isa-108 intelligent device management

IEC Plenary 2012September 26, 2012 Orlando, FL

Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

ISA-108Intelligent Device ManagementIan Verhappen – Yokogawa CanadaHerman Storey – Herman Storey Consulting LLC


What Is Asset Management?

• Activities that provide for Sustainable Managed Risk over the Life Cycle of an Asset

• Some Asset Management Activities are Mandated by Government Regulation

• All Types of Enterprises have Requirements– Financial– Transportation– Power Generation– Mining and Manufacturing (M&M)


Asset Management Goals

• Reduce Unmanaged Risk– Improve Health, Safety, Environmental, and Operability

Performance– Manage Complexity– Reduce Impact of Failures

• Achieve Sustainability– Assure Adequate Human, Financial, and Infrastructure

Resources– Lower Maintenance Cost– Improve Return On Investment

• Simultaneously


Maintenance Work Processes

• Work Processes are the Key to Success• Traditional Processes

– Run to Failure– Preventive (Scheduled) Maintenance– Predictive Maintenance

– Schedule Based on Risk and Failure History– May Include Bad Actor / Root Cause Analysis

• Condition Based Maintenance– Based on Real Time Diagnostic Data– Multivariable Model Based (Equipment / Process)– Intelligent Device Based (Instruments / Valves)


Maintenance Work Processes

• Traditional Processes– Waste Effort on Poorly Defined Problems (“Broke”)– Maintenance is Often Deferred for Non-Critical Devices– Scheduled Inspection and Testing is Wasteful But Necessary

• Intelligent Device Management– Allows Maintenance on Devices that Actually Need Work, Only

When They Need Work– Can Give Detailed Information on Problems Before a Field Visit– Can Significantly Reduce (or eliminate) the Need for Periodic

Testing– Can Reduce Impact on Operations by Advance Warning of

Failure– A Significant but Underutilized Opportunity– Biggest Incentives on Control Valves


Recognition of System Deviations “Before Problems Occur”


Standards for Traditional Asset Management• ISO 55000

– Part 1 Overview (Principles and Terminology)– Part 2 Requirements (Includes Mandatory Compliance Metrics)– Part 3 Guidelines for Application– ASTM is US TAG, No Involvement of Automation Professionals

• NAMUR– NE129 Plant Asset Management

• These Standards Do Cover Manual Inspect and Test Methods

• None of these cover use of Automated Diagnostics or would apply to Intelligent Device Management


NAMUR NE 129: The Asset Health Triangle


PAM System Information ArchitectureSupply Chain Management

Supply Chain Management

Enterprise Resource Planning (ERP) System

E-commerce Maintenance

Repair & Operations

(MRO) Procurement

System

Enterprise Asset

Maintenance (EAM)

System CMMS

Plant Asset Management

(PAM) System

Plant Automation

System (PAS)

Process Control &Process Management

Maintenance Work &Parts Management

Asset AdvisoryManagement

ControlParameters Control

Data

Asset Collaboration /Tolerances

Transducer Config.Monitoring Set-upInspection Routes

Asset UsageData

Asset MonitoringVariablesAsset Calibration / Tolerance Data

Control Device Monitoring

Portable Device Monitoring

Survey On-Line Monitors

ProtectionOn-Line Monitors

TransientOn-Line Monitors

Sample Monitoring

Smart valves & Field Devices

PLC / DCS

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Part

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Oil

Che

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Oil

Prop

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sOperation Field

Report

Smart Machines & Transducers

Plant Measurements / Inspections

Maintenance Advisories Purchase order

Order TrackingWork Histories

Process Advisories

Process Events & Data


Smart Pressure Transmitters are the Norm

Source: ARC Advisory Group

Installed Base

Smart, Microprocessor Based

Conventional or Pneumatic


Intelligent Device Management

• Intelligent Devices Are Pervasive, but Are Not Being Used Properly– Most Diagnostics are not Prioritized or Utilized

• Considered Approach to Intelligent Device Management is Required– Technology and Products are Widely Available– Work Processes and Best Practices are the Key– A New ISA Standards Effort is Needed


New ISA Intelligent Device Management Standard• Content Proposals:• Models and Terminology• Implementation Guidelines• Work Processes

