realizing the potential of intelligent device management

1Automation 2013 Mumbai

Digital Doesn’t Mean Intelligent:Realizing the Potential of

Intelligent Field Device Management

Outline

• It’s a Digital World, but what does that really mean?

• The prize is significant, but we are not using digital instrumentation to its full potential

• How can we realize this potential? What are the obstacles?

About Me

• 18 Years with ARC Advisory Group as a Process Automation Market Analyst

• 3 Years with Fieldbus Foundation as Global Marketing Manager

• Focus on DCS, Instrumentation, Field Networks, Process Safety

Fieldbus Foundation

• Dedicated to Stewardship and Advancement of FOUNDATION Fieldbus Digital Protocol & Automation Infrastructure

• Over 350 Member Companies

• Strong Regional and Local Marketing Committees and End User Councils

Process Automation: How the Digital Age Crept up on Us

• Digital Devices are Everywhere

• The Rise of Cyber Physical Systems

• Why we Cling to Analog Thinking in a Digital World

Quick Definitions

• Intelligent Field Device: Microprocessor-based field device or control valve/actuator/positioner that also utilizes a bidirectional digital communication protocol to provide information to plant systems.

• Field Communication Protocols for Process Automation: FOUNDATION fieldbus, HART, Profibus PA.

• Intelligent Device Management: Turning the diagnostic data from intelligent field devices into useful information, which is available to applications and end users as it is required, when it is required.

Intelligent Devices are now the Norm, not the Exception

Source: ARC Advisory Group

Global Installed Base of All Field Devices by Smart vs. Conventional: 2011

New Market for Wireless is Expanding the Reach of Intelligent Devices

Fieldbus Market is Growing Well into Double Digits

• Market for FOUNDATION fieldbus products (excluding EPC and system integrator services) exceed $1 billion in 2012.

• The installed base of FOUNDATION fieldbus systems and devices is over $6 billion

• Celebrating 20 years in 2014!Market for Digital Fieldbus Products and Services

(Source: ARC Advisory Group)

The Rise of Cyber Physical Systems: Everything is Connected

Mainframe computing (60s – 70s)

Large computers to execute big data processing applications

Desktop computing & Internet (80s – 90s)

One computer at every desk to do business/personal activities

Ubiquitous computing (00s)

Numerous computing devices in every place/person

Millions for desktops vs. billions for embedded processors

Cyber Physical Systems (10s)

Source: Introduction to. Cyber Physical Systems. Yuping Dong. Sep. 21, 2009

What are Cyber Physical Systems?

• Cyber Physical System is a system featuring a tight combination of, and coordination between, the system’s computational and physical elements.

• CPS uses computations and communication deeply embedded in and interacting with physical processes to add new capabilities to physical system.

• Convergence of computation,

communication, and control

Source: Introduction to. Cyber Physical Systems. Yuping Dong. Sep. 21, 2009

Sensors

Equipment

People

Safety

Software

Control

What CPS Means for Process Automation

• Process field devices are becoming computers unto themselves

• The old hierarchy of workstations, controllers, networks, field devices, and final control elements is collapsing

• CPS means that process

automation systems will be increasingly connected to other systems in the plant and enterprise

• CPAS – Collaborative Process Automation Systems – are the result

Are your Intelligent Devices Underachievers?

• Despite their large installed base, not many

companies are actually using the diagnostic

information from their intelligent devices to

improve their operating performance

• Plant Asset Management workstations

collecting dust

• Users complain they aren‘t getting the

benefits, but why is this?

• “An estimated 85% of all installed HART

devices are not being accessed to deliver

device diagnostics information with only the

Process Variable data communicated via the

4-20mA analog signal.” – HCF Web Site

Stranded Diagnostics

Why We Cling to Analog Thinking in a Digital World

• Entrenched work processes: Our

fundamental maintenance processes

have not changed much since the

1950s.

• The installed base: According to ARC,

the installed base of process

automation systems reaching the end

of their useful life is $65 billion. Most

of these are 20 years old or older.

• The workforce: Many workers are

entrenched in existing work processes

and analog technology

India is Way Ahead

• Largest Fieldbus installation in the

world is at Jamnagar Refinery

• Over 30K Fieldbus Devices,

Thousands of Segments, with

Capacity Set to Double!

• Device Diagnostics Used Heavily!

• As close to Flawless Project

Execution as you can Get!

• A Global Effort in Project

Management

The Prize, and How to Get There

• The Economic Impact of Intelligent Devices

• Why You Need a Strategy for Intelligent Device Management

• Understanding Diagnostics

• The Importance of Work Processes and Ownership

Impact of Automation is Often Overlooked

Intelligent Device Management is Risk Management!

The Economic Impact of Fieldbus Devices

10-15 percent 20-40 Percent 20-40 Percent

“Saves”Reduced

Unplanned Shutdowns

The Economic Impact of Fieldbus Devices

Economic Payback Of Intelligent Device Management

• Source: ARC Advisory Group

-60 -40 -20 0 20 40

Unplanned Breakdowns

Inventory Costs

Downtime

Defects

Equipment Life

Workforce Efficiency

Equipment Productivity

% Improvement vsTraditional Maintenance

-60 -40 -20 0 20 40

Unplanned Breakdowns

Inventory Costs

Downtime

Defects

Equipment Life

Workforce Efficiency

Equipment Productivity

% Improvement vsTraditional Maintenance

Almost 2/3 of Maintenance Labor is Unnecessary

Let’s Change the Mix of Maintenance in Our Plants

Reducing Preventive Maintenance Hours

With device management

software

• Source: Emerson Process Management

Why You Need a Strategy for Intelligent Device Management

A Broad Mix of Applications can Benefit from Intelligent Device Data

Get Started Early!

