorer\iexplore.exe
<params> 192.168.10.10. The text following <params> serves as program parameters.
If an analyzer should change to validation mode and the ASM should record the validation
values then the analyzer property "Validation Strategy" has to be set to "Automatic
Reference Method". If the analyzer has a validation mode signal without any validation
values, the "Validation Strategy" parameter should be set to a "Manual validation type" and
the validation timeout message should be removed from the corresponding PCS7 ASM_ANA
function block.

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Analyzer ASM GC settings


Using this element type you can configure or modify a ASM analyzer GC.
The 'Analyzer ASM GC' interface is generated particularly for a MAXUM GC analyzer due to
a specific programming in the database and certain specific properties which are necessary
for its configuration.

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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● ASTM Validation Settings:


These settings are also used in case of a line sample validation method. ‘ASTM
validation settings’ is configured within a process stream. ‘Component deviation settings’
must also be added to a component of a line sample validation.
The following screenshot shows an example of the ASTMValidationSettings properties:

● Diagnostic component for SSS (smart sampling system) GC:


These are values which are related to the smart sampling system, such as temperature,
pressure and flow. Since these parameters are not components of an analyzer system
we need to read them as diagnostic components. The option ‘Diagnostic component for
SSS GC’ is used to read the diagnostic components related to a MAXUM GC analyzer
using the 'MonAnl' blocks.
This function uses the 'AddressInfo4' settings to communicate with the OPC server.
The following screenshot shows an example of the GC smart sampling system properties:

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● Diagnostic component for SSS


In this type a component value is not received via the OPC server, but via a hardwired,
Modbus or any other connection.
The following screenshot shows an example of the smart sampling system properties:

● Diagnostic component for SSS OPC


In this type a component value is received via an external OPC server. Since the
component does not have any transmit ID, we have to configure the tags manually in the
OPC server.
The following screenshot shows an example of the smart sampling system OPC
properties:

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Analyzer ASM CGA settings


Using this element type you can configure or modify a ASM analyzer CGA.
A CGA analyzer can provide values only after having been calibrated. Since there is no
validation procedure for a CGA analyzer as default a validation command must be triggered
by the ASM system to run an actual CGA analyzer calibration. Following completion of the
calibration procedure the analyzer will send a drift value which can be used for correction.
Since the analyzer sends a drift value and not an absolute value an additional block must be
added to compare the drift value to a reference value. Thus an absolute value can be
provided to the comp block and then the final value calculated. A drift value of zero after a
calibration means the analyzer is working fine.
In the ASM manager, streams and components are added as shown in the following
screenshot:

● 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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Analyzer ASM CEMS settings


Using this element type you can configure or modify a ASM analyzer CEMS.
This analyzer type communicates with the ASM via an OPC server. To do so it uses third
party OPC software i.e. 'Tops Server'.
A CEMS analyzer is in fact an analyzer system consisting of multiple devices but is
addressed in the system as an analyzer. Since a CEMS is individually configured to a
customer's requirement there is no standard CEMS type. To design a CEMS analyzer for the
ASM we have to consider some additional properties such as temperature failure. Some of
these properties are listed in the following screenshot:

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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Analyzer ASM settings


Using this element type you can configure or modify a ASM analyzer
If not all validation values are received, and the validation signal (IS_VAL) fails, a validation
calculation will not be started since the validation values are incomplete. Even if the missing
values are available the validation will not start once a timeout signal is triggered.
The following screenshot shows an example of an ASM structure for an analyzer ASM
element type:

● 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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8.2.6.6 Process stream settings


Depending on the analyzer type an analyzer process stream must be added and configured.
To change the name of the stream, use the configuration interface in the tree view.

8.2.6.7 Component settings


The selected component for the analyzer/stream is displayed with name and description.
Basic process component settings are:
● Name: This entry will be read from the corresponding WinCC tag during runtime.
● Tag instance: This entry in the header of the property interface connects the component
to a tag in WinCC
● AdressInfo4: This info is needed to generate the corresponding OPC tag in WinCC
● Position: This entry can be used to arrange to order of the components.

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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.

8.2.6.8 Validation stream settings

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To configure a validation stream the following parameters can be used:

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

For deviation calculations refer to Calculations for deviation validation procedures


(Page 154)
For deviation monitoring rules refer to Section Deviation rules (Page 56).

