Advance Plant Management Module in FF Controlled Process Industry

Transcription

1 Fieldbus Foundation A Way Forward Advance Plant Management Module in FF Controlled Process Industry Jasbir Singh Essar Oil Ltd 1

2 ROI Improvement Increase ROI Reduce Capital Cost Increase Profitability Reduce conversion Costs Increase Revenue Increase Productivity Reduction of losses 2 Reduced Project Capital Installation & Commissioning Cost Warehouse Inventory / Spares Product mix/ Feed stock Reduced Feed stocks Energy and Utilities Maintenance waste Abnormal Events Low grade product Penalties Increased Yield Product Consistency New product Equipment Capacity Equip. Efficiency Reduced Unscheduled Downtime & Small stoppages Planned Shutdowns Low Maintenance time Optimize Maintenance Resources, Minimum Spare parts Inventory, Reliable Maintenance history

3 PM Plan for time base proactive maint. Asset Wear Pattern: PROBEBLITY OF FAILURE AGE DESCRIPTION GRAPHICAL REPRESENTATION Type of Asset Maint. EXAMPLES A. Traditional view B. Bath Tub Curve Time Base Wear & Tear Failure of control Valves moving parts, Mechanical drive items (gear box, chain) Electro-mechanical items, Electronic components (positioners) give rise to infant failure at the left side of curve, while mechanical component give late life failure, (Internal failure of control Valves) C. Slow Aging Control Valves (external affects) D. Best New Random Wear Hydraulic & compressed air System E. Constant Random Failure F. Worst New 3 Rolling element bearing Electronic Instruments (transmitters, Sensors, Cards, FF accessories, Switching Hub, Operator /Touch Screen

4 Maintenance Practices Process devices start deteriorating and wear out from the minute it s placed in service. Types of maintenance: Run to failure No maintenance till device fail Preventative maintenance Based on schedule given by equipment vendor or past history Predictive maintenance Based on future prediction of condition of devices 4

5 Maintenance Practices Run to failure If it s not broke, why to fix it? It s been in operation for years Do not touch it will give more problem We ve never had a problem It was already calibrated at the factory No budget this year No schedule given by vendor for maintenance this year Process running and outage not possible We do everything by ourselves, if broke we can repair 5

6 Maintenance Practices Preventive Maintenance Strip down all Devices & Control valves for maintenance during annual Turn around? Workshop to be equipped to calibrate and maintenance of all instruments & valves Spare parts to be procured based on experience Large Resources to be arranged to complete the job Long turn around time to finish all jobs Manual data entry for history of problem & maintenance High budget Large inventory of unused spare parts 6

7 Maintenance Practices Predictive Maintenance Condition Monitoring by On Line instruments on machine & OFF line tools (NDT tools) by schedule checking Gather information from intelligent devices Use of Hand held tool for monitoring health of equipments & devices Human intelligence for analysis of data Prediction based on Various tools Not very accurate probability: Accuracy of plan based on judgment Some maintenance missed out due to result in uncertainty of failure 7

8 Maintenance Practices 8

9 Three- Level Diagnostics Module - Abnormality Analysis Level 3 Level 2 Drift Operations Level 1 µp Loop Electronics Defective Sensor Drift External influence 9 Device

10 Three- Level Diagnostics Module - Abnormality Analysis Device Checking & Maintenance: Maintenance based on vendor s recommendation Decisions and actions based primarily on the passed history Maintenance by reactions triggered by what has happened and some corrective action has been taken Schedule maintenance by CMMS (Computerised Maintenance Management System) to warranty for its functioning till next turn around Information collected from log book and some time device show flag of deterioration 10

11 Three- Level Diagnostics Module - Abnormality Analysis Loop Testing & Maintenance: Mostly limited to loop checking by current / voltage injection from field Tightening of terminals Inspection of Junction boxes DCS input card, Signal conditioner calibration 11

12 Three- Level Diagnostics Module - Abnormality Analysis Process Diagnosis & Corrective actions: No boundary between Process abnormalities and device failure, unless checked physically More effective analysis with DCS process real time & historical trends Monitoring long term process deviation by use of Analytical tool like Graphs, Run Charts, Control Chart, Cause & Effect diagram, Check Sheets, Histogram, Gauge R & R etc. Use of Log books or CMMS in Text form to capture long term historical deviation / changes 12

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14 When maintenance is to be done? What kind of maintenance is needed? 14

15 Four - Level Management Module - Abnormality Analysis Level 4 Enterprise Network Level 3 Level 1A Level 2 FF Accessories Drift Operations Communication & Networking Loop Level 1 FF Sensors µp Electronics Defective Sensor Drift External influence 15 Device

16 Advance tool: Process knowledge captured by machine in terms of logics & algorithms. Knowing better what you are doing now by capturing real time data and its historical trends Developing model and continuously improving its algorithms Comparing what you are doing now against what you expected to do and understanding difference Systematic storage and graphical display representation of the measurement & fault Graphical Display the deterioration trend & alarming the operator Forecasting the future failure time limit before it become critical Allow Engineer to take decision for plant stoppage basing decisions more on facts and data and less on intuition Detecting problems before they become critical 16 ON LINE ALERT

17 Device Level (Sensing): Device Health Information: Electronics Defective µp Sensor Drift External influence Electronic Failure Sensor not responding Device communication problem Communication Hardware component deterioration Power supply failure 17

18 Device Level (Sensing): Device Configuration: FF Basic-to-LM device wizard Safe way to enable/disable Backup LAS Provides wizard to step through sequence Insures BLAS will work when needed 18

19 Device Level (Sensing): Device Replacement: Device Replacement by Operator Replacement from Operator Station or Engineering Station Auto replacement Upgrading devices on-line 19

