System 800xA Training

Chapter 3 Creating and Loading Basic Asset Monitor

TABLE OF CONTENTS

Chapter 3 Creating and Loading Basic Asset Monitor ............................................................................................................. 1

3.1 General Information...................................................................................................................................................... 2
3.1.1 Objectives .............................................................................................................................................................. 2
3.1.2 Legend................................................................................................................................................................... 2
3.1.3 Documentation References ..................................................................................................................................... 2
3.2 General Asset Monitor Operation .................................................................................................................................. 3
3.2.1 Asset Optimization Server ...................................................................................................................................... 3
3.2.2 Asset Monitor Aspects ........................................................................................................................................... 4
3.3 Common Asset Monitor Tabs ....................................................................................................................................... 5
3.3.1 Asset Monitor Tab ................................................................................................................................................. 5
3.3.1.1 AO Server Assignment Section ........................................................................................................................ 5
3.3.1.2 Asset Monitor Section ..................................................................................................................................... 6
3.3.1.3 Asset Monitor Configuration Lifecycle Section ................................................................................................ 7
3.3.2 Conditions Tab....................................................................................................................................................... 8
3.3.2.1 Condition and Sub-Conditions Settings ............................................................................................................ 8
3.3.2.2 Trigger Execution ............................................................................................................................................ 9
3.3.2.3 Data Source Aspect ......................................................................................................................................... 9
3.3.2.4 Corrective Action Taken, Possible Cause, and Suggested Action .................................................................... 10
3.3.2.5 Severity......................................................................................................................................................... 11
3.3.3 Asset Parameters Tab ........................................................................................................................................... 11
3.3.4 Input Records Tab ................................................................................................................................................ 12
3.3.4.1 Input Records ................................................................................................................................................ 12
3.3.5 Logic Tab ............................................................................................................................................................ 13
3.3.6 Other Tabs ........................................................................................................................................................... 14
3.4 Signal Conditioning .................................................................................................................................................... 15
3.4.1 Masking ............................................................................................................................................................... 15
3.4.2 Inhibiting ............................................................................................................................................................. 16
3.5 Asset Monitor Inheritance ........................................................................................................................................... 18
3.5.1 Normal Inheritance Behavior................................................................................................................................ 18
3.5.2 Special Asset Monitor Inheritance ........................................................................................................................ 19
3.5.3 Configuring Asset Monitors on Types .................................................................................................................. 21
3.6 How to Create and Configure an Asset Monitor........................................................................................................... 22
3.6.1 Overview ............................................................................................................................................................. 22
3.6.2 Example............................................................................................................................................................... 22

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3.1 General Information

3.1.1 Objectives
On completion of this chapter you will be able to:
Describe examples of use for various basic Asset monitors
Navigate the various dialogs associated with a basic Asset monitor demonstrating
what they have in common and what is unique to each type
Configure all basic Asset monitor types

3.1.2 Legend
> Indicates when you go from one menu to a sub-menu
Italic Indicates object and file names
“ “ Indicates dialog box buttons, tabs, menus etc.
Bold Indicates important topics
Indicates start/explanation of student activity

3.1.3 Documentation References

3BUA000118 Industrial IT 800xA – Asset Optimization
800xA Asset Optimization Configuration

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3.2 General Asset Monitor Operation

3.2.1 Asset Optimization Server

In a previous lesson, an Asset Optimization Server (AO Server) Object was created
and configured in the system. It is assigned to run on a specific physical server node in
the system.
The AO Server Object provides the “intelligence” for Asset Optimization by:
Constantly watching and monitoring data
Analyzing the data
Deciding if the analysis indicates an abnormal condition or trend
Notifying and alerting operator or maintenance personnel of the conditions or
possible impending conditions

NOTE! The Asset Optimization Server Object in the Control Structure

is connected to a particular Service Group/Service Provider. This
configuration can be seen in the Asset Optimization Server Aspect of
this Object

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3.2.2 Asset Monitor Aspects

The AO server, by itself, provides no functionality. It has to be specified which data
points need to be monitored, how often to monitor them, the logic it needs to execute
in order to properly analyze the data, and what conditions exist that plant personnel
need to be informed about.
The Asset Monitoring Aspects define these configuration settings for a particular
Object. Once the Asset Monitor (AM) is configured, the settings are “uploaded” to the
Asset Optimization server which performs the actual monitoring functions. Once the
AM exists in the AO server, it is referred to as an Asset Condition Document (ACD).
Asset Monitors are specific Aspect types that can be instantiated on any Object or
Object type within 800xA system.

