field device diagnostics - endress+hauser · pdf file · 2014-08-27remote access to...
TRANSCRIPT
08/21/2014
Products Solutions Services
Field Device Diagnostics
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Products Solutions Services
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1. Challenge in plant operation
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Challenge: Balance of maintenance for best reliability at minimum cost.
Measures for maintenance savings
Predictive, event-driven maintenance concept
Assignment of maintenance tasks to the right people to do the task
Remote access to field devices
Significant field diagnostics information
Cost-conscious plant operation
FOUNDATION fieldbus Technology
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Effective maintenance
Detailed Diagnostics
Know when to take action
Effective Maintenance
0%
5%
10%
15%
20%
25%
30%
35%
Routinecheck
NoProblem
Calibrationshift
Zero Off Pluggedlines
Failed
35%
28%
20%
6% 6% 4%
Maintenance effort in 4..20mA networks
63% result in no action taken and could’ve been avoided!
FOUNDATION fieldbus Technology
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Diagnostic Categories: FF-890 / NAMUR NE 107
FOUNDATION fieldbus Technology
Maintenance required – M
Although the device is still able to provide a valid output signal, the device is about to
lose some of its functionality or capability due to some external operation conditions.
Failure – F
The device provides a non-valid output signal due to some malfunction at the device
level.
Function Check – C
The device value is temporarily non-valid due to some activities, e.g. maintenance
activities on the device (PV frozen)
Out of specification – S
The device operates outside of the specified measurement range
Internal diagnostics in the device indicate a drift in the measurement (internal problems
in the device or as consequence of some process influence (cavitation, empty pipe, ...).
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System integration of device diagnostics
FOUNDATION fieldbus Technology
Maintenance console
Performance and condition management of fieldbus devices
Field Diagnostics
Standardized communication of device diagnostics
Diagnostic messages are clustered into 4 categories
Role based information management of device diagnostics (operator, maintenance)
UNCERTAIN
GOOD
BAD
Operator station
Process configuration,monitoring and operation
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2. Benefits and applications
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Benefit Advantage FeatureProject EngineerConvenience and efficiency during design
Single design approach for all parameters
Unified implementation of device diagnostics
OperatorSafe and reliable process operation
Process pending handling of measuring loops
Separate handling of single process inducted diagnostic information
Prevention of overload onfield device information
Masking of device diagnostic information
Service EngineerEfficient management of measuring loops with high up-time for plants
Best preparation for on-site tasks and easy trouble shooting
Distinctive remedy information
Opportunity for preventive maintenance concepts
Predictive maintenanceinformation available
Benefits diagnostics of Endress+Hauser field devices
FOUNDATION fieldbus Technology
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Example with Liquiline CM42
Customer challenges
• Keep people away from dangerous environment
• Reliable information to prevent unnecessary maintenance jobs
Benefits Endress+Hauser offering
• Reduction of preventive maintenance tasks through evaluation of diagnostic information (i.e. reference impedance of the electrode)
• Increased safety through less on-site maintenance effort thanks to process specific configuration of calibration timer and Memosens technology
Copper extraction- flotation cell -
FOUNDATION fieldbus Technology
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Example with Promass 83
Customer challenges
• Ensure, that smelter works stable at the operating point to • save costs (i.e. for consumables like fuel)• reduce environmental impact
Benefits Endress+Hauser offering
• Safe and cost-conscious operation based on reliable measurement using diagnostic information (i.e. mass flow deviation)
• Opportunity to implement predictive maintenance concept instead of preventive maintenance through evaluation of field device diagnostics
Copper smelter- oil lead to burner -
FOUNDATION fieldbus Technology
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Example with Liquiline CM42
Customer challenges
• Prevention of any environmental impact for example through acid steam
• Reduction of operational costs
Benefits Endress+Hauser offering
• Safe and cost-conscious operation based on reliable measurement through evaluation of diagnostic information (for example reference impedance of the electrode) provided by Memosens and forwarded via FOUNDATION fieldbus
Wet gas scrubbers
FOUNDATION fieldbus Technology
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Products Solutions Services
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3. Implementation
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Endress+Hauser implementation field device diagnostics
FOUNDATION fieldbus Technology
Manufacturer: Implementation User: Configuration
DiagnosticsSensor Highest SeverityElectronic Highest SeverityConfig. Highest Severity Process Highest SeveritySensor High SeverityElectronic High SeverityConfiguration High SeverityProcess High SeveritySensor Low SeverityElectronic Low SeverityConfiguration Low SeverityProcess Low SeveritySensor Lowest SeverityElectronic Lowest SeverityConfig. Lowest SeverityProcess Lowest Severity….Process Diagnostic 23….Process Diagnostic XProcess Diagnostic Z
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
…………………………………………
……………………………………………………………………………………
…………………………………………
…………………………………………
Assignment
Info 1
Info 5
Info 11
Info 16
Info 31 (max.)
