ff presdentation user conference mumbai automation 2008

1

© 2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai

Jasbir SinghEssar Oil Ltd

Fieldbus Foundation – A Way Forward

Advance Plant Advance Plant Management Management Module in FF Module in FF

Controlled Process Controlled Process IndustryIndustry

2



ROI – Improvement

Increase ROI

ReducedProject Capital Installation &

CommissioningCost

WarehouseInventory /

SparesProduct mix/Feed stock

ReducedFeed stocks

Energy and UtilitiesMaintenance

wasteAbnormal Events

Low grade productPenalties

Increase Productivity

IncreasedYield

Product ConsistencyNew product

Equipment CapacityEquip. Efficiency

Reduction of losses

ReducedUnscheduled Downtime

& Small stoppagesPlanned Shutdowns

Low Maintenance timeOptimize Maintenance

Resources,Minimum Spare parts

Inventory,Reliable Maintenance

history

Increase RevenueReduce conversion Costs

Reduce Capital Cost Increase Profitability

3



Asset Wear Pattern:Asset Wear Pattern:AGEAGE

PROBEBLITY OFPROBEBLITY OFFAILUREFAILURE

PM Plan for time base proactive maint.

Electronic Instruments (transmitters, Sensors, Cards, FF accessories, Switching Hub, Operator /Touch Screen

F. Worst New

Rolling element bearingE. Constant Random Failure

Hydraulic & compressed air System

Random Wear

D. Best New

Control Valves (external affects)C. Slow Aging

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)

B. Bath Tub Curve

Failure of control Valves moving parts, Mechanical drive items (gear box, chain)

Time Base Wear

& Tear

A. Traditional view

EXAMPLESEXAMPLESType of AssetAsset

Maint.

GRAPHICAL REPRESENTATIONGRAPHICAL REPRESENTATIONDESCRIPTIONDESCRIPTION

4



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 failPreventative maintenance – Based on schedule given by

equipment vendor or past history Predictive maintenance – Based on future prediction of

condition of devices

Maintenance PracticesMaintenance PracticesMaintenance Practices

5



“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”

Run to failure


6



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”


7



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”

8




9



Three- Level Diagnostics Module - “Abnormality Analysis”ThreeThree-- Level Diagnostics Module Level Diagnostics Module -- ““Abnormality AnalysisAbnormality Analysis””

Operations

Loop

Device

Drift

µP

Externalinfluence

ElectronicsDefective

Sensor Drift

Level 1

Level 2

Level 3

10



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

Device Checking & Maintenance:Device Checking & Maintenance:


11




Mostly limited to loop checking by current / voltage injection from field

Tightening of terminals

Inspection of Junction boxes

DCS input card, Signal conditioner calibration

Loop Testing & Maintenance:Loop Testing & Maintenance:

12




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

Process Diagnosis & Corrective actions:Process Diagnosis & Corrective actions:

13



Maintenance Practices in Digital WorldMaintenance Practices in Digital WorldMaintenance Practices in Digital World

14




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

15



Enterprise Enterprise NetworkNetwork

Operations

Loop

Device

Communication& Networking

Level 4

Drift

µPExternalinfluence

ElectronicsDefective

Sensor Drift

FF SensorsLevel 1

Level 2

Level 3

FF AccessoriesLevel 1A

Four - Level Management Module - “Abnormality Analysis”Four Four -- Level Level Management ModuleManagement Module -- ““Abnormality AnalysisAbnormality Analysis””

16




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 algorithmsComparing what you are doing now against what you expected to do

and understanding differenceSystematic storage and graphical display representation of the

measurement & faultGraphical Display the deterioration trend & alarming the operator Forecasting the future failure time limit before it become criticalAllow Engineer to take decision for plant stoppage basing decisions

more on facts and data and less on intuitionDetecting problems before they become critical

ON LINE ALERT

Advance tool:Advance tool:

17




Device Level (Sensing):Device Level (Sensing):

۩۩ Electronic FailureElectronic Failure۩۩ Sensor not respondingSensor not responding۩۩ Device communication Device communication problemproblem۩۩ Communication Hardware Communication Hardware component deteriorationcomponent deterioration۩۩ Power supply failurePower supply failure

Device Health Information:Device Health Information:

µP

ElectronicsDefective Sensor

Drift

Externalinfluence

18





۩ FF Basic-to-LM device wizard“Safe” way to enable/disable

Backup LASProvides wizard to step

through sequenceInsures BLAS will

work when needed

Device Configuration:Device Configuration:

