healthy instrument relationships – are yours really listening?
TRANSCRIPT
Healthy Instrument Relationships – Are Yours Really Listening? John Yingst, Product Manager Bart Winters, Product Line Manager
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• Comstock Load Discovered in Gold Canyon 1859
History Lesson
Problem – Growing Piles of Blue-Gray Mud
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• Smart instruments are smarter than ever ‒ Diagnostic messages readily available ‒ Large amount of information about health and maintenance
• Where does the information go? ‒ Are devices set up during the project and forgotten? ‒ Are device alerts and alarms sent to the journal and ignored? ‒ Is a process in place to take advantage of this wealth of
information? • Leading companies putting this information to work…
‒ Detecting issues ‒ Taking proactive actions ‒ Preventing process and equipment problems before they
happen!
Where is your Blue-Gray “Mud”?
Are You Getting the Value? Are You Listening?
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Valve_Stuck_Sensor_Arm_Damage IP_Primary_Nozzle_Plugged Processor_Impaired IP_Latched Relay_Cross_Misadjusted Air_Line_Blocked Relay_Jammed Performance_Critical_Alert Press_Fallback_Alert Travel_Sensor_Alert Press_ABSensor_Alert Supply_Press_Sensor_Alert Temp_Sensor_Alert External_Relay_Ring_Leak External_Relay_Ring_Leak_Alert ... Etc…
What Is All of This “Noise”?
• Device off net (disconnected) • C300 – redundancy / FTE state / soft fail state • FIM – state / CPU / Memory • Series C IO – channel status/ redundancy status / fail status • Segment health (jitter/ variance/ noise…) • Control loop – stiction / oscillation / bias / drift / hysteresis
/ deviation
Device Diagnostic Information
Other Diagnostic Information
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Uniformance Asset Sentinel for Instruments
Maint. Mgt
Engineering Reliability, Maintenance, & Process
Mgt. Reporting & KPI’s
Dashboards / Displays / Trends Asset Sentinel
Operator
Historian
Alerts & Data
Calc Results
Work Requests
Real-time / Historical Data
Event Detection (Symptoms/Faults)
Analytics • Embedded • User Defined • UniSim • Other
Notifications (E-mail & Alerts)
Equipment Lib.
Templates • Attributes • Calculations • Rules
Asset Model
Unified real-time asset and process monitoring solution
Historian Vibration Monitoring
Other Applications
DCS / PLC Smart Instruments
Visual Inspections
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Providing Structure – Grouping & Organization
Symptom Name Fault Name Software_Error
Failure
Sensor_DB_Error Probe_Missing Electronics_Failure Software_Compatibility_Error Memory_Failure Com_Failure Temp_Critical
Off Spec Measure_Error Level_Measure_Failure Volume_Measure_Failure Config_Error Temp_Outof_Limit
Maintenance
Volume_Measure_Warning Measure Warning Lost_SD_NV Config_Warning Data_Integrity_Error Algorithm_Error RB_SimAct
Function Check AI_SimAct PWA_SimAct RB_OOS AI_OOS
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• Experion ERDB Synchronization ‒ Import Adv Alarming or DD file definition
• Define ‘Template’ for device types ONCE ‒ Organize diagnostic messages (per NAMUR 107) ‒ Time delay to minimize chatter ‒ Define ‘Severity’ of fault ‒ Define Action (OPC, Email, CMMS) ‒ Corrective Action
• Instances ‘Auto Created’ ‒ Define Criticality - (instrument on compressor vs back-up pump) to calculate priority
Listening To Your Devices
Experion Control Builder Asset Mgr Fault
Diagnostic Criticality Failure 6-Critical Out of Specification 5-Serious Maintenance Required 4-Important Function Check 2-Minor Information 1-None
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Taking Action
• Real-time Dashboard • Drill-down • Fault Summary • Fault Help • Work-flow
‒ Close-out
• Info Links ‒ FDM Client ‒ Info displays (graphics) ‒ Data sheets
• Notifications ‒ E-mail ‒ OPC ‒ CMMS (SAP/Maximo)
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Reporting
• Reporting – KPI’s ‒ Standard Reports ‒ Custom reports
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FDM Basics FDM simplifies smart instrument management
Configuration, Diagnostics and Maintenance
Supports configuration, diagnostics and management tasks Displays device health status to help
maintenance personnel find problems Handles a large database of devices from
the entire plant (up to 16K) Saves effort by auto-building database
from live connected devices Uses open standard DDs/EDDLs and DTMs to create templates for
devices Allows easy download from FDM to devices or upload from devices to
save valuable configurations Works with Experion, non-Experion, Wireless, RTU, TPS, and Safety
networks
SIMPLIFYING SMART INSTRUMENT MAINTENANCE
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• Maintenance ‒ Performing routine maintenance (especially valves) ‒ Checking device status (alarms) and troubleshooting ‒ Device database upload (history) for archive/reference ‒ Device replacement and needed setup/reconfiguration
• Engineers ‒ Configuring and setup of devices during FAT ‒ Device commissioning during startup ‒ Assisting maintenance with troubleshooting ‒ Assisting operations with problem solving
• Operators ‒ Device diagnostics/status checks ‒ Device information reference for running the process
Typical FDM Use Cases
ALWAYS THE RIGHT TOOL!
