callibratie onderhoud en communicatie interfaces

22/06/2012

Advantages of digital communicationUnlocking the potenitial of diagnostic information

Slide 1

Jeroen Wynants

22/06/2012

OpEx savings maintenance

Source: HPI market data 2003 Gulf publishing company

Instrument & valves

Mechanical equipment

Process equipment

Electrical equipment

22/06/2012

Customer survey and questionnaire

Which maintenance strategy to apply?

22/06/2012

Typical maintenance strategies

Corrective Maintenance

Device is maintained when it failed> uncontrolled plant shutdowns

Preventive Maintenance

Device is periodically maintained to prevent failures> controlled but high maintenance intervals

Condition Based Maintenance

Device detects when a maintenance is necessaryand notifies in advance

> controlled and optimized low maintenance intervals

CorrectiveMaintenance

PreventiveMaintenance

Conditionbased

Maintenance

Con

sequ

ence

offa

ilure

Increasing effectiveness and efficiency

Cos

ts

Availability

22/06/2012

Typical maintenance strategies

Corrective Maintenance

Device is maintained when it failed> uncontrolled plant shutdowns

Preventive Maintenance

Device is periodically maintained to prevent failures> controlled but high maintenance intervals



> controlled and optimized low maintenance intervals

Source: ARC Advisory Group

020406080100

Type of maintenance

65%

30%

5%

60% of preventive maintenance activities is unnecessary!

22/06/2012



-> controlled and optimized low maintenance intervals

Condition based maintenance strategyC

ondi

tion

Time

Failure occur

Reduction offunctional

reserve

Condition basedInitialized on condition

(basic diagnosis: diagnosis value 1 device

Pro-ActiveStatic analysis‘Reference value’• evaluation: <,>, =, hyst.,…

PredictiveDynamic analysis‘Reference trend’• extrapolation, time, …


(advanced diagnosis: correlated diagnostic values)

Pro-ActiveStatic analysis‘Reference value’

• evaluation: <, >, =, hyst., .…• Boolean logic (AND, OR, …)• Methods algorithms,…

PredictiveDynamic analysis‘Reference trend’

• evaluation: <, >, =, hyst., .…• Boolean logic (AND, OR, …)• methods, algorithms,…


(process diagnosis: correlated devices)

Pro-ActiveStatic analysis‘Reference value’

• evaluation: <, >, =, hyst., .…• Boolean logic (AND, OR, …)• correlation algorithms,…

PredictiveDynamic analyses‘Reference trend’

• evaluation: <, >, =, hyst., .…• Boolean logic (AND, OR, …)• correlation, algorithms,…

ValueB-E-F

ValueB-E-F

ValueB-E-F

ValueB-E-F

ValueB-E-F

ValueB-E-F

22/06/2012

Service technician

diagnostics in automotive industry

Slide 7

Jaap Westeneng

Driver

Quality Manager

• As detailed as possible• Includes suggestions for possible

remedies

• All information for safe driving• Only essential information,

summary messages• As early as possible

22/06/2012

Maintenance technician Process operator

diagnostics in process industry

Slide 8

Jaap Westeneng

Reliability Manager

• All information for safe operation• Only essential information,

summary messages• As early as possible

• As detailed as possible• Includes suggestions for possible

remedies

22/06/2012

Challenges faced by today

Difficult to get overview status of process.

Operators are bombarded with nuisance alarms.

Inconsistencies in diagnostics information from differentvendors and product classes.

Different applications, terminals, interfaces withunsynchronized data.

Operators are integral part of control loops and need to takedecisions in critical situations.

22/06/2012

Status today

Large part of the production and quality losses areprimarily result of operator error which can be prevented byensuring that the right information is available to the rightperson at the right time.

Global process industry loses $ 20 billion, or 5 % of annualproduction, due to unscheduled downtime and poor quality.

ARC estimates that almost 80 % of these losses are preventable and40 % are primarily the result of operator error.

22/06/2012

Purpose of diagnostics

Analyze status information (i.e. from field devices) With the objective of detecting causes for potential

malfunction.

Diagnostics form the basis to remove malfunctions

Value of diagnostics: Minimizes ad-hoc maintenance Enables proactive maintenance Minimizes unwanted plant shutdowns Enables event triggered inspections Forms the basis for Plant Asset Management Reduces costs

22/06/2012

NAMUR NE107Standardisation of diagnostics

Slide 12

Jeroen Wynants

22/06/2012

NAMUR

NormenArbeitsgemeinschaft für Meß- Und Regeltechnik in der chemischen Industrie

NAMUR is an international association of users of automation inprocess industries.

• Membership of NAMUR is open only to companies of the processindustries, provided that these companies are

• Manufacturers of chemical or pharmaceutical products, or

• Users of process plants which bear responsibility for operating theseplants, or

• Providers of services to chemical/pharmaceutical manufacturerswith or without plant operating responsibility;

• Also eligible for membership are organizations with a technical orscientific purpose, e.g. scientific bodies, associations, universitiesetc.

