PV-WAVE® Gains Companywide Popularity at Litwin Process Automation

Solutions
Benefits
  • Process data analysis
  • Tightly integrated graphics, statistics, image processing, signal processing and animation allow rapid interpretation of complex data sets
Getting engineers to agree on the best software tools for process data analysis and display is difficult enough at small firms with centralized operations. At a large company, where process control teams are dispersed widely among various plants and divisions, it is nearly impossible. And yet, when six teams of engineers from a large chemical company in Louisiana met to analyze process data from several polyethylene plants, one tool emerged as the standard: PV-WAVE from Visual Numerics, Inc.

"All the other visual data analysis products that we tried tended to choke on the tremendous volume of data," says Ronald A. Bray, formerly a process control specialist at the company. "They lacked functionality and didn't easily line up with our varying data sources."

Bray's first use of PV-WAVE occurred in 1990 during a project that required statistical analysis and display of process data for control and optimization. He built several PV-WAVE routines to pull data from a historical archive, where process control data, descriptions, units and time stamps were stored. Time periods and tag lists were entered as parameters.

Later, as the six teams met for the massive process-control project, Bray spent some time reworking his existing PV-WAVE routines to see if they would prove useful. "During a short demonstration, the other engineers were immediately impressed with PV-WAVE's ability to organize and display results," Bray says. "A previous project of this type required two weeks of effort just to collect and organize the data. But with PV-WAVE, the entire data-analysis portion was essentially complete within that amount of time.

"Interest in PV-WAVE grew quickly as the engineers discovered they could become productive with the application in less than an hour," Bray says. "Other data-analysis tools were quickly abandoned in favor of PV-WAVE," he adds.

A New Standard for Visual Data Analysis (VDA)

PV-WAVE lets technical and business computing professionals interactively explore, manipulate and analyze complex numeric data. Tightly integrated graphics, statistics, image processing, signal processing and animation let users rapidly interpret complex data sets, quickly identify important features and trends and share their results.

The emphasis during the multiteam project was on analyzing process control data to improve manufacturing productivity throughout the company. Data on temperatures, pressures, flows and other process control information were collected and analyzed. "One of the teams collected nine hours of one-second data on 40 tags [about one million samples] and was able to get the data from the disk into PV-WAVE in just two or three minutes," Bray says. "And that was using a VAX®station 3100 computer, which is considered slow by today's standards." The key to PV-WAVE's speed is an array-oriented, fourth-generation programming language (4GL) designed specifically for visual data analysis. "The code is compact and efficient," Bray says. "Also, since it is an interpreted language, it is very easy to develop and debug applications. It has the speed of a compiled language, where calculations are done with large arrays."

Bray's custom VDA routines were developed with PV-WAVE Foundation, Visual Numerics' flagship UNIX® product for data visualization. "Other visualization tools that I had tried were painfully slow and inadequate for these large data sets," Bray explains. "They usually required data to be put in their own special format before they could be accessed, which required tedious programming.

"PV-WAVE's 4GL, by contrast, reduces coding efforts by up to 80 percent compared with traditional programming languages, such as C and FORTRAN," Bray adds. "It takes time to get used to the syntax and language constructs. But once you get used to it, you can become very proficient at data analysis and visualization. It is my preferred language because you can quickly create applications that are easy for users to understand, yet have all the capabilities required by power users." Bray's early work with PV-WAVE was performed on Digital's VMS-based VAXstations. As interest in PV-WAVE spread, Bray was able to port his PV-WAVE routines to a variety of UNIX platforms, as well as Windows® NT and MS-Windows.

"PV-WAVE runs as an X application on the VAX, so any PC or Macintosh® computer that does X emulation can be used to access PV-WAVE applications," Bray says. "Porting a PV-WAVE application among platforms takes minimal effort. Any calls specific to a particular operating system must be changed, but there are very few of these."


An On-going Commitment to PV-WAVE

Today, Bray is employed at another company, Houston-based Litwin Process Automation. Litwin provides advanced control and training simulator applications to the refining and petrochemical industry. PV-WAVE is still playing a critical role in Bray's work. His team purchased five licenses of PV-WAVE to assist with their work creating dynamic simulations to help regulate manufacturing processes for Litwin clients. They work with large data sets, typically 50 to 400 tags, with anywhere from 5,000 to 30,000 points per tag.


Bray has also experimented with PV-WAVE: GTGRIDTM, an option for the UNIX product that supports general-purpose data gridding to accommodate irregularly sampled data sets.

All in all, Bray credits himself for creating the actual PV-WAVE routines, but credits Visual Numerics for making it possible for one person to quickly develop applications that improve the overall productivity of several process control project teams.

"Without PV-WAVE, it would have been impossible for a single engineer to develop and support such a powerful and useful application as a sideline to the usual work that must be done," Bray concludes. "We have been very impressed with the speed and robustness of the Visual Numerics products, yet I feel we are just beginning to explore their full potential. They integrate well with many types of data and software tools and dramatically increase productivity where visual data analysis is concerned."