commissioning issues and solutions - fieldbus · commissioning issues and solutions arasu thanigai...
TRANSCRIPT
1 1 Successful Implementation & Improved Operation
Commissioning issues and
solutions
Arasu Thanigai
Pepperl+Fuchs Pte Ltd
Singapore
Fieldbus Foundation Seminar Kaohsiung – 10th April 2013
2 2 Successful Implementation & Improved Operation
Install the Cables
Check out the cable installation
Install the Devices
Check the device installation
Install the DCS
Assigning the I/O
Calibration the Sensor
Ranging
Calibration the 4~20mA
System Ranging
System Calibration 4~20mA
Commissioning Process
3 3 Successful Implementation & Improved Operation
4~20mA Install the Cables
Check out the cable installation
Install the Devices
Check the device installation
Install the DCS
Assigning the I/O
Calibration the Sensor
Ranging
Calibration the 4~20mA
System Ranging
System Calibration 4~20mA
Foundation Fieldbus • Install the Cables
• Check out the cable installation
• Install the Devices
• Check the device installation
• Install the DCS
• Assigning the I/O
• Calibration the Sensor
• Ranging
• Calibration the 4~20mA
• System Ranging
• System Calibration 4~20mA
Commissioning Process Comparison.
4 4 Successful Implementation & Improved Operation
4~20mA
Foundation Fieldbus
4-20mA
P.S.
fieldbus
P.S.
Distance and relevant issue
Artificial hours and relevant cost
Cable connection Quantity
Hidden trouble points
Cable installation
5 5 Successful Implementation & Improved Operation
4~20mA Install the Cables
Check out the cable installation
Install the Devices
Check the device installation
Install the DCS
Assigning the I/O
Calibration the Sensor
Ranging
Calibration the 4~20mA
System Ranging
System Calibration 4~20mA
Foundation Fieldbus • Install the Cables
• Check out the cable installation
• Install the Devices
• Check the device installation
• Install the DCS
• Assigning the I/O
• Calibration the Sensor
• Ranging
• Calibration the 4~20mA
• System Ranging
• System Calibration 4~20mA
Commissioning Process Comparison.
6 6 Successful Implementation & Improved Operation
4~20mA
Foundation Fieldbus
4-20mA
P.S.
fieldbus
P.S.
Test
Report
Distance and connection Quantity
Tools
Checking of cable installation.
7 7 Successful Implementation & Improved Operation
4~20mA Install the Cables
Check out the cable installation
Install the Devices
Check the device installation
Install the DCS
Assigning the I/O
Calibration the Sensor
Ranging
Calibration the 4~20mA
System Ranging
System Calibration 4~20mA
Foundation Fieldbus • Install the Cables
• Check out the cable installation
• Install the Devices
• Check the device installation
• Install the DCS
• Assigning the I/O
• Calibration the Sensor
• Ranging
• Calibration the 4~20mA
• System Ranging
• System Calibration 4~20mA
Commissioning Process Comparison.
8 8 Successful Implementation & Improved Operation
Install the Device
Distribution
Block
Cable
Power supply
/ Conditioner
Foundation Fieldbus
Host
FF field
devices
9 9 Successful Implementation & Improved Operation
4~20mA Install the Cables
Check out the cable installation
Install the Devices
Check the device installation
Install the DCS
Assigning the I/O
Calibration the Sensor
Ranging
Calibration the 4~20mA
System Ranging
System Calibration 4~20mA
Foundation Fieldbus • Install the Cables
• Check out the cable installation
• Install the Devices
• Check the device installation
• Install the DCS
• Assigning the I/O
• Calibration the Sensor
• Ranging
• Calibration the 4~20mA
• System Ranging
• System Calibration 4~20mA
Commissioning Process Comparison.
10 10 Successful Implementation & Improved Operation
Assigning the I/O
Foundation fieldbus devices are recognized by three
mechanisms: a traditional node address for communication, a
human readable device tag corresponding to the project P&I
diagram, and a unique identifier allowing the system to
automatically resolve any tag or address conflicts.
The system automatically assigns the address to all devices,
avoiding human errors such as address duplication associated
with manually managed protocols, and saving time.
Therefore technicians work based on tag and need not be
concerned with address.
Thanks to the unique identifier, multiple devices can be
connected and commissioned at the same time.
It is plug-'n'-play.
11 11 Successful Implementation & Improved Operation
4~20mA Install the Cables
Check out the cable installation
Install the Devices
Check the device installation
Install the DCS
Assigning the I/O
Calibration the Sensor
Ranging
Calibration the 4~20mA
System Ranging
System Calibration 4~20mA
Foundation Fieldbus • Install the Cables
• Check out the cable installation
• Install the Devices
• Check the device installation
• Install the DCS
• Assigning the I/O
• Calibration the Sensor
• N/A
• N/A
• N/A
• N/A
Commissioning Process Comparison.
