fieldbus commissioning benefits · fieldbus foundation™ freedom to choose. power to integrate...

Fieldbus Foundation™Freedom to choose. Power to integrate

2005 General Assembly

Fieldbus Commissioning benefits

Copyright Fieldbus Foundation, October 2007

Fieldbus Commissioning Benefits

• Commissioning - Device integration• Commissioning - Physical layer



• Commissioning - Device integration


Easier - Real Number Engineering Unit

• No range mismatch• Unit downloaded when device is replaced

Transmitter PositionerFF FF

BUSFF

CTRL

CPU

CPU

CPUDigital

Digital

DigitalDigital

TransmitterRange

0-800 kPa

SystemRange

0-400 kPa

8 mAProcess200 kPa

Reading100 kPa

...alarms and tripsnot working

AIA/D

D/A 4-20 mA

AOD/A

A/D4-20 mA

RangeRange


Lower Cost & Faster:- Device Commissioning

• Traditional: 2 hours / device for 2 technicians– Attach device– Verify 4-20 mA signal

• five points– Verify link to control

strategy– Check device parameters

with handheld

• Foundation fieldbus: 25 minutes / device for 1 technician– Attach device– Drag-and-drop

commissioning wizard– Compare configuration

faster on computer

•Devices are auto-recognized•Devices are auto-addressed•Devices identify themselves

Plug-n-Play

Only FF has automatic

addressing


Fieldbus Maintenance Made Easy:Device Commissioning Wizard


Fieldbus Maintenance Made Easy:Protective Decommission

• Removing device in an orderly fashion– “Safely remove

hardware”• Temporary removal

– To remove for calibration etc. with intention to put back into same place soon after

• Permanent removal– To remove for

replacement etc.

Control-in-the-field does not mean just

“simple” PID


Easier FF Device Commissioning and Replacement

• Commission or replace device without touching the software

• System automatically logs process in background

Automatic configuration reconciliation with device database

Automatic configuration

download

View details in historian and

log


Intelligent Devices via Fieldbus is a Must

• Process Industries worldwide require fieldbus based systems because of cost reduction– Reduction of wiring and cabinet costs– Less system and instrumentation hardware– Reduced commissioning time

• Intelligent devices enable Asset Optimization– Increase of maintenance effectiveness– Improves process availability– Enhances productivityAventis says: Fieldbus technology

saves costs and enables innovative applications. Future plant will be

equipped with fieldbus


Intelligent Devices Enable Asset Optimization

OK!Oops!BAD!

• Scheduled monitoring of asset health status• Smart condition reporting• Notification of key personnel independent of their location• Generation of fault reports and submission to CMMS



• Commissioning - Physical layer


The physical layer – alive and well?

– Proper termination– Water ingress– Ground faults



– Proper termination– Water ingress– Ground faults– Loose wiring – Faulty devices



– Proper termination– Water ingress– Ground faults– Loose wiring – Faulty devices– Unstable communication– Short circuits– Bulk power failure– …


Online monitoring of the physical layer

Time

Equipment Health100%

Minimum device health FAILURE

Time to respond

Warning level

Monitoring the physical layer protects you from unwanted shutdowns!


Advanced Diagnostics for physical layer

•Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Advanced Diagnostics for physical layer

•A portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Diagnostic Manager Software

•User interface in the control room:– Display of values – Warnings with actionable information– Color coding for easy recognition

•Value-add:– Automated commissioning

procedures and documentation– Live segment monitoring with alarms– Expert troubleshooting tools

•Embedded expert-knowledge


Asset Management Integration

•One Plant Asset Management – Includes fieldbus now as asset– Customary look and feel– Reduces required training – Reduces potential for errors

•Open Architecture Integration:– AMS Suite– PRM– FieldCare – FieldMate– PACTware– OPC Interface

Automatic Setup

Included


Open Architecture Integration

– ADM uses a simple infrastructure for data integration– ADM automates display of diagnostic information

• Benefits– No Planning:

• No planning of system resources required• Last minute decisions are possible on ADM implementation

– No Engineering: • Software configures alarm settings for segments and device tags• Commissioning wizard automatically configures ADM settings

– No Worries: • Easy to use graphical user interface and actionable information


Commissioning until now

– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires

• Screw driver• Check sheet• Pencil• Multimeter• Oscilloscope

– Connect one device at a time– Disconnect after testing

Test Report


Simple Commissioning Steps with ADM

– Verify address setting– Wire up devices in the right location– Check shielding– Activate communication– Use automated work procedures

