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Copyright Industrial Automation Networks Inc. - 2013
How Good Are Your Numbers?
Ian Verhappen
Director, Industrial AutomationNetworks Inc.
About the Presenter – Ian Verhappen
• P.Eng. ISA Fellow, ISA CAP
• Industrial Automation Networks Inc
– Field level networks (buses & wireless) and process analyserengineering consulting firm
• MTL (2006 – 2009)
– Responsible for all digital communications products– Responsible for all digital communications products
• 20 years in the oil sands /mining industry with SyncrudeCanada Ltd.
• Past Vice-President ISA Standards & Practices Dept. Vice-President Strategic Planning Dept.– Past Director ISA Analysis and ISA Communications Divisions
• IEC TC65, SC65B, SC65E Chair for Canada
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The Problem
Too much data No information
Where do we want to be?
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Getting from Problem to Solution
Real Time EquipmentHealth DataHealth Data
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MicroprocessorsMicroprocessors
MobileInfo
Devices
Static InfoAppliances
1.4billion*
1.0billion*
Mobile ITAppliances,Telephony &Terminal DevicesWill BecomeIntegrate IntoSystems ThatInclude Signals &Data FromSensors, Machines
Mobile Phones,Smart Phones,Notebooks MobileTerminals Tablets,Media Players
Desktop PCsServers/StorageRouters/Switches/GatewaysPrinters/ImagingGame/Media Equipment & Players
Intelligent Device Hierarchy - 2010
Source: Harbor Research, Inc.
* 2010 IT-Centric Device Shipments ** 2010 Machine-Centric Device Enablement Potential
Appliances Sensors, Machines& Equipment
Consumer/CommercialVehicles Off-Highway VehiclesAir/Rail/Transit/MarineNavigation SystemsMobile Healthcare Devices
Building EquipmentRetail/Vending/POS/ATMsIndustrial MachineryHealthcare EquipmentPower Distribution EquipInfrastructureEquipmentControllersSensors,InstrumentsMetersMicroprocessorsMicrocontrollers
Approximately 130Million Machine-Centric DevicesExpected To BeIntegrated in 2010
20 billion To Avoid DoubleCounting, EmbeddedComponents Are A Sub-Set Of The OverallOpportunity
MobileDevices
StaticDevices
EmbeddedDevices
.25Billion**
5billion**
Game/Media Equipment & Players
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Diagnostics Examples
Generic
• Watchdog timer
• Temperature
• BIOS check on startup
Automation Specific
• Sensor failure– Thermocouple failure
– Impulse line plugging• BIOS check on startup
• Battery
• Memory
– pH probe fouled
• Communications Error– No acknowledgment from
“next” device
Ambient ConditionsAmbient Conditions
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Power Quality
• Ground loop errors
• ‘Noise’
– ElectromotiveInterfence (EMI)Interfence (EMI)
• Cable spacing
– Radio FrequencyInterference (RFI)
• Low voltage orCurrent
– Too long cables
Temperature
• Maximumtemperature ≈60 oC
– Heating effect ofelectronicselectronics
• Minimumtemperature (- 50oC)
– Cold start-up
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Humidity
• Condensation
– Plugged vents &drains in enclosure
– Improperly poured– Improperly pouredseals
• Instrument Air
– Ambient temperaturechanges
Status InformationStatus Information
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Maintenance Alerts
• Valves
– Cycles, distancetravelled, air supplypressurepressure
• Estimate ofremaining time tofailure
– Schedule repairappropriately
Control Loops
• Status signal
– Good, bad,uncertain,maintenancemaintenance
• Only control offgood / validinformation
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Electronic Device DescriptionLanguage (EDDL)
• Basis for smart devices in process industryHART
HARTCommunicationsFoundation
IEC 61804-3IEC 61804-4
FDI work beginswith IEC
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90
19
93
Foundation
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96
FoundationFieldbus
20
00
Profibus
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04
20
11
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14
FDI Specification& Products
Data IntegrationData Integration
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StandardsStandards
ISA-95.00.03 4-Layer Model
Business Planning &Logistics
Plant Production, Scheduling,Operational Management, etc.
