FF Device Diagnostics Encompassing Asset Management to Lifecycle Management Mr. Dattaprasad Natekar FF Technology Conference IATF 2013, Mumbai-India Slide 1
Introduction to FF Device Diagnostics Diagnostic Information from FF Devices Challenges faced by Process Operators Overload due to Diagnostic Data Harmonizing Device Status Information Fieldbus Foundation & NAMUR FF 912 Specification Compliance Future Challenges and Enhancements KPI Matrix - Reliability/Yield/Quality Interactive Lifecycle Management Integrated LCM - Transparency in OPEx. Summary & Conclusion Slide 2
Introduction to FF Device Diagnostics It is said that the true benefits of Foundation Fieldbus come in the operational phase of the plant, where in FF devices provide a wealth of data both about themselves and about the process condition in which they operate. Today s FF device have unparalleled capability to diagnose its own state along with its operating process environment and the same is getting better with every newer versions of the devices being released. Source: www.fieldbus.org Slide 3
Example - Traditional Alarming PIC -101 Slide 4 Hemal Desai
Example - Traditional Alarming Device Problem manifests as process problem PIC -101 Slide 5 Hemal Desai
Device Alarm before the Process Alarms No Low Pressure yet! FY-01 Slide 6 Hemal Desai
Equipment Health Advance warning - Calls for Intervention 100% Protection advanced warning = time to respond 0% Time Slide 7 Endress+Hauser Hemal Desai
Maintenance intervention - No Failure Slide 8
Diagnostic Information from FF Devices Electronics Failure Sensor Failure Process Condition Configuration Warning RTD Drift RTD Life Estimation etc... Electronics Failure Sensor Failure Process Condition Configuration Warning Plugged Impulse Lines etc... ph Electrode Aging Glass Electrode Failure Reference Electrode Failure Reference Electrode Coating Reference Electrode Poisoning etc... Travel Deviation Cycle Counter Valve Signature Step Response Dynamic Error Band Drive Signal Output Signal etc... Electronics Failure Sensor Failure Reverse Flow Empty Pipe Calibration Error Process Condition Configuration Warning etc...
Challenges Faced by Process Operators Responsibility and process complexity are growing. Operators are expected to make quick decisions in critical situations. Difficult to get overview status of the process. Operators are bombarded with Nuisance alarms Inconsistencies in diagnostics information from different vendors & product classes Operators are integral part of control loops and need to take decisions in critical situations. Different applications, terminals, interfaces with unsynchronized data. Slide 10
Overload due to Diagnostic Data Over range Reverse Flow Empty Tube Sensor Fail Electrode coated Sensor disconnect Leakage Sensor failure Valve stuck Travel Deviation Friction RTD failure Coil open High Temperature Plugged lines Slide 11
Harmonizing Device Status Information The challenge was to transform this valuable diagnostic data into useful information and provide the same in the right form and more importantly to the right people. The objective was to harmonize the status information from process devices for more efficient plant operation and maintenance. Realizing this the Fieldbus Foundation began working with end user group i.e. NAMUR to provide more structured information in context to operations and maintenance. Slide 12
Fieldbus Foundation and NAMUR May 2006 Fieldbus Foundation announced cooperation with NAMUR Working Group 2.6 for development of device diagnostic profiles to further enhance FF technology. Objective was to provide the right information to the right person at right time. NAMUR NE 107 recommendation called Self Monitoring & Diagnostics of Field Devices The Foundation updated its specifications in Aug 2010 to incorporate NE 107 recommendations Slide 13
NAMUR Organization Slide 14
What does NAMUR do? NAMUR promotes the interests of the process industry (users) in the field of automation e.g. instrumentation with sensors and actuators, electrical engineering communication between process control equipment, batch control, advanced process control, plant and process monitoring, DCS, MES process management, plant asset management Logistic systems and Supply Chain Management covering the whole plant life cycle from engineering, procurement, installation, operation, and maintenance right through to decommissioning, by enabling the exchange of experience among its members and with manufacturers and other associations. Slide 15
NAMUR 107 Benefits Summary of what will NAMUR 107 do? Bring Reliable & Viewable status diagnostics from field devices Status diagnostics are categorized as 5 standard status signals (easier diagnostics) Status diagnostics will be presented in the context of application e.g. Plant Asset Management, Process Control application etc. Status will be forwarded to the right person at right time (fewer spurious alarms) Actionable Diagnostics Allocation of status signals in field devices. Independent of DCS! Detailed information available for device specialist Slide 16
Example E200 Coriolis 1. Measurement page with warning 2. Event page Icon/text according NE 107 (F,M,C,S) 3. Info page An event occurred. Depending on event status the status symbol for the event level is shown Diagnostic event page. Maintenance instructions
Coriolis Device Diagnostic Information Instrument issues Human intervention issues (during commissioning, setup, function check and service activities) Application issues or process conditions affecting measurement Slide 18 Slide 18
Coriolis mass flowmeter diagnostics Slide 19
Coriolis mass flowmeter diagnostics Slide 20