• Testing • Documentation

– All devices at once– Wiring remains undisturbed

Commissioning Wizard

Test Report


Commissioning Wizard

– Simple to use– Eliminates manual test procedures – Ensures compliance with

AG181 and IEC 61158-2– Creates baseline report:

• Snapshot of all measurements • Complete documentation

– Recommends warning and alarm limits for the ADM– Stores limits in non-volatile memory– Reduces pre-commissioning

time by up to 80%


Commissioning process

■ Segment Checker: design of the physical layer

Cas

h Fl

ow

Plan and purchase

■ Verify against original design■ Automated checkout procedures

Commission

Install and commission

■ Longer plant uptime■ Know before you act■ Actionable information in clear text

TroubleshootMonitor

Operate and maintain

Engineering


■ Segment Checker: design of the physical layer

Engineering



■ Verify against original design

■ Automated checkout procedures

Commission



Commission

■ Printable Segment report in pdf format.

■ Save in Harddisk.



■ Know before you act■ Actionable information

in clear text

Troubleshoot



■ Longer plant uptime■ Know before you act

Monitor



■ Segment is still operaating with good preformance.■ Setting of pre-alarm.■ Warning – maintenance required.

Monitor


Good valueMaintenance required

Out of specification


■ Oscilloscope function.

Troubleshoot



■ Oscilloscope function.■ Readable Manchester

code.■ Able to identify

device ID.

Troubleshoot

Operate and maintain



Automated Pre-commissioning Saves Time

• Case Study with cost comparison for pre-commissioning: – 4…20 mA– Fieldbus– Fieldbus with Advanced Diagnostics

Case Study – SpecificationsNumber of instruments 1,200Number of segments 100Instruments per segment 12Hours per work day 8 hoursMean time to repair (MTTR) a fault

4 hours

Pre-commissioning is defined as work steps taken to install and validate the hardware configuration and the physical layer.

Source: Fieldbus Testing with Online Physical Layer DiagnosticsTechnical White Paper available from Pepperl+Fuchs Part No: 198636



Task 1 of 2 Model 4-20 mAFieldbus without

diagnostics

Fieldbus with Advanced

Diagnostics

Constructional checks:

Time/Unit 5 min 10 min Not required

Units 1200 loops

100 segments Not required

Total Time 12½ days 2 days 0

Construction failures (1%):

Time/Unit 4 h MTTR 4 h MTTR Not required

Units 12 loops 1 Trunk, 12 Spurs Not required

Total Time 6 days 6 ½ days 0



Tasks 2 of 2 Model 4-20 mA Fieldbus without diagnostics

Fieldbus with Advanced

Diagnostics

Pre/commissioning instrument checks:

Time/Unit 10 min 60 min 8 min

Units 1200 loops 100 segments 100 segments

Total Time 25 days 12½ days 1.6 days

Pre/commissioning failure:

Time/Unit 4h MTTR 4h MTTR 4h MTTR

Units 0.5% =6 loops

0.5% = 1 segment

1.5% = 2 segments

Total Time 24 h =3 days

4 h =½ day

8 h =1 day

Totals 46.5 days U 21.5 days U 2.6 days U


Commissioning saves time and money

– A few mouse clicks conduct automatic testing

– Reports on the actual installation with all devices connected

– Automatic setting of warning and alarm limits


Monitoring increases plant up-time

– The ADM increases the number of detectable faults

– The physical layer becomes a managable asset

– The ADM is prevention from unwanted shut downs


Accelerated Commissioning

– Actionable information guides to potential sources of faults

– ADM provides expert knowledge and advice

– For anyone working with fieldbus

– Accessible from remote for consultation with fieldbus experts


Accelerated Commissioning ( ADM makes the physical layer visible )

– Fieldbus itself becomes a managable asset

– ADM integrates into Asset Management Systems

– Available as stationary or mobile module

– Display in the safety of the control room


Accelerated Commissioning

– Rapid commissioning: Accelarates loop check

– Longer operation: Warns before failure

– Faster troubleshooting: Assists with actionable information


Conclusion

– Foundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof.

– Advanced Diagnostics tools for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEX


QUESTIONS?

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