FTD/DTM ASSET MAINTENANCE AND MANAGEMENT An end user perspective..

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1 FTD/DTM ASSET MAINTENANCE AND MANAGEMENT An end user perspective.. ARC Twelfth India Forum, Bangalore July, 2014 Industry in Transition: The Information Driven Enterprise in a Connected World Mouleswara Reddy Sr. Manager Flowserve India Controls Pvt. Ltd. Rmouleswara@flowserve.com

Transition: The Information Driven Enterprise in a Connected World

2 Contents Overview of the FDT Standard The CHECK ENGINE Light Intelligent Device Information Move from Reactive to Predictive Maintenance Examples of Bottom Line Benefits FDT2 Features and Benefits Migration to FDT2 Conclusion

to Predictive Maintenance Examples of Bottom Line

3 Acronyms FDT Field Device Tool (FDT Technology Standard) DTM Device Type Manger (Device Driver) AMS Asset Management System PLC - Programmable Logic Controller DCS Distributed Control System FDI Field Device Integration EDDL Electronic Device Description Language

PLC - Programmable Logic Controller DCS Distributed Control

4 The FDT Standard The FDT Standard Integrates Any compliant device chosen by the end user On any network Into any compliant control or asset management system Fully Enables Intelligent Device Features Device driver is device manufacturer supplied o Rich graphic interface o Best in class configuration and diagnostics without programming Is Publically Available and Widely Deployed IEC ISA / ANSI 103 China GB/T Part 3xy Communication Profile Integration Part 2 Concepts and detailed detailed description Part 61 DTM Style Guide Part 5xy Communication Profile Implementation Part 4z Object Model Integration Profile

5 The FDT Standard - Terminology Frame Application High level application that needs access to intelligent devices PLC, DCS, Asset Management, Calibration, etc. A Frame hosts any number of DTMs DTM (Device Type Manager) The device driver for an intelligent device Supplied by the device vendor

6 DTM Example Configuration

7 DTM Examples Network Diagnostics

8 DTM Example Device Diagnostics

9 Frame Example The project tree represents the physical or logical architecture of the plant You configure each device with its DTM from the project tree DTM

10 Many Frame Applications FDT Frame Applications ABB: 800xA, Freelance, Asset Vision Basic, SMART VISION E+H: FieldCare Honeywell: Asset Manager ifak: isfdt PlugInFrame KW-Software: FieldDeviceXplorer (FDX) Metso: DNA Field Device Manager M&M Software : FDT Frame Application Moeller: FDT Navigator Omron: CX-Profibus ProSoft: PROSOFT fdt Rockwell Automation: Asset Center Schneider Electric: Unity Pro SICK: SICK FDT Container WAGO: WAGOframe Wiedmueller: WI Manager Yokogawa: FieldMate and PRM And many others You may have a Frame Application already in your plant! Contact your automation suppliers!

Omron: CX-Profibus ProSoft: PROSOFT fdt Rockwell Automation: Asset Center Schneider Electric: Unity Pro SICK: SICK FDT Container WAGO: WAGOframe

11 Versatile Communications Point to Point Network Workstation or Field Commissioning Maintenance Diagnostics Transparent routing across networks All networks are supported Remote diagnostics and maintenance Smart information access is available using many standard devices like multiplexers, remote I/O and others

networks are supported Remote diagnostics and maintenance Smart information

12 Today s Production Environment Global competition Internal company competition Aging facilities Limited resources Need to do more with less Measurement device are becoming smarter Does this sound familiar?

Limited resources Need to do more with less

13 The Challenge Is To Take action Learn to better use your existing equipment Help increase your company competitiveness

14 You Need To Be Part Of The Solution! Think out of the box Think differently about your job Take a big picture view of the problem Think about what you have not what you don t have! Increase Profitability Yes, I said the P word! Realize the potential of your existing assets Fully Utilize Your Assets

view of the problem Think about what you have not what you don t have!

15 What Do You Do When. It could mean a Minor, Major or Vital issue! But how do you know? How does your mechanic know? Or, does anyone really know?

16 Check Engine - Example Computer checks all sensors Computer detects problems Check Engine light is activated Mechanic without a diagnostic tool says, it could be. or but maybe I need to. Mechanic with a diagnostic tool (FDT) says It is just your gas cap you didn t tighten it! FDT Technology is the diagnostic tool that is used to better know, use, listen to and maintain your intelligent measurement devices!

Mechanic with a diagnostic tool (FDT) says It is just your gas cap you didn t tighten it!

17 FDT Technology FDT Technology works with your control, monitoring, asset management, Frame or other application to help you really see into your smart device to allow Faster configuration Better problem diagnostics Predictive maintenance And much more! DTMs run here to help you know what is going on here! Protocols delivers the data! HART, FF Profibus, Device Net, etc.