19





۩۩ Device Replacement by Operator۩ Replacement from Operator Station or Engineering Station۩ Auto replacement۩ Upgrading devices on-line

Device Replacement:Device Replacement:

20




FailureFailure

Predictive AlarmPredictive Alarm

Time

Device Level Performance (Sensing):Device Level Performance (Sensing):

Advance Prediction:Advance Prediction:

21




Device Level (Final Element):Device Level (Final Element):

REASONSREASONS FAILURE TYPEFAILURE TYPE

External / External / Environmental EffectEnvironmental Effect

Valve corrosion, Gland packing degradation Valve corrosion, Gland packing degradation (leakage of toxic, expansive fluid), lubricating (leakage of toxic, expansive fluid), lubricating oil attritionoil attrition

Internal Effect / Internal Effect / Improper Process Improper Process control control

Stem deformation , Stem linkage damage, Stem deformation , Stem linkage damage, Spring failure, Stem & plug scuffing, Actuator Spring failure, Stem & plug scuffing, Actuator air leakage, air insufficient, Air loss, Positioner air leakage, air insufficient, Air loss, Positioner failure, Positioner linkage loose or improper failure, Positioner linkage loose or improper setting, Seat ring damage, Plug damage, High setting, Seat ring damage, Plug damage, High Packing torque, Change in friction etc.Packing torque, Change in friction etc.


22





Packing Stick - slip Positioner fail

HuntingAir Loss Linkage loose

Accurate analysis (No Human error)Information available at Control room (Problem Description)Stroke repetitionHysteresis data, Input output deviationValve signature Overshoot / Undershoot stem travel


23





REASONSREASONS ANALYSIS & ACTIONSANALYSIS & ACTIONS

External / Environmental Effect

Mostly Physical Inspection & decision, Some information from software (steam / high temp fluid leakage from gland)

Internal Effect / Improper Process control

Captured at AMS module & Maintenance Planning through online prediction.

Deterioration type is indicatedAvailable operating time can be predictedExact spare parts can be plannedCorrection, corrective and preventive action

can be planned

Asset Measurement & Solutions:Asset Measurement & Solutions:

24






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 neededSurrounding temperature information

25






Effectiveness for diagnosticDetecting 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.

26



Advance diagnosismodule

Common issue in Electrical wiringCommon issue in Electrical wiring(loose wire strands, water ingress, faulty devices, EMC, etc..)Bus topology connects multiple devicesBus topology connects multiple devices

Serial communications signalOne fault can affect several devices

Available tools are for conventional Available tools are for conventional technologytechnology

Tools lacks ability to visualize Fieldbus related signals

Locating the problem is difficult and time consuming many devices in one loop; interoperability)Field Bus installationField Bus installation

Tools to commission, Supervise & trouble shoot (signal distortion)

Issue with FF:Issue with FF:Plant level Communication:Plant level Communication:


27



Plant level Communication:Plant level Communication:۩۩ Segment Voltage, CurrentSegment Voltage, Current۩۩ Segment & device NoiseSegment & device Noise۩۩ Segment & Device Signal Segment & Device Signal levellevel۩۩ Device Termination Device Termination ۩۩ Segment / Shield earth faultSegment / Shield earth fault۩۩ Device communication Device communication ۩۩ Earth fault informationEarth fault information۩۩ Cable degradationCable degradation۩۩ Device configurationDevice configuration۩۩ Device remote accessDevice remote access۩۩ Signal quality & strengthSignal quality & strength

Measurement & Solutions:Measurement & Solutions:



28



Plant level Communication:Plant level Communication:Predictive maintenance:Predictive maintenance:

۩۩ Supervision & DiagnosisSupervision & Diagnosis۩۩ Measurement, alarming & Measurement, alarming & trendingtrending۩۩ Online and real time data Online and real time data from DCS / HMIfrom DCS / HMI۩۩ Digital Oscilloscope function Digital Oscilloscope function ۩۩ Signal (Segment voltage, Signal (Segment voltage, current), Actual Noise level current), Actual Noise level ۩۩ Proper termination, Isolation Proper termination, Isolation to ground and polarity to ground and polarity



29



Plant level Communication:Plant level Communication:

Maintenance Practices in Digital WorldMaintenance Practices in Digital WorldMaintenance Practices in Digital WorldPredictive maintenance:Predictive maintenance:


30



۩۩ Identify kind of failure & Identify kind of failure & guided actions guided actions Grounding, Software, hardware& wiring problem۩۩ Highlight Problem with helpHighlight Problem with help۩۩User configure warning & User configure warning & Alarm alerts before segment Alarm alerts before segment failsfails۩۩ Can be used as a Can be used as a Commissioning toolCommissioning tool۩۩ Digital Oscilloscope function Digital Oscilloscope function (Lost telegram)(Lost telegram)۩۩ Log of each event at DCS / HMILog of each event at DCS / HMI