Slide 13

Jeroen Wynants

22/06/2012

NAMUR

NAMUR promotes the interests of the process industry in thefield of automation

127 member companiesSlide 14

Jeroen Wynants

22/06/2012

NAMUR

• NAMUR promotes the interests of the process industry in thefield of automation, including

• Instrumentation with sensors and actuators

• Batch control, advanced process control, plant and processmonitoring,

• DCS, MES and Logistic systems

• Communication between process control equipment

• Process management, plant asset management and

• Electrical engineering

• Covering the whole plant life cycle from engineering,procurement, installation, operation, and maintenance rightthrough to decommissioning,

Slide 15

Jeroen Wynants

22/06/2012

NAMUR Publications

• The results of the work carried out by NAMUR are published:

• In NAMUR recommendations (NE) and worksheets

• In presentations at the Annual General Meeting

• In publications which appear in technical journals(e.g. atp, at, C&A, ChemManager, CIT, etz, GIT,process , P & A,Messtech & Automation, SPS-Magazin, tm )

• In speeches made at workshops and conferences organized bycooperating partners(ARC, DECHEMA, GMA, GVC, ISA, WIB)

Slide 16

Jeroen Wynants

22/06/2012

NAMUR Recommendations

Slide 17

Jeroen Wynants

Current ranges for signal levels of digital transmitters

NE 43 (1988): Standardization of the Signal Level for FailureInformation• Discrimination between process and failure information• μP based devices

NE 107 (2005): Self-Monitoring and diagnostics of Field DevicesDiagnostics• Analyze status information (i.e. from field devices)• With the objective of detecting causes for potential malfunction.Diagnostics form the basis to remove malfunctions.

22/06/2012

NAMUR Recommendation NE107Plant Asset Management - Evolution of diagnostics

NE107 Self-Monitoring and diagnostics of Field Devices

diagnostics results must be reliable, bad diagnostic is worsethan none at all.

The diagnostics results must always be viewed in the context ofthe application.

Each diagnostic information must be mapped to one of the fourcategories (FMCS)

The configuration of the mapping between the diagnostic andthe category should be free but predefined.

The plant operator to see only the status signals.

Detailed information can be read out by the device specialist.Slide 18

Jeroen Wynants

22/06/2012

NAMUR Categories (FMCS)

Failure – F

The device provides a non-valid output signal due to somemalfunction at the device level.

Maintenance required – M

Although the device is still able to provide a valid output signal,the device is about to loose some of its functionality or capabilitydue to some external operation conditions. The maintenance canbe needed short-term or mid-term.

Check function – C

The device is temporary non-valid due to some activities,maintenance activities on the device

Off-specification – S

The Device operates out of the specified measurement rangeSlide 19

Jeroen Wynants

22/06/2012

NAMUR recommendations

Maintenance required

Out of specification

Check function

Failure

Diagnostics active

Diagnostics passive

Diagnostic symbols (NE 107)

Slide 20

Jeroen Wynants

22/06/2012

Detailed Device Diagnostics

e.g. Process Automation, Asset Management, Data Acquisition

HART / PROFIBUS / FOUNDATION Fieldbus

Detailed Diagnostic EventsSlide 21

Jeroen Wynants

22/06/2012

e.g. Process Automation, Asset Management, Data Acquisition

HART / PROFIBUS / FOUNDATION Fieldbus

MaintenanceRequired Failure Functional

CheckOut of

Specification

Condensed Status and DiagnosticsPlant Asset Management - Evolution of diagnostics

Slide 22

Jeroen Wynants

22/06/2012


Instrument diagnostics

e.g. SIL certified devices(IEC 61508/61511)

Application diagnostics (NE 107)

e.g. Coriolis mass flow meterGas bubbles in the liquid, fouling, clogging, erosion, corrosion,faulty mounting, external vibrations, pulsating flow, incompletefilling

Application diagnostics are defined for flow -, level -, pressure -,temperature measurements and control valves

Plant Asset Management - Evolution of diagnostics

Slide 23

Jeroen Wynants

22/06/2012Connect diagnostic to

one status signal


On / off switchdiagnostics

Example: mass flowmeter

Coriolis mass flow meterGas bubbles in the liquidFouling, cloggingErosion, corrosionFaulty mountingAsymmetry of measuring tubes(dual tube only)External vibrationsPulsating flowIncomplete filling

Application diagnostics (NE 107)

Plant Asset Management - Evolution of diagnostics

Slide 24

Jeroen Wynants

22/06/2012

Communication protocols

Slide 25

Jeroen Wynants

24/10/2012

Products Solutions Services

HART

Technology

Slide 26

Jeroen Wynants

22/06/2012

History

HART: Highway Addressable Remote Transducer 1986 Developed by Rosemount 1989 HART communication protocol made an open standard 1993 Standards developed and supported enabled by HART

Communication Foundation in Austin, Texas, U.S.Ahttp://www.hartcomm.org

2007 HART added to IEC-61158 International Standard for Fieldbus 2008 HART 7 (Wireless) Specifications finalized.

Most instruments in field today HART 5. HART 6 and later require prescribed testing to registration.

