Fieldbus Commissioning benefits

Transcription

1 Fieldbus Foundation Freedom to choose. Power to integrate Fieldbus Commissioning benefits 2005 General Assembly

2 Fieldbus Commissioning Benefits Commissioning - Device integration Commissioning - Physical layer

3 Fieldbus Commissioning Benefits Commissioning - Device integration

4 Easier - Real Number Engineering Unit No range mismatch Unit downloaded when device is replaced Process 200 kpa Transmitter Range kpa 8 ma System Range kpa Reading 100 kpa...alarms and trips not working Range Range BUS AI Digital CTRL AO Transmitter CPU D/A FF Digital 4-20 ma A/D FF CPU Digital D/A 4-20 ma Positioner A/D FF CPU Digital

5 Lower Cost & Faster: - Device Commissioning Devices are auto-recognized Devices are auto-addressed Devices identify themselves Plug-n-Play Only FF has automatic addressing Traditional: 2 hours / device for 2 technicians 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 Attach device Drag-and-drop commissioning wizard Compare configuration faster on computer

6 Fieldbus Maintenance Made Easy: Device Commissioning Wizard

7 Fieldbus Maintenance Made Easy: Protective 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

8 Easier FF Device Commissioning and Replacement 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

9 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 productivity Aventis says: Fieldbus technology saves costs and enables innovative applications. Future plant will be equipped with fieldbus

10 Intelligent Devices Enable Asset Optimization Oops! BAD! OK! 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

11 Fieldbus Commissioning Benefits Commissioning - Physical layer

12 The physical layer alive and well? Proper termination Water ingress Ground faults

13 The physical layer alive and well? Proper termination Water ingress Ground faults Loose wiring Faulty devices

14 The physical layer alive and well? Proper termination Water ingress Ground faults Loose wiring Faulty devices Unstable communication Short circuits Bulk power failure

15 Online monitoring of the physical layer Equipment Health 100% Time to respond Warning level Monitoring the physical layer protects you from unwanted shutdowns! Minimum device health FAILURE Time

16 Advanced Diagnostics for physical layer Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need

17 Advanced Diagnostics for physical layer A portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need

18 Diagnostic Manager Software 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

19 Asset Management Integration 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 Automatic Setup Included

20 Open Architecture Integration ADM uses a simple infrastructure for data integration ADM automates display of diagnostic information Benefits No Planning: No planning of system resources required Last minute decisions are possible on ADM implementation No Engineering: Software configures alarm settings for segments and device tags Commissioning wizard automatically configures ADM settings No Worries: Easy to use graphical user interface and actionable information

21 Commissioning until now 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 Report

22 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 Test Report Commissioning Wizard

23 Commissioning Wizard Simple to use Eliminates manual test procedures Ensures compliance with AG181 and IEC 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%

24 Commissioning process Plan and purchase Install and commission Operate and maintain Engineering Commission Monitor Troubleshoot Cash Flow Longer plant uptime Know before you act Actionable information in clear text Verify against original design Automated checkout procedures Segment Checker: design of the physical layer

25 Commissioning process Engineering Segment Checker: design of the physical layer

26 Commissioning process Commission Verify against original design Automated checkout procedures

27 Commissioning process Commission Printable Segment report in pdf format. Save in Harddisk.

28 Commissioning process Troubleshoot Know before you act Actionable information in clear text

29 Commissioning process Monitor Longer plant uptime Know before you act

30 Commissioning process Monitor Good value Maintenance required Out of specification Segment is still operaating with good preformance. Setting of pre-alarm. Warning maintenance required.

31 Commissioning process Troubleshoot Oscilloscope function.

32 Commissioning process Troubleshoot Oscilloscope function.

33 Commissioning process Operate and maintain Troubleshoot Oscilloscope function. Readable Manchester code. Able to identify device ID.

34 Automated Pre-commissioning Saves Time Case Study with cost comparison for precommissioning: 4 20 ma Fieldbus Fieldbus with Advanced Diagnostics Case Study Specifications Number of instruments 1,200 Number of segments 100 Instruments per segment 12 Hours per work day Mean time to repair (MTTR) a fault 8 hours 4 hours 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 Diagnostics Technical White Paper available from Pepperl+Fuchs Part No:

35 Automated Pre-commissioning Saves Time Task 1 of 2 Model 4-20 ma Fieldbus without diagnostics Fieldbus with Advanced Diagnostics Time/Unit 5 min 10 min Not required Constructional checks: Units Total Time 1200 loops 100 segments 12½ days 2 days 0 Not required Time/Unit 4 h MTTR 4 h MTTR Not required Construction failures (1%): Units Total Time 12 loops 1 Trunk, 12 Spurs 6 days 6 ½ days 0 Not required

36 Automated Pre-commissioning Saves Time Tasks 2 of 2 Model 4-20 ma Fieldbus without diagnostics Fieldbus with Advanced Diagnostics Time/Unit 10 min 60 min 8 min Pre/commissioning instrument checks: Units 1200 loops 100 segments 100 segments Total Time 25 days 12½ days 1.6 days Time/Unit 4h MTTR 4h MTTR 4h MTTR Pre/commissioning failure: Units 0.5% = 6 loops 0.5% = 1 segment 1.5% = 2 segments Total Time 24 h = 3 days 4h = ½ day 8h = 1 day Totals 46.5 daysu 21.5 daysu 2.6 daysu

37 Commissioning saves time and money A few mouse clicks conduct automatic testing Reports on the actual installation with all devices connected Automatic setting of warning and alarm limits

38 Monitoring increases plant up-time The ADM increases the number of detectable faults The physical layer becomes a managable asset The ADM is prevention from unwanted shut downs

39 Accelerated Commissioning Actionable information guides to potential sources of faults ADM provides expert knowledge and advice For anyone working with fieldbus Accessible from remote for consultation with fieldbus experts

40 Accelerated Commissioning ( ADM makes the physical layer visible ) Fieldbus itself becomes a managable asset ADM integrates into Asset Management Systems Available as stationary or mobile module Display in the safety of the control room

41 Accelerated Commissioning Rapid commissioning: Accelarates loop check Longer operation: Warns before failure Faster troubleshooting: Assists with actionable information

42 Conclusion Foundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof. Advanced Diagnostics tools for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEX

43 QUESTIONS?