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8.2.6.9 Validation component settings


The basic validation component settings are as follows:
● Tag instance: This entry in the header of the property interface connects the component
to a tag in WinCC
● AdressInfo4: This info is needed to generate the corresponding OPC tag in WinCC
● Position: This entry can be used to arrange to order of the components
● Exclude form Validation: This entry offers exclusion of the component from validation

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8.2.6.10 Reference bottle/Reference bottle certificate


This configuration is used to store the information of a reference bottle.
The following screenshot shows an example of a Reference bottle element type structure:

The properties of a Reference Bottle Certificate are as follows:


● Certificate Number:
Identifier of the bottle certificate
● Date of first use:
Date when the bottle was used the first time.
● Expiration Date:
Date when bottle should not be used any longer.
● 'Maintenance requested' reminder:
Time span in days used to calculate the planned start time for a maintenance request ‘ref
bottle will expire’.
● 'Maintenance required' reminder:
Time span in days left until the planned start time for a maintenance request ‘ref bottle
will expire’.
● Pressure:
Bottle pressure.
● State:
Shows the actual state of a bottle. Possible states are:
– New: bottle can be activated
– Used: bottle is active
– Old: bottle is outdated
● Supplier:
Name of supplier of the bottle.
● Validate date:
Date of the latest validation.
● Volume:
Volume of the bottle.
● Weight:
Weight of the bottle.
● Will expire reminder:
Time span in days before bottle will expire.

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8.3 Maintenance configuration


Within the 'Manage activities' tab of the WinCC ASM view 'Maintenance', the configuration of
maintenance activities is possible. This can be done for equipment of the following types:
● analyzer houses (shelters) and
● analyzers.

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.

8.3.1 Configure maintenance activity


On the right side of the view, where all defined activities are listed, a maintenance activity
can be entered, modified or deleted. A name must be specified and a description can be
entered as well. Within the activity details area the following parameters can be added to
each maintenance activity:
● a step by step list
● an activity type
● a planned duration and
● a documentation reference.
As type of maintenance activity one of following can be selected :
● Normal maintenance
● Validation
● Calibration
● Operator Activities
● Others
Changing an already effective activity also effects all other equipment which are using the
same activity.

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8.3.2 Activate/deactivate a maintenance activity


To activate:
When an activity is selected on the right side of the view, this activity will become effective
for the equipment, if the upper button (<) in the middle of the view is clicked.
To deactivate:
If no maintenance request for a selected effective activity was created before, the activity
can be removed from the equipment by clicking the lower button (>) in the middle of the
view.

8.3.3 Maintenance schedule


For an effective maintenance activity, a schedule can be set. By clicking on the schedule
button, a dialog opens, where the name of the schedule and the recurrence pattern can be
specified. The default name is the name of the maintenance activity. The following scheduler
options, with different details, are available:
● none
● run once
● daily
● weekly
● monthly

Figure 8-1 Specify schedule

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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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The following screen then appears.

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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8.4.2 Reference bottle attributes

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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8.4.3 Adding a new bottle


A new bottle can be created by entering a new bottle name in the field at the end of the
bottle list. This is only possible if the ‘Site’ element in the tree view is selected (root element).

Figure 8-2 Reference bottles - Adding a new bottle

After entering the bottle name, the bottle can be specified using the 'Modify bottle details'
dialog.

8.4.4 Modifying a bottle


There are three possible ways to start the modification of an existing bottle:
● Double-click on the bottle name.
● Right mouse click on the bottle name and select the option ‘modify bottle’ in the context
menu.
● Select the bottle name in the list and press the modify button in the toolbar.

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The modify bottle dialog appears.

On the left side, details of the bottle can be specified such as


● certificate number
● expiration date
● weight or volume of the bottle.
On the upper right side, the components included in the bottles can be entered manually or
can be copied from an existing analyzer/stream. To copy the components, press the button
‘Use template" and select the analyzer/stream you want to copy the components from.
On the lower right side, relevant documents can be stored for this bottle.
If you use this dialog for a new bottle there is no problem to do but sometimes it is necessary
to modify the parameters of a bottle already in use (e. g. if a wrong value had been entered
by error). To do this only an operator with the appropriate rights (analyzer configuration) can
modify bottle parameters. In that case the operator will also be asked whether he wants to
change the current certificate or wants to enter a new one.

