Realizing the Potential of Intelligent Device Management

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Understanding the value that intelligent devices and digital diagnostics brings to the world of process automation

Understanding the value that intelligent devices and digital diagnostics brings to the world of process automation

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  • The core of FDI Technology is the scalable FDI Package. The FDI Package is a collection of files: The Electronic Device Description (EDD), includes the device definition (Def), business logic (BL) and user interface description (UID). It is based on Electronic Device Description Language (EDDL, IEC 61804-3). The optional user interface plug-in (UIP) offers the advantages of freely programmable user interfaces familiar from FDT, based on Windows Presentation Foundation (WPF). The device manufacturers define via the FDI Device Package which data, functions and user interfaces are stored on the FDI Server.The device definition describes the field device data and the internal structure (e.g. blocks). The business logic primarily ensures that the device data remain consistent, e.g. refresh data when unit is changed. The dynamic dependencies, in particular, play a part here, e.g. options and ranges that depend on prior selection of other settings like only show temperature units if temperature value is chosen, or only display custom settings if custom probe is selected. User interface descriptions and user interface plug-ins define the field device user interfaces. Product documentation, protocol-specific files, such as GSD or CFF, etc. will all be added to the FDI Package as attachments. In the FDI technology, EDDL is largely harmonized and standardized across the protocols. A uniform EDDL is the foundation for uniform multiprotocol FDI Package development tools (FDI IDE), and uniform host components, such as EDD Engine (interpreter) and the client-side components UID Renderer and UIP Hosting. The result is sustainable strengthening of the key factors interoperability and quality. At the same time, cost savings can be achieved for device and system manufacturers, fieldbus organizations and, last but not least, end users. FDI has defined a single protocol independent encoded file format for the EDD part of the FDI Package.

