©2013 Fieldbus Foundation
FOUNDATION Fieldbus: the Diagnostics Difference
©2013 Fieldbus Foundation
• There’s Diagnostics and There’s Diagnostics.
• The Value of Fieldbus Diagnostics
• Physical Layer Diagnostics
• Managing the Diagnostics Storm
• PAM and IDM Software, Work Processes and Training
©2013 Fieldbus Foundation
©2013 Fieldbus Foundation
Why do we Use Diagnostics?
• Diagnostics can be a valuable tool that can help save you time and money and avoid unplanned shutdowns.
• Diagnostic data can be vague and require a lot of digging to get to the root cause.
• Diagnostic data can also provide you with avalanche of useless information that can grind your process to a halt.
• Not all technologies handle diagnostic information the same way.
• Trick is to get only the right information, at the right time, to the right people.
©2013 Fieldbus Foundation
The Current State of Non Digital Diagnostics: Or the Idiot Light
• Doesn’t tell you what’s wrong
• No predictive guidance
• Is it a process problem or device problem?
• Sensor problem? Electronics problem? Who knows.
• Doesn’t tell you what’s wrong
• No predictive guidance
• Is it a process problem or device problem?
• Sensor problem? Electronics problem? Who knows.
©2013 Fieldbus Foundation
The FOUNDATION Fieldbus Diagnostics Difference
• FOUNDATION fieldbus has a unique approach to management of device diagnostics.
• The publish/subscribe structure of FOUNDATION fieldbus means that diagnostic information is available immediately to a wide range of workers in the plant.
• Data is available at all times and is constantly being updated.
• Allows you to organize and prioritize data in a way that turns it into useful information for the right people at the right time.
• FOUNDATION fieldbus has a unique approach to management of device diagnostics.
• The publish/subscribe structure of FOUNDATION fieldbus means that diagnostic information is available immediately to a wide range of workers in the plant.
• Data is available at all times and is constantly being updated.
• Allows you to organize and prioritize data in a way that turns it into useful information for the right people at the right time.
©2013 Fieldbus Foundation
Fieldbus Device Alerts Bring the Data to the Front
Early warning systemGives operators more time to take
action before device problem affects the process
Time-stampedSequence of event recordingRelate problem time to true
causative factors
©2013 Fieldbus Foundation
Actionable Information
In the past, device alarms were not displayed with actionable information Just error messages or cryptic codes – “Error 13” The technician didn’t know what to do
Device alarms must be displayed with advice that maintenance technicians can act upon
Use devices which provide guidance for the device diagnostic alarms...
Understandable Provide a clear message that is easily understood, not a cryptic code
Diagnostic Helps with the identification of the problemAdvisory Provides guidance towards the correct actionFocusing Directs attention to the important aspects
©2013 Fieldbus Foundation
Distinctions should be made between Instrument and Process Diagnostics
Sensorincluding process connection and sensor
electronic
Instrument Electronic
Configuratione.g. Linearization
ProcessProcess/
Environment
Information
Root GroupInformationInformation
RootRoot GroupGroup
InstrumentInstrument
Process/Environment
Process/Environment
SensorSensor
ElectronicsElectronics
ConfigurationConfiguration
ProcessProcess
©2013 Fieldbus Foundation
Data Quality Indication in Action
©2013 Fieldbus Foundation
Device Problem or Process Problem – Do you have sufficient data to guide you?
Hardwired
Device drives current <4 mA or >20 mA on device failure
Masquerades as a process problem
PID counteracts thus tripping the loop
Operator cannot tell the difference between a process alarm and a device alarm
Fieldbus
Device health indicated by associated status
Clear distinction between device problem and process problem
Controller holds last position and alarms on device failure
Shutdown is optional
Operator can easily distinguish process problem from a device problem
©2013 Fieldbus Foundation
After the Fix – Embedded Causes?
When was device configuration changed?
Who did it?
What was changed?
©2013 Fieldbus Foundation
Fieldbus Pressure Transmitter Data Provides:
More versatile statistical process monitoring
Uses process “noise” to detect process problems:
Pulsation indicative of pump or compressor damage
Entrained air = flow measurement errors
Leaks in impulse lines and manifolds
Plugged impulse line
©2013 Fieldbus Foundation
Fieldbus Temperature Transmitter Data Provides:
Statistical process monitoring:Hydrate formation, scaling formation,thermowell coating, etc.
Predictive thermocouple degradation diagnostics - before a T/C or RTD fails,
Extreme Temperature Tracking
Heat conducted from integral sensor to transmitter housing
©2013 Fieldbus Foundation
Fieldbus Control Valve Positioner Data Provides:
Continuous (not on-demand) Performance Diagnostics:Actuator/tubing leakage, air supply
availability, calibration shift, etc.
