Enhancing Usability Through Physical Layer Diagnostics

Transcription

1 Foundation Fieldbus - Looking Forward. Enhancing Usability Through Physical Layer Diagnostics Unnikrishnan R Pepperl+Fuchs (India) Pvt. Ltd.

2 FF Usability What is Usability?? Usability is all about how easy, effective and pleasant the features are for the end customer to use Simplicity, logical, orderly processes that are well defined and organized steps to use the digital network The objective is to make FF easier than conventional instrumentations by Fieldbus Foundation

3 FF Usability - Simplicity The iphone did not introduce anything particularly new or exciting to the mobile industry upon its release. Blackberry Iphone Simple Apps usability and vendor participation Adaptable Constant improvements by Fieldbus Foundation

4 FF Usability Interoperability Automated Device replacement Backwards compatibility PV Interchangeability Device Templates Managing Diagnostics by Fieldbus Foundation

5 FF Usability New ITK 6.2+ profile New ITK 6 profile improves device commissioning Improves Maintenance activities Improves self monitoring and diagnostics of field devices ( diagnostics alerts) Device replacement Supports new EDDL features ( integrating data from multiple blocks, multiple views, mode control etc) by Fieldbus Foundation

6 FF Usability Physical Layer Diagnostics End users require actionable diagnostics information from physical layer Expert systems advices Components level diagnostics Relevant tools to help the plant during installation / operation / maintenance Integrating the physical layer diagnostics into the AMS by Fieldbus Foundation

7 Field Devices Field Devices Field Devices Field Devices Fieldbus Physical layer Power Supplies Types and Causes of faults Components with a view on availability Assessment of risk of failure Surge Protec. Device Coupler (Zone2 ExiC) Device Coupler (Zone1 Exd) Device Coupler (Zone1 Exia) Terminator Surge Protect. Fieldbus Process Interfaces by Fieldbus Foundation

8 Corrosion by Fieldbus Foundation 8

9 Hazardous safety rules not followed Ground faults Fieldbus and power cables tied together by Fieldbus Foundation

10 Poor cable installation by Fieldbus Foundation

11 Poor cable installations Cable gland not tight Seal missing by Fieldbus Foundation

12 Poor Device Installation by Fieldbus Foundation

13 Poor maintenance by Fieldbus Foundation

14 Typical locations and Fieldbus issues by Fieldbus Foundation

15 by Fieldbus Foundation

16 Diagnostics Tools Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need by Fieldbus Foundation

17 Diagnostics Tools Handheld by Fieldbus Foundation

18 Advanced Diagnostic Options A single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need Integrated version Handheld Portable by Fieldbus Foundation

19 Fieldbus Diagnostic Handheld Display interface for stand-alone operation Multi-language support Intrinsically safe fieldbus interface (Ex ia) FISCO, Entity, DART Operation in Zone 1/Div. 1 Focused on practical application Operating modes for novice and expert users With expert system advice Data backup and documentation on PC by Fieldbus Foundation

20 Suitability check for existing cable by Fieldbus Foundation

21 Failure margin check Communications check by Fieldbus Foundation

22 Device coupler short-circuit check by Fieldbus Foundation

23 Oscilloscope Built into the Hand Held Tool Many trigger conditions selectable Operation on the display or via software Trigger output for external oscilloscope by Fieldbus Foundation

24 Intuitive Handling One-button, quick check with NAMUR signals (NE 107) Recording and storage for 32 segments with 32 devices each Data backup on laptop/pc by Fieldbus Foundation

25 Expert system on board Interprets raw physical layer measurements Translates into possible causes Suggests corrective action NAMUR NE 107 status by Fieldbus Foundation

26 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 by Fieldbus Foundation

27 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 by Fieldbus Foundation

28 Relay contact optional) Example ADM and DCS integration Diagnostics at DCS Station Address switches Industrial Switch Ethernet or FF H1 RS by Fieldbus Foundation

