Predictive Intelligence in Foundation Fieldbus Binoy Kamath AGM Project Pursuit Pepperl+Fuchs India Pvt. LTd.,Bangalore
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
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
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
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
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
Fieldbus Diagnostic Capabilities Have Evolved ARC Report
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
Diagnostics in plant upkeep Information for maintenance personal: As detailed as possible Includes suggestions for possible remedies Workshop diagnostic tool with 773 diagnostic codes
Symbols acc. to NE 107 Status: Diagnostics: Maintenance required Out of specification Check function Failure Diagnostics active Diagnostics passive
Strategies to Minimize unplanned shutdowns Equipment health 100% Time to respond Warning Level FAILURE Minimum Device Health Time
Basic Principles: Typical Topology Host Power Supply Advanced Diagnostic Module Surge Protector Trunk Device Couplers with Short-circuit protection Terminator Spurs Field Instruments
Basic Principles: Typical Topology Plant Asset Management Surge Protector Diagnostic Gateway Trunk Segment Protectors Terminator Spurs Field Instruments
Basic Principles: Typical Topology Plant Asset Management Surge Protector Diagnostic Gateway Trunk Segment Protectors Terminator Spurs Field Instruments
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
Are you protected from EMI? Ground faults Fieldbus and power cables tied together
Did they get it right? Cable gland not tight Seal missing
And corrosion as a consequence Water ingress or worse: Aggressive media
Will it hold next time? Wear of surge protectors unknown
Fieldbus Cabinet Too hot? Unauthorized access? Fan is not working Door not closed Water ingress
Is your topology protected?
Diagnostic Device Couplers
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
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
Diagnostic Surge Protector
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
Diagnostic Device Coupler + SPD Slide 27
Water Ingress Sensor ELS-1
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
Take Control of your Control Cabínet
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
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
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 1 2 3 Slide 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
Online trending and history Monitoring Reveals long term changes Exports into many formats
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
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
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
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
Thank You Fieldbus Foundation India Committee Live Demo @ FF Booth 2H 815 23 rd November, 2012 www.fieldbus.org