oscar viganò alphacon , massimiliano veronesi yokogawa · oscar viganò – alphacon ,...
TRANSCRIPT
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December, 2014
L’automazione al servizio della manutenzione Oscar Viganò – Alphacon , Massimiliano Veronesi – Yokogawa
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Process Control System Maintenance Automation
A combination of hardware, software and services used to assess the heal of plant assets by monitoring asset condition periodically or in real-time to identify potential problems before they affect the process or lead to a catastrophic failure.
Plant Measurements & Historian Information
PCSMA
Maintenance Operations
Information Flow
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Approach
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Approach
Minimum plant downtime, maximum asset utilization
Reduce blind spots Monitor plant-wide asset conditions
Preempt bottlenecks Optimize operation and maintenance
Avoid surprises Predict asset conditions and avoid downtime
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Solutions
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Device status viewing
Audit Trail
Tuning, Adjustment & Calibration
Maintenance Information Management
Maintenance Alarm
Diagnostics
Platforms for Maintenance & Diagnosis
Online Maintenance Core
Predictive Diagnostics Core
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Typical System Architecture of PCSMA
Ethernet
Control Network
Temperature Transmitter
Wireless Gateway
Pressure Transmitter
ENG HIS SENG
OPC Server
SQL Server
PIMS Client
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Requirement for LNG projects
Transfer process data between Exaquantum systems, for example sea based:
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How does it Work?
Two simple functions
– Extract process data from the Publisher’s Exaquantum system
– Store process data into the Consumer’s Exaquantum system
Exaquantum RDS Publisher Exaquantum RDS Consumer
Exaquantum
Historian
Exaquantum
Historian
OPC HDA TCP/IP Network
Connection OPC HDA
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OPC Servers
DCS OWS and Controllers
VNet
Ethernet
Ethernet
SQL Servers
SQL Servers
Environmental parameters under control
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User Interface – Publisher (Settings)
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Remote communication with on-shore terminal
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Beneficial Concepts and Features of PCSMA
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Beneficial Concepts of PCSMA
1. Minimize Risks & Cost (lead-time) for commissioning & start-up work
Centralized Plug & Play remote device connection check
Centralized remote setting of field device parameters
Quick online diagnosis
Standardized approach for multi-vendor devices
2. Minimize the risk of unnecessary site trips By monitoring device healthiness thru diagnostics
3. Minimize scheduled maintenance downtime Optimize maintenance work by advanced device diagnostics
4. Generate collaboration between Operation and Maintenance
Maintenance work to assure Reliability, but not repair work after breakdown.
Shift maintenance paradigm from event-driven to scheduled work
Maintenance to contribute better operation availability.
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1. Real time Plant Asset Management Environment – Cyclic device patrol of device health condition check – Maintenance alarm to maintenance personnel – User-friendly device configuration tools (EDDL and FDT/DTM base)
2. Full integration with DCS and SIS – Device alarm message equalization – Time synchronization – Device diagnosis alarm to be shown on the DCS HMI
3. Wide Openness
– Remote alarm & event monitoring, analysis and reporting
– Integration: Host diagnostics server interface of both field devices and machinery units
– Open interface: CommDTM/DeviceDTM are available
Safer plant operation – PST Scheduler to extend the available time of SIL3 safety loop without
process shutdown
Features of PCSMA
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Main Functions of PCSMA
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Main Functions and Features of PRM
1. Device Management
– Device Master Information
– Historical Messages
2. Device Configuration
– DTM Works
3. Alarm Notification
– Device Status Icons
– Device Diagnostics Monitor
4. Historical and Maintenance Records
– Historical Messages
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1. Device Management - Device Master Information
Device Navigator
Window
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3. Alarm Notification - Device Diagnosis (DeviceViewer function)
* DeviceViewer can be shown in both DCS HMI and PRM Client if integrated.
Normal
Abnormal
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3. Alarm Notification – Maintenance Alarm
(Blue) GE System 1 Status -Device to be investigated
(Orange) GE System 1 Status –
Device Non Critical
Icon Detail
(Green) Healthy by Device Patrol
(Red) Maintenance alarming
by Device patrol
(Yellow) Maintenance Warning
By Device patrol
(Gray) Communication failure
(White) Status not yet confirmed
(Background
Gray)
Alarm Off
Un-confirmed alarm
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4. Historical and Maintenance Records – Historical Messages
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Maintenance Related Functions
Schedule – Records maintenance schedule
Memo – Records maintenance memorandum
Parts – Records necessary parts for devices
Doc – Records necessary documents for maintenance such
as instruction manual
Tool – Setup the necessary tools for maintenance
Plug-in – Setup to ranch necessary tools for devices configuration
Cal. Data – Records calibration data for devices
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Maintenance Mark and Operation Mark Synchronization
PRM is able to electronically assign “Maintenance Mark” to each device by online. Users can assign this mark when they adjust or maintain the field devices. Once assigning it, users can give the restriction to handle with field devices management and what they has been in the status of adjustment and maintenance. When the Maintenance Mark is set on PRM, Operation Mark to prohibit the operation is automatically set on the HIS faceplate.
Operation Mark
HIS PRM
Synchronization
Maintenance Mark
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Some Real Examples
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Some Real Examples
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Some Real Examples
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Some Real Examples
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Some Real Examples
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Some Real Examples
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Some Real Examples
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Some Real Examples
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Plant Historian
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Stores
- Secure - Scheduled reports - Email reports to users - SQL Server 2005 - Multi-dim. RDB/OLAP
Provides
- KPIs Definition & Reporting - Alarm Reporting - Report Grouping - Time selection & filtering - Export to Microsoft Excel
Collects
- A&E
Alarm Reporting and Analysis (ARA)
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Alarms that remain active beyond a specified time period (i.e. 12 hours) are called Long standing Alarms, also referred as Stale Alarms
Chart and Tabular
The list of Long standing alarms
Duration for which the alarm remained stale
X-axis displays the day
Y-axis displays stacked alarm duration
Long Standing Alarms
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Top most frequent alarms are listed and ranked
Tabular and Chart
The x-axis shows time
The y-axis the alarm count
Alarm Frequency Report
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– MV and SV change count over the specified time period • changes made to MV for PID controller in MAN mode • changes made to SV for PID controller in AUT mode • Acknowledge time is also reported
Manual operation monitoring
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• Changes to Alarm Threshold Settings are captured
• The Document Map (on the left) aids navigation to other pages within the report
Alarm setting changes
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Excel Add-In
Create your
report by
simple Tags
“Drag &
Drop” into
Excel cells
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An Example Excel Report
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Some Historian Examples
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Some Historian Examples
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Next developments: Trends by web
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Summary
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Summary
Process Control Systems architectures nowadays can integrate nodes for supporting diagnosis and maintenance functions
System performance monitoring and maintenance operations can be done both by local and remote workstations – Process Trends, Process/System alarms can be viewed
by remote through redundant connected SQL servers
– Field instruments and devices status can be checked and updated even by remote
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- 65 - <ISD-MASP-S11070> Copyright © Yokogawa Electric Corporation <August, 2012>
Thanks you for your attention