Commissioning issues and solutions - Fieldbus · Commissioning issues and solutions Arasu Thanigai...

1 1 Successful Implementation & Improved Operation

Commissioning issues and

solutions

Arasu Thanigai

Pepperl+Fuchs Pte Ltd

Singapore

Fieldbus Foundation Seminar Jakarta - 23rd May 2012


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


4~20mA Install the Cables


Install the Devices


Install the DCS

Assigning the I/O


Ranging


System Ranging


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.


4~20mA

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




Install the Devices


Install the DCS

Assigning the I/O


Ranging


System Ranging






• Install the DCS



• Ranging


• System Ranging




4~20mA

Foundation Fieldbus

4-20mA

P.S.

fieldbus

P.S.

Test

Report

Distance and connection Quantity

Tools

Checking of cable installation.




Install the Devices


Install the DCS

Assigning the I/O


Ranging


System Ranging






• Install the DCS



• Ranging


• System Ranging




Install the Device

Distribution

Block

Cable

Power supply

/ Conditioner

Foundation Fieldbus

Host

FF field

devices




Install the Devices


Install the DCS

Assigning the I/O


Ranging


System Ranging






• Install the DCS



• Ranging


• System Ranging




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.




Install the Devices


Install the DCS

Assigning the I/O


Ranging


System Ranging






• Install the DCS



• N/A

• N/A

• N/A

• N/A



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


4~20mA

Foundation Fieldbus


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


Why Foundation Fieldbus


Commissioning Issues

Fieldbus Device Commissioning

Physical Layer commissioning.


Lower Cost & Faster

Traditional: 2 hours / device for

2 technicians

(Calibration) – Attach device

– Verify 4-20 mA signal • five points

– Verify link to control strategy

– Check device parameters with

handheld

Foundation fieldbus: 25

minutes / device for 1

technician (Remote) – Attach device

– Drag-and-drop

commissioning wizard

– Compare configuration

faster on computer

•Devices are

auto-recognized

•Devices are

auto-addressed

•Devices identify

themselves

Plug-n-Play

Only FF has

automatic

addressing


Fieldbus Maintenance Made Easy: Device Commissioning Wizard


Fieldbus Maintenance Made Easy: Protective Decommission

Removing device in

an orderly fashion – “Safely remove

hardware”

Temporary removal – To remove for

calibration etc. with

intention to put back

into same place soon

after

Permanent removal – To remove for

replacement etc.

Control-in-the-field

does not mean just

“simple” PID


Easier FF Device Commissioning and Replacement

Commission or replace

device without touching

the software

System automatically logs

process in background

Automatic

configuration

reconciliation

with device

database

Automatic

configuration

download

View details in

historian and

log


Common issues

Check DD file

Check ITK version

Check if HIST done

Check if the device listed at www.fieldbus.org

http://www.fieldbus.org/


How to Check


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


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


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


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


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


Intelligent Field Devices - A Rich Source of Diagnostics


Commissioning Issues

Physical Layer commissioning.


Fieldbus Life Cycle Benefits

Plan and Installation Reduction in cost for wiring, barrier, marshalling rack and Junction box Reduction in cost for control system - I/O interface Reduction in cost for power supply unit and number of cabinets Reduction in control room size

Operation Increased information for better operation Improved accuracy of measurement & control Enhancement in control function and the performance Fewer Process Upsets ( Reduced Emmissions) Improved throughput (Sustained Operations, Increased PM interval)

Maintenance and Improvement On-line diagnosis enables true preventive maintenance.( Increased

Reliability) Reduction of instrument stock for maintenance (Man-hour reduction in

Maint.) Increased Asset Intelligence Methods to Enhance Variable cost

Management

Installation Operation Maintenance Improvement Plan


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


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.


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


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


Commissioning issues

• Simple wiring checks and validation tools

From ARC Independent Research


– 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.


A portable tool for commissioning, monitoring,

troubleshooting and printout.

Portable Commissioning Tool


Online Commissioning Tools


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


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


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


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


Example Commissioning via DCS Asset management

Diagnostics at

DCS Station

Rela

y c

on

tact

op

tio

nal)

RS485

Industrial Switch

Intrinsically Safe

High power Trunk

23V,

360mA

Advanced Diagnostics



PRM Alarm window view

PRM Network view

Segment-specific status of the physical layer

ADM status view with PRM TAG

FF-Segment

FF-Host



Diagnostic Bus

FF H1

Ethernet to RS-485

converter DeltaV

Power Hub

with ADM

Diagnostic

Manager

AMS

Suite



FieldConnex

Diagnostic Server

Diagnostic Manager

AMS Alert

Adapter AMS Alert

Monitor

Commissio

n Monitor

Diagnose

Summar

y

Alarms

communicate



Physical Layer

Message

Single-Click launch

to view all details


Diagnostic Bus

Up to 62 modules

Fieldbus

Diagnostic Server

FDS

Ethernet

RS 485 COM-Converters

Fully integrated

Local on same PC or

Remote via Ethernet / Web / TCP/IP



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


Online monitoring

Clean layout shows boundaries – Displays measurement values

– Highlights violations with color coding:

– Issues diagnostic messages

Good value

Maintenance required

Out of specification


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


Online trending and history

Monitoring – Reveals long term changes

– Exports into many formats


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


Bad Wiring


54

Bad wiring technique

Welding, variable frequency drives (VFD),

Motors, machinery:

Increase of HF noise

Increasing number of retransmissions

Can be a combination of both


Practical Example

In this example the frequency of noise was

approx. 150Hz

7 ms


Automated Pre-commissioning Saves Time

Case Study with cost comparison for pre-

commissioning: – 4…20 mA

– Fieldbus

– Fieldbus with Advanced Diagnostics

Case Study – Specifications

Number of instruments 1,200

Number of segments 100

Instruments per segment 12

Hours per work day 8 hours

Mean time to repair (MTTR) a

fault

4 hours

Pre-commissioning is

defined as work steps taken

to install and validate the

hardware configuration and

the physical layer.

Source: Fieldbus Testing with Online Physical Layer Diagnostics

Technical White Paper available from Pepperl+Fuchs Part No: 198636



Task 1 of 2 Model 4-20 mA

Fieldbus

without

diagnostics

Fieldbus with

Advanced

Diagnostics

Constructional checks:

Time/Unit 5 min 10 min Not required

Units 1200 loops 100 segments Not required

Total Time 12½ days 2 days 0

Construction failures (1%):

Time/Unit 4 h MTTR 4 h MTTR Not required

Units 12 loops 1 Trunk,

12 Spurs Not required

Total Time 6 days 6 ½ days 0

Source: Fieldbus Testing with Online Physical Layer Diagnostics

Technical White Paper available from Pepperl+Fuchs Part No: 198636



Tasks 2 of 2 Model 4-20 mA

Fieldbus

without

diagnostics

Fieldbus with

Advanced

Diagnostics

Pre/commissioning

instrument checks:

Time/Unit 10 min 60 min 8 min

Units 1200 loops 100 segments 100 segments

Total Time 25 days 12½ days 1.6 days

Pre/commissioning failure:

Time/Unit 4h MTTR 4h MTTR 4h MTTR

Units 0.5% =

6 loops

0.5% =

1 segment

1.5% =

2 segments

Total Time 24 h =

3 days

4 h =

½ day

8 h =

1 day

Totals 46.5 days U 21.5 days U 2.6 days U


Conclusion – Physical Layer

– 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


60

Future is Digital

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