– Diagnostics Based Maintenance– Configuration Management– Auditing


Work Process Life Cycle

• FED– Criticality Ranking– Vendor Qualification & Templating

• Design / FAT– Work Process Selections and Design– Initial System Configuration (Build Tools)– Training

• Install, Commission, Loop Check– Device and System Integration– Initial Use of Diagnostics

• Pre-Startup Safety Review• Routine Maintenance• Turnaround Management


Intelligence Device Management

• Most Diagnostics Go Directly to a Black Hole– Diagnostics May Need to go to Engineering, Maintenance,

and/or Operations• Use and Priority of Diagnostics are Determined by

Application Criticality– Criticality Ranking should be established in FED– Alert Priority Depends on Impact Severity – Not Likelihood– Send Alerts to Operator and well as Maintenance Only if

Operator Action is Required– Log All Alerts regardless of Priority– Different from process alarm management

• Needs Definition Before Configuration Activities


Intelligent Device Management

• Proper Use of Diagnostics Depends on a Graphical User Interface – Would you give an Operator an Explorer Tree?– Requirement: Navigate from Overview to Detail in 3 Mouse

Clicks– Cover all System Devices, Nodes, Networks, & Modules

• Free Format Diagnostic Reports are Necessary– Individual Alerts are Not Generally Useful and are Often

Repetitive– Reports can Summarize and Clarify Large Amounts of Raw Data

• See Fieldbus Foundation User Guide (AG-181) for More Information & Examples


Graphical User Interface for Maintenance

CCGCTL01 CCGCTL02 CCGCTL03

03-01-29-02MF2

03-01-29-01MF2

03-01-19-01MF2

03-01-17-02MF2

03-01-17-01CSS

03-01-13-02MF2/CSS

03-01-01-01MF2

03-01-01-02MF2

03-01-03-01MF2

03-01-03-02CSS/MF2

03-01-05-01CSS/MF1

03-01-05-02MF2

03-01-09-01CSS/MF2

03-01-09-02MF2

03-01-11-01CSS/MF2

03-01-11-02CSS

03-01-13-01MF2/CSS

01-01-01-01CCS/RR2

01-01-01-02CSS

01-01-03-01CSS/RR2

01-01-03-02CSS/RR2

01-01-05-01CSS

01-01-05-02CSS

01-01-09-01CSS

01-01-17-02CSS/RR2

01-01-19-01CSS/RR2

01-01-19-02CSS/RR2

01-01-21-01CSS/RR2

01-01-21-02RR2

01-01-25-01CSS/RR2

01-01-25-02CSS

01-01-27-01CSS/RR2

01-01-27-02RR2

01-01-29-01RR2

01-01-29-02CSS/RR2

02-01-01-01RR1

02-01-01-02RR1

02-01-03-01RR1

02-01-03-02NONE

02-01-05-01RR1

02-01-05-02RR1

02-01-09-01RR1

02-01-09-02RR1

02-01-23-02RR1

02-01-23-01RR1

02-01-21-02RR1

02-01-21-01NONE

02-01-19-02RR1

02-01-19-01CSS

02-01-17-02RR1

02-01-17-01RR1

02-01-25-01RR1

02-01-25-02RR1/CSS

02-01-27-01RR1

02-01-27-02RR1

02-01-29-01RR1

02-01-11-01RR1

02-01-11-02CSS/RR1

02-01-13-01CSS/RR1/MF1

02-01-13-02RR1

02-01-15-01RR1

01-01-09-02CSS

01-01-11-01CSS

01-01-11-02CSS

01-01-13-01CSS

01-01-13-02CSS

01-01-31-01RR2

01-01-31-02RR2

01-01-17-01RR2

02-01-15-02NONE

02-01-29-02RR1/CSS

03-01-27-02MF2/CSS

03-01-27-01MF2/CSS

03-01-21-02MF2

03-01-21-01MF2

03-01-19-02CSS/MF2

FIELDBUS MAINTENANCE OVERVIEW

Good

Source: AG-181


Automated Use of Diagnostics

• Diagnostics Must Flag Data Quality– Data Quality (PV Status) Must Propagate to All Applications and