NOTE! An example of the BOOL CHECK Asset monitor for process

filter

When an Object in your 800xA system has an Asset Optimization Aspect associated
with it, you will frequently hear the Object referred to in Asset Optimization
documentation as a plant “Asset”.
The Asset Monitor Aspects contain the information regarding:
Which of 800xA system Object property data points needs to be monitored to
effectively evaluate the status, or condition, of the Object
How often to collect data and analyze it
Static settings or values, also known as “parameters” into the analysis logic
The designation of which particular Asset Optimization Server node in the system
will be responsible for data collection and analysis
The actual logic which will be performed to make the analysis
The settings are made on the Asset Monitor Aspect configuration view on a variety of
“tabs” along the top edge of the view window. Since each of many of the pre-defined
Asset Monitor types have these tabs in common, familiarity of these settings is
required
Later sections in this course describing the pre-defined Asset Monitor Aspect types
will only discuss the configuration information which is specific with a particular
Aspect. The following sections concern ALL Asset Monitor Aspects.

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3.3 Common Asset Monitor Tabs

3.3.1 Asset Monitor Tab

The Bool Check Asset Monitor monitors a signal with two states: normal and alarm.
Depending on the configuration, it notifies if the signal is in its alarm state, or not in
normal state. In the “Config View” of the “Bool Check” Aspect, select the AO Server
and the Execution Interval. Right-click on the Bool Check Aspect, select “Config
View”.

3.3.1.1 AO Server Assignment Section

The Asset Monitor must be assigned to an AO Server in your system. You can assign
it to a specific Asset Optimization Server in your system, or you can designate the
assigned AO Server to be a “default” server. If a specific server is not specified and
“Default” is selected, then the AO Server designated to be the default will be used to
execute the logic in the Asset monitor.
One thing you should note if you plan on having multiple Asset Monitor Aspects on
the same Object is that all AM’s on that Object must run in the same AO Server.
When you add additional Asset Monitors on an Object which already has one, the AO
Server value from the existing Asset Monitor will be assigned to the new one. If no
other Asset Monitors exist on the Object, then the copied, or template, value is used.

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3.3.1.2 Asset Monitor Section

Logic Execution Interval: The requested time interval in seconds between data
collection and logic execution of this monitor in the Asset Optimization server.
The actual execution interval may be longer than the configured one on heavily loaded
systems; the execution times may even be shorter than requested in some instances.
The “Asset URL:” setting allows entering of a web page address which can provide
relevant information about the Asset. When this configuration parameter is specified
the Diagnostics menu entry is enabled in the Asset Monitor and Asset Reporter views
which will be discussed in other lessons.
Asset Monitor Failure Alarm Severity sets the severity value of the alarm (from 1 to
1000) which is generated should a problem occur when the logic of the Asset Monitor
is executed. The alarm severity is used in alarming the abnormal status of an Asset
Monitor, such as bad configuration or bad Input Records values.
The Asset Structure contains the Plant Assets Objects to see the respective alarms

These kinds of alarms are of the “Asset Monitoring Status” category and they do not
generate a Fault Report when they become active. Right click on the blinking alarm,
select “Details”.

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3.3.1.3 Asset Monitor Configuration Lifecycle Section

This section provides information about the Asset Monitor Aspect as it relates to the
assigned Asset Optimization Server. The possible values for the lifecycle “status” are:
Lifecycle State Description
Configuration error, Object not in The Object containing the Asset Monitor Aspect is not in
Control Structure the Control Structure. This is an invalid configuration
and must be fixed by inserting the Object at least once
in the Control Structure
Not loaded, enabled The Asset Monitor Aspect configuration is not loaded to
an AO Server
Loaded, not current The Asset Monitor Aspect configuration has been
modified since it was last loaded to an AO server
Will not load, disabled The Asset Monitor Aspect is not enabled; it is not (and
will not) be loaded into an AO Server
Loaded, current The current Asset Monitor Aspect configuration is
loaded into an AO Server
Unknown, unable to contact the Unable to contact the AO Server. The communication
AO Server attempt to the AO server that is needed to compare the
AM Asset to failed.

This section on the “Asset Monitor” tab will also indicate the date and time when this
Asset Monitor Aspect was last modified as well as the Date and time when this AM
was last loaded into an AO Server node and indicates which server it was loaded into.

