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Fieldbus Foundation India CommitteeFieldbus Foundation – India Committee
Automation 2012Automation 2012Fieldbus Foundation“ d i i ldb i h h h ”“Foundation Fieldbus, Easier Than You Thought”
Control ValveControl ValveControl ValveControl Valve“Device diagnostics”“Device diagnostics”
Date: Saturday, 8th September, 2012Time: from 10:00 am to 04:30 pm. Venue: Automation 2012
Conference Hall, Automation 2012, NSE Grounds, Goregoan, Mumbai - INDIA
Presenter :
Hisashi Sasajima
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Azbil Corporation
C t tContents
I. PrologueII. Possibilities of CV failureIII. CV diagnoses (Three phases with field reports)IV ConclusionsIV. ConclusionsV. Progress beyond conclusionsVI bil l ti f C t l V l i tVI. azbil solution for Control Valve maintenance
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I. Prologue
Output signal
Valve Position
Hey, Mr. Ashok, something wrong with CV Tag # LIC013. Maintenance is required immediately!
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I P lI. Prologue
M A h k A i d i t iOur system operator tells me something wrong
Mr. Ashok - An experienced maintenance engineery p g g
with this control valve but it is not so easy to find what is the nature of problem.pIf it is clear from the beginning, my work can be much faster and easier Is it just a dream?much faster and easier… Is it just a dream?
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I P lI. Prologue
No, it is not a dream!
We can help you using Fieldbus technology.OK, Mr. Ashok, we are pleased to explain how to do it butbefore let’s think together why control valve is so important?g y p
Because control valve may give:-d t- severe damages onto process.
- bad influences on production and safety of entire plant
Control Valves are the HEART of the plant5
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II P ibiliti f CV f ilII. Possibilities of CV failure
Control valve failure might occur due to:-
Trim part leak Corrosion Stick by process Air leakage Actuator degradationActuator degradation Grand part degradation Others Others
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1 Situation of control valve maintenance1. Situation of control valve maintenance
Repair or part Cleaning
Typical decision method for CV maintenance policy Maintenance
operation
Repair or part replacement
42%
Cleaning
58%
Ploperat
operation
lant tion risk
TBMDisassembly
inspection
TBM:
Result of CV overhaul maintenance
undertaken by azbil service shop
MaintenancePolicy
TBM:
Time Based Maintenance
undertaken by azbil service shop
318 minor troubles were
caused bySpent 830 man/hourPolicy
Proc
BM Daily maintenance
caused by control valve
faultto recover the troubles
cess load
BM
BM:
Daily maintenancewith on- site check
1400 minor troubles / year occurred
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Break-down MaintenanceA case of pulp and paper mill in Japan
III CV di ti (Th h )III. CV diagnostics (Three phases)
Phase-1: Real time diagnoses (online)
Phase-2: Shutdown Maintenance (offline)
Phase 3: Maintenance plan based on historical dataPhase-3: Maintenance plan based on historical data
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III. CV diagnosticsIII. CV diagnosticsPhase-1: Real time diagnoses
D t t “Z Shift Al t”“Z Shift Al t” (POS ALERT LO)Detect “Zero Shift Alert”“Zero Shift Alert” (POS_ALERT_LO)Actual feedback position is +3% (shift) although Set Point goes below 0%
ゼロ点推移
4.000
Graph visualization
1 000
2.000
3.000
%)
-1.000
0.000
1.000
ro d
rift
(%
-3.000
-2.000Zer
-4.000
2006/11/15
2006/11/22
2006/11/29
2006/12/6
2006/12/13
2006/12/20
2006/12/27
2007/1/3
2007/1/10
2007/1/17
2007/1/24
2007/1/31
2007/2/7
2007/2/14
2007/2/21
2007/2/28
2007/3/7
2007/3/14
2007/3/21
2007/3/28
2007/4/4
2007/4/11
2007/4/18
2007/4/25
2007/5/2
2007/5/9
2007/5/16
2007/5/23
2007/5/30
2007/6/6
2007/6/13
2007/6/20
2007/6/27
2007/7/4
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III CV diagnosticsIII. CV diagnosticsPhase-1: Real time diagnoses
Detect “Zero Shift Alert”“Zero Shift Alert” (POS ALERT LO)Initial zero i t l
Mull function of Plug
Detect Zero Shift AlertZero Shift Alert (POS_ALERT_LO)As a result of inspection, accumulated solid around plug and trim was found. Then the valve was cleaned up and safely re-installed to the process
point angle
θ
ゼロ点推移
4.000
Mull function of Pluginstalled to the process.