Graphics in Host Systems for Automated Failure Handling• Data Quality Should Include:

– Active Alerts (Follow NAMUR NE107)– Good, Bad, Advisory, Bubba is Working on it– Full Support by Fieldbus Foundation Devices and Hosts

– Configuration Mismatch with Host– Excess Communication Errors– All Device and Loop Blocks in Normal Mode

• Utilization of Data Quality in Control Schemes Requires Extra Engineering


Automated Use of Diagnostics

• Data Quality (Fieldbus Foundation vs. HART)– HART Devices Support Good and Bad Status for Analog Inputs

(Measurements) Through NAMUR NE 43– NAMUR NE 43 Does Not Work for Analog Outputs (Valves)– Additional HART Information is Available by Polling Devices– Foundation Fieldbus Provides more Complete Information for all

Devices – Much Faster• Diagnostic Performance (Fieldbus Foundation vs. HART)

– Polling Requirement and Speed– Multiple Simultaneous Polling Groups (Modems) for HART

– 64 Maximum Recommended Devices per Group– Utilize Data Cache in HART Modems


Required Intelligent Device Management Tools• Maintenance History• Resource Planning, Tracking, Accounting

– Example: SAP• Design Calculation, Drawing, Documentation

– Example: SPI (Intools)• Host Systems

– Integrated Host (Example: DCS)– Visitor or Bench Host (Handheld or Laptop)– Provide Configuration Management, Troubleshooting, and

Human Interface


Intelligent Device Management Interactions

DCS Host

CMMS

Plant Asset Management System

Event Historian

Alarm Management System

Intelligent Devices

Configuration Database

Work Orders

Reporting & Analysis


Integrated Data System

Device server

FDT/DTMEDDL

HART FF Profibus DeviceNet Others

AlertMonitor

Database(s)Tag data

Audit Trail

Calibration Data

Instrument Asset

Management System

User Interface

Database Rules Engine

Enterprise Asset

Manager System

Interface

User Interface (Configuration & Monitoring)

Enterprise Asset

Management System

B2MML

XMLSQL & ODBC

Enterprise Server /

Middleware


Intelligent Device Management Tools

• Tools, Hosts, and Devices Need:– Remote Access– Multiple Simultaneous Access– Cyber Security

– Role Based Security– Required for Hosts and Devices– A Standardized Security Model Would be Nice


Configuration Data Management

• Each Tool has a Database– Each Tool is Designed to Use its Data as Master– The Actual Data Master Changes During the Lifecycle

• Tools, Devices, and Systems Must Manage Data– Import, Export, and Reformat are Needed for Exchange– Data Comparison and Reconciliation is Necessary– Template Process Required for Default Settings– History and Change Tracking are Needed

• Field Experience– Use of Visitor Hosts (Handhelds)– Configuration Management (or Configuration Drift)


What Is Exception Based Surveillance?

Seconds Minutes Hours Days Weeks Months Years Life of Asset

Operation Diagnostics & Surveillance

Planned Maintenance and Design

Improvements

Real Time Activities

Semi Real Time

Activities

Planned Activities

Exception based Surveillance provides for Reactive Response in Semi Real Time to Diagnostic Alerts filling a Gap between Operation and Traditional Planned Activities and makes use of Diagnostic Capabilities of Field Devices


Conclusion

• Large Incentives for Intelligent Device Management– Most Efficient System for Maintenance– Reduced Impact of Failures

• Barriers are Significant– Changes in Engineering Practices– Culture Change for Maintenance– Management Ownership

• Standards Will Help– Get Engaged


To Learn More:

ISA108 Committee• http://www.isa.org/

MSTemplate.cfm?MicrositeID=1528&CommitteeID=7281

Ellen Fussell Policastro, Standards AdministratorInternational Society of AutomationPO Box 12277, 67 Alexander DriveResearch Triangle Park, NC 27709+1 (919) [email protected]

Managing Director:Ian Verhappen+1 403 258 2681 [email protected]

mailto:[email protected]

isa-108 intelligent device management

Documents

control valves iec plenary

instruments valves iec

detailed information

sustainable managed

failure historymay

life cycle

us tag

overview principles