Better problem diagnostics Predictive maintenance And much more!

18 FDT Technology - Application Interchangeability Interchange upgraded devices seamlessly Interoperability Multivendor product work together Commissioning offline network set up & device configuration. Maintenance Condition monitoring optimized maintenance. Diagnostics On line diagnostics Alarms and Alerts Simulation/ Calibration

offline network set up & device configuration.

19 Intelligent Device Diagnostics Common and Universal Attributes Alerts and Device Status Information Analog and Digital process measurement values (PV) does not match might indicate condensation (water) in the device housing Device status alerts device malfunction, loop current fixed, PV out of limits, maintenance required, etc. Cold start or reset potential power failure or loop power supply problems data items standard in most devices including 4-8 process variables and range values Remote Access check all diagnostics from the safety of the control room or instrument shop Device Specific Attributes Device Performance of Process Information Magnetic Flowmeter empty pipe detection or coated electrodes, conductivity variations, etc. Pressure Transmitter plugged impulse lines, flow rate, internal temperature, etc. ph Analyzer electrode performance problems reference or measurement electrodes Valve Positioner stem position, supply or actuator pressure, total strokes, deviation from SP, etc. Vortex Flowmeter shedder bar frequency, flow rate too low, Coriolis Mass Flowmeters presence of trapped air, build up, etc.

Cold start or reset potential power failure or loop power supply problems 30-40 data items standard in most devices including 4-8 process variables and range values Remote Access check all

21 MOL - From Reactive to Predictive

22 MOL Bottom Line Benefits Breakdown of the activities Diagnostic experts Crane (optional) Valve technicians (repair, test) Mechanic staff (remove, disassemble, reassemble) Case 1: Maintenance cost without diagnostics Case 2: Maintenance cost with HART diagnostics

23 MOL - Business Drivers Needs and drivers leading to increased use of Smart Device Information Tight Cost Control Manufacturer service support Increasing number of assets Engineering Procurement Contracts Technology efficiency and complexity Built-in Diagnostic (HART) Number of the staff decreased Embedded Informatics Internal driving forces External driving forces

24 Dow - The Case for Change Our Opportunity 67 Process Units 2011 DPO Instrument / CV Equipment Failures Rest of Plant (62 Process Units) 5 Reactors 48% of Total $Millions Primary Goal Identify the Biggest Bang for our Buck 8% of the Production Units Account for 48% of the Downtime These 5 reactors have similar process technology (Leverage!!)

25 The Case for Change Value Creation Rest of Plant (62 Process Units) 5 Reactors 48% of Total 16% of Total 10% of Total Validation that We re on the Right Track

26 Business Results Achieved Trip Reduction of 67% Millions of $$ in EBIT savings!!

27 Dow - Use of Data to Mitigate Reactor Trips Though the use of the Asset Management Software (AMS) and IP21 monitoring tools, we are identifying bad acting instrumentation and control valves. This effort involves members from operations, maintenance, process automation, and the tech center. Identify bad actors Collaboration meeting with key stakeholders Develop an execution plan Execute and leverage where most applicable. Deficiency Results (YTD): AMS (control valves) 12 identified, 9 completed. At least 5 trips avoided. Critical Instruments 18 identified, 15 completed. Lessons Learned / Recommendations: Condition Base Maintenance is based on using real-time data to prioritize and optimize maintenance resources and it can be used as a part of an equipment maintenance strategy. At least 3 trips avoided.

28 FDT2 Products are Shipping FDT2 - the latest update to the FDT standard Faster execution for mega installations Improved security Client / server or standalone.net throughout Backward compatible with FDT 1.X DTMs Continued EDDL compatibility Common components for developers Developers toolbox speeds time to market Improves compliance Reduces certification effort Ready for FDI device packages

29 FDI Ready FDI Device Packages will be available in 2015 Based on EDDL (only for HART, FF, and Profibus networks) Enhanced with an optional graphical user interface FDT2 is fully FDI ready The FDI standard is required to be compatible with FDT2 DTM s, DD s, and FDI Device Packages can be freely mixed in an FDT2 Frame

30 Learn More FDT Quarterly Newsletter Register to receive our quarterly newsletter: FDT Group Website Whitepapers Videos Technical Information You Tube Linked In k=my_groups-b-grp-v

31 FDT is Widely Supported

32 India FDT Association

Using HART with asset management systems

Using HART with asset management systems Since it s the most broadly deployed smart device platform, is HART the right choice for your plant? Here are some considerations for end users. John Yingst, Sr.