12 12 Successful Implementation & Improved Operation
No range mismatch
Unit downloaded when device is replaced
Transmitter Positioner
FF FF
BUS
FF
CTRL
CPU
CPU
CPU
Digital Digital Digital
Transmitter
Range
0-800 kPa
System
Range
0-400 kPa
8 mA Process
200 kPa
Reading
100 kPa
...alarms and trips
not working
AI
Unit
Unit
AO
Unit
Unit
Commissioning Process Comparison.
4~20mA
Foundation Fieldbus
13 13 Successful Implementation & Improved Operation
Why Foundation Fieldbus
The global process industry loses $20
billion, or five percent of annual production,
due to unscheduled downtime and poor
quality.
ARC estimates that almost 80 percent of
these losses are preventable, with 40 percent
largely due to operator error.
Source ARC Insight June 10 2010
14 14 Successful Implementation & Improved Operation
Common issues
Check DD file
Check ITK version
Check if HIST done
Check if the device listed at www.fieldbus.org
15 15 Successful Implementation & Improved Operation
How to Check
16 16 Successful Implementation & Improved Operation
Collaboration with NAMUR
Using the power of FOUNDATION Fieldbus, and considering NAMUR requirements, the new standard diagnostic profile aim to: – Standardize the integration of diagnostic information – Guarantee valuable information to the user
17 17 Successful Implementation & Improved Operation
Diagnosis results must be reliable
Diagnosis results must always be viewed in the context of the application.
Internal diagnosis must be categorized into 4 standard “status signals”
Configuration must be free, as reactions will depend on the user's requirements
Detailed information can be read out by the device specialist
NAMUR NE107: Self-Monitoring and Diagnosis
of Field Devices
18 18 Successful Implementation & Improved Operation
Namur - Diagnostic categories
Maintenance Required The output from the device is
valid but the wear reserve is nearly exhausted or function
will be restricted due to operational conditions
Out of Specification Measurement uncertainty, or
output position deviation, is greater than expected due to
deviations in ambient or process conditions.
Function Check Output invalid due to ongoing work on the device
Failure Output is invalid due to a malfunction in the field device
19 19 Successful Implementation & Improved Operation
Distribution of information
Maintenance
Required
Out of
Specification
Function
Check
Failure
Output is valid
Measurement is
uncertain
Ongoing work on the
device, output invalid
Wear reserve is
exhausted
due to deviations in
ambient conditions.
Output is invalid malfunction in the field
device
OPERATOR
INSTRUMENT
TECH
20 20 Successful Implementation & Improved Operation
Mapping to FF Quality Status & Block Error bits
Maintenance
Required
Out of
Specification
Function
Check
Failure
Output is valid
Measurement is
uncertain
Ongoing work on the
device, output invalid
Wear reserve is
exhausted
due to deviations in
ambient conditions.
Output is invalid
malfunction in the field
device
INSTRUMENT TECH
GOOD
UNCERTAIN
OUT OF SERVICE
BAD
NEEDS MAINT SOON
NEEDS MAINT SOON
NEEDS MAINT NOW
QUALITY STATUS BLOCK ERROR
OPERATOR
21 21 Successful Implementation & Improved Operation
Commissioning Issues
Physical Layer commissioning.
22 22 Successful Implementation & Improved Operation
AG 181
23 23 Successful Implementation & Improved Operation
Typical problems
Improperly closed housing
Loose wire
Internally modified
Error log showing
intermittent faults
Interoperability testing
by end user
Electro-magnetic interference
Faulty field device Cable degradation Wrong termination
24 24 Successful Implementation & Improved Operation
Need for diagnostics
• Field study by installation and commissioning
Engineers around the world shows that more
than 80% of the plant disturbances come from
the physical layer level be it conventional
4-20mA applications or Fieldbus applications.
• Unless the engineers sufficiently trained for
Fieldbus applications the most common
mistakes are made at the physical layer level
such as wiring faults, wrong termination etc.
25 25 Successful Implementation & Improved Operation
Asset/Resource System Influencers
• Maintenance Cost Reduction Drives End Users
• 40% of Mfg. Cost is Maintenance
• 50% of Maintenance Is Corrective
– 10 times More Costly Than Preventative Maintenance
• Preventative Maintenance is Done 25% of Time
– 5 Times More costly Than Predictive Maintenance
• 60% of Preventative Maintenance is Unnecessary
• What has been largely missing up to now is timely,
relevant, and accurate information
From ARC Independent Research
26 26 Successful Implementation & Improved Operation
Segment
Protectors FieldBarrier
Fie
ld D
evic
es
Fie
ld D
evic
es
Fie
ld D
evic
es
Junction Boxes Terminator Surge
Protec.
Surge
Protect.
