Arasu Thanigai Business Development Manager Pepperl+Fuchs ... · Vietnam FF Seminar 20th Apr 2011...

Vietnam FF Seminar20th Apr 2011

1

Arasu ThanigaiBusiness Development Manager

Pepperl+Fuchs - Singapore

ON BEHALF OF FUNDATION FIELDBUS

Commissioning Benefits


Device CouplerZone2

Device Coupler / FieldBarrier

Zone1Fi

eld

Dev

ices

Fiel

d D

evic

es

Fiel

d D

evic

es

Device Coupler TerminatorSurgeProtec.

SurgeProtect.

Fiel

d D

evic

es FieldbusProcess

Interfaces

Fieldbus Infrastructure

PowerSupplies



• Commissioning - Device integration• Commissioning - Physical layer



• Commissioning - Device integration


Device Integration

Continuous Productivity Improvements• Integrated system environment• Freedom of choice• Information availability• Fieldbus solutions to meet all plant requirements

– Plug and produce– Device Integration


Easier Easier -- Real Number Engineering UnitReal Number Engineering Unit

• No range mismatch• Unit downloaded when device is replaced

Transmitter PositionerFF FF

BUSFF

CTRL

CPU

CPU

CPUDigital

Digital

DigitalDigital

TransmitterRange

0-800 kPa

SystemRange

0-400 kPa

8 mAProcess200 kPa

Reading100 kPa

...alarms and tripsnot working

AIA/D

D/A 4-20 mA

AOD/A

A/D4-20 mA

RangeRange

Range mismatch

Range exceed (more

than100%)


Lower Cost & FasterLower Cost & Faster

• Traditional: 2 hours / device for 2 technicians

• (Calibration)– Attach device– Verify 4-20 mA signal

• five points– Verify link to control strategy– Check device parameters with

handheld

• Foundation fieldbus: 25 minutes / device for 1 technician (Remote)– Attach device– Drag-and-drop

commissioning wizard– Compare configuration

faster on computer

•Devices are auto-recognized•Devices are auto-addressed•Devices identify themselves

Plug-n-Play

Only FF has automatic addressing


Fieldbus Maintenance Made Easy:Fieldbus Maintenance Made Easy:Device Commissioning WizardDevice Commissioning Wizard


Fieldbus Maintenance Made Easy:Fieldbus Maintenance Made Easy:Protective DecommissionProtective Decommission

• Removing device in an orderly fashion– “Safely remove

hardware”• Temporary removal

– To remove for calibration etc. with intention to put back into same place soon after

• Permanent removal– To remove for

replacement etc.

Control-in-the-field does not mean just

“simple” PID


Easier FF Device Commissioning and Easier FF Device Commissioning and ReplacementReplacement

• Commission or replace device without touching the software

• System automatically logs process in background

Automatic configuration reconciliation with device database

Automatic configuration

download

View details in historian and

log


Faster Project StartupFaster Project StartupExpress and Batch DownloadExpress and Batch Download

• Reduced commissioning time

•Initiate multiple downloads at the same time•Runs unattended•At pre-commissioning need not run as a background communication to real-time control


Intelligent Devices via Fieldbus is a Must• Process Industries worldwide require

fieldbus based systems because of cost reduction– Reduction of wiring and cabinet costs– Less system and instrumentation hardware– Reduced commissioning time

• Intelligent devices enable Asset Optimization– Increase of maintenance effectiveness– Improves process availability– Enhances productivityAventis says: Fieldbus technology

saves costs and enables innovative applications. Future plant will be

equipped with fieldbus


Incorporating intelligent devices via fieldbus integration streamlines work processes, improves process and product quality, maximizes plant availabilityintegrates fieldbus seamlessly

Exploiting new levels of field device informationMaking device resident information available to the right people at the right time

Device Management lowers costs over life cycle in design, implementation, operation and maintenance