1 000
2.000
3.000
Sheet damage%) Sudden zero-shift
Stick on plug
-1.000
0.000
1.000 Sheet damage
ro d
rift
(%
Stick on seat
-3.000
-2.000Zer
-4.000
2006/11/15
2006/11/22
2006/11/29
2006/12/6
2006/12/13
2006/12/20
2006/12/27
2007/1/3
2007/1/10
2007/1/17
2007/1/24
2007/1/31
2007/2/7
2007/2/14
2007/2/21
2007/2/28
2007/3/7
2007/3/14
2007/3/21
2007/3/28
2007/4/4
2007/4/11
2007/4/18
2007/4/25
2007/5/2
2007/5/9
2007/5/16
2007/5/23
2007/5/30
2007/6/6
2007/6/13
2007/6/20
2007/6/27
2007/7/4
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III CV di tiIII. CV diagnosticsPhase-1: Real time diagnoses
Summary
• System operators realize some abnormal signals on control valves
• Serious issues should be solved immediatelySerious issues should be solved immediately• Minor issues can be recorded to do overhauling
d i th t h td i tduring the next shutdown maintenance
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III. CV diagnosticsPhase-2: Shutdown Maintenance
Standard diagnosisT h kTo check:-1. Tightness of grand packing2. Position according to air supply
Stroke between 10% and 90% to record relation P
between position and air supply as historical data
Automatically calculates
PositionAutomatically calculatesspring range and friction
n (%)
Supply (kPa)
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pp y ( )System Vender: Yokogawa Electric
III CV diagnosticsIII. CV diagnosticsPhase-2: Shutdown Maintenance
Advanced Diagnoses
Various simulations:-
1 Travel vs Actuator pressure 1 Travel vs Actuator Pressure1. Travel vs. Actuator pressure2. Travel & SP vs. Time3. Actuator signature4 Travel signature
1. Travel vs. Actuator Pressure
Seating , Spring Range ,
4. Travel signature2. Travel & Set point vs. Time
Overshoot , Resolution
3. Actuator Signature
Friction , Spring Range , Pressure
System Vender : GE(Dresser Masoneilan)4. Signature ( travel vs. set point)
Hystersis , Dead band , Linearity
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III CV Di tiIII. CV DiagnosticsPhase-2: Shutdown Maintenance
Summary
Compare data (valve signature, step response and etc.) with those previously collected data so that daily and/or shut-down maintenance can ybe planned efficiently .
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III. CV Diagnostics
A possible damage of bellows seal would be detected by
III. CV DiagnosticsPhase-3: Maintenance plan based on historical data
A possible damage of bellows seal would be detected byTotal_Stroke parameter. (TRAVEL_ACCUM)
This TOTAL_STROKE is as same as 40,000 times full open and full close .
Actual bellows seal after used
System Vender: Azbil
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Replacement period
III. CV DiagnosticsgPhase-3: Maintenance plan based on historical data Example (Chemical Plant-1)
O ti f il f d i ti k liOperation failure was found in stick-slipdiagnostic function of control valve:-
According to index of gland packing deterioration:-1. Detect abnormal sliding motion of plug guide2 Detect plug bend scratch & other mechanical damages2. Detect plug bend, scratch & other mechanical damages
Detect Stick SlipDetect Stick Slip
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System Vender: Azbil
III. CV DiagnosticsgPhase-3: Maintenance plan based on historical dataExample (Chemical plant-1)
JJun
Jul
Stick-slip
Stick-slip
Aug
Stick-slip
p movem
en
p movem
en
Stic
S operation h
nt has been
nt has been
ck-slip is no
Sep
has started
n increased
n increased
ot operated
Oct
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d. d. d.
d.