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3.3.2 Conditions Tab

In this tab, complete the Severity, Action Taken text, Possible Cause text and
Suggested Action that will be appear when the alarm gets active. Right-click on the
Bool Check Aspect, select “Config View”.

3.3.2.1 Condition and Sub-Conditions Settings

The “Conditions” tab allows you to specify a name for the Condition being monitored
as well as name(s) and description(s) for the possible values for the condition. In the
example shown above, the condition being monitored is named “FilterStatus” and,
there are two possible sub-conditions for this condition: the “FilterStatus” can be
either “OK” or “NotOK”.
When this Asset Monitor logic evaluates these Assets and determines that an Asset
condition notification needs to be made, the condition information can be seen in the
plant Asset alarm list.
Make sure you check the drop-down list on the conditions tab as a monitor may have
several different conditions available, such as High and High-High, or High, and Low,
etc.
The Asset Structure contains the Plant Assets Objects to see the respective Alarms

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3.3.2.2 Trigger Execution

When the “Trigger Execution” setting is set to “True”, the Asset Monitor will be
scheduled for immediate execution when it is notified that a subscribed OPC value has
changed through a client-callback. Thus, setting this configuration parameter to True
may increase the actual Asset Monitor execution frequency based on the Input
Record's Data Source Aspect OPC Group Update Rate.
Regardless of whether “Trigger Execution” setting is enabled or not, the Asset
Monitor will still be periodically executed based on the overall Execution Interval
configuration parameter of the Asset Monitor.

3.3.2.3 Data Source Aspect

For each of the input records which require the Asset Optimization server to subscribe
for data, the correct “Data Source Aspect” needs to be configured.

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3.3.2.4 Corrective Action Taken, Possible Cause, and

Suggested Action
The Possible Cause and Suggested Action fields allow you to enter text which will be
made available to other applications, such as Maximo, and other Aspects, such as the
Asset Reporter Aspect, as shown in the following example:

The “Corrective Action Taken” field is made available for other Aspects or
applications to write values back into the Asset Monitor to indicate what, if any,
actions have been taken related to that particular condition and sub-condition.

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3.3.2.5 Severity
The Values for the “Severity” setting can range anywhere from 1 to 1000. These
severity values are available to other applications and Aspects, such as an Alarm and
Event list where the severity level can be used to determine the priority on the list.

Right-click on the blinking alarm, select “Details”.

3.3.3 Asset Parameters Tab

Right-click on the Bool Check Aspect, select “Config View”. The Asset Parameters
tab provides a data entry screen to enter various other parameters which are required
by the Asst Optimization server in order to perform the logic required by the type of
Asset Monitor being used. For instance, you can define what the “normal value” of the
data should be so that the evaluation logic can determine if it is normal, above normal,
below normal, etc.

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3.3.4 Input Records Tab

The Input Records tab contains the definition of all of the data items needed by the
Asset Monitor logic in order to assess the current Asset condition.

3.3.4.1 Input Records

Which records are needed to properly analyze the Asset condition are not configurable
on the instances of the Asset Monitors, but are pre-defined by the Aspect category of
the Asset monitor being used. The “Bool Check” type of Asset Monitor Aspect
requires two input records to evaluate the Asset:
In the Aspect System Structure, notice the two inputs in the Bool Check Object

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Whereas, an Asset Monitor used to evaluate a heat exchangers performance, requires

more data to make an analysis of the Asset condition, in this case, the heater
exchanger is represented by the HXAM_G Object.

3.3.5 Logic Tab

This tab provides information regarding the logic being executed in the Asset
Optimization server. The AO Software contains pre-defined logic, shown in this
example in the ProgID box, which collects the data and analyzes the Asset condition.
The information presented here is not configurable and is provided for information
only.

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3.3.6 Other Tabs

Depending upon the Asset Monitor type, there may be additional tabs displayed on the
configuration view. This example shows the Output records tab. Output records are
the results of the Asset Optimization Server calculation or analysis results.
Output Record values are published in the Object where the Asset Monitor resides via
the AssetMonitorProperties Control Connection Aspect. This information is then
available to any other application via the standard OPC interfaces.

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3.4 Signal Conditioning

3.4.1 Masking
Input records, or signals, can be “conditioned” or manipulated to provide filtering on
the signal before it is evaluated by the Asset Monitor logic. This filtering is
accomplished by using bit “masks”.
As you can see in the example below, masks are specified in hexadecimal format, such
as &FFFF.