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8.4.5 Assigning a bottle to an analyzer


There are three possible ways to assign a bottle to an analyzer or stream:
● Double-click in the window from the tab ‘assigned analyzers’
● Right mouse click on the bottle and select the option ‘assign analyzer’
● Select the bottle in the list and press the ‘assign analyzer’ button in the toolbar
The ‘assign analyzer’ dialog opens.
On the left side of the window is a tree view with all available analyzers/streams. On the right
side are all analyzers/streams which are already assigned to this bottle. Use the arrow
buttons in the middle of the two windows to move the analyzer/stream between the available
analyzer and the assigned analyzer list.

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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8.4.6 Electronic documentation


The system is able to store electronic documents (pdf files) for each bottle. These
documents can easily be retrieved and displayed by authorized personnel, providing up-to-
date information for data sheets and storage instructions, thus providing one single location
for all maintenance-related documents.

8.4.7 Reminder functions


Parts of a bottle certificate are the expiration date and 3 settings for “Soon will expire
reminder”, “Maintenance requested”, and “Maintenance required”.
These settings have the following meanings:
● Reference bottle will expire
31 days before the expiration date the WinCC warning message “Reference bottle will
expire” will be generated. Based on this message, a maintenance request will be created.
In this request, the reminder times for maintenance requested/required are incorporated
('planned start time' and 'start until time'). This has no effect on the analyzer mode or
action.
● Maintenance requested
14 days before the expiration the WinCC warning message “Maintenance requested” will
be generated if the previously mentioned maintenance request was not finished or
documented. This has no effect on the analyzer mode but the analyzer action will change
to “Due soon”. No new maintenance request will be created based on this message.
● Maintenance required
7 days before the expiration the WinCC alarm message “Maintenance required” will be
generated if the previously mentioned maintenance request was not finished or
documented. This has no effect on the analyzer mode but the analyzer action will change
to “OverDue”. No new maintenance request will be created based on this message.

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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8.4.8 Using the ASM importer


It is also possible to import reference bottles and to assign them using the ASM importing
tool. To do so the bottles with their certificates and components must be available within a
CSV file. This file must be created by using the installed ASM import template file, entering
the data into the Excel sheet and saving this sheet as CSV file.
The assignment of the bottles to the corresponding analyzers can only work if the following
preconditions are fulfilled:
● Valid import files for bottles and analyzers
● The bottles are imported before the analyzers are
● The target analyzer must not already have a bottle assigned to it
● Correct link to the bottle on the validation stream in the analyzer import file

8.5 Diagnostic components


For each parameter of a diagnostic component, the following points can be configured:

8.5.1 Limit settings


For both methods - "absolute" and "modification" - the following limits can be specified:
● Upper and lower spec limit
(deciding for control chart if rule is set to ‘Limit’)
● Upper and lower control limit
(deciding for control chart if rule is set to ‘Limit’)
● Upper and lower warning limit
(deciding for control chart if rule is set to ‘Limit’)
● Limit value
(non-deciding for control chart)

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System Configuration
8.5 Diagnostic components

8.5.2 Rule settings


● Method
– Absolute: the reference value for the check is set to 0.
– Modification: the reference value for the check is the last stored value
● Rule
– Limit
– Increasing
– Decreasing
– Alternating
– WithinLimits
– OutsideLimits
● Comparison
The value of a comparison is only applicable to the rule „Limit“
– Equal to (=)
– Unequal (<>)
– Less than (<)
– Less than or equal to (<=)
– Greater than (>)
– Greater than or equal to (>=)
● Limit 1
This setting is the limit value to which the measured value is compared. It is not
applicable for the rules “Increasing”, “Decreasing” or “Alternating”. In the subsequent
column the currently stored value for this limit appears.
● Limit 2
This setting is the limit value to which the measured value is compared. It is only
applicable for the rules “OutsideLimits” and “WithinLimits”. In the subsequent column the
currently stored value for this limit appears.
● Num points for violation
The number of points which must exceed a limit in order to set the rule "Result" to a result
configuration.
● Num last samples
The number of last diagnostic values which will be checked for violations.

