Asset Management with Foundation Fieldbus Technology G. Mooney OGNL-OGES
Presentation What is Asset Management Present Status/Ongoing Developments Future Direction Summary
What is Asset Management in Plant Automation? Asset management in plant automation is a means to realise higher plant availability and improved operating efficiency, reducing Total Life Cycle Cost.
Asset Management Tools Position Office Domain INtools ERP (e.g. SAP, PACER) Asset Management Systems e.g. AMS, PRM, Asset Manager PKS Control Domain Plant Interfaces Process Control System Equipment/Devices Maintenance Management System
Different Types of Device Maintenance Reactive maintenance After the device has failed unexpectedly. Preventive maintenance The device is serviced at a chosen interval (scheduled), whether needed or not. Unnecessary maintenance The device is healthy, but malfunctioning is suspected, while e.g. the process might cause unexpected behaviour. Predictive maintenance The maintenance schedule is optimised on basis of failure rate and drift statistics. Proactive maintenance The device build-in diagnostics (leading indicators) alerts for maintenance.
Asset Lifecycle Asset Performance Optimal Wear Normal Loop, Process Diagnostics Predictive Maint. Out of Spec Broken Preventive Maint. Proactive Maint. Quality, Accuracy info. Diagnostic based maint. will shorten repair time Out of Service Start-up Reactive Maint. Useful life Predictive: RCM (Reliability Centred Maintenance) Proactive: DBM (Diagnostic Based Maintenance)
Maintenance Best Practices Present Best Cost Producer Reactive 55% 10% Preventive 31% 25-35% Predictive 12% 45-55% Proactive 2% 5-15% Cost ref Predictive X 10 X 5 X 1 Note 1 Note 1: 60% is not necessary Present Best Cost Producer Reliability Magazine: 2002
Sources Of Production Losses Equipment failure is the #1 contributor to refinery production losses Source: HPI Market Data 2003 Gulf Publishing Company Mechanical and Process Equipment are the major sources of unscheduled shutdown in Oil & Gas Avg. # of Failures per Year 12 10 8 6 4 KEY: Mechanical Equipment Process Equipment Instruments & Valves 2 0 Gas Turbines Compressors Motors and pumps Electric generators Turboexpanders Combustion engines Source: OREDA Failure Data Heaters and boilers Vessels Heat exchangers Instruments and valves
Profile Of Maintenance Spending KEY: Mechanical Equipment Process Equipment Instruments & Valves Electrical Equipment Materials Handling 2% Tools Insulation 2% 2% Paints/Coatings 3% Piping 5% Other 4% Instruments 20% Electricals 7% Furnaces / Boilers 6% Vessels 8% Heat Exchangers 10% Drives 7% Mixers/Agitators 2% Valves 7% Pumps 8% Compressors 7% Source: HPI Market Data 2003 Gulf Publishing Company
Maintenance Effort on Devices Process Interface 14% ReRanged 11% No Action 63% Drift 11% Configuration 1% No Action 49% ReRanged 2% Hardware 8% Drif t 18% dp flow Process Interface 26% Calibration 5% Hardware 5% Process Interface 23% dp level Source: Shell Refinery No Action 64% Pressur e
Greenfield Maintenance Philosophy & Targets Targets defined: After start-up 2007 achieve > 40% Condition Based Maint. In 2009 achieve > 70% CBM
Status Asset Management for Devices & Systems Current situation Current maintenance strategy is reactive and preventive. ReRanged 11% Process Interface 14% 50-65 % of current maintenance jobs in the category no failure, no action. Drift 11% No Action 63% Remaining part predominantly in process interface, device hardware and sensor drift. Configuration 1% In case of problems, instrument/analyser check is easier than checking process unit/performance
Status Asset Management for Devices & Systems Remarks: No-Action part can be reduced by predictive maintenance and further reduced by remote diagnostics. Current situation Current maintenance strategy is reactive and preventive. 50-65 % of current maintenance jobs in the category no failure, no action. Device hardware hardly fails today; MTBF>500 y. ReRanged 11% Process Interface 14% Drift 11% No Action 63% Remaining part predominantly in process interface, device hardware and sensor drift. Re-ranging and drift significantly reduced for fieldbus devices (fully digital communication). Configuration 1% In case of problems, instrument/analyser check is easier than checking process unit/performance Process interface diagnostics are main focus for further development in asset management tools.