22/06/2012

HART facts

Digital Frequency Shift Keying (FSK) based on theBell 202 telephone communication standard

Transmission speed 1.2 kbit/s >> 1 transaction = 500ms

Binary 0 = 2200 Hz, Binary 1 = 1200 Hz

Simple twisted pair 4-20mA wiring

Analog channel for fastest possible data transfer ofcontrol signal (main process value)

Digital channel >> HART based transmission of deviceparameters and diagnostic data to and from fielddevices

Frequency modulated signal on the 4-20 mAcurrent signal modulated

Serial data transmission

22/06/2012

HART news and highlights

Field-proven standard used by over 32 million devices aroundthe world

Most instruments in field today HART 5 or HART 6

More and more HART 7 devices are available but at themoment mostly for WirelessHART communication

Currently the HCF is working on a NE107 integration for theHART specification >> improved diagnostics

22/06/2012

Diagnostics

Acyclic access to diagnostics

Commands for transmitting diagnostics data

Command 0 (Read Unique Identifier): Universal Command,supported by every HART device.

Response Code (2nd Byte): Field Device Malfunction + More Statusavailable

Command 48 (Read Additional Transmitter Status): CommonPractice Command, containing the device status

Additional generic device status information

Command 231: Manufacturer Specific Command(Endress+Hauser) for transmission of diagnostics data

Transmission of failure number and NE107- Category (MFCS)

22/06/2012

HART topology overview

Controller

Pointto

PointMultidrop

Remote I/O

Multiplexer

WirelessHART

24/10/2012


PROFIBUS

Technology

Slide 32

Jeroen Wynants

22/06/2012

History

PROFIBUS: PROcess FIeldBUS 1989 Standards developed and supported enabled by PROFIBUS Nutzer

Organisation (PNO)http://www.profibus.com

1995 Founding of PROFIBUS International 1996 PROFIBUS PA (Process Automation) 2000 Standard field devices for process automation, Profile 3.0 2004 PROFIsafe, Condensed status and I&M functions, Profile 3.01 2008 Device integration, fast parameter transmission, Profile 3.02

Most instruments in field today have Profile 3.0 as a minimum

22/06/2012

PROFIBUS facts

Two technologies:

DP (Decentralized Periphery)

Transmission speed DP: up to 12Mbit/s

PA (Process Automation)

Transmission speed PA: fixed 31.25kbit/s)

Simple twisted pair + Shield

DP: only communication, cable length up to 1200m

PA: power and communication, cable length up to 1900m non-ex, up to 1000m

22/06/2012

PROFIBUS news and highlights

Successful fieldbus with more than 40 million devicesinstalled (6.8 million in process industries)

Latest version PA Profile 3.02 introduces the NAMUR NE107:

Mapping of diagnosis information on standardized andaccepted diagnostic categories (Condensed Status & DiagnosisMessages)

22/06/2012

Diagnostics

Continuous transmission of device status (STATUS)

Event-triggered transmission of device status (diagnostics)

Slot index for transmitting diagnostics data

Diagnosticdata

…

Calculationof Status Byte

Calculationof extended

diagnostics data

123

Slot0

1 2 3 255

…Index

0

255…

diagnostics

diagnosticsEXTENSION

Physical Block

……

PROFIBUS diagnostics

Status (cyclic data exchange)

Diagnostic Parameter:

4 + 1 Byte (Quality code)

22/06/2012

PROFIBUS topology overview

PLC/DCSCommissioning tool

PROFIBUS DP

T T

T

Remote I/O

T

PROFIBUS PA

24/10/2012


FOUNDATION fieldbus

Technology

Slide 38

Jeroen Wynants

22/06/2012

Fieldbus Foundation 1994 Standards developed and supported enabled by Fieldbus

Foundationhttp://www.fieldbus.org

1996 FOUNDATION Fieldbus H1 1998 Registration of first H1 fieldbus products 1999 High Speed Ethernet (HSE) 2001 Registration of first HSE linking devices 2005 Safety Instrumented Functions (SIF) 2006 Diagnostic Profiles Specification according to NE107

FF History

22/06/2012

FF facts

Two technologies: HSE (High Speed Ethernet) H1 (Process Automation)

Transmission speed H1: fixed 31.25kbit/s)

Simple twisted pair + Shield H1: power and communication, cable length up to

1900m non-ex, up to 1000m ex

22/06/2012

FF news and highlights

FF912 introduces the NAMUR NE107:

Mapping of diagnosis information on standardized andaccepted diagnostic categories (Condensed Status & DiagnosisMessages)

22/06/2012

Continuous transmission of device status (STATUS)

Automatically and used for control (Status Propagation)

Event-triggered transmission of device status (diagnostics)

Device diagnostic can be reflected in different parts of aFOUNDATION Fieldbus device

Device specific diagnostic parametere.g. Transducer Block parameter

Transducer Error

Block error

Alarms

Diagnostics

22/06/2012

FF topology overview

PLC/DCS Commissioning tool

T TFF H1

callibratie onderhoud en communicatie interfaces

Presentations & Public Speaking