20 Device Level Performance (Sensing): Advance Prediction: Predictive Alarm Failure Time 20

21 Device Level (Final Element): Device Health Information: REASONS External / Environmental Effect Internal Effect / Improper Process control FAILURE TYPE Valve corrosion, Gland packing degradation (leakage of toxic, expansive fluid), lubricating oil attrition Stem deformation, Stem linkage damage, Spring failure, Stem & plug scuffing, Actuator air leakage, air insufficient, Air loss, Positioner failure, Positioner linkage loose or improper setting, Seat ring damage, Plug damage, High Packing torque, Change in friction etc. 21

22 Device Level (Final Element): Device Health Information: Air Loss Hunting Linkage loose Packing Stick - slip Positioner fail Accurate analysis (No Human error) Information available at Control room (Problem Description) Stroke repetition Hysteresis data, Input output deviation Valve signature Overshoot / Undershoot stem travel 22

23 Device Level (Final Element): Asset Measurement & Solutions: REASONS External / Environmental Effect Internal Effect / Improper Process control ANALYSIS & ACTIONS Mostly Physical Inspection & decision, Some information from software (steam / high temp fluid leakage from gland) Captured at AMS module & Maintenance Planning through online prediction. Deterioration type is indicated Available operating time can be predicted Exact spare parts can be planned Correction, corrective and preventive action can be planned 23

24 Device Level (Final Element): Asset Measurement & Solutions: Reduce the unnecessary overhauling / maintenance of control valves by analyzing the degradation indexes which is determined based on the long term gathered data Valve passing in close & overshoot condition - Valve lapping or trim replacement Positioner calibration, Replacement needed Surrounding temperature information 24

25 Device Level (Final Element): Asset Measurement & Solutions: Effectiveness for diagnostic Detecting inner valve failure Wearing of seat ring Sticking the foreign object Detecting the failure by vibration Moving from proper mounting position of positioner by vibration. 25

26 26 Maintenance Practices in Digital World Plant level Communication: Advance diagnosis module Issue with FF: Common issue in Electrical wiring (loose wire strands, water ingress, faulty devices, EMC, etc..) Bus topology connects multiple devices Serial communications signal One fault can affect several devices Available tools are for conventional technology Tools lacks ability to visualize Fieldbus related signals Locating the problem is difficult and time consuming many devices in one loop; interoperability) Field Bus installation Tools to commission, Supervise & trouble shoot (signal distortion)

27 Plant level Communication: 27 Advance diagnosis module Measurement & Solutions: Segment Voltage, Current Segment & device Noise Segment & Device Signal level Device Termination Segment / Shield earth fault Device communication Earth fault information Cable degradation Device configuration Device remote access Signal quality & strength

28 Plant level Communication: 28 Advance diagnosis module Predictive maintenance: Supervision & Diagnosis Measurement, alarming & trending Online and real time data from DCS / HMI Digital Oscilloscope function Signal (Segment voltage, current), Actual Noise level Proper termination, Isolation to ground and polarity

29 Plant level Communication: Predictive maintenance: Advance diagnosis module 29

30 Plant level Communication: 30 Measurement & Online Solutions: Identify kind of failure & guided actions Grounding, Software, hardware & wiring problem Highlight Problem with help User configure warning & Alarm alerts before segment fails Can be used as a Commissioning tool Digital Oscilloscope function (Lost telegram) Log of each event at DCS / HMI

31 Loop Level: 1. Availability 2. Controllability Drift AMS 31

32 Loop Level: Drift AMS 1. Availability Vendor s s Solutions Distinguish between process and loop problem Number of loops in manual mode Specific loop taken in manual how many times a day Total % of time in manual mode in 24 Hrs. Trend graph for manual & auto Vrs. Time 32

33 Loop Level: Drift AMS 2. Controllability Vendor s s Solutions Loop performance within defined bandwidth Total % of time operation remain in Excellent zone Loop to Loop comparison Alarm management Guided actions during plant emergency 33

34 Loop Level Diagnosis: Vendor s s Solutions (Controllability)( 34

35 Process Level Diagnosis: Vendor s s Solutions Impulse line chocking ph sensor deteriorated Coating on probe of magnetic pickup Shedder bar not vibrating due to internal or external reasons High temperature around the devices Controllability problem due to process fluctuation Inappropriate step taken by Operator (SP not followed) 35

36 Communication & Networking: Asset Management ETHERNET Proprietary BUS HIS HIS HIS EWS HART Control Net Mod Bus PROCESS FIELD BUS OmROn AB PLC Device Net R I/O Optic Fibre TCP IP Local start / stop Panel with indication 36 Touch panel

37 Communication & Networking: Communication Peripheral Device Health: Camera Video Surveillance Enterprise Network Redundant Link Dual Homing Wireless Transmitte r Secure Access to Enterprise Network HiPER Ring Secure Access to Plant Floor Provision for current & Future Demands of the Industry like wireless integration, Security against Hacking & Spy worm etc. Network Traffic Control Integration of several industrial networking standards Cabling, Software Management, System Integration, Installation and Maintenance. Configuration of secure and reliable Networks in highly sophisticated Industrial environment 37

38 Communication & Networking: Measurement & Solutions: Camera Video Surveillance 38 Enterprise Network Redundant Link Dual Homing Wireless Transmitte r Secure Access to Enterprise Network HiPER Ring Secure Access to Plant Floor Communication Peripheral device Health Deterioration indication & replacement Bus cable termination Replacement of Cable on Physical health information Bus cable rerouting if interference is noticed Redundancy alert of Device Active / failure Updating the Anti virus, Firewall software High temperature alarm in & around the devices

39 New Concept: March towards Maintenance to Management 39

40 Field Bus Foundation: A Way Forward>>>> Thank You 40