callibratie onderhoud en communicatie interfaces
TRANSCRIPT
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
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
Condition Based Maintenance
Device detects when a maintenance is necessaryand notifies in advance
> 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
Condition Based Maintenance
Device detects when a maintenance is necessaryand notifies in advance
-> 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, …
Condition basedInitialized on condition
(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,…
Condition basedInitialized on condition
(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.
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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
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
NAMUR recommendations
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
NAMUR recommendations
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
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
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
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