Automation 2012Automation 2012 - Fieldbus Foundation · Automation 2012Automation 2012 ... Sti S c...

Fieldbus Foundation India CommitteeFieldbus Foundation – India Committee

Automation 2012Automation 2012Fieldbus Foundation“ d i i ldb i h h h ”“Foundation Fieldbus, Easier Than You Thought”

Control ValveControl ValveControl ValveControl Valve“Device diagnostics”“Device diagnostics”

Date: Saturday, 8th September, 2012Time: from 10:00 am to 04:30 pm. Venue: Automation 2012

Conference Hall, Automation 2012, NSE Grounds, Goregoan, Mumbai - INDIA

Presenter :

Hisashi Sasajima

1Automation 2012

Mumbai, India8th September , 2012

Azbil Corporation

C t tContents

I. PrologueII. Possibilities of CV failureIII. CV diagnoses (Three phases with field reports)IV ConclusionsIV. ConclusionsV. Progress beyond conclusionsVI bil l ti f C t l V l i tVI. azbil solution for Control Valve maintenance

2Automation 2012


I. Prologue

Output signal

Valve Position

Hey, Mr. Ashok, something wrong with CV Tag # LIC013. Maintenance is required immediately!

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I P lI. Prologue

M A h k A i d i t iOur system operator tells me something wrong

Mr. Ashok - An experienced maintenance engineery p g g

with this control valve but it is not so easy to find what is the nature of problem.pIf it is clear from the beginning, my work can be much faster and easier Is it just a dream?much faster and easier… Is it just a dream?

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I P lI. Prologue

No, it is not a dream!

We can help you using Fieldbus technology.OK, Mr. Ashok, we are pleased to explain how to do it butbefore let’s think together why control valve is so important?g y p

Because control valve may give:-d t- severe damages onto process.

- bad influences on production and safety of entire plant

Control Valves are the HEART of the plant5

Automation 2012Mumbai, India

8th September , 2012

II P ibiliti f CV f ilII. Possibilities of CV failure

Control valve failure might occur due to:-

Trim part leak Corrosion Stick by process Air leakage Actuator degradationActuator degradation Grand part degradation Others Others

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1 Situation of control valve maintenance1. Situation of control valve maintenance

Repair or part Cleaning

Typical decision method for CV maintenance policy Maintenance

operation

Repair or part replacement

42%

Cleaning

58%

Ploperat

operation

lant tion risk

TBMDisassembly

inspection

TBM:

Result of CV overhaul maintenance

undertaken by azbil service shop

MaintenancePolicy

TBM:

Time Based Maintenance

undertaken by azbil service shop

318 minor troubles were

caused bySpent 830 man/hourPolicy

Proc

BM Daily maintenance

caused by control valve

faultto recover the troubles

cess load

BM

BM:

Daily maintenancewith on- site check

1400 minor troubles / year occurred

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Break-down MaintenanceA case of pulp and paper mill in Japan

III CV di ti (Th h )III. CV diagnostics (Three phases)

Phase-1: Real time diagnoses (online)

Phase-2: Shutdown Maintenance (offline)

Phase 3: Maintenance plan based on historical dataPhase-3: Maintenance plan based on historical data

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III. CV diagnosticsIII. CV diagnosticsPhase-1: Real time diagnoses

D t t “Z Shift Al t”“Z Shift Al t” (POS ALERT LO)Detect “Zero Shift Alert”“Zero Shift Alert” (POS_ALERT_LO)Actual feedback position is +3% (shift) although Set Point goes below 0%

ゼロ点推移

4.000

Graph visualization

1 000

2.000

3.000

%)

-1.000

0.000

1.000

ro d

rift

(%

-3.000

-2.000Zer

-4.000

2006/11/15

2006/11/22

2006/11/29

2006/12/6

2006/12/13

2006/12/20

2006/12/27

2007/1/3

2007/1/10

2007/1/17

2007/1/24

2007/1/31

2007/2/7

2007/2/14

2007/2/21

2007/2/28

2007/3/7

2007/3/14

2007/3/21

2007/3/28

2007/4/4

2007/4/11

2007/4/18

2007/4/25

2007/5/2

2007/5/9

2007/5/16

2007/5/23

2007/5/30

2007/6/6

2007/6/13

2007/6/20

2007/6/27

2007/7/4

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III CV diagnosticsIII. CV diagnosticsPhase-1: Real time diagnoses

