Fieldbus Foundation India Committee Fieldbus Foundation Asset Management and Diagnosis Automation-2010, India Date Time Venue : 22dn September, 2010 ( Wednesday) : from 10:00 am to 04:00 pm. : Automation 2010 Conference Hall Bombay Exhibition Centre (NSE) Goregaon, (East), Mumbai, India Jigish Jepal Yokogawa India Limited E-mail ID : jigish.jepal@in.yokogawa.com 1
Paradigm Shift in Field Device Maintenance and Diagnosis 2
Content Paradigm shift in device maintenance Paradigm shift in device diagnosis - Emergence of diagnosis i - Difference between Conventional Smart and Foundation Fieldbus - Applications subject to diagnosis i - Advanced Diagnostics functions (Examples) - Brief details on some advance diagnosis ITK 6.0 and Diagnosis 3
PARADIGM SHIFT IN DEVICE MAINTENANCE 4
Paradigm shift - Device Maintenance New device engineering and maintenance environment is needed to make the most of digital field communication and advanced intelligent devices 250 parameters Digital communication App. 250 parameters 700 parameters Advanced intelligent field devices PC-based Versatile Device Management Wizard Field device tool (FDT) Device Type Manager (DTM) Analog setting 4-20mA 4-20mA, hybrid communication(smart) App. 50 parameters Device Description (DD) Screw driver No standard environment Handheld Terminal 5
Paradigm shift - Device Maintenance Users want: Calibration, Loop Checking and Commissioning needs to be more speedy. Finding and tracing the device fault and cause of trouble needs to be quickly and straightforward. Paper work after daily site inspection needs to be minimized Shift transfer and communication between shifts persons needs to be smooth, concise and clearly expressed. Work and operation record needs to be clearly visible, who, when, what is done. 6
Paradigm shift - Device Maintenance Easy Access 7
Paradigm shift - Device Maintenance Quick Device Diagnostics 8
Paradigm shift - Device Maintenance Sophisticated device engineering 9
The PC advantage A complete tool box P1 h2 hmax. H γs h γo γw hmin h1 PH PL 10
Paradigm shift - Device Maintenance Raise expectations of improving effectiveness and efficiency of maintenance management at large Expect more from the technology 11
PARADIGM SHIFT IN DIAGNOSIS 12
Emergence of Diagnosis Analog 4-20 ma Saturated output SMART transmitters with digital signal superimposed on analog signal Saturated output Traditionally bit level Diagnosis and now advance diagnosis Foundation Fieldbus Comprehensive device/process diagnosis 13
System Configuration of FF and Conventional SMART HIS/ENG Asset Management Software I/O Bus Control Network DCS Controller Conventional SMART Case 2 SMART AI/O Conventional SAMRT Digital (SMART Parameters) FF-H1 I/O I/O Conventional SMART I/O Case 1 I/O AI/O FF Power Supply 4-20mA(PV) + Digital Signal MUX MUX 4-20mA (PV) FF Case FF-H1 Digital (PV+FF Parameters) FF Devices Conventional SMART Devices FF utilizes push diagnostics, which allows the user to receive alerts much faster, instead of the traditional polling. 14
Applications Subject to Diagnosis 15
Typical Transmitter Diagnosis 16
Advanced Diagnostics functions (Examples) Process Diagnosis Impulse Line Blocking Diagnostics Process Diagnosis Coriolis Meter Diagnostics Steam Heat Trace Diagnostics Ta mp R t Tse 2 n R t1 Tflg Process Diagnosis Process/Device Diagnosis Clogged shedderbar Diagnostics Advance ph Electrode Diagnosis Electrode Adhesion Diagnostics & Empty Pipe detection 160.545 Common m 3 /h m 3 Electrode LEVEL3 Advance Valve Diagnosis FR FTL ADH Device Diagnosis Process/Device Diagnosis Process/Device Diagnosis 17
Some Other Diagnosis Availability Temperature Transmitters - Sensor drift diagnosis (Device) Corilolis Mass Flow Meter - Auto Zero Fluctuation (Device) - Flow tube erosion (Device) Vortex Flow meter - Excessive Vibration (Device/Process) Conductivity Analyzer - Polarization (Device/Process) Diagnosis mentioned are not comprehensive availability list from all suppliers 18
Pressure Transmitter - One of the ILBD algorithms Blockage at both H/L side Blockage at High side Blockage at Low side No Blockage DP (Differential Pressure) PH (Static Pressure H side) PL (Static Pressure L side) PL PH Outcome DP, PH, PL Low fluctuation PH Low fluctuation PL Low fluctuation Independent fluctuation Reference Data at no blockage condition? DP, PH, PL fluctuation Data for Diagnostics Statistics Calculations Normal DP = PH-PL Movie 19
Magnetic Flowmeter- Adhesion Level Diagnosis Monitor the changes of the signal Impedance caused by the insulating adhesion on Electrode surface. Electrode Common 160.5 m 3 /h 45 m 3 LEVEL3 FR FT L ADH Flow Rate Total Adhesion Level 20
Vortex Flowmeter Extended Self Diagnosis Since frequency analysis is always performed, alarm can be taken out at the time of abnormalities, such as an unstable flow and adhesion. SSP ~ Spectrum Signal Processing SUB6 SUB5 SUB4SUB3 Time SUB2 SUB1 Frequency Vortex Signal Sensitivity Curve Noise Ga ain SB6 SB5 SB4 SB3 SB2 SB1 [Separation by SAF] Frequency (log) Frequency Time 21
Coriolis Flowmeter Slug Flow Detection Bubble size: 1-5mm 0.989kg/l 2% Gas 0.949kg/l 5% Gas 0.803kg/l 20% Gas 0.7kg/l 30% Gas 0.6kg/l 40% Gas Slug flow 22
Pressure Transmitter - Heat Trace Diagnostics Transmitters have Two Temperature Sensors One in Sensing Element Other in Amplifier Temperature Sensor in Sensing Element detects actual heat tracing temperature Temperature Sensor in the Amplifier detects t ambient temperature The low deviance between een these two temperatures res can trigger the tracing failure diagnostic 23
Advance ph Electrode Diagnostics Impedance Monitoring i 60-80% of ph measuring problems are caused by plugged, poisoned, depleted reference junctions. The impedance of the junction is the indicator for junction Problems Improper installation, like non-immersed electrodes, also leads to no or wrong measurement The impedance of the Glass indicates integrity of the sensor 24
Diagnostics From A Positioner Pressure out of range Position out of range Temperature out of range Pressure/ Position/ Temp sensor diagnostic Valve hysteresis alarm Valve slip width alarm Large response speed alarm Deviation error (Time based) Operation point drift Supply air pressure warning Integration Data (Cycle count, travel time, open limit, close limit, etc.) Valve signature (Standard Actuator Signature, High resolution Actuator Sinature, Step response Test, Positioner Signature) 25
Valve Signature - Conventional SMART and FF FF is practically 2-3 time faster FF provides precise signature to detect smaller variation 12000 10000 8000 msec 6000 4000 100 Data Sample FF NI Conventional SAMRT MODEM 2000 0 0 100 200 300 400 500 600 700 Sample 26
ITK 6.0 and Diagnosis Field diagnostics is optional on current ITK versions, but will become mandatory for all fieldbus devices in compliance with soon to be released ITK 6.0 27
Thank you very much for your attention Our Commitment Your Future Preserve the core Stimulate progress 28 28