III. CV DiagnosticsIII. CV DiagnosticsPhase-3: Maintenance plan based on Historical data Example (Chemical Plant-2)
Valve Travel Distribution support on Engineering & MaintenanceConfirm if the selected control valve size is appropriate or not by visualizing the stress index of inner valve on the condition of low travel operation
Images visualization
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System Vender: Azbil
III. CV DiagnosticsIII. CV DiagnosticsPhase-3: Maintenance plan based on historical data Example (Chemical Plant-2)
Valve Travel Distribution support Engineering & MaintenanceValve opening level is shifting from 20-30 % to 30-40% due to clogging of air filter or CV inner parts. End user can judge that it is the best timing for maintenance.
20-30% 30-40%Images visualization
Boiler
Filter
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System Vender: Azbil
T l hi tTravel histogram
The histogram shows how much time the valve is operated in specific segment of valve opening for one month.
FrequencyFrequency
Time0% 1000% 100%
Valve opening
Application for control valve diagnostics L tApplication for control valve diagnostics Confirm if the valve sizing is proper or not Find out trend of valve body clogging Estimate erosion of valve plug 12 months ago
2 months ago
Last month
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Estimate erosion of valve plug 12 months ago
III. CV DiagnosticsIII. CV DiagnosticsPhase-3: Maintenance plan based on historical dataExample (Chemical Plant-3)
A possible damage of bellows seal would be detected byTotal_Stroke parameter. (TRAVEL_ACCUM)
Sliding distance value could be applied as a reference value Graph visualizationGraph visualization
High pressure Chlorine gas
Globe valve (Bellows seal type)
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System Vender: Azbil
III CV Diagnostics (Three phases)III. CV Diagnostics (Three phases)
Summary
Visualize various conditions of control valve through these analyses and historical data
Plan CV maintenance efficiently according toPlan CV maintenance efficiently according to present conditions of control valve.
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IV C l iIV. Conclusions
• Control valve diagnoses through Fieldbus are valuable . Fieldbus suits for real time notice since the data transmitting speed is much fasterspeed is much faster.
• Offline maintenance with various simulations is useful on data comparison with those collected in the past.
• Condition based maintenance it is important to analyze• Condition based maintenance, it is important to analyze historical data collected through valve positioner. Fieldbus is highly recommended collecting various data on control valve.
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V. Progress beyond conclusionsV. Progress beyond conclusionsa.) Device diagnostics
• Fieldbus Foundation has ever solved users’ requirements to define “Standard Diagnosticrequirements to define Standard Diagnostic Profile” and “Standard Transducer Block”.
• Fieldbus Foundation wishes end users to try and evaluate fieldbus diagnoses more in order toevaluate fieldbus diagnoses more in order to improve functions on the basis of user-friendliness and interoperability.and interoperability.
Continuing Device Diagnostics Continuing Device Diagnostics Enhancements for End Users Enhancements for End Users
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V P b d l iV. Progress beyond conclusionsb.) Fieldbus Foundation works with NAMUR (FF912)
Using the power of FOUNDATION Fieldbus, and considering NAMURrequirements, the new standard diagnostic profile aim to:
Standardize the integration of diagnostic information G t l bl i f ti t th
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Guarantee valuable information to the user
V. Progress beyond conclusionsV. Progress beyond conclusionsc.) NAMUR Recommendation NE107
NE107 “S lf M it i d Di i f Fi ld D i ”NE107: “Self-Monitoring and Diagnosis of Field Devices”
Diagnosis results must be reliable Diagnosis results must be reliable
The diagnosis results must always be viewed in the context of the li iapplication.