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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.

8.6 Process capability


ASM provides a time frame based Cpk calculation for each validation component. There are
three different ways for configuring a deviation calculation in the ASM Manager. There are
also three different presentations of the Cpk in the WinCC Views.
● Process view: minimum Cpk of all validation stream components of the selected analyzer
within last calendar year
● Validation view: Cpk of each validation stream component with selectable time span
● Maintenance view: minimum Cpk of all validation stream components
Detailed information about the deviation calculation formulas can be found in section
Calculations for deviation validation procedures (Page 154).

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System Configuration
8.6 Process capability

8.6.1 Deviation calculation 'absolute'


The relevant settings for this type of Cpk calculation are:
● Deviation Calculation: 'absolute'
● Upper specification limit: This entry requires an absolute value
● Lower specification limit: This entry requires an absolute value
The upper and lower specification limits are centered around the zero point. The unit of the
specification limits has to be the same than the analyzer value of the validation component.

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System Configuration
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

8.6.2 Deviation calculation 'relative to reference'


The relevant settings for this type of Cpk calculation are:
● Deviation Calculation: 'relative to reference'
● Upper specification limit: This entry requires a percentage value
● Lower specification limit: This entry requires a percentage value
The upper and lower specification limits are percentage rates of the reference values of the
validation stream. The units of the specification limits are percent (%). The resulting absolute
values are also centered around the zero point.

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System Configuration
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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System Configuration
8.6 Process capability

8.6.3 Deviation calculation 'relative to span'


Relevant settings for this type of Cpk calculation:
● Deviation Calculation: „relative to span"
● Upper specification limit: This entry requires an percentage value
● Lower specification limit: This entry requires an percentage value
● Max. range: Upper range of span
● Min. range: Lower range of span
The upper and lower specification limits are in terms of the percentage of the defined span.
The units of the specification limits are percent (%). The resulting absolute values are also
centered around the zero point.

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System Configuration
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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System Configuration
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.

Symbol Status Meaning


DISCONNECTED Indicates that no analyzer data are received

ONLINE Indicates that the analyzer is working in a regular run


state

BREAKDOWN Indicates that the analyzer is in a failure state. Possible


reasons:
• A validation or calibration failed
• A supervision function ended with a threshold viola-
tion
• The analyzer is offline
WARNING Indicates that one of the following events occured:
• A validation or calibration ended with a warning
• A supervision function ended with a threshold viola-
tion
VALIDATION Indicates that the analyzer is performing a validation

CALIBRATION Indicates that the analyzer is performing a calibration

MAINTENANCE Indicates that the analyzer is in a maintenance mode

NOT REQUIRED Indicates that no alarms of the analyzer are logged in


the system. No alarms will be generated in case of
failures and there is no influence on the KPIs.

When an analyzer is in mode “NOT REQUIRED” and changes to “DISCONNECTED” then


the analyzer mode remains as “NOT REQUIRED”.
The analyzer mode is based on the status of the analyzer and the received messages.
If an analyzer is disconnected, no messages will be received or other states will be analyzed.
In one of the following states “Validation” / “Calibration” / “Maintenance” no messages are
analyzed. Good / Breakdown (Offline) mode is set if previous modes or messages are not
active.

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Modes and action states
9.1 Analyzer modes

The mode "Warning" is triggered by one of the following messages:


● Validation timeout
● Calibration timeout
● Frequency of validation reminder
● LSV could not be completed. Too few process samples or stability limit exceeded
● Validation ended with warning
● Calibration ended with warning
● A user-defined warning of an analyzer application
● Sample system temperature violation
● Sample system pressure violation
● Sample system flow violation
● Diagnostic violation
The mode "Breakdown" is triggered by one of the following messages:
● Validation failed
● Calibration failed
● A user-defined alarm of an analyzer application
● Sample system failure
● Sample system temperature violation
● Sample system pressure violation
● Sample system flow violation
● Diagnostic violation

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Modes and action states
9.2 Analyzer house modes

9.2 Analyzer house modes


The analyzer house modes indicate the current action of an analyzer house.