Masks are typically applied to input signals and inhibit signals. The individual “bits”
of the signal and the mask are logically AND-ed together to get the resultant
conditioned signal which is then sent to the Asset Monitor’s logic for Asset condition
evaluation.
This is best explained by using an example. The hardware status properties of AC
800M controller hardware report the status with a 32-bit DWORD data type. The
following chart is an example of the bits of this DWORD value:

Bit Meaning Bit Meaning

0 Connection down 8 Forced
1 I/O error 9 Watchdog timeout
2 Module missing 10 Device failure
3 Wrong module type 11 Device not found
4 Channel error 12 Wrong device type
5 I/O warning 13 I/O connect error
6 Underflow 14 I/O configuration error
7 Overflow 15 Hardware configuration error

During normal operation of the hardware, using these bits, the value of the signal
would be:
0000000000000000 = 0
If the hardware experienced a channel error and underflow simultaneously, then those
bits would be set and the value reported would be:
000000001010000 = (64) + (16) = Decimal: 80, Hex: 50
If a value of “80” were reported to an Asset Monitor and the “normal” value of the
signal is configured as “0”, then we would get the desired Asset Monitor alarm.

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Consider, however, if an IO point was “forced” by a maintenance technician during

normal maintenance activities, then the status word reported by the hardware would
be:
0000000100000000 = (256) = Decimal: 256, Hex: 0x100
This signal would cause the same Asset Monitor alarm because the input signal is
something other than the normal value of “0”.
Masking allows us to mask out the FORCED bit (bit 8). The default mask value of
&FFFFFFFF has all bits set (1111111111111111). Since the input value bits are
AND’ed with the signal bits the resultant signal is the same as the input signal and no
masking has occurred
INPUT: 0000000100000000
MASK: 1111111111111111
RESULT: 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0
We want to “mask” or “hide” the forced bit so that it is not included in the signal sent
to the Asset Monitor logic. In order to do this, we would set the mask so that bit #8 is
set to “0”.
INPUT: 0000000100000000
MASK: 1111111011111111
RESULT: 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
As you can see, the resultant output is “0”, and the Asset Monitor logic does not detect
the non-normal status word being reported. Any other bit being set would trigger the
Asset Monitor.

3.4.2 Inhibiting
Asset Monitor execution can by dynamically inhibited to prevent condition evaluation
of the Asset. This allows the AM to prevent false triggering, for instance, during plant
shutdowns or transient conditions such as during equipment start up.

The “Inhibit” Input Record, if used, would be connected to a subscribed OPC property
in the same manner as other input records. If either the Inhibit Input Record Data
Source Aspect or Data Source Item are left blank, then the inhibit functionality is
disabled. When used, the value received for “Inhibit” is passed through an

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Inhibit_Mask and compared to the value entered for the Inhibit_Value Asset
Parameter.

If the masked Inhibit input record matches the value of the Inhibit Value parameter,
then the Asset Optimization server will perform the following actions:
All of its conditions are set to the Normal State with a quality of
goodLocalOverride and a description of Inhibited
The overall Asset Monitor Status quality is set to goodLocalOverride and the
related status text to inhibit
All of the alarms related to the Asset Monitor are deactivated (set to normal)
All of the Asset Monitor output records, if any, will have their quality set to Bad
Not Connected

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3.5 Asset Monitor Inheritance

3.5.1 Normal Inheritance Behavior

When an Object is created, or “instantiated”, the new Object will be constructed based
upon the “type” of object being created. The system will create the new Object and
create one or more Aspects on the new Object based upon the settings in the Object
“Type Definition” Aspect in the Object Type Structure.

You can not modify the settings on various Aspects on the newly instantiated Object
because these settings are inherited from the same Aspect in the Object type
structure. Any changes or modification you wish to make must be made either (a) on
the Object type itself or (b) you must “break” the chain of inheritance back to the
Object type by selecting “Override” on the instantiated Aspect.

Of course, once the inheritance chain has been broken in this manner, any subsequent
changes you make on the Aspect in the Object Type structure will NOT be reflected
on the Aspect where the inheritance is broken.
Consider the situation where you have developed an Object type for the pumps in your
process. The Object type will contain a Runtime Check Asset Monitor to alert
maintenance personnel when a specified number or running hours has been reached.
Any Objects created using this type would get the runtime hours setting from the
Object type, as shown in the example below for a Drain Pump Object and a Fill Pump
Object.

