chapter 9.pdf
TRANSCRIPT
[File Name or Event]Emerson Confidential27-Jun-01, Slide 2
Introduction
Level of Diagnostics
Function Block Diagnostics
Resource Block Diagnostics
Transducer Block Diagnostics
Agenda
Fieldbus brings dramatic savings in installation and commissioning, but the real value is seen during plant operation...
[File Name or Event]Emerson Confidential27-Jun-01, Slide 4
RoutineCheck
NoProblem
FailedInstrument
PluggedLines
ZeroOff
CalibrationShift
35%
28%
20%
6% 6%4%
Source: Dow Chemical
• 63% of trips to the field can be eliminated
0
10
20
30
40
50
Elimination of “Unneeded” Trips to the field: Transmitter Diagnostics
[File Name or Event]Emerson Confidential27-Jun-01, Slide 5
Level 3 Operations
Make Up Water
TurbineGenerator
Boiler
Pulveration
Level 2
Drift
Loop
Level 1
µP
Device
PluggedImpulse
Line
Electronics
Diagnostics
Sensor Drift
Communications
Diagnostics
Diagnostics Definitions
[File Name or Event]Emerson Confidential27-Jun-01, Slide 6
Device Maintains Statistics For Communication Diagnostics
[File Name or Event]Emerson Confidential27-Jun-01, Slide 7
Diagnostic Examples
Transmitter generates an alert when
the sensor degenerates
the device has exceeded factory maximum field temperature usage
• Cycle Counter
• Valve Signature
• Dynamic Error Band
O2 Sensor creates alert when the sensor fouls
[File Name or Event]Emerson Confidential27-Jun-01, Slide 8
Using Device Intelligence
The Device
Detects Process
Conditions
Impulse Lines Plug
0 2 4 6 8 10 12 14 16 18 201.81
1.811
1.812
1.813
1.814
1.815
1.816
1.817
1.818
1.819
1.82
Time (min)
PV
(V
)
[File Name or Event]Emerson Confidential27-Jun-01, Slide 9
Devices Provide Predictive Diagnostics
Provide Information On Life Expectancy and
Performance Degradation
Device Performance
Failure
Predictive Alarm
[File Name or Event]Emerson Confidential27-Jun-01, Slide 10
Diagnostics are Utilized in Fieldbus Blocks for Measurement and Control
PV is Marked„Uncertain‟
or „Bad‟ if Abnormal
and propagated
[File Name or Event]Emerson Confidential27-Jun-01, Slide 12
Failed Electrode Signal Fault
Communications Failure
Failed
Maintenance
Advisory
Maintenance Sensor Calibration
FT-101Inlet 3, Cooling Tower 1
TOWER_1
Conditions of FT-101
Sensor
Failed
Perform recommended sensor/wiring checksRecommended Action:
Failed Conditions
Advisory
Process
HelpClosePrint
?
Electrode Signal Fault
Grounding/Wiring Fault mV50/60 Hz Noise::
Enable
Enable
.003401
i
Electronics
Maintenance
X
[File Name or Event]Emerson Confidential27-Jun-01, Slide 13
Process plants can be tough on field devices!
[File Name or Event]Emerson Confidential27-Jun-01, Slide 14
Internal Diagnostics
Sensor failure
Sensor malfunction
Sensor disconnected
Electronic Board failure
Bad grounding
Operating conditions out of specifications
[File Name or Event]Emerson Confidential27-Jun-01, Slide 15
Process Diagnostics
Plugged line
Empty pipe
Statistical Process Monitoring
Vibration
Valve travel integration
Noise
Drift
Flame instability
>>>>>>
[File Name or Event]Emerson Confidential27-Jun-01, Slide 16
Diagnostic Examples
Transmitter generates an alert when
the sensor degenerates
the device has exceeded factory maximum field temperature usage
• Cycle Counter
• Valve Signature
• Dynamic Error Band
O2 Sensor creates alert when the sensor fouls
[File Name or Event]Emerson Confidential27-Jun-01, Slide 17
Variability Index provides additional insight into Loop Performance
Variable
Variability
Index
Acceptable
Value
VI=Measured Standard Deviation
Minimum Expected Standard Deviation
Is Detected with
Variability Index
DeltaV Inspect Identifies
Under-performing Loops
Take Corrective Action
Performance Change
Variability Index Diagnostic
[File Name or Event]Emerson Confidential27-Jun-01, Slide 18
Plugged Impulse Line Diagnostic
Manifold
Sensing
Line
Flow
Clog0 2 4 6 8 10 12 14 16 18 20
1.81
1.811
1.812
1.813
1.814
1.815
1.816
1.817
1.818
1.819
1.82
Time (min)
PV
(V
)
Both Open HP Closed LP Closed Both Closed
[File Name or Event]Emerson Confidential27-Jun-01, Slide 20
Proof Using SPM Prevents Plant Damage
SPM Data
6/4 6/6 6/8 6/10 6/12
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
23:30
23:00
PHD Data23:30
23:00
Statistical
Process
Monitoring data
coming from
3051 ADB
helped predict
catalyst problem
30 min
in advance
23:00
Source: ExxonMobil Baytown, Tx Refinery
[File Name or Event]Emerson Confidential27-Jun-01, Slide 21
Status
AI
Value: 234.5 m3/h
Status: Good, Bad or Uncertain
Sub-Status: (more status details)
Limit : High, Low, Constant or not limited
Status can be used in the control
strategy to switch a controller to
Manual when the variable goes to
a Bad status.