Common DiagnosticsPartial Stroke Testing (PST), travel
histogram, step-response, valve signature, pressure sensor failure, travel deviation, reversal count alert, accumulated travel alert, supply pressure, position feedback…
©2013 Fieldbus Foundation
Fieldbus On/Off Valve Data Provides:
Open/close travel time On/Off Valve
Cycle counts
Stuck valve
©2013 Fieldbus Foundation
Fieldbus Data Goes Beyond “Common” Transmitters and Valves
Gas Chromatographs
Tank Gauging Systems
©2013 Fieldbus Foundation
Segment data can provide a good analysis of the system’s health and may include:
Communications Data - Testers/Communicators
Monitoring and diagnostics Online and in real-time
with remote access Simple-to-interpret data reports Built-in oscilloscope for visual detail
©2013 Fieldbus Foundation
Data can Appear in a Variety of Forms
Diagnostic WindowsDiagnostic
Lamps
©2013 Fieldbus Foundation
OK, so FOUNDATION Fieldbus clearly can provide the data I have always wanted…
So what can possibly stop me from getting the most value from the data?...
©2013 Fieldbus Foundation
The Power is in the Data, and there can be a lot of data!
Manufacturer (Coded)
A B C D E F G H I J K L
Block Type Number of Parameters in each block
XD 1 (generally the measurement transducer) 44 106 85 34 37 91 45 29 45 61 45 42
XD 2 38 42 36 50 34 27
XD 3 93 20
XD 4 55 17
XD 5 33
# of parameters 230 148 121 34 37 211 45 29 79 88 45 42
# of Transducer Block Parameters in d/p transmitters.
Extracted from Differential Pressure Transmitters with similar capsule ranges
At least one device contained~75 parameters specifically for specialized diagnostics
Different Manufactures = different levels of granularity (data)
©2013 Fieldbus Foundation
The Diagnostics Storm
Sample Diagnostic Parameters of a
FOUNDATION Fieldbus Flowmeter
©2013 Fieldbus Foundation
NAMUR NE 107
Definition of NE 107 Status Signals
©2013 Fieldbus Foundation
Definition of NE 107 Status Signals
©2013 Fieldbus Foundation
32 Bit Bitstring for Prioritizing Diagnostic Data
©2013 Fieldbus Foundation
Grouping Diagnostic Conditions
©2013 Fieldbus Foundation
Diagnostic Mapping Workflow
©2013 Fieldbus Foundation
Embedded in Supplier Solution
©2013 Fieldbus Foundation
Utilizing Diagnostic Data from Multiple Devices Together
Utilizing Diagnostic Data from Multiple Devices
• Certain diagnostic anomalies expressed in multiple field devices can indicate an anomaly or impending abnormal situation in the process.
• Placing a structure around which these diagnostics can be consistently managed makes these more advanced diagnostics possible.
• Being able to diagnose the overall health of a unit, area, or even the entire plant is predicated on this good diagnostic data at the most basic level of the measurement devices and actuators.
• Certain diagnostic anomalies expressed in multiple field devices can indicate an anomaly or impending abnormal situation in the process.
• Placing a structure around which these diagnostics can be consistently managed makes these more advanced diagnostics possible.
• Being able to diagnose the overall health of a unit, area, or even the entire plant is predicated on this good diagnostic data at the most basic level of the measurement devices and actuators.
©2013 Fieldbus Foundation
Plans for Using a Plant Asset Management System
©2013 Fieldbus Foundation
Location of Intelligent Device Management Software
In the past, intelligent device management software fell into disuse because it was not easily accessible Hidden away in the workshop Local equipment room (LER) / field auxiliary room (FAR) Stand-alone workstation in the corner of the control room
• Separate login
• Must type the tag to search
Must be accessible to become a natural part of the daily work process Client integrated on the operator console
• A mindset change
• The idea is not for operators to take over maintenance Dedicated maintenance workstation for instrument technicians
©2013 Fieldbus Foundation
Engineering Operator Operator Operator Maintenance
Traditional Architecture
Operators Using Device Diagnostics as Early Warning for Process
• Intelligent device management client integrated in DCS operator console
• Device diagnostics becomes a natural part of daily operations
• Operators tend to the process, not the devices
Plus:Process visibility
Plus:Device Diagnostics
Plus:Device Configuration
©2013 Fieldbus Foundation
Training for New Competency
In the past the operators got training on the operator station software But not the device management software
The technicians got training on the handheld field communicator But not the device management software
Make sure operators and technicians are trained on the device management software Understand the NE107 status signals Navigate the device menu How to search for tags, plant unit, device
classes How to search for specific device types
©2013 Fieldbus Foundation
Work Processes Have to Be Rewritten Around Device Management Software
Standard company work processes for 4-20 mA and on/off signals are not optimized for intelligent devices Technicians start by going to the field to inspect
Rewrite work processes around the device management software Urgent maintenance:
• Troubleshoot and verify from the device management software first, before going to the field, to determine if there is a problem
Daily maintenance:
• Extract device diagnostic alarm report from intelligent device management software, and prioritize before morning meeting
Turnaround maintenance:
• Screen which devices need calibration and adjustment to better plan the turnaround activities
©2013 Fieldbus Foundation
Let’s Now See Device Diagnostics in Action!
©2013 Fieldbus Foundation
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