Detect “Zero Shift Alert”“Zero Shift Alert” (POS ALERT LO)Initial zero i t l

Mull function of Plug

Detect Zero Shift AlertZero Shift Alert (POS_ALERT_LO)As a result of inspection, accumulated solid around plug and trim was found. Then the valve was cleaned up and safely re-installed to the process

point angle

θ

ゼロ点推移

4.000

Mull function of Pluginstalled to the process.

1 000

2.000

3.000

Sheet damage%) Sudden zero-shift

Stick on plug

-1.000

0.000

1.000 Sheet damage

ro d

rift

(%

Stick on seat

-3.000

-2.000Zer

-4.000

2006/11/15

2006/11/22

2006/11/29

2006/12/6

2006/12/13

2006/12/20

2006/12/27

2007/1/3

2007/1/10

2007/1/17

2007/1/24

2007/1/31

2007/2/7

2007/2/14

2007/2/21

2007/2/28

2007/3/7

2007/3/14

2007/3/21

2007/3/28

2007/4/4

2007/4/11

2007/4/18

2007/4/25

2007/5/2

2007/5/9

2007/5/16

2007/5/23

2007/5/30

2007/6/6

2007/6/13

2007/6/20

2007/6/27

2007/7/4

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III CV di tiIII. CV diagnosticsPhase-1: Real time diagnoses

Summary

• System operators realize some abnormal signals on control valves

• Serious issues should be solved immediatelySerious issues should be solved immediately• Minor issues can be recorded to do overhauling

d i th t h td i tduring the next shutdown maintenance

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III. CV diagnosticsPhase-2: Shutdown Maintenance

Standard diagnosisT h kTo check:-1. Tightness of grand packing2. Position according to air supply

Stroke between 10% and 90% to record relation P

between position and air supply as historical data

Automatically calculates

PositionAutomatically calculatesspring range and friction

n (%)

Supply (kPa)

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pp y ( )System Vender: Yokogawa Electric

III CV diagnosticsIII. CV diagnosticsPhase-2: Shutdown Maintenance

Advanced Diagnoses

Various simulations:-

1 Travel vs Actuator pressure 1 Travel vs Actuator Pressure1. Travel vs. Actuator pressure2. Travel & SP vs. Time3. Actuator signature4 Travel signature

1. Travel vs. Actuator Pressure

Seating , Spring Range ,

4. Travel signature2. Travel & Set point vs. Time

Overshoot , Resolution

3. Actuator Signature

Friction , Spring Range , Pressure

System Vender : GE(Dresser Masoneilan)4. Signature ( travel vs. set point)

Hystersis , Dead band , Linearity

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III CV Di tiIII. CV DiagnosticsPhase-2: Shutdown Maintenance

Summary

Compare data (valve signature, step response and etc.) with those previously collected data so that daily and/or shut-down maintenance can ybe planned efficiently .

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III. CV Diagnostics

A possible damage of bellows seal would be detected by

III. CV DiagnosticsPhase-3: Maintenance plan based on historical data

A possible damage of bellows seal would be detected byTotal_Stroke parameter. (TRAVEL_ACCUM)

This TOTAL_STROKE is as same as 40,000 times full open and full close .

Actual bellows seal after used

System Vender: Azbil

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Replacement period

III. CV DiagnosticsgPhase-3: Maintenance plan based on historical data Example (Chemical Plant-1)

O ti f il f d i ti k liOperation failure was found in stick-slipdiagnostic function of control valve:-

According to index of gland packing deterioration:-1. Detect abnormal sliding motion of plug guide2 Detect plug bend scratch & other mechanical damages2. Detect plug bend, scratch & other mechanical damages

Detect Stick SlipDetect Stick Slip

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III. CV DiagnosticsgPhase-3: Maintenance plan based on historical dataExample (Chemical plant-1)

JJun

Jul

Stick-slip

Stick-slip

Aug

Stick-slip

p movem

en

p movem

en

Stic

S operation h

nt has been

nt has been

ck-slip is no

Sep

has started

n increased

n increased

ot operated

Oct

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d. d. d.

d.

