Arasu Thanigai Commissioning Solutions
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Transcript of Arasu Thanigai Commissioning Solutions
11 Successful Implementation & Improved Operation
Commissioning issues and solutions
Arasu ThanigaiPepperl+Fuchs Pte LtdSingapore
Fieldbus Foundation Seminar Perth – 15th May 2013
22 Successful Implementation & Improved Operation
Device Commissioning
Physical layer Commissioning
Commissioning Process
33 Successful Implementation & Improved Operation
Install the CablesCheck out the cable installationInstall the DevicesCheck the device installation
Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAPhysical Parameters
Commissioning Process
44 Successful Implementation & Improved Operation
4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installation
Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mA
Foundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation
• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mA
Commissioning Process Comparison.
55 Successful Implementation & Improved Operation
4~20mA Foundation Fieldbus4-20mA
P.S.
fieldbus
P.S.
Distance and relevant issueArtificial hours and relevant costCable connection QuantityHidden trouble points
Cable installation
66 Successful Implementation & Improved Operation
4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installation
Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mA
Foundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation
• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mA
Commissioning Process Comparison.
77 Successful Implementation & Improved Operation
4~20mA Foundation Fieldbus4-20mA
P.S.
fieldbus
P.S.
Test Report
Distance and connection QuantityTools
Checking of cable installation.
88 Successful Implementation & Improved Operation
4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installation
Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mA
Foundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation
• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mA
Commissioning Process Comparison.
99 Successful Implementation & Improved Operation
4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installation
Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mA
Foundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation
• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mA
Commissioning Process Comparison.
1010 Successful Implementation & Improved Operation
Device Commissioning
1111 Successful Implementation & Improved Operation
Assigning the I/OFoundation fieldbus devices are recognized by three mechanisms: a traditional node address for communication, a human readable device tag corresponding to the project P&I diagram, and a unique identifier allowing the system to automatically resolve any tag or address conflicts. The system automatically assigns the address to all devices, avoiding human errors such as address duplication associated with manually managed protocols, and saving time. Therefore technicians work based on tag and need not be concerned with address. Thanks to the unique identifier, multiple devices can be connected and commissioned at the same time. It is plug-'n'-play.
1212 Successful Implementation & Improved Operation
4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installation
Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mA
Foundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation
• Install the DCS• Assigning the I/O• Calibration the Sensor• N/A• N/A• N/A• N/A
Commissioning Process Comparison.
1313 Successful Implementation & Improved Operation
No range mismatchUnit downloaded when device is replaced
Transmitter PositionerFF FF
BUSFF
CTRL
CPU
CPU
CPUDigital DigitalDigital
TransmitterRange
0-800 kPa
SystemRange
0-400 kPa
8 mAProcess200 kPa
Reading100 kPa
...alarms and tripsnot working
AIUnit
Unit
AOUnit
Unit
Commissioning Process Comparison.
4~20mA
Foundation Fieldbus
1414 Successful Implementation & Improved Operation
Why Foundation Fieldbus
The global process industry loses $20billion, or five percent of annual production,due to unscheduled downtime and poorquality.
ARC estimates that almost 80 percent ofthese losses are preventable, with 40 percentlargely due to operator error.
Source ARC Insight June 10 2010
1515 Successful Implementation & Improved Operation
Common issues – Device Commissioning
Check DD file and integrate into Engineering systemCheck ITK versionCheck if HIST doneCheck if the device listed at www.fieldbus.org
1616 Successful Implementation & Improved Operation
How to Check
1717 Successful Implementation & Improved Operation
Collaboration with NAMUR
Using the power of FOUNDATION Fieldbus, and considering NAMUR requirements, the new standard diagnostic profile aim to:– Standardize the integration of diagnostic information– Guarantee valuable information to the user
1818 Successful Implementation & Improved Operation
Diagnosis results must be reliable
Diagnosis results must always be viewed in the context of the application.
Internal diagnosis must be categorized into 4 standard “status signals”
Configuration must be free, as reactions will depend on the user's requirements
Detailed information can be read out by the device specialist
NAMUR NE107: Self-Monitoring and Diagnosis of Field Devices
1919 Successful Implementation & Improved Operation
Namur - Diagnostic categories
Maintenance Required The output from the device is valid but the wear reserve is nearly exhausted or function will be restricted due to operational conditions
Out of Specification Measurement uncertainty, or output position deviation, is greater than expected due to deviations in ambient or process conditions.
