Conditie gebaseerd onderhoud met PROFIBUS in overeenstemming met NAMUR NE107

Transcription

1 De PROFINET, PROFIBUS & IO-Link dag Conditie gebaseerd onderhoud met PROFIBUS in overeenstemming met NAMUR NE Jaap Westeneng Product Manager Asset Management

2 Praktijkcase 2 Conditie gebaseerd onderhoud met PROFIBUS in overeenstemming met NAMUR NE107. Een nieuwe, unieke oplossing die op eenvoudige, genormaliseerde manier de meerwaarde van intelligente procesinstrumentatie op basis van PROFIBUS ontsluit en valoriseert. Met de nieuwe Fieldgate SFG500 Asset Monitor als kloppend hart. Een stand van zaken met reële fieldtrials en mooie resultaten.

3 Diagnostics in automotive industry Quality Manager Engine ering Cours e - Diagn ostics and Plant Asset Manag ement Service technician Driver As detailed as possible Includes suggestions for possible remedies All information for safe driving Only essential information, summary messages As early as possible

4 Diagnostics in process industry Reliability Manager Engine ering Cours e - Diagn ostics and Plant Asset Manag ement Maintenance technician Process operator As detailed as possible Includes suggestions for possible remedies All information for safe operation Only essential information, summary messages As early as possible

5 Challenges faced by operators today Difficult to get overview status of process. Operators are bombarded with nuisance alarms. Inconsistencies in diagnostics information from different vendors and product classes. Different applications, terminals, interfaces with unsynchronized data. Operators are integral part of control loops and need to take decisions in critical situations. Engine ering Cours e - Diagn ostics and Plant Asset Manag ement

6 Purpose of diagnostics Analyze status information (i.e. from field devices) With the objective of detecting causes for potential malfunction. Diagnostics form the basis to remove malfunctions Value of diagnostics: Minimizes ad-hoc maintenance Enables proactive maintenance Minimizes unwanted plant shutdowns Enables event triggered inspections Forms the basis for Plant Asset Management Reduces costs Engine ering Cours e - Diagn ostics and Plant Asset Manag ement

7 History of SMART technologies in Process Industry Engine ering HART added to IEC Cours e - Developed By Rosemount Open Standard HCF HART 7 specification HART 7.4 Diagn specification Diag. Profiles ostics and PROFIBUS PA Plant Asset Manag PNO Founding of PI Standard Device Profile 3.0 PROFIsafe Cond. Status Profile 3.01 Device Integration Profile 3.02 ement FOUNDATION Fieldbus H1 Diagnostic Profiles Specification Registered Host Profile 61b FDT = Field Device Tool Normen Arbeitsgemeinschaft für Meß- Und Regeltechnik in der chemischen Industrie Fieldbus Foundation High Speed Ethernet Safety Instrumented Functions (SIF) Diagnostic Profiles Release Diagnostic Profiles FF912 J. Westeneng Slide

8 Purpose of NAMUR NE107 NAMUR Recommendation NE 107 (2005) Self-monitoring and diagnosis of field devices Engine ering Cours e - Status signals and their evaluation There are four defined standard signals for all field devices. They tell us about device condition. The defined status signals are: Device is operating normally Maintenance required (M) Check function (C) Off spec (S) Failure (F) The self monitoring and diagnosis results must be mapped to and displayed by these four status signals and kept in readiness by the field device. Status signals must be capable of being generated irrespective of the transmission media used (type of bus, protocol, contacts...) Examples of detailed information Maintenance needed short term Maintenance needed mid term Change of configuration Local operation, Substitute value entered Cause of failure device internal Cause of failure process related Device being operated off spec Uncertain value due to process influence Diagn ostics and Plant Asset Manag ement

9 Typical maintenance strategies Consequence of failure Costs Corrective Maintenance Preventive Maintenance Condition based Maintenance Increasing effectiveness and efficiency Corrective Maintenance Device is maintained when it failed > uncontrolled plant shutdowns Preventive Maintenance Device is periodically maintained to prevent failures > controlled but high maintenance intervals Condition Based Maintenance Device detects when a maintenance is necessary and notifies in advance > controlled and optimized low maintenance intervals Availability J. Westeneng Slide 9

10 Typical maintenance strategies Engine ering Cours 65% Corrective Maintenance Device is maintained when it failed > uncontrolled plant shutdowns e - Diagn ostics and Plant 30% 60% of preventive maintenance activities is unnecessary! 5% Preventive Maintenance Device is periodically maintained to prevent failures > controlled but high maintenance intervals Condition Based Maintenance Asset Manag ement Device detects when a maintenance is necessary and notifies in advance > controlled and optimized low maintenance intervals Type of maintenance Source: ARC Advisory Group J. Westeneng Slide 10