III. CV DiagnosticsIII. CV DiagnosticsPhase-3: Maintenance plan based on Historical data Example (Chemical Plant-2)

Valve Travel Distribution support on Engineering & MaintenanceConfirm if the selected control valve size is appropriate or not by visualizing the stress index of inner valve on the condition of low travel operation

Images visualization

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III. CV DiagnosticsIII. CV DiagnosticsPhase-3: Maintenance plan based on historical data Example (Chemical Plant-2)

Valve Travel Distribution support Engineering & MaintenanceValve opening level is shifting from 20-30 % to 30-40% due to clogging of air filter or CV inner parts. End user can judge that it is the best timing for maintenance.

20-30% 30-40%Images visualization

Boiler

Filter

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T l hi tTravel histogram

The histogram shows how much time the valve is operated in specific segment of valve opening for one month.

FrequencyFrequency

Time0％ 1000％ 100％

Valve opening

Application for control valve diagnostics L tApplication for control valve diagnostics Confirm if the valve sizing is proper or not Find out trend of valve body clogging Estimate erosion of valve plug 12 months ago

2 months ago

Last month

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Estimate erosion of valve plug 12 months ago

III. CV DiagnosticsIII. CV DiagnosticsPhase-3: Maintenance plan based on historical dataExample (Chemical Plant-3)

A possible damage of bellows seal would be detected byTotal_Stroke parameter. (TRAVEL_ACCUM)

Sliding distance value could be applied as a reference value Graph visualizationGraph visualization

High pressure Chlorine gas

Globe valve (Bellows seal type)

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III CV Diagnostics (Three phases)III. CV Diagnostics (Three phases)

Summary

Visualize various conditions of control valve through these analyses and historical data

Plan CV maintenance efficiently according toPlan CV maintenance efficiently according to present conditions of control valve.

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IV C l iIV. Conclusions

• Control valve diagnoses through Fieldbus are valuable . Fieldbus suits for real time notice since the data transmitting speed is much fasterspeed is much faster.

• Offline maintenance with various simulations is useful on data comparison with those collected in the past.

• Condition based maintenance it is important to analyze• Condition based maintenance, it is important to analyze historical data collected through valve positioner. Fieldbus is highly recommended collecting various data on control valve.

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V. Progress beyond conclusionsV. Progress beyond conclusionsa.) Device diagnostics

• Fieldbus Foundation has ever solved users’ requirements to define “Standard Diagnosticrequirements to define Standard Diagnostic Profile” and “Standard Transducer Block”.

• Fieldbus Foundation wishes end users to try and evaluate fieldbus diagnoses more in order toevaluate fieldbus diagnoses more in order to improve functions on the basis of user-friendliness and interoperability.and interoperability.

Continuing Device Diagnostics Continuing Device Diagnostics Enhancements for End Users Enhancements for End Users

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V P b d l iV. Progress beyond conclusionsb.) Fieldbus Foundation works with NAMUR (FF912)

Using the power of FOUNDATION Fieldbus, and considering NAMURrequirements, the new standard diagnostic profile aim to:

Standardize the integration of diagnostic information G t l bl i f ti t th

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Guarantee valuable information to the user

V. Progress beyond conclusionsV. Progress beyond conclusionsc.) NAMUR Recommendation NE107

NE107 “S lf M it i d Di i f Fi ld D i ”NE107: “Self-Monitoring and Diagnosis of Field Devices”

Diagnosis results must be reliable Diagnosis results must be reliable

The diagnosis results must always be viewed in the context of the li iapplication.