I/O Diagnostic Potential with HART Devices 4-20 ma 4-20 ma & HART AMS HART Asset management tool (e.g. AMS) converts raw diagnostic data into diagnostic information Data provider of raw diagnostic data
Diagnostic Potential with HART Devices I/O Remarks: 4-20 ma still drifts and (re-)ranging required. 4-20 ma 4-20 ma & HART Some 3 ma only for running diagnostics in the device, hence limited capabilities and most processing AMS done at the DCS. HART Hart protocol slow: 2 messages/sec. High Asset operator management skills and tool much (e.g. time needed to acquire AMS) converts diagnostics raw results diagnostic data into diagnostic As information result asset management tools (like AMS) mainly used in configuration, but not for remote diagnostics. Data provider of raw diagnostic data
Diagnostic Potential with FF Devices I/O FF comm.: PV s + status AMS Asset management tool receives processed diagnostic information and alerts Data provider of processed diagnostic data; capable of alerting needed maintenance
I/O Diagnostic Potential with FF Devices Remarks: Fully digital, hence no drift and (re-)ranging. FF comm.: PV s + status Sufficient power for running diagnostics in the device; most processing done at the device. AMS Data provider of processed FF protocol fast: >200 messages/sec. diagnostic data; capable of Ongoing development work (suppliers) alerting on application needed packages Asset management to convert data tool into information. maintenance Asset receives management processed tools (like AMS Suite, PRM, Asset Manager diagnostic PKS) information become good and platforms for diagnostics. alerts
Diagnostics Coverage in FF systems Level 1 and 2 readily available Communications Diagnostics Level 3 selectively available Device Diagnostics Level 2 Level 4 early development Field Performance Diagnostics Level 3 Fisher actuators, elements valves, connections Level 4 Plant Diagnostics process or equipment Level 1 electronics communications Fisher
Development of Asset Management Development direction Devices Process interfaces Plugged impulse lines Loss of fill fluid in wet leg Valve/positioners Signature, leak detection In-line flow devices US, vortex, coriolis Moisture in transmitters P, T Transmitters TC impedance.
Development of Asset Management Development direction Systems Alarm/Alert handling Routing to Operations or/and Maintenance Traffic light presentation Enhanced diagnostics for FF communications Translate diagnostics data into maintenance information Info on possible cause Suggestion for repair Consequences on accuracy, useful time Integration with ERP (SAP, PACER,.) using open communication standards Proactive maintenance tools
Example of Plugged Impulse Line Detection Process noise/variation are analysed to identify plugged impluse lines; local data processing attractive! Normal (measuring process pressure) ) Plugged (measuring pressure of process plug)
Example of Plugged Impulse Line Detection Remarks: (measuring process pressure) ) (measuring pressure of process plug) Process noise/variation are analysed to identify plugged impluse lines; local data processing attractive! First successful tests executed with the 3051 from EPM in the SRTCA test site on a gas flow application using DeltaV. Interoperability demonstrated of 3051 plugged line diagnostics Normal Plugged with Plantscape. Tests planned for: -Yokogawa EJA (available end 2004) with PRM and CS3000. - Field trial with the 3051 at a NAM site using DeltaV and Hart (ongoing).
Example of Smart Valve positioner Smart Valve Features Configuration Remote calibration Actual valve position Diagnostics Valve travel alerts Packing leakage Signature Step response Valve/positioner combinations under test: EPM: Baumann/DVC5000 HW: Valtek/Logix1400 Metso: Metso/ND800 Positioners Yokogawa: Metso/YVP are data servers Samson: Samson/Pos3787 ABB: ABB/TZIP Maintenance history
Example of Smart Valve positioner Remarks: Smart Valve Features Valve/positioner combinations Interfacing Configuration positioners with asset under management test: tools is restricted in interoperability: DVC5000 with Valvelink (AMS Remote calibration EPM: Baumann/DVC5000 Suite) and YVP with ValveNavi (PRM); i.e. single vendor Actual valve position HW: Valtek/Logix1400 approach for best results with advanced diagnostics. Diagnostics Signature Step response Maintenance history Metso: Metso/ND800 Work ongoing Valve to travel broaden alertsinteroperability with e.g. Metso Positioners Yokogawa: Metso/YVP are data servers valve/postioners, ValveCare package with PRM and Packing leakage Samson: Samson/Pos3787 ValveLink on PRM. ABB: ABB/TZIP
Future Asset Management for Devices & Systems Strategic response to the new developments Recognise the required changes in maintenance own organisation Training to implement new capabilities Own interpretation of diagnostics data before going to ISC Plan the maintenance more efficiently Work on the devices requiring real attention Bad Actor Manager Increase diagnostic coverage for safety systems Reduce test intervals Benefits Reduced maintenance effort/cost Improved process availability
Summary Foundation Fieldbus and open-system-architectures is the best diagnostics platform to achieve optimised asset management. Advanced/process diagnostics in FF devices is vendorselectively available; products are improving rapidly. Ongoing OGES test programme focuses on diagnostics for process interface and valve positioners. Best results with diagnostics and asset management tools are currently achieved with a single vendor approach. Own maintenance organisation needs to be trained to exploit new asset management tools