11 Condition Based Maintenance strategy Engine ering Condition Reduction of functional reserve Failure occur Time Condition Based Maintenance Device detects when a maintenance is necessary and notifies in advance ostics -> controlled and optimized low maintenance intervals Condition based Initialized on condition (advanced (basic (process diagnosis: diagnosis: diagnosis correlated correlated value diagnostic devices) 1 device) values) Cours e - Diagn and Plant Asset Manag ement Value Value B-E-F Value B-E-F B-E-F Value Value B-E-F Value B-E-F B-E-F Pro-Active Static Static analysis analysis value Reference value value evaluation: <,>, =, hyst., Predictive Dynamic analysis analyses trend Reference trend extrapolation, time, evaluation: evaluation: <, <, >, >, =, =, hyst., hyst.,.. Boolean Boolean logic logic (AND, (AND, OR, OR, ) ) correlation Methods algorithms, algorithms, evaluation: evaluation: <, <, >, >, =, =, hyst., hyst.,.. Boolean Boolean logic logic (AND, (AND, OR, OR, ) ) methods, correlation, algorithms, algorithms, J. Westeneng Slide 11

12 Supporting diagnostics for CBM strategy Engine ering Proactive Condition Based Predictive Maintenance (CBM) Protective Reactive Course - Reduction of functional reserve Diagno stics and Calibration indication operation hours life time indicator Electronic or sensor error Plant Asset Manag Functional reserve Process values out of device specification, e.g. over/under pressure, temperature, flow finger print function Corrosion Stored pressure/ temperature bumps Glass electrode broken Failure occur ement Linearization incomplete time Echo quality Corrosion/Drift J. Westeneng Slide 12

13 Gen-X Project at DuPont, Dordrecht (Netherlands) Projec ts with Digital Comm unicati on Jaap Westeneng Slide 13

14 Gen-X Project DuPont at Dordrecht (Netherlands) Projec ts with DuPont has committed to eliminate the use of a polymer processing aid in the Fluoropolymers production facilities before (Planned investment 9 million EURO) To realize this, new facilities for chemical dosing, waste water - and air abatement should be installed. (3 separate projects fully operational before September 1, 2012) Technology selection based on pilot tests. (Pilot project executed in 2009) Automation technology selection to provide a fully automated plant with high availability. Digital Comm unicati on

15 Gen-X Project Projec ts with DuPont at Dordrecht, chemical industry. Full continuous operation 24/7/365. High availability technical installation. Digital Comm unicati on Siemens PCS7 process automation system. Endress+Hauser FieldCare Plant Asset Management system with Fieldgate SFG500 PROFIBUS intelligent access points. (>> PROFIBUS Device Health Status) PROCENTEC COMBricks modular repeaters. (>> PROFIBUS network diagnostics) Pepperl+Fuchs PROFIBUS DP/PA Gateway with advanced diagnostics. (>> PROFIBUS PA network diagnostics)

16 Gen-X Project Projec ts with PROFIBUS DP (80 slaves) Siemens remote IO Siemens variable speed drives Festo valve islands E+H plant access points (MC2) PROCENTEC modular repeater Digital Comm unicati on PROFIBUS DP/PA P+F DP/PA Gateway PROFIBUS PA (200 slaves) E+H flow E+H level E+H pressure E+H temperature E+H analyse Metso valve positioners Jaap Westeneng Slide 16

17 Gen-X Project DuPont at Dordrecht Projec ts with Digital Comm unicati on

18 Gen-X Project DuPont at Dordrecht Projec ts with Digital Comm unicati on

19 Gen-X Project DuPont at Dordrecht Projec ts with Digital Comm unicati on Jaap Westeneng Slide 19

20 Gen-X Project DuPont at Dordrecht Projec ts with Digital Comm unicati on

21 Gen-X Project DuPont at Dordrecht Projec ts with Digital Comm unicati on

22 Plant Asset Management at Dordrecht Projec ts with Digital Comm unicati on Jaap Westeneng Slide 22

23 PROFIBUS Network Diagnostics PROFIBUS network is remotely monitored by means of integrated web server of COMbricks. Projec ts with Digital Comm unicati on

24 PROFIBUS PA Network Diagnostics PROFIBUS PA network is remotely monitored by means of Advanced Diagnostics Module. Projec ts with Digital Comm unicati on

25 PROFIBUS Device Health Status PROFIBUS devices are remotely monitored by means of integrated web server of Fieldgate SFG500. Projec ts with Digital Comm unicati on

26 PROFIBUS Diagnosis 26 What is difference? Both PROFIBUS access points are able to evaluate PROFIBUS diagnosis. Traffic light approach seems to be different, not in compliance with industry standard.

27 PROFIBUS Device Health Status 27 BUT what is the added value of PROFIBUS intelligent access point in your PROFIBUS network? If devices from different vendors and product classes notifies consistent and standardized diagnostics (Traffic light approach conform NE-107)

28 PROFIBUS Device Health Status 28 If device is continuously monitored and in case of status change, diagnostics can be easily evaluated and are reported automatically (web - and mail notification). If in case of device problem the maintenance engineer is informed what is origin of the problem and supported how to solve the issue (cause - remedy).

29 Project Results 29 By continuous monitoring device health status a condition based maintenance strategy is achieved. Standardized and categorized diagnosis is achieved in accordance to NAMUR NE107 which invalidates the interpretation of manufacturer specific diagnosis. Time to identify, quantify and qualify and solve an issue is significantly reduced (commissioning and start-up). More results expected in asset optimization and life cycle cost reduction.