Symbol Status Meaning


DISCONNECTED Indicates that no analyzer house data are received

ONLINE Indicates that the analyzer house is working in a regular


run state

BREAKDOWN Indicates that the analyzer house is in a failure state.


Possible reasons:
• An alarm message from an analyzer was received
• A diagnostic violation occurred
WARNING Indicates that one of the following events occured:
• A warning message from an analyzer was received
• A diagnostic violation occurred
MAINTENANCE Indicates that the analyzer house is in a maintenance
mode

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

9.3 Maintenance action states


The maintenance action states indicate the current or last executed maintenance and the
corresponding actions to be performed.

Symbol Status Meaning


NONE No maintenance actions required

DOCREQ Indicates that one or more former maintenance operations


need to be documented

WARNING Indicates that a scheduled maintenance operation needs to


be done in the close future

ACTIVE The analyzer is set to maintenance

OVERDUE Indicates that the scheduled time for a maintenance opera-


tion has passed without having executed the task

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

9.4 Validation states and results


This field shows the last validation result or the current validation status.
During a validation process the following states are possible:

Symbol Status Meaning


INITIATED Indicates that the validation has been initiated

WAITING Indicates that the system waits for the permis-


sion from the DCS

ACTIVE Indicates that a validation is currently in progress

For the last validation result the following states are possible:

Symbol Status Meaning


UNDETERMINED Indicates that the analyzer has never been
validated

VALID Indicates that the last validations where valid


and everything works in order

WARNING Indicates that the last validation results trig-


gered warning levels during the validation
checks
TIMEOUT Indicates that the last validation did not finish.
A common reason for this failure is a miscon-
figuration of a reference gas bottle. Check the
component names and concentrations in the
bottle. Use the templates if a new bottle must
be implemented.
DENIED Indicates that the DCS refused the permission
to start a validation

PERMISSION Indicates that the permission for a validation


TIMEOUT from the DCS has not arrived in time

NOT APPLICABLE Indicates that some validation methods need


several historical validation datasets.
This means, that an operator needs to run
more validations before the ASM can start
calculations.
FAILED Indicates that the validation failed.
Check the validation details to receive more
information on the specific reason

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Modes and action states
9.5 Quality Codes

9.5 Quality Codes


Quality codes have the following binary structure: QQSSSSLL, which has the following
meaning:
● Q: Quality
● S: Sub-status of the quality
● L: Limits
This value is optional.
Quality codes are grouped in three types of quality:
● GOOD: This value can be used in control.
● UNCERTAIN: The quality of this value is less than normal, but the value may still be
useful.
● BAD: This value is not useful.
The quality codes represented in this section are based on the quality codes used in PCS7
(see PCS7 Document: WinCC Information System – Communication – Quality of Tags).
Quality codes are set in hexadecimal and decimal figures.

Quality codes of type GOOD

Quality code Description


hex dec
0x80 128 OK - No error or special condition is associated with this value
0xA4 164 Maintenance required
0xA8 168 Maintenance demanded
0xD8 218 Function check - Local override

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 codes of type UNCERTAIN

Quality code Description


hex dec
0x40 64 Non-specific - There is no specific reason why this value is uncertain. Used for prop-
agation.
0x44 68 Last usable value during validation or calibration
0x4C 76 Initial value - Value of volatile parameters during and after reset of the device or of a
parameter
0x60 96 Simulated value - set when the process value is written by the operator while the
block is in manual mode
0x68 104 Maintenance demanded

Quality code 0x40 is set to "Reason could be: Initial/simulated value or maintenance
demanded" by the WinCC OPC Server.

Quality codes of type BAD

Quality code Description


hex dec
0x00 0 Non-specific - There is no specific reason why this value is bad. Used for propaga-
tion.
0x04 4 Configuration error - Set if the value is not useful because there is some inconsisten-
cy regarding the parameterization or configuration, depending on what a specific
manufacturer can detect
0x08 8 Not connected - Set if this input is required to be connected and is not
0x0C 12 Device failure - Set if the source of the value is affected by a device failure
0x11 17 Sensor failure - Low limited - The value has exceeded its lower limit
0x12 18 Sensor failure - High limited - The value has exceeded its upper limit

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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".