29 Relay contact optional) Example ADM and DCS integration Operator station AMS VnetIP Ethernet RS by Fieldbus Foundation

30 Relay contact optional) Example ADM and DCS integration Operator station AMS VnetIP Ethernet RS by Fieldbus Foundation

31 Cabinet Control via Diagnostic Gateway Inputs for monitoring the control cabinet Namur sensors / Frequency input (6x) Analog input for temperature (2x) Humidity sensor on board Power outputs (240 V, 2x) On/Off controller Configurable via Foundation Fieldbus H1 Fan is not working Door not closed Water ingress by Fieldbus Foundation

32 Diagnostic Device Couplers Measures in the field: Measures fieldbus signal conditions at the spur level Reports changes all the way to Plant Asset Management Feeds the expert system Better advice better knowledge focused plant upkeep fewer trips to the field by Fieldbus Foundation

33 Diagnostic Segment Protector Improved and innovative spur fault protection: Progressive spur short-circuit protection Jabber protection cuts off devices talking too much Maintenance work causing contact bounce or short-circuits Reliable containment of gradual overload conditions Protects operations from manual intervention and device failure Loose wire strands Bad installations causing multiple devices to talk at the same time Water ingress with ground faults or corrosion by Fieldbus Foundation

34 Water Ingress by Fieldbus Foundation

35 Water Ingress Sensor Monitoring the inside of the enclosure Placed inside the enclosure of choice Connects in parallel to the fieldbus segment Sends alarm all the way to plant asset management Know what the housing looks like on the inside by Fieldbus Foundation

36 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 x by Fieldbus Foundation

37 Commissioning Wizard With Expert System Support Takes snapshot Identifies wiring errors Ensures compliance with AG181 and IEC Recommends limits for ADM messages Stores limits in non-volatile memory Automatic Tag Readout Creates baseline report: Snapshot of all measurements Complete documentation Saves significant (almost 80%) of pre-commissioning time by Fieldbus Foundation

38 Online monitoring as per NAMUR ADM increases the number of detectable faults Displays measurement values Issues warnings and alarms Highlights violations with color coding: Good value Maintenance required Out of specification The segment is still operating with good performance by Fieldbus Foundation

39 Diagnostic Menu ADM delivers actionable information for fast fault finding 1 Active messages Actionable information with solution guideance based on expert knowledge 3 History with timestamps When the failure occured disappeared 2 Export function for external analysis and storage by Fieldbus Foundation

40 Basic Principles: Typical Topology Plant Asset Management Diagnostic Gateway Surge Protector Trunk Segment Protectors Terminator Spurs Field Instruments by Fieldbus Foundation

41 Poor Wiring by Fieldbus Foundation

42 Poor Wiring by Fieldbus Foundation

43 Practical Example of Frequency disturbance 7 ms In this example the frequency of noise was approx. 150Hz by Fieldbus Foundation

44 Not a good device location FF Device Moved away from Drive by Fieldbus Foundation

45 Surge Protection by Fieldbus Foundation

46 by Fieldbus Foundation

47 Diagnostic in Surge Protector Condition-based replacement Monitors strike severity and count Reports end of functional reserve to AMS Instead of repetitive scheduled maintenance Surely protects you from the next strike At Junction box Trunk input At junction box Spur output At Power supply output at Control room by Fieldbus Foundation

48 Diagnostic Surge Protection On Device Coupler by Fieldbus Foundation

49 Diagnostic Surge Protection On IS Device Coupler by Fieldbus Foundation

50 Surge Protection at PowerHub by Fieldbus Foundation

51 Integrated Diagnostic by Fieldbus Foundation

52 Summary Advanced Diagnostics tools and components for physical layer have reduced physical layer commissiong time and provide online monitoring and reporting system that brings savings at 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 USABILITY of Foundation Fieldbus physical is greatly improved by Fieldbus Foundation

53 Thank you Unnikrishnan by Fieldbus Foundation