Internal diagnosis categorized into 4 standard status signalsInternal diagnosis categorized into 4 standard status signals
Configuration should be free, as reactions to a fault in the device may be very different depending on the user's requirementsmay be very different depending on the user s requirements
The plant operator to see only these status signals
Detailed information can be read out by the device specialist
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NAMUR NE 107 Di ti C bilitNAMUR NE 107 Diagnostics Capability
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V. Progress beyond conclusionsV. Progress beyond conclusionsd.) Device diagnostic alarms (NE107) scope
PlantDiagnostics
Step 4Field
Performance
Device Diagnostics Support Function
d
p PerformanceDiagnostics
Step 3D i
•Device status•Diagnostics to host system
process andequipment
Step 3
Fisher
DeviceDiagnostics
St 2Asset Management
actuators, elementsvalves, connections
Step 2
CommunicationsDiagnostics Device
Management
electronicsStep 1
Management
FF Device Status
communications
Fisher
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Control System
FOUNDATION™ for
Safety Instrumented FunctionsSafety Instrumented Functions
(SIF)
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SIF End User Demonstration ParticipantsEnd User Demonstration Sites
BP G l ki h G H ll L i S l
SIF End User Demonstration Participants
BP – Gelsenkirchen, Germany – Honeywell Logic SolverChevron – Houston, TX – Emerson Logic SolverSaudi Aramco – Dhahran – Triconex Logic Solver and Yokogawa Logic SolverShell Global Solutions Amsterdam HIMA Logic Solver
EmersonHIMA Logic Solver
Asset Management
Basic ProcessControl System
Shell Global Solutions – Amsterdam – HIMA Logic Solver
Logic Solver
HIMAHoneywell
Invensys - TriconexYokogawa
Logic SolverEngineering Workstation
Management Control System
Level SIF Protocol
ValveMagnetrol
Siemens MilltronicsProtocol
Pres H1 Network BIFFIEmerson
ABBE+HSmar
Moore
Other ProvidersFieldbus Diagnostics
RisknowlogyWestlock
AzbilYokogawa Moore
MTLP+F
RuggedComSofting
TÜV RheinlandTÜV SÜD
TempSmar
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TempSmar
Control Valve Stroke Test(Partial Stroke Test)
PST CompleteTimeout (Sec)PST Start
PST Break outTime out (Sec) PST
CompletePST Stroke Travel
100
CompletePST Stroke TravelTimeout
(Sec)
Valve Stroke
(%)
PSTStroke Travel (%)
PSTPSTPST(%) PSTPause(Sec)
PSTRumpRate
(%/Sec)
PSTBreak
outTime(S )
0
(Sec)
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Transient Time(Sec)
St d d T d Bl kStandard Transducer Blocks
Pressure Block Completed and in ITK 5.0 Temperature Block Completed and in ITK 5.1 Positioner Block (PST/FST) Completed in in ITK 5.2
N t Bl k• Next Block Flow Transducer with High Performance Totalizer
Validation Complete Publication completed Mar 2011 Validation Complete. Publication completed Mar 2011 Support scheduled for ITK 6.1
PST – Partial Stroke Test; FST – Full Stroke Test
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St d d T d Bl kStandard Transducer Blocks
Pressure Block Completed and in ITK 5.0 Temperature Block Completed and in ITK 5.1 Positioner Block (PST/FST) Completed in in ITK 5.2
N t Bl k• Next Block Flow Transducer with High Performance Totalizer
Validation Complete Publication scheduled Mar 2011 Validation Complete. Publication scheduled Mar 2011 Support scheduled for ITK 6.1
PST – Partial Stroke Test; FST – Full Stroke Test
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© 2011 Fieldbus Foundation
Device / Host RegistrationDevice / Host Registration
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ITK 6 Test CoverageITK 6 Test Coverage
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FDI Cooperation LLCFDI Cooperation LLCFDI Cooperation LLCFDI Cooperation LLC
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D i I t tiDevice Integration
Commissioning OperationCommissioning
Engineering MaintenanceGeräteintegrationGeräteintegration
GeräteintegrationGeräteintegration
…
Field DeviceAutomation System
With the Device Integration, a Host can get access (from a central location) to the Device functions and information.