Internal diagnosis categorized into 4 standard status signalsInternal diagnosis categorized into 4 standard status signals

Configuration should be free, as reactions to a fault in the device may be very different depending on the user's requirementsmay be very different depending on the user s requirements

The plant operator to see only these status signals

Detailed information can be read out by the device specialist

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NAMUR NE 107 Di ti C bilitNAMUR NE 107 Diagnostics Capability

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V. Progress beyond conclusionsV. Progress beyond conclusionsd.) Device diagnostic alarms (NE107) scope

PlantDiagnostics

Step 4Field

Performance

Device Diagnostics Support Function

d

p PerformanceDiagnostics

Step 3D i

•Device status•Diagnostics to host system

process andequipment

Step 3

Fisher

DeviceDiagnostics

St 2Asset Management

actuators, elementsvalves, connections

Step 2

CommunicationsDiagnostics Device

Management

electronicsStep 1

Management

FF Device Status

communications

Fisher

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Control System

FOUNDATION™ for

Safety Instrumented FunctionsSafety Instrumented Functions

(SIF)

29Automation 2012


SIF End User Demonstration ParticipantsEnd User Demonstration Sites

BP G l ki h G H ll L i S l

SIF End User Demonstration Participants

BP – Gelsenkirchen, Germany – Honeywell Logic SolverChevron – Houston, TX – Emerson Logic SolverSaudi Aramco – Dhahran – Triconex Logic Solver and Yokogawa Logic SolverShell Global Solutions Amsterdam HIMA Logic Solver

EmersonHIMA Logic Solver

Asset Management

Basic ProcessControl System

Shell Global Solutions – Amsterdam – HIMA Logic Solver

Logic Solver

HIMAHoneywell

Invensys - TriconexYokogawa

Logic SolverEngineering Workstation

Management Control System

Level SIF Protocol

ValveMagnetrol

Siemens MilltronicsProtocol

Pres H1 Network BIFFIEmerson

ABBE+HSmar

Moore

Other ProvidersFieldbus Diagnostics

RisknowlogyWestlock

AzbilYokogawa Moore

MTLP+F

RuggedComSofting

TÜV RheinlandTÜV SÜD

TempSmar

30Automation 2012


TempSmar

Control Valve Stroke Test（Partial Stroke Test）

PST CompleteTimeout (Sec)PST Start

PST Break outTime out (Sec) PST

CompletePST Stroke Travel

100

CompletePST Stroke TravelTimeout

(Sec)

Valve Stroke

(%)

PSTStroke Travel (%)

PSTPSTPST(%) PSTPause(Sec)

PSTRumpRate

(%/Sec)

PSTBreak

outTime(S )

0

(Sec)

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Transient Time（Sec）

St d d T d Bl kStandard Transducer Blocks

Pressure Block Completed and in ITK 5.0 Temperature Block Completed and in ITK 5.1 Positioner Block (PST/FST) Completed in in ITK 5.2

N t Bl k• Next Block Flow Transducer with High Performance Totalizer

Validation Complete Publication completed Mar 2011 Validation Complete. Publication completed Mar 2011 Support scheduled for ITK 6.1

PST – Partial Stroke Test; FST – Full Stroke Test

32Automation 2012


St d d T d Bl kStandard Transducer Blocks

Pressure Block Completed and in ITK 5.0 Temperature Block Completed and in ITK 5.1 Positioner Block (PST/FST) Completed in in ITK 5.2

N t Bl k• Next Block Flow Transducer with High Performance Totalizer

Validation Complete Publication scheduled Mar 2011 Validation Complete. Publication scheduled Mar 2011 Support scheduled for ITK 6.1

PST – Partial Stroke Test; FST – Full Stroke Test

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© 2011 Fieldbus Foundation

Device / Host RegistrationDevice / Host Registration

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ITK 6 Test CoverageITK 6 Test Coverage

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FDI Cooperation LLCFDI Cooperation LLCFDI Cooperation LLCFDI Cooperation LLC

Automation 2012Mumbai, India

8th September , 2012

D i I t tiDevice Integration

Commissioning OperationCommissioning

Engineering MaintenanceGeräteintegrationGeräteintegration

GeräteintegrationGeräteintegration

…

Field DeviceAutomation System

With the Device Integration, a Host can get access (from a central location) to the Device functions and information.