Class Type Prio Message text Mode Action Maint


related related req
System Message Failure 1 Status quality is bad
Warning Low 2 Maintenance requested by asm X
Alarm High 3 Maintenance required by asm X
Alarm High 3 User-defined alarm X X
Warning High 2 User-defined warning X X
Alarm High 3 Analyzer is in failure X
Alarm High 3 Diagnostic violation X X
Warning High 2 Diagnostic violation X X
Warning Low 2 Analyzer Maintenance requested X X
Alarm High 2 Analyzer Maintenance required X X
Warning High 2 Maintenance activated X
Operator Prompt Stand- 1 Ongoing maintenance activity
ard

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".

Class Type Prio Message text Mode Action Main


related relat- t req
ed
System Message Failure 1 Status quality is bad
Warning Low 1 Scheduled validation requested X
Alarm High 2 Scheduled validation timed out X
Warning Low 1 Scheduled calibration requested X
Alarm High 2 Scheduled calibration timed out X
Warning Low 2 Maintenance requested by asm X
Alarm High 3 Maintenance required by asm X
Warning High 3 Validation timeout X
Warning High 3 Calibration timeout X
Warning High 1 Permission request timeout X
Warning High 1 Permission request denied X
System Message Failure 1 Value quality is not good

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Alarm list

Class Type Prio Message text Mode Action Main


related relat- t req
ed
Warning High 3 Frequency of validation reminder X
Warning High 2 Reference Bottles will expire
Warning High 3 LSV could not be completed. X
Too few process samples or stability
limit exceeded
Alarm High 3 Validation failed X X
Warning Low 2 Validation finished with warning X X
Alarm High 3 Calibration failed X X
Warning Low 2 Calibration finished with warning X X
Alarm High Reference Bottles expired X X
Alarm High User-defined alarm X X
Warning High User-defined warning X X
Alarm High Sample system failure X X
Alarm High Sample system temperature violation X X
Alarm High Sample system pressure violation X X
Alarm High Sample system flow violation X X
Warning High Sample system temperature violation X X
Warning High Sample system pressure violation X X
Warning High Sample system flow violation X X
Alarm High Analyzer is in failure X
Alarm High Diagnostic violation X X
Warning High Diagnostic violation X X
Warning Low Analyzer Maintenance requested X X
Alarm High Analyzer Maintenance required X X
Warning High Maintenance activated X
Operator prompt Standard Ongoing maintenance activity

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Service and maintenance 11
11.1 Service and support

Worldwide contact partners


If you have any further questions relating to the products described in this documentation,
contact your local representative at the Siemens office nearest you.
You will find information on whom to contact at our Contact partners
(https://w3.siemens.com/aspa_app/?lang=en).

Product information on the Internet


The instructions are included on the CDs which are already supplied or may be ordered. In
addition, the instructions are available on the Internet on the Siemens homepage.
A signpost to the range of technical documentation, the online catalog, and the online
ordering system for individual SIMATIC products and systems is available at our website
(http://www.automation.siemens.com)
Here you will find:
● Products & solutions, including our newsletter containing up-to-date information on your
products.
● Electronic trading over the Internet.
● Support with e.g. certificates, brochures and catalogs.

Training center
Siemens offers corresponding courses for newcomers to laser spectroscopy. Please contact
the central Training Center in Karlsruhe.

Training Center Europe


Process Instrumentation and Analytics
Siemensallee 84
D-76181 Karlsruhe, Germany
at (http://www.siemens.com/automation/support-request)

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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.

A.1 General functions

A.1.1 Arithmetic average


The average (or mean) is a way to describe the location of a distribution. The average of a
number of samples is calculated using the arithmetic mean formula:

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

A.1.3 Standard deviation (stdev)


The standard deviation is the positive square root of the variance. It is calculated using the
following formula:

in which
● S represents the variance of the samples.

A.2 Calculations for deviation validation procedures


The following calculations are used for deviation validations.