Measurement & Online Solutions:Measurement & Online Solutions:


Plant level Communication:Plant level Communication:

31



1.1. AvailabilityAvailability2.2. ControllabilityControllability

Loop Level:Loop Level:


DriftAMSAMS

32



1.1. AvailabilityAvailabilityLoop Level:Loop Level:

Distinguish between process Distinguish between process and loop problem and loop problem

Number of loops in manual Number of loops in manual modemode

Specific loop taken in Specific loop taken in manual how many times a daymanual how many times a day

Total % of time in manual Total % of time in manual mode in 24 Hrs.mode in 24 Hrs.

Trend graph for manual & Trend graph for manual & auto Vrs. Time auto Vrs. Time

VendorVendor’’s Solutionss Solutions


DriftAMSAMS

33



2.2. ControllabilityControllabilityLoop Level:Loop Level:

Loop performance within Loop performance within defined bandwidthdefined bandwidth

Total % of time operation Total % of time operation remain in Excellent zoneremain in Excellent zone

Loop to Loop comparisonLoop to Loop comparisonAlarm management Alarm management Guided actions during plant Guided actions during plant

emergency emergency

DriftAMSAMS



34



Loop Level Diagnosis:Loop Level Diagnosis: VendorVendor’’s Solutions (s Solutions (Controllability)Controllability)


35



Process Level Diagnosis:Process Level Diagnosis:

Impulse line chockingImpulse line chockingpH sensor deterioratedpH sensor deterioratedCoating on probe of magnetic pickupCoating on probe of magnetic pickupShedder bar not vibrating due to Shedder bar not vibrating due to

internal or external reasonsinternal or external reasonsHigh temperature around the devicesHigh temperature around the devicesControllability problem due to Controllability problem due to

process fluctuationprocess fluctuationInappropriate step taken by Inappropriate step taken by

Operator (SP not followed)Operator (SP not followed)



36



Asset Asset ManagementManagement

ETHERNET

Proprietary BUS

HARTHART

PROCESS FIELD BUS

Optic Optic FibreFibre TCP IPTCP IP

EWSEWSHISHISHISHIS HISHIS

Mod BusMod Bus

OmROn

DeviceDeviceNet R I/ONet R I/O

Local start / stopLocal start / stopPanel with indicationPanel with indication

Touch panelTouch panel

Control NetControl Net

AB PLCAB PLC

Communication & Networking:Communication & Networking:


37




Provision for current & Future Provision for current & Future Demands of the Industry like Demands of the Industry like wireless integration, Securitywireless integration, Security against against Hacking & Spy worm etc.Hacking & Spy worm etc.

Network Traffic Control Network Traffic Control Integration of several industrial Integration of several industrial

networking standardsnetworking standardsCabling, Software Management, Cabling, Software Management,

System Integration, Installation and System Integration, Installation and Maintenance.Maintenance.

Configuration of secure and Configuration of secure and reliable Networks in highly reliable Networks in highly sophisticated Industrial environmentsophisticated Industrial environment

Camera


Dual Homing

HiPER Ring

Secure Access to Plant Floor

Secure Access to Enterprise Network

Wireless Transmitter

Video Surveillance

Redundant Link

Communication Peripheral Device Health:


38




Communication Peripheral device Communication Peripheral device Health Deterioration indication & Health Deterioration indication & replacementreplacement

Bus cable termination Bus cable termination Replacement of Cable on Physical Replacement of Cable on Physical

health informationhealth informationBus cable rerouting if interference Bus cable rerouting if interference

is noticedis noticedRedundancy alert of Device Active Redundancy alert of Device Active

/ failure/ failureUpdating the Anti virus, Firewall Updating the Anti virus, Firewall

software software High temperature alarm in & High temperature alarm in &

around the devicesaround the devices

Measurement & Solutions:Measurement & Solutions:


Camera


Dual Homing

HiPER Ring

Secure Access to Plant Floor

Secure Access to Enterprise Network

Wireless Transmitter

Video Surveillance

Redundant Link

39



MaintenanceMaintenanceto to

ManagementManagement

March towardsMarch towardsNew Concept:New Concept:New Concept:

40



Field Bus Foundation: A Way Forward>>>>Field Bus Foundation: A Way Forward>>>>

Thank YouThank You

ff presdentation user conference mumbai automation 2008

Technology