Predictive Intelligence in Foundation Fieldbus

Transcription

1 Predictive Intelligence in Foundation Fieldbus Binoy Kamath AGM Project Pursuit Pepperl+Fuchs India Pvt. LTd.,Bangalore

2 Agenda Need For Predictive Intelligence What does FF Enable? Where to implement Predictive Intelligence Key Diagnostics Basic Principles of Diagnostics FF Monitoring and Diagnosis Summary and Conclusion

3 Why do we need Predictive Intelligence? Maintenance Cost Reduction Drives End Users 40% of Mfg. Cost is Maintenance 50% of Maintenance is Corrective 10 times More expensive than preventative maintenance Preventative Maintenance is Done 25% of Time 5 Times More expensive Than Predictive Maintenance 60% of Preventative Maintenance is Unnecessary Lack of Proactive Maintenance strategy

4 What Does Foundation Fieldbus Enable? FF is a digital plant architecture that uses the power of Predictive intelligence to improve plant performance FF Predictive intelligence helps to detect and correct potential problems before they can affect Plant Performance FF Predictive Diagnostics will help users develop a proactive maintenance strategy FF Predictive Diagnostics avoid unplanned shutdown and help enduser's reap the real cost benefit of FOUNDATION technology during the operational phase of the plant Goal = Improved operational efficiency Result = increase plant availability FFIC : IA 2012

5 Areas to Implement Predictive Intelligence Field study by installation and commissioning Engineers around the world shows that more than 80% of the plant disturbances come from the Physical Layer level be it conventional 4-20mA applications or Fieldbus applications Unless the engineers sufficiently trained for Fieldbus applications the most common mistakes are made at the Physical Layer level such as wiring faults, wrong termination etc Field Devices

6 Key to Predictive Intelligence - Diagnostics Diagnostics analyze status information (i.e. from field devices with the objective of detecting causes for potential malfunction. Diagnostics form the basis to remove malfunctions. Value of diagnostics: Minimizes ad-hoc maintenance Enables proactive maintenance Minimizes unwanted plant shutdowns Enables event triggered inspections Forms the basis for Plant Asset Management Reduces costs

7 Fieldbus Diagnostic Capabilities Have Evolved ARC Report

8 Diagnostics in Plant Operation Information for the driver: All information for safe driving Only essential information: summary messages As early as possible Operator/ Driver Plant/ Vehicle Diagnostic Information

9 Diagnostics in plant upkeep Information for maintenance personal: As detailed as possible Includes suggestions for possible remedies Workshop diagnostic tool with 773 diagnostic codes

10 Symbols acc. to NE 107 Status: Diagnostics: Maintenance required Out of specification Check function Failure Diagnostics active Diagnostics passive

11 Strategies to Minimize unplanned shutdowns Equipment health 100% Time to respond Warning Level FAILURE Minimum Device Health Time

12 Basic Principles: Typical Topology Host Power Supply Advanced Diagnostic Module Surge Protector Trunk Device Couplers with Short-circuit protection Terminator Spurs Field Instruments

13 Basic Principles: Typical Topology Plant Asset Management Surge Protector Diagnostic Gateway Trunk Segment Protectors Terminator Spurs Field Instruments

14 Basic Principles: Typical Topology Plant Asset Management Surge Protector Diagnostic Gateway Trunk Segment Protectors Terminator Spurs Field Instruments

15 Basic Principles: Diagnostic Functions Today At the power supply Measure signal level, noise, jitter, earth leakage At the operator station Simple summary alarms At the maintenance station Expert system interprets measured data Produce actionable information in clear text Increase availability through pro-active handling of fieldbus as manageable asset

16 Are you protected from EMI? Ground faults Fieldbus and power cables tied together

17 Did they get it right? Cable gland not tight Seal missing

18 And corrosion as a consequence Water ingress or worse: Aggressive media

19 Will it hold next time? Wear of surge protectors unknown

20 Fieldbus Cabinet Too hot? Unauthorized access? Fan is not working Door not closed Water ingress

21 Is your topology protected?

22 Diagnostic Device Couplers

23 Diagnostic Device Couplers Improved and innovative spur fault protection: Progressive spur short-circuit protection Jabber protection cuts off devices talking too much Contact bounce protection suppresses unintentional bounce Reliable containment of gradual overload conditions Protects operations from manual intervention and device failure

24 Diagnostic Device Couplers Measures in the Field: Measures fieldbus signal conditions at the spur level Reports changes all the way to Plant Asset Management Feeds the expert system Better advice better knowledge focused plant upkeep fewer trips to the field

25 Diagnostic Surge Protector

26 Diagnostic Surge Protector Condition-based replacement Monitors strike severity and count Reports end of functional reserve to AMS Reduces repetitive scheduled maintenance Surely protects you from the next strike

27 Diagnostic Device Coupler + SPD Slide 27

28 Water Ingress Sensor ELS-1

29 Water Ingress Sensor ELS-1 Monitoring the inside of the enclosure Placed inside the enclosure of choice Connects in parallel to the fieldbus segment Sends alarm all the way to plant asset management Know what the housing looks like on the inside

30 Take Control of your Control Cabínet

31 Take Control of your Control Cabínet Diagnostic Gateway With FF-H1 integration and Ethernet Discrete, frequency, temperature and humidity inputs Solid state high-power outputs The cabinet becomes a supremely managed asset

32 Online monitoring The Diagnostic Module: Monitors physical layer health Detects changing conditions Sends messages with time stamps Expert System diagnoses faults: Precisely diagnoses causes Creates messages with clear text Enables proactive plant up keep Alerts before the segment fails Slide 33

33 Diagnostic Menu Expert System delivers clear text information for fast fault finding 1 Active messages 2 Actionable information with solution guideance based on expert system 3 History with timestamps When the failure occured disappeared Export function for external analysis and storage Slide 34

34 Online monitoring Clean layout shows boundaries Displays measurement values Highlights violations with color coding: Issues diagnostic messages Good value Maintenance required Out of specification Slide 35

35 Online trending and history Monitoring Reveals long term changes Exports into many formats

36 Built-in fieldbus oscilloscope Provides expert tools for fast fault finding For diagnosing complex scenarios For the fieldbus expert With fieldbus specific triggers Captures up to 10 shots in a row Slide 37

37 With Diagnostics of Physical Layer We Can. Commission Segments Monitor Segments Online Predictive Fault finding of Segments SEE KNOW ACT SEE what's going on in your physical layer KNOW when and how to act ACT in your Asset Management tool

38 Cash Flow The effect of Advanced Diagnostics Plan and purchase Install and commission Operate and maintain ACT Commission Monitor Troubleshoot KNOW SEE Longer plant uptime Know before you act Actionable information in clear text Verify against original design Automated checkout procedures Segment Checker: design of the physical layer

39 Summary Implementation of Diagnostics for Predictive Intelligence Protects your blind side Improves fieldbus availability reduces OpEx Lowers CapEx: Easy to implement The fieldbus physical layer is an important asset Fieldbus under control improves the bottom line Goal = Improved operational efficiency Method = Predictive Intelligence With Diagnostic Tools Result = Increased plant availability

40 Thank You Fieldbus Foundation India Committee Live FF Booth 2H rd November,