Asset Management with FOUNDATION fieldbus

Jonas Berge Director, PlantWeb Consulting Emerson Process Management

2011 General Assembly Mumbai, India

Topics
Fieldbus Device Diagnostics

Diagnostics available in devices Diagnostics from discrete devices Diagnostics from advanced devices and subsystems Reporting of diagnostic alarms Real-time status in control strategy

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More Device Diagnostics

2011 General Assembly Mumbai, India

Power to Perform
Two-wire bus-powered devices have more power (> 10 mA) for:

More electronics More frequent testing More powerful microprocessor More sophisticated firmware

Caveat: Not all manufacturers have extensive diagnostics in their devices

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2011 General Assembly Mumbai, India 1994 2011 Fieldbus Foundation

Fieldbus Control Valve Positioner Diagnostics

Continuous (no on-demand) Performance Diagnostics:

Actuator/tubing leakage, air supply availability, calibration shift, etc. Partial Stroke Testing (PST), travel histogram, step-response, valve signature, pressure sensor failure, abnormal drive current, travel deviation, reversal count alert, accumulated travel alert, low supply pressure, high supply pressure, position feedback sensor failure, etc.

Common Diagnostics

2011 General Assembly Mumbai, India 1994 2011 Fieldbus Foundation

Fieldbus Pressure Transmitter Diagnostics

More versatile statistical process monitoring

Uses process noise to detect process problems:

Fast stick slip flow" of FCC catalyst before standpipe damage Furnace flame instability before flameout Pulsation indicative of pump or compressor damage Entrained air causing measurement errors Distillation column flooding before separation is affected Leaks in impulse lines and manifolds Liquid carryover in gas stream

2011 General Assembly Mumbai, India 1994 2011 Fieldbus Foundation

Fieldbus Pressure Transmitter Diagnostics (Continued)

Common Diagnostics

Plugged impulse line before reading sizes up, pressure or temperature sensor failure, electronics or memory failure, pressure or temperature reading degraded, or local operator interface error

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Fieldbus Temperature Transmitter Diagnostics

Statistical process monitoring

Uses process noise to detect process problems:

Detect hydrate formation in natural gas lines Detect scaling formation, Detect thermowells coating etc.

Predictive thermocouple degradation diagnostics

Alerts before the thermocouple completely fails

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Fieldbus Temperature Transmitter Diagnostics (Continued)

Extreme Temperature Tracking

Detect if excessive heat from integral sensor is conducted to transmitter housing Capture transients process temperature or cold-junction temperature sensor failure, sensor drift, hot backup warning, calibration error, process temperature or coldjunction temperature reading degraded, electronics or memory failure, configuration error, and hardware/firmware incompatibility.

Common Diagnostics

2011 General Assembly Mumbai, India 1994 2011 Fieldbus Foundation

Diagnostics from Discrete Devices

2011 General Assembly Mumbai, India

All Devices Digitally Integrated

Traditional Smart Devices
Transmitter Flow meter Liquid analyzer Valve positioner (pneumatic)

Fieldbus Additions
On/Off valve coupler (pneumatic) On/Off valve actuator (pneumatic) Electric actuator Gas chromatograph

Half the plants devices are discrete Predictive maintenance for all devices in the plant, not just some

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Fieldbus Electric Actuator / Motor Operated Valve (MOV) Diagnostics

Cores I/O Description 4 3 DO Open/stop/close control Desired valve position 2 1 AO control 2 1 DO Emergency shut down Valve position status 3 2 DI (limit switches) 2 1 AI Percentage open 1 1 DI Available for control 1 1 DI Local/remote switch Motor running open 1 1 DI direction Motor running closed 1 1 DI direction 1 1 DI Torque switch tripped 2 1 AI Percentage torque Motor thermostat 1 1 DI tripped 1 1 DI Battery condition low 22 16 ch TOTAL

Hardwiring diagnostics is too costly Proprietary protocols and Modbus dont integrate with common device management software
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Fieldbus On/Off Valve Diagnostics

Open/close travel time

Indicates poor valve performance Leading indicator of wear and tear to drive scheduling Hand operation required

Cycle counts Stuck valve

...

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Diagnostics from Advanced Devices and Subsystems

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Fieldbus Gas Chromatograph Diagnostics

Proprietary protocols and Modbus dont integrate with common device management software Fieldbus integrates all devices around the plant

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Fieldbus Inventory Tank Gauging System Diagnostics

Proprietary protocols and Modbus dont integrate with common device management software Fieldbus integrates all devices around the plant

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Faster Device Diagnostics Delivery

2011 General Assembly Mumbai, India

Hardwired Device Polling

500 tags/hour

Depending on architecture

Not very early warning Intermittent problems may be missed

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Fieldbus Device Alerts

Diagnostics is pushed to the system

Almost instantaneous Gives operators more time to take action before device problem affects the process Sequence of event recording

Early warning

Time-stamped

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Integrated Smart Diagnostics Incorporated in Daily Workprocesses

Normal operation... Device failure... Faceplate... Diagnostics

No device configuration by operator

Detailed diagnostics in two clicks Help on the third

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Real Time Status in Control Strategy

2011 General Assembly Mumbai, India

Process Problems Do Not Masquerade As Device Problems

Hardwired
Device drives current <4 mA or >20 mA on device failure

Fieldbus
Device health indicated by associated status Controller holds last position on device failure

Looks like process problem

PID counteracts thus tripping the loop Operator cannot tell the difference between a process alarm and a device alarm
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Shutdown is optional

Operator can easily distinguish process problem from a device problem

2011 General Assembly Mumbai, India 1994 2011 Fieldbus Foundation

Why Do Reliable Devices Need Diagnostics?

63%
50% 40% 30% 20% 10% 0%

Unneeded Trips To The Field - Avoided Through Remote Diagnostics

35%

28% 20%

Source: Dow Chemical Company

6%

6%

4%
Failed Instrument

Routine Check

No Calibration Problem Shift

Zero Off

Plugged Lines

...because they still get blamed...

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Conclusion

2011 General Assembly Mumbai, India

Summary
Fieldbus device have more diagnostics

Because they have more power Predictive maintenance also for discrete devices

Fieldbus digitally integrates all devices Fieldbus integrates diagnostics from advanced devices and subsystems

Previously used proprietary protocols and software

Fieldbus reports diagnostic alarms faster Fieldbus distinguishes device problems from process problems

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Real-time status in control strategy

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One Piece of the Pie

Wire reduction Elimination of D/A and A/D conversion delay and inaccuracy Elimination of range mismatch Closed loop digital control, High-density devices Complex devices More diagnostics Remote firmware download
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