Function Check Output invalid due to ongoing work on the device
Failure Output is invalid due to a malfunction in the field device
2020 Successful Implementation & Improved Operation
Distribution of information
Maintenance Required
Out of Specification
Function Check
Failure
Output is valid
Measurement is uncertain
Ongoing work on the device, output invalid
Wear reserve is exhausted
due to deviations in ambient conditions.
Output is invalid malfunction in the field device
OPERATORINSTRUMENT TECH
2121 Successful Implementation & Improved Operation
Mapping to FF Quality Status & Block Error bits
Maintenance Required
Out of Specification
Function Check
Failure
Output is valid
Measurement is uncertain
Ongoing work on the device, output invalid
Wear reserve is exhausted
due to deviations in ambient conditions.
Output is invalidmalfunction in the field device
INSTRUMENT TECH
GOOD
UNCERTAIN
OUT OF SERVICE
BAD
NEEDS MAINT SOON
NEEDS MAINT SOON
NEEDS MAINT NOW
QUALITY STATUS BLOCK ERROR
OPERATOR
2222 Successful Implementation & Improved Operation
Commissioning Issues
Physical Layer commissioning.
2323 Successful Implementation & Improved Operation
AG 181
2424 Successful Implementation & Improved Operation
Typical problems
Improperly closed housing
Loose wire
Internally modified
Error log showingintermittent faults
Interoperability testingby end user
Electro-magnetic interferenceFaulty field deviceCable degradationWrong termination
2525 Successful Implementation & Improved Operation
Need for diagnostics
• 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.
2626 Successful Implementation & Improved Operation
Asset/Resource System Influencers
• Maintenance Cost Reduction Drives End Users• 40% of Mfg. Cost is Maintenance• 50% of Maintenance Is Corrective
– 10 times More Costly Than Preventative Maintenance
• Preventative Maintenance is Done 25% of Time– 5 Times More costly Than Predictive Maintenance
• 60% of Preventative Maintenance is Unnecessary• What has been largely missing up to now is timely,
relevant, and accurate information
From ARC Independent Research
2727 Successful Implementation & Improved Operation
Zone1Device Coupler
IS Device Coupler
Fiel
d De
vice
s
Fiel
d De
vice
s
Fiel
d De
vice
s
Zone2Device coupler TerminatorSurge
Protect.
SurgeProtect.
Fiel
d De
vice
s FieldbusProcess
Interfaces
Complete Interface
PowerSupplies
2828 Successful Implementation & Improved Operation
Hazardous safety rules not followed
– Ground faults– Fieldbus and power
cables tied together
2929 Successful Implementation & Improved Operation
Poor cable installation
3030 Successful Implementation & Improved Operation
ANSI recommendation
CommunicationCables(Fieldbus)
Shielded/UnshieldedCables Carrying>60 VDC or>25 VAC but<= 400 V
Shielded/UnshieldedCables Carrying> 400 V
Any Cables at risk ofLighting
Communication
Cables
(Fieldbus)
10 cm 20 cm 50 cm
Shielded/Unshielded
Cables Carrying
>60 VDC or
>25 VAC but
<= 400 V
10 cm 10 cm 50 cm
Shielded/Unshielded
Cables Carrying
> 400 V
20 cm 10 cm 50 cm
Any Cables at
risk of Lighting 50 cm 50 cm 50 cm
3131 Successful Implementation & Improved Operation
Poor cable installations– Cable gland not tight– Seal missing
3232 Successful Implementation & Improved Operation
And corrosion as a consequence
– Water ingress or worse: – Aggressive media
3333 Successful Implementation & Improved Operation
Poor Device Instalation
3434 Successful Implementation & Improved Operation
Poor maintenance
3535 Successful Implementation & Improved Operation
Typical locations and Fieldbus issues
3636 Successful Implementation & Improved Operation
– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires
• Screw driver• Check sheet• Pencil• Multimeter• Battery Powered Oscilloscope
– Connect one device at a time– Disconnect after testing
Test Report
Commissioning in the Past.