Method Formula
Get maximum samples Max Samples = <Maximum samples>

Get validation samples insert into tEquip_ValidationInputData (ID_RawData, ID_Validation, Suitable)


select top (Max Samples) rawdataid, id_validation, 1
from vASM_Validation_RawData
where Propertyid = id_property
and [state] <> ‘INV’ and [state] <> ‘EXC’ and start <= finish
and(elapsed <> 1 or elapsed is null)
order by start desc
Check minimum samples minSamples = <Minimum validation samples>
num_validations_out = count(values)
if (num_validations_out<minSamples or num_validation_out < 2)
set state = 'N/A' → no further calculations
else
set state = 'SUCC'
Average of analyzer values = avg (analyser values)

Average of reference values = avg (refvalues)


Deviation relative to ref. = ( (value - refvalue)/ refvalue) * 100 %

Deviation relative to span = ( (value - refvalue)/span) * 100 % (with span = max range – min range)

Deviation = (value - refvalue)

Get control limit dev_avg = avg (value - refvalue)


StandardDeviation = stdev (value - refvalue)
upperctrlLevel = dev_avg + 3 * StandardDeviation
lowerctrlLevel = dev avg - 3 * StandardDeviation
Get warning limit dev_avg = avg (value - refvalue)
StandardDeviation = stdev (value - refvalue)
upperwrnlLevel = (dev_avg + 2 * StandardDeviation)
lowerwrnLevel = (dev avg - 2 * StandardDeviation)
Get deviation limit (thresh- dev_avg = avg (value - refvalue)
StandardDeviation = stdev (value - refvalue)
old) upperdevlLevel = (dev_avg + 1 * StandardDeviation)
lowerdevLevel = (dev avg - 1 * StandardDeviation)
Standard deviation = stdev (value - refvalue)

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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A.2 Calculations for deviation validation procedures

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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ASM calculations
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

A.3 Calculations for ASTM validation procedures


The following calculations are used for ASTM validations. These validations are based on
ASTM 3764.

Method Formula
Get maximum samples Max Samples = <Maximum samples>

Get validation samples insert into tEquip_ValidationInputData (ID_RawData, ID_Validation, Suitable)


select top (Max Samples)rawdataid, id_validation, 1
from vASM_Validation_RawData
where Propertyid = id_property
and [state] <> ‘INV’ and [state] <> ‘EXC’ and start <= finish
and (elapsed <> 1 or elapsed is null)
order by start desc
Check minimum samples minSamples = <Minimum validation samples>
num_validations_out = count(predictedvalue)
(included in Dixon test) if (num_validations_out < minSamples)
set state = 'N/A' → no further calculations
else
set state = 'SUCC'

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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).

Procedure A: variances are essentially the same


1. Calculate the pooled standard deviation of the difference:

2. Calculate the t-value:

Procedure B: variances are significantly different


1. Calculate the t value:

2. Determine the degrees of freedom:

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:

2. Determine the critical x2 value from a x2 distribution table based on the


95th percentile (n - 1)/2 degrees of freedom (if n is even, interpolate
the result):

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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A.4 KPI calculations

A.4 KPI calculations


For the KPI calculations, the operation time is set to:
● Operation time = Online time + checking time + failure time
The number of validations is set to:
● Number of validations = counted validations with state "not excluded"

A.4.1 Absolute values


Based on the analyzer modes/actions and maintenance activities, the following values are
calculated:
● Online Time (TOT) →The total ‘Online Time’ shows the time period during which the last
validation of a device was in a ‘Valid’ state.
● Checking Time (TCT) → Time spent in mode ‘Validation/Calibration’ and/or
"Predictive/Preventive/Corrective Maintenance"
● Failure Time (TFT) → Time spent in mode „Breakdown" and/or "Breakdown Maintenance"
● Report Time (TRT) → The total ‘Reporting Time’ is the time period during which
documentation was open and required.
● Not Required Time (TNRT) → The total ‘Not Required Time’ is the time period during
which the device was set in the ‘Not Required’ mode.
● Mean Time Between Failure (MTBF) → This time indicates the mean failure-free time
between two failures.
Calculation: MTBF = (Operation Time – Failure Time) / Number of failures
● Mean Time To Repair (MTTR) → This time indicates the mean time that was needed to
set the device in a failure-free state again.
Calculation: MTTR = (Failure Time) / Number of failures
● Availability Time → The ‘Availability Time’ is the addition of the ‘Online Time’ and the
‘Checking Time’. It indicates the whole time period during which the device was in a
regular, failure-free state.
Calculation: Online Time + Checking Time
● Capability Index (CpK) → The Capability Process Katayori indicates the process capability
and is calculated after validation, see "Deviation Validation Procedures" table for details.
● Number of breakdowns → The number of all breakdowns and/or failures (modes
„Breakdown" and/or "Breakdown Maintenance")
● Number of predictive maintenances → The number of all predictive maintenance events.