Level 4 4 – Establishing the basic plant schedule –production, material use, delivery, andshipping. Determining inventory levels.
Time frame: Months, weeks, days
Manufacturing OperationsManagement
Dispatching Production, DetailedProduction Scheduling, Reliability
Assurance
Level 3 3 – Work flow / recipe control to produce thedesired end products. Maintainingrecords and optimizing the productionprocess
Time frame: Hours, Minutes, SecondsAssurance
Time frame: Hours, Minutes, Seconds
2 – Monitoring, supervisory control andautomated control of the productionprocess.
Time frame: Hours, Minutes, Seconds, subseconds
Level 2
1 – Sensing the production process,manipulating the production process
Level 1
0 – The actual production processLevel 0
BatchControl
Continuous
ControlDiscreteControl
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ISO 18435 Application DomainIntegration Diagram
A4.2 – Inter-enterprise activities: Supply ChainPlanning, Logistics Strategy
A3.1 – Operations Planning& Scheduling
A3.2 – CapabilityAssessment & Order
Fulfillment
A3.3 – MaintenancePlanning & Scheduling
A2.1 – Supervisory Control A2.2 – Asset Prognostics andA2.3 – Maintenance
Level R4Enterprise/Site
Level R3Area
Level R2
A4.1 – Intra-enterprise activities: BusinessPlanning, Orders & Production and
Maintenance
Assets(Equipment/Facilities, Serialized
components / Sensors / Transducers / Software /Documents)Resources (Material /Personnel)
A2.1 – Supervisory Control& Human Machine
Interface
A2.2 – Asset Prognostics andHealth, Quality, Safety &
Environment Management
A2.3 – MaintenanceExecution & Tracking
A1.3 – AssetConfiguration, Calibration
& Repair / Replace
A1.2 – Asset ConditionMonitoring & Sample / Test /
Diagnostic & Quality Monitoring
A1.1 – Control, I/O DataAcquisition, Data Historian,Asset Utilization & Displays
A0.1 – Resource Identification and Location A0.2 – Asset Identification and Location
Level R2Work Center
Level R1Work Unit
Level R1Asset
Intelligent Device Management Interactions
CMMS
Intelligent Devices
Work Orders
DCS Host
CMMS
Plant AssetManagement System
EventHistorian
Alarm ManagementSystem
ConfigurationDatabase Reporting &
Analysis
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Data FlowData Flow
Alarm Management Lifecycle• ANSI/ISA-18.2-2009
• Includes practices for newfacilities and existingplants
• Includes practices to solvethe common alarm
Philosophy
Rationalization
Identification
Detailed Design
Managementof Change
D
C
A J
B I
Philosophy
Rationalization
Identification
Detailed Design
Managementof Change
D
C
A J
B I
the common alarmproblems
• Builds on the work of ASMand EEMUA
• Documents what isrequired andrecommended , but nothow to do it.
ASM = Abnormal Situation Management Consortium
EEMUA = Engineering Equipment and Materials Users’ Association
Monitoring &Assessment
AuditDetailed Design
Implementation
Maintenance
Operation
E
G
HF
Monitoring &Assessment
AuditDetailed Design
Implementation
Maintenance
Operation
E
G
HF
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Industrial Ethernet Application Protocols
Protocol SponsoringOrganizations
TargetApplications
TransportLayer
ApplicationLayer
EtherNet/IP ODVA, Control-NetInternational, RockwellAutomation, Omron,
Any discreteor hybridmanufacturing
TCP and UDP Control andInformation Protocol(CIP)
FoundationFieldbus-HSE
Fieldbus Foundation Process control UDP Fieldbus FunctionBlocks
IDA-Modbus IDA Group, Schneider, Discrete TCP IDA Object modelIDA-Modbus IDA Group, Schneider,Jetter, Sick, Kuka,Phoenix Contact
Discretemanufacturingespecially motioncontrol
TCP IDA Object model
(Modbus/TCP)
PROFInet Profibus International ComplexMachinery
UDP, TCPplusproprietary
DCOM, PROFI-netObject Model
Source: ARC Advisory Group 2003
eXtensible Markup Language (XML)
• Language used totransfer betweenbusiness systems
– Used by ISA95– Used by ISA95(B2MML)
– Mimosa
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CybersecurityCybersecurity
Open Systems
Risks
• Easier to ‘attack’– Same vulnerabilities as