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• “Teach” instruments to tell you the right information! ‒ Set alerts and alarms properly ‒ Correctly set ranges, options, etc. ‒ Compare configurations against known's
• “Check up” on instruments to make sure they are doing their jobs! ‒ View status of instruments ‒ Check performance criteria ‒ Prevent surprise failures with proper care
• Better organize instrument information ‒ Plant Area View (PAV) for viewing status ‒ History records of all your instruments
• “Remedial Training” through “tune ups” ‒ Run valve diagnostics ‒ Perform instrument calibrations
What You Can Do With FDM
ARE YOU TRAINING YOUR INSTRUMENTS?
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• Experion compatibility ‒ R430, R410, R400, and R311
• Foundation Fieldbus DD/EDDL Support ‒ Complements previously introduced DTM support
• OneWireless/ISA100 Wireless Support ‒ Through Honeywell’s Wireless Device Manager
• New RTU2020 Support ‒ Geographically distributed wellhead monitoring and pipeline solutions
• EDDL Enhancements ‒ Visualization and layout improvements
• Plant Area View ‒ Provides organization of smart device asset health for easy monitoring ‒ Originally released in FDM R430 Patch
• Virtualization Support ‒ All FDM components tested with VMWare and are fully supported
FDM R440 New Capabilities Summary
FOCUS ON EXPANDED PROTOCOL SUPPORT
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ESV-TPS TPN Server
ES-TPS TPS DocTool
HPMs
NIMs
UC
N
LCN
• Experion compatibility ‒ R431, R430, R410, and R400
• Partial Valve Stroke Test (PVST) Planner ‒ New optional feature to automatically
validate emergency shutdown devices • TPS DE Protocol Device Integration
‒ Support for DE Protocol devices connected to HPMs (TPS Networks)
• Other Enhancements ‒ EDDL enhancements ‒ FDT enhancements ‒ Support for 40-character
Experion tags ‒ Support for 32-character
MUX Monitoring tags
FDM R450 New Capabilities Summary
EXPANDING THE ROLE OF FDM
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FDM Supported Protocols • HART devices via Experion and Safety Manager
HART I/O • HART devices via non-Experion-connected
HART multiplexers and modems • Profibus networks and PA or DP devices using
Profibus Communication and Device Type Managers (DTMs)
• Profibus Gateway (same capabilities) • HART devices connected to Profibus networks
via HART-over-Profibus gateway devices • Foundation Fieldbus devices via Experion-
connected Fieldbus I/O • OneWireless and ISA100 Wireless • HART IP (RTU2020, WDM, WirelessHART GW) • DE Protocol devices (TPS-connected)
SUPPORTING OPEN STANDARDS
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Sentinel/FDM Architecture
PMIO AI/AO Series-A (1756) AI/AO Series-A FIM
Series C FIM
Wireless Devices
IP
Wireless Device Manager
Universal Safety I/O Universal Safety Logic Solver
Safety Manager
Experion Server
FDM Server
MUX Monitoring Gateway PC
Profibus Gateway Module
MUX
Remote PC with RCI
Remote PC with RCI
Experion Flex Station with FDM Client
Sentinel Web Client
FDM Client
One Wireless Adaptor
Series C I/O AI/AO Series C Universal I/O
Instrument Sentinel Server
Instrument Sentinel Shadow Server
Inst. Engr Desktop Sentinel Web
Client
Enterprise Apps CMMS, E-Mail…
Firewall
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Where It All Fits
Field Devices (Smart & Traditional)
Field Device Manager Device Configuration Management
Trouble shooting Maintenance (e.g., Methods)
DCS & Safety System
Asset Sentinel Device Health Management
Fault Modeling Reporting
Device Alarms (OPC A&E)
Device Status (OPC DA)
Visual Integration
Device Access (Remote
Communications)
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Value Proposition
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Reducing Unplanned Capacity Loss
Rare Frequent
High
Cos
t Im
pact
Low
Frequency
Process Deviations
Unit Shutdown
Degraded Efficiency
Non-Critical Eq. Failure
Critical Eq. Failure
Reduced Capacity Loss
Original Capacity Loss
Mitigation Strategies
Leading Cause
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• Combined solution of Configuration Management and Health Management equals Integrated Instrument Asset Management!
• Important to take full advantage of the investment in your smart instruments!
• Find the “Blue-Grey Mud” and listen to your devices!!
So, What Are the Messages?
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QUESTIONS?