With devices getting more complex the device integration becomes a must

37Automation 2012


With devices getting more complex, the device integration becomes a must

A Common ApproachFDI is supported by Manufacturers and Foundations

H i d

Device Package

H i d AdvancedEDDL

Harmonized

HarmonizedEDD

Advanced Features(optional)

EDDL

ABB FDT Group Invensys ABB Emerson Endress + Hauser

FDT Group Fieldbus Foundation HART Communication Foundation

Invensys Siemens Yokogawa

Honeywell OPC Foundation PROFIBUS/PROFINET International

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FDI C ti LLCFDI Cooperation LLC

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T t A i l D i D iTarget: A single Device DriverFDI Device Package StandardFDI Device Package Standard

(mandatory)

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WPF: Windows Presentation Foundation

VI bil l ti f t l l i tVI. azbil solution for control valve maintenance

• Improve the maintenance performance of Control valves in the plant life cycle.Control valves in the plant life cycle.

A) Early detection of

OperationStartup

C) Fast commissioningControl valve abnormalities

ValstafffunctionValstaff

functionfunction

Turnaround Maintenance

ShutdownB) Assistance in reducing valve maintenance costsCV data

41Automation 2012


valve maintenance costsCV data Analysis Service

S t fi tiSystem configuration

PLUG-INDCS

DCS HMI

DCS Device Management

System

DCS Controller Required system environment to use PLUG-IN Valstaff

Case Vender DCS Device Mgt. System

1 A bil H DEO IFO

Required system environment to use PLUG IN Valstaff

1 Azbil Harmonas-DEO IFO

2 Yokogawa CENTUM PRM*AVP 303/203

AVP 302/202

* PRM t b R3 10 l t t i t ll PLUG IN V l t ff

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* PRM must be R3.10 or later to install PLUG-IN Valstaff.

Fast commissioning Automated CV step response test

Step response test for 42 CVsSt tt SP Step response test for 42 CVs

With IFOConventional methodStep pattern SP

Completed in 45 minutes

Valve travel

Require 2 persons for 8 hours.

Visualize CV motion abnormalityVisualize CV motion abnormality

By comparing with the past test resultthe past test result on millisecond level.

43Automation 2012


A. Certain and fast commissioninggLoop check progress status

• Grasp the progress status of loop check work at a glance• Grasp the progress status of loop check work at a glance.– Visualize devices which are not completed loop check.

Check itemsList of field device

接続確認

Checked date and time ＋ the result: OKChecked date and time ＋ the result: not OK

44Automation 2012


No check

B. Early detection of the field device problemsy pa. Device status monitoring 365 days/yr, 24 hours/day

Retrieval condition of device alert historyy

Retrieval and filtering condition for d i i di ti

Segment1Segment1

device indication

List of device

Segment2Segment3Segment4Segment5


List of device alert history

Device Tree Segment6Segment7Segment8

Segment6Segment7Segment8

Device Tree

45Automation 2012


Full-time monitoring to all devices

B. Early detection of the field device problemsa. Device status monitoring 365 days/yr, 24 hours/day

• Grasp the status of all devices at a glance G asp e s a us o a de ces a a g a ceSegment1

Segment2Segment3Segment4Segment5Segment6Segment6Segment7Segment8

Symbols of device status recommended by NAMUR NE 107 Full-time monitoringNAMUR NE 107 Full time monitoring

to all devices

46Automation 2012


B. Early detection of the field device problemsa. Device status monitoring 365 days/yr, 24 hours/day

• If the symbol shows abnormal status, confirm the detail ystatus and device parameters without going out into the plant field.

Segment1Segment1


Segment2Segment3Segment4Segment5Segment6Segment7Segment8

Segment6Segment7Segment8

47Automation 2012


B. Early detection of the field device problems

• Configure/calibrate field

a. Device status monitoring 365 days/yr, 24 hours/day

• Configure/calibrate field devices in the control room.Support multi vender• Support multi-vender devices by using FDT/DTM technologiestechnologies.

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Thank you for your attention!!Thank you for your attention!!

Hisashi SasajimaA bil C tiAzbil Corporation

“Human centered automation”

49Automation 2012


Human-centered automationURL http://jp.azbil.com

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