……………………
……………………
Masking
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Management of field device diagnostics
Device status
AlarmingProcess variables
Device configuration
Ope
rato
rSe
rvic
e, M
aint
enan
ce
GOOD
GOOD
BAD
GOOD
Status process value Category diagnostic
List of non masked alarms with category
Assignment category Masking for DCS
Detailed field diagnostics Remedy information
FOUNDATION fieldbus Technology
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Configuration of field device diagnostics • Default mapping of field diagnostic, developed by the supplier• Easy modification through end -user modifying based on process requirements.
FOUNDATION fieldbus Technology
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Configuration of field device diagnostics • Example
• In case of sensor corrosion; send „Instrument health status „Failure“
FOUNDATION fieldbus Technology
Diagnostic view (DTM)
Device configuration view (DTM)
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Product and technology roadmap FF
FF-912 – portfolio update until end of 2014
Levelflex FMP5x
Micropilot FMR5x
Cerabar S/Deltabar S/Deltapilot S
Pressure
Level
Temperature
Flow
Analysis
Promass 83Promag 53 /55 T-mass 65Prosonic Flow 93
Promass 200Prowirl 200
TMT85
CM42
FOUNDATION fieldbus Technology
• FF product portfolio for “FF-912” diagnostic capability will be complete for all relevant devices by end 2014
released
scheduled
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Products Solutions Services
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4. Extended functionality
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4321
FOUNDATION fieldbus Technology
Status
• All input and output and some parameter values (e.g. process value) are accompanied by a status
• The status and the value are evaluated from the following depending block
• 1 Byte status comprises• Quality• Substatus• Limits
5
4 Byte Process ValueIEEE 754 floating point
1 Byte Status
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4321
FOUNDATION fieldbus Technology
Status
BAD - The value is not useful.
UNCERTAIN - The quality of the value is less than normal, but the value still be useful.
Good - The value is useful
All Process Data has a Value and a Status
5
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PV status config (E+H specific)
FOUNDATION fieldbus Technology
• With PV status configuration you have the possibility to influence the PV status information according to your actual plant process.
• This is done directly in the field device. • Example; in case of corrosion PV status = “bad”
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Products Solutions Services
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5. System integration
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Quality gate for FOUNDATION fieldbus devicesHOST
SupplierControl System
Installation Tool
Comment
Delta V AMSDownload area Emersonwww2.emersonprocess.com/en-US/documentation/deviceinstallkits/Pages/deviceinstallkitsearch.aspx
Centum VP PRM / FieldmateList of HIST completed deviceswww.yokogawa.com/fbs/Interoperability/fbs-hist-en.htm
AC800M Fieldbus Builder List of HIST completed deviceshttp://search-ext.abb.com/library/Download.aspx?DocumentID=3BDD013119&LanguageCode=en&DocumentPartID=&Action=LaunchAC800F Control Builder F
ControlLogix
Experion PKS Control BuilderList of HIST completed deviceswww.honeywellprocess.com/library/support/Public/Documents/ExperionPKS%20HIST%20Completed%20Devices.pdf
IA Series Archestra
Endress+Hauser as HOST independent supplier ensures seamless integration into all major control systems
FOUNDATION fieldbus Technology
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FOUNDATION fieldbus Technology
http://www.fieldbuslab.endress.com/index.html
Integration environment – System World
Our Competence Center for Device Integration
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Challenge: Device replacement during MRO phase
Requirement for device replacement
Device on
stock
Order device
SameDev. Rev.
Replace device
Install new DDModify design
Install new DDModify design
SameDev. Rev.
No
NoNo
Yes
Yes Yes
Working packages MRO phase
• HOST specific trainings
• Technology training
• Maintenance of FF field devices
• Field network maintenance
• Field network audit
FOUNDATION fieldbus Technology
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6. Conclusion
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Conclusion
• Reduced maintenance effort implementing corresponding concepts (e.g. predictive, event-driven maintenance) using device diagnostics
• Foundation fieldbus specification enables end user to adjust diagnostic messages easily according to process requirements
• Endress+Hauser provides complete product portfolio of field devices with standardized device diagnostics
• HOST independent approach ensures seamless integration in all major DCS
• Endress+Hauser offers unique workingpackages for MRO phase
FOUNDATION fieldbus Technology
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Products Solutions Services
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Thank You for your attention!
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