Professional Documents
Culture Documents
5
8.4 pH DATA: THREE-SHIFT SUBGROUP CONTROL CHART
UCL
AVERAGES
8.3
8.2 MEAN
8.1
LCL
8.0
7.9
MEAN
0.5 pH DATA
DISTRIBUTION
RANGES
0.4 UCL
0.3
0.2
MEAN
0.1
0.0
0 2 4 6 8 10 12 14 16 20 24 28 DATE
40
PERCENT OF DATA
30 NORMAL
DISTRIBUTION
20
10 -4 -3 -2 -1 +1 +2 +3 +4 std.
Table of Contents
Preface............................................................................................................................................. i
Legal Notice ................................................................................................................................... ii
Table of Contents..........................................................................................................................iii
1 Why Do We Need to Look Deeper? ..................................................................................... 1
1.1 Troubleshooting ............................................................................................................................ 2
1.2 Historical Data .............................................................................................................................. 3
1.3 Performance Indicators ................................................................................................................. 4
2 Data Formats ......................................................................................................................... 5
2.1 Tabulation ..................................................................................................................................... 6
2.1.1 Significant Figures ................................................................................................................... 6
2.2 Graphical Trends........................................................................................................................... 7
2.2.1 Scatter Plots.............................................................................................................................. 7
2.2.2 Runs Charts .............................................................................................................................. 7
2.2.3 Curve Fitting ............................................................................................................................ 8
2.2.4 Auto-Scaling............................................................................................................................. 8
2.2.5 Multi-Parameter Plotting .......................................................................................................... 9
2.3 Histograms.................................................................................................................................... 9
3 Data Distributions ............................................................................................................... 12
3.1 The Normal Distribution............................................................................................................. 12
3.2 The Poisson Distribution............................................................................................................. 17
3.3 The Binomial Distribution .......................................................................................................... 19
3.4 Combining and Comparing Distributions ................................................................................... 22
3.5 Precision, Accuracy, Bias and Repeatability............................................................................... 26
4 Medians and Percentiles ..................................................................................................... 29
4.1 Percentiles................................................................................................................................... 29
4.2 Data Sorting ................................................................................................................................ 29
4.3 The Box and Whisker Plot.......................................................................................................... 30
5 Time-Series Analysis ........................................................................................................... 32
5.1 Random Movements ................................................................................................................... 32
5.1.1 Positive First Difference Test ................................................................................................. 32
5.1.2 Turning Points Test................................................................................................................. 32
5.1.3 Runs Test ................................................................................................................................ 33
5.2 Periodicity................................................................................................................................... 35
5.3 Trends ......................................................................................................................................... 35
6 Statistical Process Control .................................................................................................. 36
6.1 Process Capability ...................................................................................................................... 36
6.2 Control Charts............................................................................................................................. 38
6.2.1 Moving Averages.................................................................................................................... 43
6.3 Median Control Chart ................................................................................................................. 45
6.4 CuSum Control Chart ................................................................................................................. 46
6.5 Sum and Difference Control Charts ............................................................................................ 46
6.6 Attribute Control Charts ............................................................................................................. 47
6.6.1 Control Charts for Defects...................................................................................................... 47
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6.6.2 Control Charts for Defectives................................................................................................. 49
6.7 What do you do with a bad data point?....................................................................................... 51
7 The Electronic Log Sheet.................................................................................................... 53
7.1 Off-the-Shelf Products ................................................................................................................ 56
7.2 Do More than Plot Data .............................................................................................................. 56
7.2.1 The Appearance is Important.................................................................................................. 58
7.2.2 Incorporating the Graphics into the Text ................................................................................ 59
7.2.3 Significant Figures ................................................................................................................. 60
8 Applications in the Field ..................................................................................................... 61
8.1 Laboratory Samples vs. Field Instrumentation............................................................................ 61
8.1.1 Cost ........................................................................................................................................ 61
8.1.2 Reliability ............................................................................................................................... 61
8.1.3 Availability ............................................................................................................................. 61
8.1.4 Sensitivity............................................................................................................................... 62
8.1.5 Service Requirements............................................................................................................. 62
8.1.6 Calibration and Stability......................................................................................................... 62
8.2 Monitoring the Controlled System.............................................................................................. 63
8.2.1 If all additions are stopped ..................................................................................................... 63
8.2.2 Removal process is stopped.................................................................................................... 64
8.2.3 Isolating the system ................................................................................................................ 65
8.2.4 Transients ............................................................................................................................... 65
8.3 Mode of Addition........................................................................................................................ 65
8.3.1 Continuous Addition:.............................................................................................................. 65
8.3.2 Intermittent or Batch Addition:............................................................................................... 65
8.4 Steady-State vs. Batch Operation................................................................................................ 66
8.5 The Continuously Varying Process ............................................................................................. 68
8.6 Relationships Among Parameters ............................................................................................... 69
9 Applying Quality Methods ................................................................................................. 70
9.1 Quality Assurance ....................................................................................................................... 70
9.1.1 Established Procedures........................................................................................................... 70
9.1.2 Repeatability, Reproducibility and Bias: ................................................................................ 71
9.1.3 Record Keeping:..................................................................................................................... 71
9.1.4 Chain of Command: ............................................................................................................... 71
9.1.5 QA Manual ............................................................................................................................. 72
9.1.6 ISO-9000 Compliance ............................................................................................................ 72
9.2 Introducing a Statistically-Based Program.................................................................................. 73
9.2.1 Continuous Processes ............................................................................................................. 73
9.2.2 Batch Processes ...................................................................................................................... 75
9.2.3 Linking Statistical and Quality-Assurance Programs ............................................................. 76
9.3 Meeting Performance Indicators ................................................................................................. 76
9.4 Troubleshooting and Assigning Priorities ................................................................................... 76
9.4.1 Cause-and-Effect Analysis ..................................................................................................... 76
9.5 Assigning Priorities..................................................................................................................... 78
9.6 A Concluding Thought................................................................................................................ 79
Bibliography ................................................................................................................................ 80
Index ............................................................................................................................................. 81
Appendices ................................................................................................................................... 83
Rev: 2007-May-27
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Optimizing Water Treatment
for Plant Utilities, Offsites
and Electrical Generation
Marvin D. Silbert
(c) 2006
Marvin Silbert and Associates
ISBN 0-9695133-8-0
Table of Contents
Table of Contents...................................................................................................... i
INTRODUCTION ................................................................................................... 1
1 What is this Liquid called Water? ..................................................................................... 2
1.1 The Hydrologic Cycle............................................................................................................... 2
2 Why Do We Need Water Treatment? ............................................................................... 8
2.1 Scaling ...................................................................................................................................... 8
2.2 Corrosion ................................................................................................................................ 15
2.3 Microbiological Species.......................................................................................................... 25
2.4 Natural Organic Material ........................................................................................................ 27
2.5 Hydrocarbons.......................................................................................................................... 28
2.6 Solids ...................................................................................................................................... 29
2.7 … in the Real World ............................................................................................................... 31
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16 Treatment of Low and Medium-Pressure Boilers........................................................ 223
16.2 Erosion-Corrosion / Flow-Accelerated Corrosion ................................................................ 230
17 Treatment of High-Pressure Boilers.............................................................................. 231
17.1 All Volatile Treatment (AVT) .............................................................................................. 231
17.2 Oxygenated Treatment (OT) ................................................................................................. 231
17.3 Phosphate .............................................................................................................................. 231
17.4 Optimizing High-Pressure Phosphate Programs ................................................................... 240
17.5 Hideout.................................................................................................................................. 241
17.6 Monitoring and Controlling an EPT Program....................................................................... 244
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