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MyPumpType

The maintenance requirements of these two pumps may require that one pump
requires inspection after 1000 running hours and the other after 1500 hours. You could
modify the hours setting on a pump by overriding the inheritance and making the
changes to the instance, however, by doing so, you would loose ALL inheritance from
the settings made on the Object type.

3.5.2 Special Asset Monitor Inheritance

Asset Monitor Aspects provide a special inheritance behavior to allow modified
Aspect data on the instance level without stopping inheritance for other parts of the
same Aspect.
It is possible to modify Aspect configuration data for certain sections of an Asset
Monitor Aspect while still keeping inheritance for those Configuration sections that do
not need customization. This functionality increases the granularity of inheritance
from the entire Aspect to the following Asset Monitor configuration sections:
Asset Monitor Tab

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Condition Tab

Asset Parameters Tab

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Input Records Tab

3.5.3 Configuring Asset Monitors on Types

Create the Objects in the Object Type Structure and add the needed Asset
Monitor Aspects
Configure the Asset Monitor Aspects on the Object Type as far as possible by
disabling the Inherit Configuration check box and entering the Object Type
specific information
By disabling the Inherit Configuration check box the information will not be
inherited from the category anymore regardless of whether or not it was edited
It is possible to re-enable the Inherit Configuration check box if it is necessary to
go back to the original information. The manually edited data will be overwritten
Open the Object Type Definition Aspect on the new Object Type and select Copy
to all instances in the Aspect Control tab for the newly added Asset Monitor
Aspects. This setting translates into copying the Asset Monitor Aspects to all of its
Object instances, but these instance Asset Monitors will, by default, inherit from
the Object Type
Whenever the Object Type gets instantiated, the Asset Monitors for this particular
instance will inherit their information from the Object Type
An instance specific modification of an Asset Monitor Aspect coming from an
Object Type is still possible by disabling the Inherit Configuration check box on
the specific TAB of the instance

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3.6 How to Create and Configure an Asset Monitor

3.6.1 Overview
Right-click the Object to which the Asset Monitor will be associated and select
“New Aspect…” from the context menu. The Object being monitored must exist
in the Control Structure.
Select the desired Asset Monitor Aspect to add and give it a descriptive name
Right-click the newly-created Aspect and select the “Config View” option
Enter the appropriate configuration data on each of the configuration tabs.
Override inheritance only where necessary
Assign the desired Asset Optimization Server and execution parameters on the
“Asset Monitor Tab”
Upload the Asset Monitor to the Asset Optimization server node for execution

3.6.2 Example
In this example, we will be adding the Bool Check Asset Monitor Aspect to a single
instance of an Object in the control structure. The example assumes that we want to
monitor the boolean value “ObjErr” of the Heater and Cooler Function Block and alert
when the value of “ObjErr” is “true”.
1. Right-click the S01CM_H/C1 Object in the Reactor application and select New
Aspect. The Bool Check Aspect type was selected and given a name
“EXAMPLE”.

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2. Open the “Config View” of the Aspect by right-click, and select the “Conditions”
tab. The Bool Check type only has a single Condition defined called “STATE” by
default. Because this is not very descriptive, it is a good idea to rename the
condition from state to something else, such as “Object Error”, to describe the
point being monitored. Because the information displayed on the screen is
“inherited”, the Inherit Configuration checkbox must be unchecked and
information entered into the desired fields.

3. Nothing on the “Asset Parameters” tab needs to be modified because the values
entered are correct for this application of the Asset monitor; the “normal”
condition of the point being monitored is “false”.

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4. On the Input Records tab, the inherited values are not suitable because there is no
data source identified and nothing entered for the point to be monitored. Disable
inheritance for this tab, and select the appropriate Asset Monitor Data Source from
the list of available sources.

5. Clicking the “Open Properties browser” opens the Property Browser window
where you navigate to the desired point to monitor and copy the path information
for that item to the windows clipboard by clicking the “Copy” button on the
browser window when you have the item selected.

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6. Paste the copied clipboard contents into the cell.

7. Apply all changes and navigate to the Asset Monitor tab and observe the Asset
Monitor lifecycle status as “Enabled, not loaded”.
8. Assign the AM to the desired Asset Optimization server.

9. Uploading can be done for this monitor only by clicking the “Load Configuration
to AO Server” button. You can also load this monitor to the Asset Optimization
server by performing a Load All AM” operation on the Asset Optimization Server
Object in the Asset Optimization Control Network.

10. Always check for proper operation of the newly created Asset Monitor in its
“Main view”.

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