3737 Successful Implementation & Improved Operation
A portable tool for commissioning, monitoring, troubleshooting and printout.
Portable Commissioning Tools
3838 Successful Implementation & Improved Operation
Online Commissioning Tools
3939 Successful Implementation & Improved Operation
Online Commissioning Tools
4040 Successful Implementation & Improved Operation
Online Commissioning Tools
4141 Successful Implementation & Improved Operation
Online Commissioning Tools
4242 Successful Implementation & Improved Operation
What parameters to look for– External power supply– Fieldbus Output Power– Fieldbus Segment current– Grounding and shielding– Communicaiton quality ( jitter) of segment and
devices– Signal amplitude– Noise at segment and deivces– FF Signal Waveform of the semgent– Terminators– Surge protection– Water / Moisutre
4343 Successful Implementation & Improved Operation
Simple Commissioning Steps with ADM
– 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 Reportx
4444 Successful Implementation & Improved Operation
One Plant Asset Management – Includes fieldbus now as asset– Customary look and feel– Reduces required training – Reduces potential for errors
Open Architecture Integration:– AMS Suite– PRM– FieldCare – FieldMate– PACTware– OPC Interface– Experion– Many More
Commissioning now via DCS
4545 Successful Implementation & Improved Operation
Commissioning done from control room
Spurs
Field Instruments
Power Supply
Advanced Diagnostic Module
Device coupler
Trunk
Surge Protector
Terminator
Host
4646 Successful Implementation & Improved Operation
Just an Example - ADM via DCS Asset Management
Diagnostics atDCS Station
Rela
y co
ntac
top
tiona
l)
RS485
Industrial Switch
Ethernet or
FF H1
Address switches
4747 Successful Implementation & Improved Operation
Just an Example - Commissioning via DCS Asset management
PRM Alarm window view
PRM Network view
Segment-specific status of the physical layer ADM status view with PRM TAG
FF-Segment
FF-Host
4848 Successful Implementation & Improved Operation
Commissioning Wizard
With Expert System Support– Takes snapshot– Identifies wiring errors– Ensures compliance with
AG181 and IEC 61158-2– Recommends limits for ADM
messages– Stores limits in non-volatile memory
Automatic Tag ReadoutCreates baseline report: – Snapshot of all measurements – Complete documentation
Saves pre-commissioning time significantly
4949 Successful Implementation & Improved Operation
Online monitoringClean layout shows boundaries– Displays measurement values – Highlights violations with color coding: – Issues diagnostic messages
Good value
Maintenance required
Out of specification
5050 Successful Implementation & Improved Operation
Diagnostic MenuExpert System delivers
clear text information for fast fault finding
1 Active messages2 Actionable information
with solution guideance based on expert system
3 History with timestampsWhen the failure…
… occured… disappeared
– Export function for external analysis and storage
11
222
33
5151 Successful Implementation & Improved Operation
Built-in fieldbus oscilloscope Feature
ADM 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
5252 Successful Implementation & Improved Operation
Wiring issues
5353 Successful Implementation & Improved Operation53
Bad wiring technique
Welding, variable frequency drives (VFD), Motors, machinery:Increase of HF noiseIncreasing number of retransmissionsCan be a combination of both
5454 Successful Implementation & Improved Operation
Practical Example – Line frequency coupled
In this example the frequency of noise was approx. 150Hz
7 ms
5555 Successful Implementation & Improved Operation
Not a good device location
FF Device Moved away from Drive
5656 Successful Implementation & Improved Operation
Loose wiring issues
“Make” Disturbance
"Break" disturbance
Vibration frequency
FF signal
Failed telegram
Telegram
5757 Successful Implementation & Improved Operation
Does Surge Protection works?
FIELDBUS TERMINATOR
SEGMENT PROTECTORS
HOST
FIELDBARRIERS
PROCESSINTERFACE
POWER SUPPLY
CONVENTIONAL FIELD DEVICES
FIELDBUS DEVICES
JUNCTION BOX
But Practically this setup is not possible due to cost reasons.Protection at both trunk ends is more feasible
During commissioning or normal operation, surge protection devices can be check if it works
5858 Successful Implementation & Improved Operation
Conclusion – 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