thum's up! : wireless troubleshooting of intermittent upsets
DESCRIPTION
Presented by Emerson's Steven Moore at the 2010 Emerson Exchange in San Antonio, Texas.TRANSCRIPT
THUM'S UP! : Wireless Troubleshooting of Intermittent Upsets
THUM'S UP! : Wireless Troubleshooting of Intermittent Upsets
Steven Moore– Wireless Specialist
PresenterPresenter
Steven Moore
THUM'S UP! : Wireless Troubleshooting of Intermittent UpsetsTHUM'S UP! : Wireless Troubleshooting of Intermittent Upsets
Introduce the Process Identify the Process Impediment Investigate the Solution Options Implement a Solution Indicate the Business Results
The ProcessThe Process
Paper Producer Flows in a Waste Water area
– Remote Operation– EPA Spill Concerns– Process Critical Inventory
Instrumentation and Controls Overview– Multiple Control Systems– Process Enhancements– Old and New Instrumentation
Instrumentationand Wireless Network LayoutInstrumentationand Wireless Network Layout
Instrumentationand Wireless Network LayoutInstrumentationand Wireless Network Layout
Control Room & Shops
Instrumentationand Wireless Network LayoutInstrumentationand Wireless Network Layout
Control Room & Shops
Instrumentationand Controls DiagramInstrumentationand Controls Diagram
Plant Network
DCS Network
PLC Network
Operator Station
Powerhouse
station with AMS
Device Manager
Emerson Smart
Wireless Gateway
The ProblemThe Problem
Conflicting Information– Operator saw unacceptable flow variability– Technician saw stable flow at the flow meter
Instrumentation Accessibility– Technician not typically stationed near flow meter– Tied to Remote PLC– Outdoors
Intermittent Behavior– Operator would see stable flow when technician present at
flow meter– No obvious process or environmental condition created
upset.
The CostsThe Costs
Risk of EPA Violation or Process Upset Operator Attention to Non-Profit Making Task Instrument Technician Trip to Field Disruption of Process during Diagnosis Harmony Among Employees
The OptionsThe Options Options Using Traditional Diagnostic Tools
– Station technician in area for faster response– Add local data acquisition– Replace transmitter and flow tube, and wiring…….
Options Changing the Process– Change I/O location to DCS– Change Pump/Pipe configuration– Additional Instrumentation
Options Using Wireless Technology with Improved Diagnostic Tools– Add THUM Wireless HART adapter for full HART connectivity– Activate Diagnostic option in Magnetic Flow transmitter– Monitor Diagnostics with Wireless Network’s On-Line AMS Device
Manager
Instrumentationand Wireless Network LayoutInstrumentationand Wireless Network Layout
Control Room & Shops
The SolutionThe Solution Diagnostic Tools in the Field Device
– Activated Diagnostic Tools in Magnetic Flow Transmitter• Continuously Monitor Grounding Faults• Continuously Monitor Wiring Faults• Continuously Monitor for High Process Noise
Diagnostic Tools in the Shop– AMS Device Manager
• Alert Monitor• Audit Trail
Wireless Tools to Integrate All the Tools– THUM Wireless HART Adapter to Magnetic Flow Transmitter– Wireless HART Gateway– AMS Device Manager
Instrumentationand Controls DiagramInstrumentationand Controls Diagram
Plant Network
DCS Network
PLC Network
Operator Station
Powerhouse
station with AMS
Device Manager
Emerson Smart
Wireless Gateway
The CostsThe Costs
Diagnostic Upgrade to Magnetic Flow Transmitter THUM Wireless HART Adapter Installation Time and Materials Adding Device to Wireless Network Activate Monitoring in AMS Device Manager
The ResultsThe Results
Project Implementation– Time : Less than 2 hours– Cost : Less than $2000
Process Performance– No AMS Device Manger Alerts since implementation– No operator alerts since implementation
Profitability Impact– No operator distractions– No technician call outs– Confidence in operation
The SummaryThe Summary
The Problem and The Solution The Payback
The SummaryThe Summary
The Problem and The Solution The Payback
Where To Get More InformationWhere To Get More Information
Visit the Smart Wireless and Rosemount Flow Booths in the exhibit hall Featured demos:
• Emerson Smart Wireless solutions• Smart Wireless THUM Adapter• Wireless & Control
Attend any of the numerous wireless sessions Visit www.EmersonSmartWireless.com Visit www.hartcomm.org/