Fie
ld D
evic
es
Fieldbus
Process
Interfaces
Complete Interface
Power
Supplies
Surge
protection
27 27 Successful Implementation & Improved Operation
Hazardous safety rules not followed
– Ground faults
– Fieldbus and power
cables tied together
28 28 Successful Implementation & Improved Operation
Poor cable installation
29 29 Successful Implementation & Improved Operation
ANSI recommendation
Communication
Cables
(Fieldbus)
Shielded/Unshielded
Cables Carrying
>60 VDC or
>25 VAC but
<= 400 V
Shielded/Unshielded
Cables Carrying
> 400 V
Any Cables at
risk of
Lighting
Communication
Cables
(Fieldbus)
10 cm
20 cm
50 cm
Shielded/Unshielded
Cables Carrying
>60 VDC or
>25 VAC but
<= 400 V
10 cm
10 cm
50 cm
Shielded/Unshielded
Cables Carrying
> 400 V
20 cm
10 cm
50 cm
Any Cables at
risk of Lighting
50 cm
50 cm
50 cm
30 30 Successful Implementation & Improved Operation
Poor cable installations
– Cable gland not tight
– Seal missing
31 31 Successful Implementation & Improved Operation
And corrosion as a consequence
– Water ingress or worse:
– Aggressive media
32 32 Successful Implementation & Improved Operation
Poor Device Instalation
33 33 Successful Implementation & Improved Operation
Poor maintenance
34 34 Successful Implementation & Improved Operation
Typical locations and Fieldbus issues
35 35 Successful Implementation & Improved Operation
– 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
Commissioning in the Past.
36 36 Successful Implementation & Improved Operation
A portable tool for commissioning, monitoring,
troubleshooting and printout.
Portable Commissioning Tool
37 37 Successful Implementation & Improved Operation
Online Commissioning Tools
38 38 Successful Implementation & Improved Operation
What parameters to look for
– External power
– Fieldbus Output Power
– Fieldbus Segmetn current
– Grounding and shielding
– Communicaiton quality ( jitter) of segment and
devices
– Signal amplitude
– Noise of segment and deivces
– Waveform of the semgent
– Terminators
39 39 Successful Implementation & Improved Operation
Commissioning in the past
– 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
40 40 Successful Implementation & Improved Operation
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! Commissioning Wizard
Test
Report
x
41 41 Successful Implementation & Improved Operation
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
Commissioning now via DCS
42 42 Successful Implementation & Improved Operation
Example - ADM and DCS integration
Diagnostics at
DCS Station
Rela
y c
on
tac
t
op
tio
na
l)
RS485
Industrial Switch
Ethernet
or
FF H1
Address switches
43 43 Successful Implementation & Improved Operation
Example Commissioning via DCS Asset management
PRM Alarm window view
PRM Network view
Segment-specific status of the physical layer
ADM status view with PRM TAG
FF-Segment
FF-Host
44 44 Successful Implementation & Improved Operation
Commissioning Wizard
With Expert System Support – Takes snapshot
– Identifies wiring erros
– Ensures compliance with
AG181 and IEC 61158-2
– Recommends limits for ADM
messages
– Stores limits in non-volatile memory
Automatic Tag Readout
Creates baseline report: – Snapshot of all measurements
– Complete documentation
Saves 80% of pre-commissioning
time
45 45 Successful Implementation & Improved Operation
Online monitoring
Clean layout shows boundaries – Displays measurement values
– Highlights violations with color coding:
– Issues diagnostic messages
Good value
Maintenance required
Out of specification
46 46 Successful Implementation & Improved Operation
Diagnostic Menu
Expert System delivers
clear text information for
fast fault finding 1 Active messages
2 Actionable information
with solution guideance
based on expert system
3 History with timestamps
When the failure… … occured
… disappeared
– Export function for
external analysis and
storage
1
2 2
3
47 47 Successful Implementation & Improved Operation
Built-in fieldbus oscilloscope
ADM provides expert tools
for fast fault finding – For diagnosing complex scenarios
– For the fieldbus expert
– With fieldbus specific triggers
– Captures up to 10 shots in a row
48 48 Successful Implementation & Improved Operation
Bad Wiring
49 49 Successful Implementation & Improved Operation
49
Bad wiring technique
Welding, variable frequency drives (VFD),
Motors, machinery:
Increase of HF noise
Increasing number of retransmissions
Can be a combination of both
50 50 Successful Implementation & Improved Operation
Practical Example
In this example the frequency of noise was
approx. 150Hz
7 ms
51 51 Successful Implementation & Improved Operation
Practical Example
“Make” Disturbance
"Break" disturbance
Vibration
frequency
Trunk signal
Failed telegram
Telegram
52 52 Successful Implementation & Improved Operation
Surge Protection
FIELDBUS
TERMINATOR
SEGMENT
PROTECTORS
HOST
FIELDBARRIERS
PROCESS
INTERFACE
POWER
SUPPLY
CONVENTIONAL
FIELD DEVICES
FIELDBUS
DEVICES
JUNCTION
BOX
But Practically this setup is not
possible due to cost reasons.
Protection at both trunk ends is
more feasible
53 53 Successful Implementation & Improved Operation
Conclusion
– Advanced Diagnostics tools for for physical layer
reduced physical layer commissiong time and
provided online monitoring and reporting system that
saves 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