Device Management


Expectations on Fieldbus Technology• Industry proven and

reliable• High system availability

through redundancy concepts

• Intrinsically safe solutions• Seamlessly integrated

into control system • Access to device internal

data• Openness for all device

manufacturers• Easy to use

Optimization Engineering Operations

ControllerDiagnosisMaintenanceCalibration

ConfigurationParameterizationCommissioning

OperationDisplayAlarm signals

Process variablesTime synchronizationStatus

07

Field Devices


Fieldbus and Field Device Configuration• Integrated fieldbus

management tools and comprehensive Device Libraries for– Configuration of function

block applications– Device parameterization

with graphical user interfaces

– Online and offline configuration

• All devices accessible from a central workplace

• Early plausibility checks ensure proper and fast configuration


Fieldbus and Change History

Maintenance Event & Work Order History

Calibration Changes

Operator Changes

Configuration Changes

Process Event & Alarm History

Audit List


Intelligent Devices Enable Asset OptimizationOK!Oops!BAD!

• Scheduled monitoring of asset health status• Smart condition reporting• Notification of key personnel independent of their location• Generation of fault reports and submission to CMMS


Device ManagementDevice Management HART

– Fieldbus Builder PROFIBUS/HART

– Basic HART DTM / HART DTM Builder

– OPC Server HART– HART Device Library– HART Multiplexer Connect

Device Management FOUNDATION Fieldbus– Fieldbus Builder FOUNDATION

Fieldbus– OPC Server FOUNDATION

Fieldbus – FOUNDATION Fieldbus Device

Library

Object Types

800xA

SystemDevice Library

Wizard



• Commissioning - Physical layer


The physical layer – alive and well?

– Proper termination– Water ingress– Ground faults



– Proper termination– Water ingress– Ground faults– Loose wiring– Faulty devices



– Proper termination– Water ingress– Ground faults– Loose wiring– Faulty devices– Unstable communication– Short circuits– Bulk power failure– …


Diagnostics in process automation today

DCS with intelligent hosts■ Asset management and diagnostics■ Proactive plant upkeep

Fieldbus infrastructure■ Simplistic tools■ Reactive maintenance

Field instrumentation■ Asset management and diagnostics■ Proactive plant upkeep


Online monitoring of the physical layer

Time

Equipment Health100%

Minimum device health FAILURE

Time to respond

Warning level

Monitoring the physical layer protects you from unwanted shutdowns!


Advanced Commissioning for physical layer

•Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Advanced Commissioning for physical layer

•A portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Commissioning Tools expectations

•User interface in the control room:– Display of values– Warnings with actionable information– Color coding for easy recognition

•Value-add:– Automated commissioning

procedures and documentation– Live segment monitoring with alarms– Expert troubleshooting tools

•Embedded expert-knowledge


Commissioning Tools Expectaions

■ Design Verification tools: design of the physical layer

■ Verify against original design■ Automated checkout procedures

■ Longer plant uptime■ Know before you act■ Actionable information in clear text

TroubleshootMonitorCommission

Cas

h Fl

ow

Plan and purchase

Install and commission Operate and maintain


Commissioning in the past

– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires

• Screw driver• Check sheet• Pencil• Multimeter• Oscilloscope

– Connect one device at a time– Disconnect after testing

Test ReportTest Report


Commissioning now

– Verify address setting– Wire up devices in the right location– Check shielding– Activate communication– Use automated work procedures

• Testing• Documentation

– All devices at once– Wiring remains undisturbed

Commissioning Wizard

Test Report

Test Reportx


Commissioning based on Standards

– Simple to use– Eliminates manual test procedures – Ensures compliance with

AG181 and IEC 61158-2– Creates baseline report:

• Snapshot of all measurements • Complete documentation

– Recommends warning and alarm limits for the ADM– Stores limits in non-volatile memory– Reduces pre-commissioning

time by up to 80%


Automated Commissioning Saves Time

• Case Study with cost comparison for pre-commissioning: – 4…20 mA– Fieldbus– Fieldbus with Advanced Diagnostics

4 hoursMean time to repair (MTTR) a fault

8 hoursHours per work day 12Instruments per segment100Number of segments1,200Number of instruments

Case Study – Specifications

Pre-commissioning is defined as work steps taken to install and validate the hardware configuration and the physical layer.