All connectable variables have
STATUS.
STATUS VALUE
Diagnostics
[File Name or Event]Emerson Confidential27-Jun-01, Slide 23
Diagnostics are Utilized in Fieldbus Blocks for Measurement and Control
PV is Marked„Uncertain‟
or „Bad‟ if Abnormal
and propagated
[File Name or Event]Emerson Confidential27-Jun-01, Slide 24
Classic I/O
H1
Other Buses
Other Buses
Event is Time Stamped At The Source!
[File Name or Event]Emerson Confidential27-Jun-01, Slide 25
Plantweb alerts
Sensor
Failure
Maintenance
Soon
Maintenance
Soon
Maintenance
Soon
Maintenance
Soon
Sensor
FailureInstallation
Problems
Installation
Problems
Sensor
FailureInstallation
Problems
Installation
Problems
Sensor
Failure
Failed Maintenance Advisory
Route to appropriate plant organization
Recommended Action
Troubleshooting guide
[File Name or Event]Emerson Confidential27-Jun-01, Slide 26
Failed Electrode Signal Fault
Communications Failure
Failed
Maintenance
Advisory
Maintenance Sensor Calibration
FT-101Inlet 3, Cooling Tower 1
TOWER_1
Conditions of FT-101
Sensor
Failed
Perform recommended sensor/wiring checksRecommended Action:
Failed Conditions
Advisory
Process
HelpClosePrint
?
Electrode Signal Fault
Grounding/Wiring Fault mV50/60 Hz Noise::
Enable
Enable
.003401
i
Electronics
Maintenance
X
[File Name or Event]Emerson Confidential27-Jun-01, Slide 27
Operation
Devices are identified by Tag
Variables are identified by:TAG.Desired Parameter
No need to remember the Transmitters Hardware Address .
FT102A, not CTL01C03A01
FT
102A
FIC
102A
FCV
102A
FIC102A.OUT
[File Name or Event]Emerson Confidential27-Jun-01, Slide 28
Transducer, Resource and Function Blocks
Every Field device has to have a Resource Block and one or more Transducer blocks.
Function Blocks are desirable, but not mandatory.
Resource Block contains information about the device resources: hardware and software.
Transducer blocks control access to Input and Output interfaces such as sensors, switches, actuators etc.
Transducer decouples the process interface from the Function Blocks. They can run as fast as they can.
Transducer blocks also allow calibration and access to diagnostics.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 29
Resource Block
Hardware and Software resources.
When Mode is Out of Service, all other blocks will be Out of Service.
Allow Device resetting, including resetting with Default values.
All Emerson devices have a common Resource Block, with very small variations.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 30
Pressure Resource Block - Identification
[File Name or Event]Emerson Confidential27-Jun-01, Slide 35
Pressure Resource Block – Suppressed Alarms
[File Name or Event]Emerson Confidential27-Jun-01, Slide 36
Transducer Blocks
Transducer blocks provide the interface to sensors, switches, actuators, etc.
Transducer blocks also allow access to calibration and I/O diagnostics.
If the Transducer Block is in Out of Service Mode, the Function Blocks will have measurement value with Bad Status.
Transducer communicates the values to the I/O Function Blocks via Channels.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 37
Transducer
Sensor 1
Sensor 2
Sensor 3
AI 1Channel 1 Ch. 1
AI 2Channel 2 Ch. 2
AI 3Channel 3 Ch. 3
AI 4Channel 4 Ch. 4calc
Transducer
ScheduleFree Running
[File Name or Event]Emerson Confidential27-Jun-01, Slide 38
Important to remember
AI or AO block has to have the Channel configured accordingly. Channel = 0, no measurement or actuation.
AI or AO block XD_SCALE parameter has to have the same valid Engineering Unit. Pressure measurement should be inH2O@68F, mbar, psi,etc. Temperature should be deg. C, not C.
Transducer should be in Auto.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 46
Pressure Transducer – Advanced Diagnostic Block
[File Name or Event]Emerson Confidential27-Jun-01, Slide 47
Pressure Transducer – Advanced Diagnostic Block