office environment
Rewards
• Lower cost
• Increased supportavailableavailable
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Regulations
• NERC
– North AmericanElectric ReliabilityCouncilCouncil
• ISA99/IEC 62443
– Cybersecuritystandards
• DHS
– Useful links and tools
Defence in Depth - Zones and Conduits
Copyright © ISA
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ProactiveMaintenanceMaintenance
Asset ManagementAsset Management
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Standalone systems
• Most commonlyused
– Stranded data
Instrument Management Systems
• Real time datacollection fromsmart devices
• Heuristics to aid in• Heuristics to aid ininterpretation,generate workorders
• “Island” of expertise
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System Information ArchitectureSupply ChainManagement
Supply ChainManagement
Enterprise ResourcePlanning (ERP) System
E-commerceMaintenance
Repair &Operations
(MRO)
EnterpriseAsset
Maintenance (EAM)System
Plant AssetManagement
(PAM)System
PlantAutomation
System
Process Control &Process Management
Maintenance Work &Parts Management
Asset AdvisoryManagement
MaintenanceAdvisories
PurchaseorderProcess Advisories
(MRO)Procurement
System
SystemCMMS
SystemSystem(PAS)
ControlParameters Control
Data
Asset Collaboration /Tolerances
Transducer Config.Monitoring Set-upInspection Routes
Asset UsageData
Asset MonitoringVariablesAsset Calibration /Tolerance Data
Control DeviceMonitoring
Portable DeviceMonitoring
Survey On-Line Monitors
ProtectionOn-LineMonitors
TransientOn-Line Monitors
SampleMonitoring
Smartvalves& FieldDevices
PLC /DCS
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Pro
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sOperationField
Report
SmartMachines &Transducers
Plant Measurements / Inspections
OrderTrackingWork HistoriesProcess Events
& Data
Data MiningData Mining
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Data Capture
• What to capture and where
• Experience is retiring
– Fewer ‘experts’ available
Inferential Data
• Information frompatterns in datareceived
– Identify anomaly not– Identify anomaly notmeasured directly
• Bad sensor
• Vessel fouling
• Loop tuning
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Trends Tell All
• Need forMaintenance isbased on changesover timeover time
Work PracticesWork Practices
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Culture Change
• Knowledge = Power
– Difficult to release
• Big Brother
– Watching /spying– Watching /spying
• Fewer ‘Smarter’workers
Getting Help
• Outsource
– Remote assistance• ‘Dial in’
• Send formatted files• Send formatted files
• Training
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NAMUR NE 129: The Asset HealthTriangle
StrategicAsset
Management
EquipmentStandardization
RAM
Life CycleAnalysis
VendorReliability
RCM
Stage 4
Reliability Engineering
Stage 5
Operational Excellence
CraftFlexibility
OPM
Maintenance /Operations Integration
ExternalBenchmarking
Asset Strategies/ SRCM
FailureAnalysis
Asset Integrity
Craft SkillsEnhancement
EquipmentHistory
Condition BasedMaintenance
ManagingSystem
CMMS /Metrics
PreventativeMaintenance
Planning &Scheduling
TurnaroundManagement
Work Identification/ Prioritization
Work ExecutionReview
Stage 3
Organizational Excellence
Stage 2
Proactive Maintenance
Stage 1
Planned Maintenance
There is Incentive to Change.
Are you ready to invest in the future?
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Useful Reference Documents
“Foundation Fieldbus” 4th EditionIan Verhappen & Augusto PerieraPaper:http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm&ProductID=11959E-pub:http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm&ProductID=12461Mobi:Mobi:http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm&ProductID=12451
Questions & Contact Information
Ian VerhappenIndustrial Automation Networks Inc.53 Inverness Lane SE53 Inverness Lane SECalgary, AlbertaCanada T2Z 2Y3+1 403 829 [email protected]://www.industrialautomationnetworks.com