Source: Fieldbus Testing with Online Physical Layer DiagnosticsTechnical White Paper available from Pepperl+Fuchs Part No: 198636



06 ½ days6 daysTotal Time

Not required1 Trunk, 12 Spurs

12 loopsUnits

Not required4 h MTTR4 h MTTRTime/Unit

Construction failures (1%):

02 days12½ daysTotal Time

Not required100 segments1200 loopsUnits

Not required10 min5 minTime/Unit

Constructional checks:

Fieldbus with Advanced

Diagnostics

Fieldbus without

diagnostics4-20 mAModelTask 1 of 2



2.6 days U21.5 days U46.5 days UTotals

8 h =1 day

4 h =½ day

24 h =3 days

Total Time

1.5% = 2 segments

0.5% = 1 segment

0.5% =6 loops

Units

4h MTTR4h MTTR4h MTTRTime/Unit

Pre/commissioning failure:

1.6 days12½ days25 daysTotal Time

100 segments100 segments1200 loopsUnits

8 min60 min10 minTime/Unit

Pre/commissioning instrument checks:

Fieldbus with Advanced

Diagnostics

Fieldbus without diagnostics

4-20 mAModelTasks 2 of 2


Commissioning saves time and money

– A few mouse clicks conduct automatic testing

– Reports on the actual installation with all devicesconnected

– Automatic setting of warning and alarm limits


Online monitoring

• Advanced Commissioning tools increases the number of detectable faults

– Monitors continuous operation – Notifies when deviations occur – Enables proactive plant up keep – Keeps the plant up and running

• The Advanced Commissioning Tools helps to:– Monitor the health condition of the physical layer – Detect changing conditions– Report limit violations with time stamps– Alert operators before the segment fails


Online monitoring – Continuous health check

•Commissioning Tools increase the number of detectable faults

– Displays measurement values– Issues warnings and alarms– Highlights violations with color coding:

Good valueMaintenance required

Out of specification


Fault Finding is Easier

•Commissioning Tools delivers actionable information to minimize the time spent for fault finding

1 Active messages2 Actionable information with solution guideance based on

expert knowledge3 History with timestamps

When the failure…… occured… disappeared

– Export function for external analysis and storage


Bad cable impedanceBad cable impedance

Loose wireLoose wire

Troubleshooting is easier•Advanced Diagnostics Tools provide expert tools for fast fault finding

– Simplifies testing– Captures intermittent problems– Pinpoints the issue – Guides to potential solutions– Is accessible from remote for consultation with fieldbus experts.


Simplified commissiong leads CAPEX and OPEX savings

– Rapid commissioning: Accelarates loop check

– Longer operation: Warns before failure

– Faster troubleshooting: Assists with actionableinformation


Conclusion- Device

– Foundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof.

– Fieldbus devices transmit measurements are unaltered.

– For most Fieldbus transmitters there is no need to set a range. Avoids Rang mismatch, the reading for controls and alarms in the system will be correct. Therefore, traditional five point loop test can be replaced by a simple plausibility check thus speeding up project completion

– Fieldbus devices have no error due to analog signal calibration (4-20 mA) differences between transmitter output and DCS input, saving time on re-

calibration

– Foundation Fieldbus address assignment is automatic and error free. Some systems have wizards to guide the technician, even commission the devices without using software, thus demystifying Fieldbus commissioning


Conclusion- Device– The configuration for all Fieldbus devices is maintained in a database and

can be downloaded remotely in a single click saving time as compared to checking devices one by one, parameter by parameter, with a handheld field communicator and maintaining documentation separately.


Conclusion – Physical Layer

– Advanced Diagnostics tools for for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEX

– Most problems at early bus installations were due to poor installation. However, simple, user-friendly, Fieldbus testers are now available, allowing the installation crew to easily check the wiring, and the device commissioning crew to check network operation, spotting any problems early

– Many contractors and Technicians are trained and are skilled in Fieldbus installation and commissioning, and have the test equipment and in-house procedures to ensure reliable operation


QUESTIONS?QUESTIONS?QUESTIONS?

Arasu Thanigai Business Development Manager Pepperl+Fuchs ... · Vietnam FF Seminar 20th Apr 2011...

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