A Broad Mix of Applications can Benefit from Intelligent Device Data

Understanding Diagnostics

• Diagnostics can be a valuable tool that can help save you time and money and avoid unplanned shutdowns.

• Diagnostic data can be vague and require a lot of digging to get to the root cause.

• Diagnostic data can also provide you with avalanche of useless information that can grind your process to a halt.

• Not all technologies handle diagnostic information the same way.

• Trick is to get only the right information, at the right time, to the right people.

The Current State of Non Digital Diagnostics: Or the Idiot Light

• Doesn’t tell you what’s wrong

• No predictive guidance

• Is it a process problem or device problem?

• Sensor problem? Electronics problem? Who knows?

Distinctions should be made between Instrument and Process Diagnostics

Sensorincluding process connection and sensor

electronic

Instrument Electronic

Configuratione.g. Linearization

ProcessProcess/

Environment

Information

Root Group

Information

Root Group

Instrument

Process/Environment

Sensor

Electronics

Configuration

Process

A Mechanism for Data Quality Helps

Utilizing Diagnostic Data from Multiple Devices Together

• Certain diagnostic anomalies expressed in multiple field devices can indicate an anomaly or impending abnormal situation in the process.

The Diagnostics Storm

Sample Diagnostic Parameters of a

FOUNDATION Fieldbus Flowmeter

NAMUR NE 107

Definition of NE 107 Status

Signals

Grouping Diagnostic Conditions

Diagnostic Mapping Workflow

The Importance of Work Processes and Ownership

Major Work Process Tasks for: 2.0 Execute Daily Proactive Maintenance (Unit)

Work Process Owner: Instrument Technical Discipline Network (ITDN)

WHO Input

Responsible Organization or Individual

Work Process Analysis Output

Instrument Specialist

CSE/Inspector

Maintenance Planner

Maintenance Coordinator /

Team Leader

Technician

T/A Manager

MOC Request

T/A Work List Item (CMMS)

2.1 Assign Daily PM Work Order

b2.5.1Emergency

Priority?

Device Alarm/Alert

Report

2.9 Order Parts/Service and re-plan

PM Work Order

LEGEND

Start or End Task Decision a Connector 1 Metric / Control Point

EmbeddedExternalWork Process

LEGEND

Start or End Task Decision a Connector 11 Metric / Control Point

EmbeddedExternalWork Process

2.6.2Enter notification in

CMMS(Documents status in Log)

Work Request (CMMS)

Repaired Equipment

2.3Select Next Priority Item

(from A/A List and A/A Report)

2.4 Secure Work

Permit

Determine Urgency, Enter notification into

CMMS (e-Ticket) and communicate priority to OMC for appropriate Action.(Technician documents

status in log)

CMMS Condition History*

2.6.1 MOC or Mitigation Required?

2.7.1 Parts/ Service

Available?

2.7.2Repair and Enter

Notification to capture history

(Documents status in Log)

2.10.1 Daily PM

Complete?

2.8 Enter Notification in

CMMS(Documents status in Log)

2.10.2Update

Maintenance Coordinator / Team Leader and Closeout

PM Work Order

NOTE: An Excel Spreadsheet that records status of all actions taken by Alarm/Alert will be maintained in Log until the Site has implemented Level 5 CMMS

Original Issue Date: Aug 10, 2006Last Revision:

Revision Date: Dec 31, 2011Rev 1.3

2.2Obtain Daily PM & A/A report

Removing Obstacles to IDM

• The Integration Dilemma

• The Importance of Adopting Open Standards

• Train, Train, Train

The Integration Dilemma

• Historically there have been multiple integration technologies for intelligent field devices

• EDDL, FDT/DTM, OPC, etc.

• FDI is a current industry effort that will unify device integration technologies and make things easier for users and suppliers

One Device Driver: the FDI Package

Device Package

EDDFDI encoded file format

UIP(optional)

Attach-ments

Electronic Device Description Language

(EDDL)

Windows Presentation Foundation

Device Definition (Def) Business logic (BL) User Interface (UID

Programmed User Interface

Device Applications

Manuals Certificates Protocol specific

Files (GSD(ML), etc.)

The Importance of Adopting Open Standards

• OPEN standards are continuously subject to scrutiny, review and improvement

• OPEN standards and specifications are publicly available can be purchased by anyone

• OPEN standards have better security

• OPEN standards can adapt to new technologies and market dynamics

• OPEN standards make it easier to test and register devices and host systems

There is a lot to Learn, and Good Training is Essential

Many sources of training are available in the marketplace

Very few are audited and certified to ensure that they adhere to a set of standards

You will need more than a two day course or online video

We are serious about training! Eight certified centers with one in India soon to come.

Conclusions

• Adopt an Intelligent Device Management Philosophy

• Take an intelligent approach to managing diagnostics

• Start early

• Appoint a champion to manage the IDM processes

• Get the right work processes & train your people

• You can be successful! The Prize is significant!

Thank You

realizing the potential of intelligent device management

fieldbus devices

fieldbus foundation

foundation fieldbus

digital fieldbus products

intelligent field devices

plant systems

installed hart devices

rise of cyber physical

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