Example Summary of what will NAMUR 107 do? Bring Reliable & Viewable status diagnostics from field devices Status diagnostics are categorized as 5 standard status signals (easier diagnostics) Status diagnostics will be presented in the context of application e.g. Plant Asset Management, Process Control application etc. Status will be forwarded to the right person at right time (fewer spurious alarms) Actionable Diagnostics Allocation of status signals in field devices. Independent of DCS! Detailed information available for device specialist Slide 21
Diagnostics information mapped - FMCS Slide 22
Context of Application Operator s Console Maintenance Console SD_MAINT_ALM Active SD_MAINT_ACTIVE Clogged Pressure Sensor SD_RECOMMENDED_ACTION H1 Clean Sensor Slide 23
Example Summary of what will NAMUR 107 do? Bring Reliable & Viewable status diagnostics from field devices Status diagnostics are categorized as 5 standard status signals (easier diagnostics) Status diagnostics will be presented in the context of application e.g. Plant Asset Management, Process Control application etc. Status will be forwarded to the right person at right time (fewer spurious alarms) Actionable Diagnostics Allocation of status signals in field devices. Independent of DCS! Detailed information available for device specialist Slide 24
Context of Application Operator s Console Maintenance Console SD_FAIL_ALM Active SD_FAIL_ACTIVE Pressure sensor failure SD_RECOMMENDED_ACTION H1 Change Sensor Slide 25
Example Summary of what will NAMUR 107 do? Bring Reliable & Viewable status diagnostics from field devices Status diagnostics are categorized as 5 standard status signals (easier diagnostics) Status diagnostics will be presented in the context of application e.g. Plant Asset Management, Process Control application etc. Status will be forwarded to the right person at right time (fewer spurious alarms) Actionable Diagnostics Allocation of status signals in field devices. Independent of DCS! Detailed information available for device specialist Slide 26
Device Diagnostic and Integration Operator s Console Maintenance Console Process Configuration, Monitoring and Operation H1 Performance and Condition Management of Fieldbus devices Slide 27 Slide 27
Summary of NAMUR NE 107 Objectives Standardization of diagnostics information from field devices via e.g. Foundation Fieldbus protocol Improved Operator Efficiency Improve Productivity Reduce cost Make maintenance more efficient. Slide 28
FF 912 Specification - Compliance FF 912 - Field Diagnostic Profile The technical specification which describes the implementation of the NE 107 into Foundation Fieldbus Endress+Hauser was part of the specialist team which defined the FF 912 Slide 29
Future Challenges and Enhancements Time by which device & host vendors will become compliant to FF 912 Specifications. Overview of alert conditions in a KPI matrix form depicting Device Criticality v/s Maintainability/Yield. Using the power of FF 912 specification and Foundation Fieldbus technology to Lifecycle management (LCM). Fully interactive FF-LCM platform to help achieve much more benefits in the operational phase with far superior ROI generated by measurable KPI and transparency in Operational expenses (OPEx.) Slide 30
KPI Matrix - Reliability/Yield/Quality The key performance indicators give you a quick overview of the criticality and maintainability of all FF devices in installed base based on Installed Base Audit Slide 31 Dattaprasad Natekar
Criticality Criticality Matrix Overview Avoids Info. Overload Operator s Console Maintenance Console Quality / Yield Maintainability Process Configuration, Monitoring and Operation H1 Performance and Condition Management of Fieldbus devices Slide 32 Slide 32
Interactive Lifecycle Management W@M portal Control Network CMMS Internet 1 0 0 1 0 0 1 Slide 33 Endress+Hauser Hemal Desai
Interactive Asset Data Access Control Network 1 0 0 1 0 0 1 - Calibration Shifts - Glass electrode coated - Glass electrode crack - Reference electrode coated Slide 34 Endress+Hauser Hemal Desai
Interactive Asset Optimization Control Network Asset Management Software uses fieldbus for Asset Optimization Solutions 1 0 0 1 0 0 1 Digital Communication from Sensor to Asset Management inductive signal transmission Slide 35 inductive energy transmission Endress+Hauser Hemal Desai
Interactive Calibration Management Control Network 1 0 0 1 0 0 1 Manage complete life cycle of a sensor Trace the calibration and adjustment history Customized calibration protocols are generated automatically Slide 36 Endress+Hauser Hemal Desai
Interactive Internet based remote Access Any time any where updated information of installed base to manage the entire lifecycle of Asset Slide 37
Percent of Total Equipment Costs Integrated LCM - Transparency in OPEx. Most Asset Management systems are static and focus on just one phase of the life Cycle. Operations being the most important phase, the biggest part of the total costs of ownership is coming from the Maintenance & Operations expenditure i.e. Life cycle cost 100 % CAPex* Opex** Enhanced Savings Potential 80 % 60 % 40% 20% Initial Costs Maintenance & Operation costs 0% Total equipment Life-cycle * Capital expenditure ** Operational expenditure Source: ARC Advisory Group Slide 38
Summary & Conclusion Following the NAMUR NE 107 recommendations provide Good overview of Process & Status for Condition monitoring. It offers Harmonized information Independent of source of data in easy to use environment - Plant Asset Management. Going forward there is a need to extend the FF Device Diagnostics beyond Condition Monitoring & Asset Mgt. FF 912 has laid the foundation for Enhancing Device Diagnostics to a future possibility of an Interactive and Dynamic Asset s Lifecycle Management. FF technology is best suited to integrate into Lifecycle Management systems (LCM) with implementation of FF 912. Such integrated FF-LCM system can unlock the hidden potential of FF Digital infrastructure. Slide 39
Thank You 2 nd February, 2013 www.fieldbus.org Slide 40