With devices getting more complex the device integration becomes a must
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With devices getting more complex, the device integration becomes a must
A Common ApproachFDI is supported by Manufacturers and Foundations
H i d
Device Package
H i d AdvancedEDDL
Harmonized
HarmonizedEDD
Advanced Features(optional)
EDDL
ABB FDT Group Invensys ABB Emerson Endress + Hauser
FDT Group Fieldbus Foundation HART Communication Foundation
Invensys Siemens Yokogawa
Honeywell OPC Foundation PROFIBUS/PROFINET International
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FDI C ti LLCFDI Cooperation LLC
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T t A i l D i D iTarget: A single Device DriverFDI Device Package StandardFDI Device Package Standard
(mandatory)
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WPF: Windows Presentation Foundation
VI bil l ti f t l l i tVI. azbil solution for control valve maintenance
• Improve the maintenance performance of Control valves in the plant life cycle.Control valves in the plant life cycle.
A) Early detection of
OperationStartup
C) Fast commissioningControl valve abnormalities
ValstafffunctionValstaff
functionfunction
Turnaround Maintenance
ShutdownB) Assistance in reducing valve maintenance costsCV data
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valve maintenance costsCV data Analysis Service
S t fi tiSystem configuration
PLUG-INDCS
DCS HMI
DCS Device Management
System
DCS Controller Required system environment to use PLUG-IN Valstaff
Case Vender DCS Device Mgt. System
1 A bil H DEO IFO
Required system environment to use PLUG IN Valstaff
1 Azbil Harmonas-DEO IFO
2 Yokogawa CENTUM PRM*AVP 303/203
AVP 302/202
* PRM t b R3 10 l t t i t ll PLUG IN V l t ff
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* PRM must be R3.10 or later to install PLUG-IN Valstaff.
Fast commissioning Automated CV step response test
Step response test for 42 CVsSt tt SP Step response test for 42 CVs
With IFOConventional methodStep pattern SP
Completed in 45 minutes
Valve travel
Require 2 persons for 8 hours.
Visualize CV motion abnormalityVisualize CV motion abnormality
By comparing with the past test resultthe past test result on millisecond level.
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A. Certain and fast commissioninggLoop check progress status
• Grasp the progress status of loop check work at a glance• Grasp the progress status of loop check work at a glance.– Visualize devices which are not completed loop check.
Check itemsList of field device
接続確認
Checked date and time + the result: OKChecked date and time + the result: not OK
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No check
B. Early detection of the field device problemsy pa. Device status monitoring 365 days/yr, 24 hours/day
Retrieval condition of device alert historyy
Retrieval and filtering condition for d i i di ti
Segment1Segment1
device indication
List of device
Segment2Segment3Segment4Segment5
Segment2Segment3Segment4Segment5
List of device alert history
Device Tree Segment6Segment7Segment8
Segment6Segment7Segment8
Device Tree
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Full-time monitoring to all devices
B. Early detection of the field device problemsa. Device status monitoring 365 days/yr, 24 hours/day
• Grasp the status of all devices at a glance G asp e s a us o a de ces a a g a ceSegment1
Segment2Segment3Segment4Segment5Segment6Segment6Segment7Segment8
Symbols of device status recommended by NAMUR NE 107 Full-time monitoringNAMUR NE 107 Full time monitoring
to all devices
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B. Early detection of the field device problemsa. Device status monitoring 365 days/yr, 24 hours/day
• If the symbol shows abnormal status, confirm the detail ystatus and device parameters without going out into the plant field.
Segment1Segment1
Segment2Segment3Segment4Segment5
Segment2Segment3Segment4Segment5Segment6Segment7Segment8
Segment6Segment7Segment8
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B. Early detection of the field device problems
• Configure/calibrate field
a. Device status monitoring 365 days/yr, 24 hours/day
• Configure/calibrate field devices in the control room.Support multi vender• Support multi-vender devices by using FDT/DTM technologiestechnologies.
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Thank you for your attention!!Thank you for your attention!!
Hisashi SasajimaA bil C tiAzbil Corporation
“Human centered automation”
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Human-centered automationURL http://jp.azbil.com