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A.4 KPI calculations

A.4.2 Relative values

Method Description and Forrmula


Online Rate The ‘Online Rate’ is the percentage of time during which the analyzer is complete-
ly available for process tasks.
OR = (online time) / operation time * 100%
Checking Rate The ‘Checking Rate’ is the percentage of time during which the analyzer is not
available for reasons of validation/calibration or maintenance.
CR = checking time / operation time * 100%
Failure Rate The 'Failure Rate' is the percentage of time during which the analyzer is in failure
(breakdown).
FR = failure time / operation time * 100%
Availability rate The ‘Availability Rate’ is the percentage of time during which the analyzer is func-
tioning correctly.
AR = (operation time – failure time) / operation time * 100%
Reproducibility The Reproducibility Rate is the percentage of passed validations
Rate RR = number of valid validations / number of validations * 100%
“Validations out The number of validations out of control in relation to the number of all validations
of control” rate that have been executed.
“Validations out of control” rate = number of validations out of control / number of
validations * 100%
“Validations out The number of validations that exceeded the Specification limits in relation to the
of spec” rate number of all executed validations.
“Validations out of spec” rate = number of validations out of spec / number of
validations *100%
Completed / Number of all validations relative to all scheduled validations.
scheduled valida- Result = number of validations / number of ASM scheduled validations * 100%
tion rate
Corrective / This rate indicates the relation between corrective maintenances and scheduled
scheduled maintenances.
maintenance rate Result = number of corrective maintenance / number of scheduled maintenance *
100% (time filter applied to submission time)
PPM completed / Shows the relation between the number of predictive, corrective and preventive
scheduled maintenances and the number of all scheduled maintenance actions.
maintenance rate Result = number of completed predictive/preventive/corrective maintenance /
number of scheduled maintenance * 100% (time filter applied to planned start
time)

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A.4 KPI calculations

A.4.3 KPI recalculation


After inserting or deleting a historical maintenance request, the analyzer mode history will be
adapted and the following KPIs will be recalculated based on the new mode history and the
time range of the inserted/deleted maintenance:
● Online time
● Checking time
● Failure time
● Number of breakdowns
The following KPIs can be affected by the recalculation of the previously mentioned KPIs:
● Availability
● Mean time between failure
● Mean time to repair
● Number of predictive maintenances
● Corrective / scheduled maintenance rate
● PPM completed / scheduled maintenance rate
If the type of the maintenance request is "non freezing" or the end time of the maintenance
request is before the first analyzer mode entry no recalculation will be done.

Inserting a historical maintenance request


For the given start and end time of a maintenance request, the analyzer mode history will be
changed to “Maintenance” if the current analyzer mode is different from one of the following
modes:
● Not required
● Disconnected
● Validation / Calibration
● Maintenance

Deleting a historical maintenance request


If the analyzer history mode changes between the start and the end time of the historical
maintenance request this request will be deleted and the KPIs will be recalculated.

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A.5 Validation limit conversions

A.5 Validation limit conversions


If the deviation calculation of the ASM Manager is different from deviation calculation display
option of the validation view, the limits will be converted as follows:
● DeviationCalculation = “absolute”
DisplayOption = “relative to ref.” → limit = (limitConfig/refValue) * 100
DisplayOption = “relative to span” → limit = (limitConfig /span) * 100
● DeviationCalculation = “relative to reference”
DisplayOption = “absolute” → limit = (refValue * limitConfig / 100)
DisplayOption = “relative to span” → limit = (((limitConfig * refValue) /100)/ span) * 100
● DeviationCalculation = “relative to span”
DisplayOption = “absolute” → limit = (span * limitConfig / 100)
DisplayOption = “relative to ref.” → limit = (((limitConfig * span) /100)/ refValue) * 100
Meanings:
● refValue = actual configured reference value of a reference component
● span = (max range – min range) of a validation component

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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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