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  • 1. 1 Automation 2013 Mumbai © 2013 Fieldbus Foundation Digital Doesn‟t Mean Intelligent: Realizing the Potential of Intelligent Field Device Management
  • 2. 2 Automation 2013 Mumbai © 2013 Fieldbus Foundation • It‟s a Digital World, but what does that really mean? • The prize is significant, but we are not using digital instrumentation to its full potential • How can we realize this potential? What are the obstacles?
  • 3. 3 Automation 2013 Mumbai © 2013 Fieldbus Foundation • 18 Years with ARC Advisory Group as a Process Automation Market Analyst • 3 Years with Fieldbus Foundation as Global Marketing Manager • Focus on DCS, Instrumentation, Field Networks, Process Safety
  • 4. 4 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Dedicated to Stewardship and Advancement of FOUNDATION Fieldbus Digital Protocol & Automation Infrastructure • Over 350 Member Companies • Strong Regional and Local Marketing Committees and End User Councils
  • 5. 5 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Digital Devices are Everywhere • The Rise of Cyber Physical Systems • Why we Cling to Analog Thinking in a Digital World
  • 6. 6 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Intelligent Field Device: Microprocessor-based field device or control valve/actuator/positioner that also utilizes a bidirectional digital communication protocol to provide information to plant systems. • Field Communication Protocols for Process Automation: FOUNDATION fieldbus, HART, Profibus PA. • Intelligent Device Management: Turning the diagnostic data from intelligent field devices into useful information, which is available to applications and end users as it is required, when it is required.
  • 7. 7 Automation 2013 Mumbai © 2013 Fieldbus Foundation Source: ARC Advisory Group Global Installed Base of All Field Devices by Smart vs. Conventional: 2011
  • 8. 8 Automation 2013 Mumbai © 2013 Fieldbus Foundation Source: ARC Advisory Group
  • 9. 9 Automation 2013 Mumbai © 2013 Fieldbus Foundation Source: ARC Advisory Group • Market for FOUNDATION fieldbus products (excluding EPC and system integrator services) exceed $1 billion in 2012. • The installed base of FOUNDATION fieldbus systems and devices is over $6 billion • Celebrating 20 years in 2014! Market for Digital Fieldbus Products and Services (Source: ARC Advisory Group)
  • 10. 10 Automation 2013 Mumbai © 2013 Fieldbus Foundation Mainframe computing (60s – 70s) Large computers to execute big data processing applications Desktop computing & Internet (80s – 90s) One computer at every desk to do business/personal activities Ubiquitous computing (00s) Numerous computing devices in every place/person Millions for desktops vs. billions for embedded processors Cyber Physical Systems (10s) Source: Introduction to. Cyber Physical Systems. Yuping Dong. Sep. 21, 2009
  • 11. 11 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Cyber Physical System is a system featuring a tight combination of, and coordination between, the system‟s computational and physical elements. • CPS uses computations and communication deeply embedded in and interacting with physical processes to add new capabilities to physical system. • Convergence of computation, communication, and control Source: Introduction to. Cyber Physical Systems. Yuping Dong. Sep. 21, 2009 CPS Sensors Equipment People Safety Software Control
  • 12. 12 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Process field devices are becoming computers unto themselves • The old hierarchy of workstations, controllers, networks, field devices, and final control elements is collapsing • CPS means that process automation systems will be increasingly connected to other systems in the plant and enterprise • CPAS – Collaborative Process Automation Systems – are the result Source: ARC Advisory Group
  • 13. 13 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Despite their large installed base, not many companies are actually using the diagnostic information from their intelligent devices to improve their operating performance • Plant Asset Management workstations collecting dust • Users complain they aren„t getting the benefits, but why is this? • “An estimated 85% of all installed HART devices are not being accessed to deliver device diagnostics information with only the Process Variable data communicated via the 4- 20mA analog signal.” – HCF Web Site Stranded Diagnostics
  • 14. 14 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Entrenched work processes: Our fundamental maintenance processes have not changed much since the 1950s. • The installed base: According to ARC, the installed base of process automation systems reaching the end of their useful life is $65 billion. Most of these are 20 years old or older. • The workforce: Many workers are entrenched in existing work processes and analog technology
  • 15. 15 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Largest Fieldbus installation in the world is at Jamnagar Refinery • Over 30K Fieldbus Devices, Thousands of Segments, with Capacity Set to Double! • Device Diagnostics Used Heavily! • As close to Flawless Project Execution as you can Get! • A Global Effort in Project Management
  • 16. 16 Automation 2013 Mumbai © 2013 Fieldbus Foundation • The Economic Impact of Intelligent Devices • Why You Need a Strategy for Intelligent Device Management • Understanding Diagnostics • The Importance of Work Processes and Ownership
  • 17. 17 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 18. 18 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 19. 19 Automation 2013 Mumbai © 2013 Fieldbus Foundation 10-15 percent 20-40 Percent 20-40 Percent “Saves” Reduced Unplanned Shutdowns
  • 20. 20 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 21. 21 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Source: ARC Advisory Group - 6 0 - 4 0 - 2 0 0 2 0 4 0 U npla nned Brea kdow ns Inventory Costs D ow ntim e D efects Equipm ent Life W orkforce Efficiency Equipm ent Productivity % Im provem ent vs Tra ditiona l M a intena nce - 6 0 - 4 0 - 2 0 0 2 0 4 0 U npla nned Brea kdow ns Inventory Costs D ow ntim e D efects Equipm ent Life W orkforce Efficiency Equipm ent Productivity % Im provem ent vs Tra ditiona l M a intena nce
  • 22. 22 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 23. 23 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 24. 24 Automation 2013 Mumbai © 2013 Fieldbus Foundation With device management software • Source: Emerson Process Management
  • 25. 25 Automation 2013 Mumbai © 2013 Fieldbus Foundation A Broad Mix of Applications can Benefit from Intelligent Device Data
  • 26. 26 Automation 2013 Mumbai © 2013 Fieldbus Foundation A Broad Mix of Applications can Benefit from Intelligent Device Data
  • 27. 27 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Diagnostics can be a valuable tool that can help save you time and money and avoid unplanned shutdowns. • Diagnostic data can be vague and require a lot of digging to get to the root cause. • Diagnostic data can also provide you with avalanche of useless information that can grind your process to a halt. • Not all technologies handle diagnostic information the same way. • Trick is to get only the right information, at the right time, to the right people.
  • 28. 28 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Doesn‟t tell you what‟s wrong • No predictive guidance • Is it a process problem or device problem? • Sensor problem? Electronics problem? Who knows?
  • 29. 29 Automation 2013 Mumbai © 2013 Fieldbus Foundation Sensor includingprocessconnectionandsensor electronic Instrument Electronic Configuration e.g.Linearization Process Process/ Environment Information Root Group Information Root Group Instrument Process/ Environment Sensor Electronics Configuration Process
  • 30. 30 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 31. 31 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Certain diagnostic anomalies expressed in multiple field devices can indicate an anomaly or impending abnormal situation in the process.
  • 32. 32 Automation 2013 Mumbai © 2013 Fieldbus Foundation Sample Diagnostic Parameters of a FOUNDATION Fieldbus Flowmeter
  • 33. 33 Automation 2013 Mumbai © 2013 Fieldbus Foundation Definition of NE 107 Status Signals
  • 34. 34 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 35. 35 Automation 2013 Mumbai © 2013 Fieldbus Foundation
  • 36. 36 Automation 2013 Mumbai © 2013 Fieldbus Foundation Yes No No No No Yes Yes Yes Major Work Process Tasks for: 2.0 Execute Daily Proactive Maintenance (Unit) Work Process Owner: Instrument Technical Discipline Network (ITDN) WHO Input Responsible Organization or Individual Work Process Analysis Output Instrument Specialist CSE/ Inspector Maintenance Planner Maintenance Coordinator / Team Leader Technician Ops T/A Manager OMC MOC Request T/A Work List Item (CMMS) 2.1 Assign Daily PM Work Order b2.5.1 Emergency Priority? Device Alarm/Alert Report 2.9 Order Parts/ Service and re- plan d PM Work Order LEGEND Start or End Task Decision a Connector 1 Metric / Control Point Embedded External Work Process LEGEND Start or End Task Decision a Connector 11 Metric / Control Point Embedded External Work Process 2.6.2 Enter notification in CMMS (Documents status in Log) Work Request (CMMS) b Repaired Equipment 2.3 Select Next Priority Item (from A/A List and A/A Report) 2.4 Secure Work Permit 2.5.2 Determine Urgency, Enter notification into CMMS (e-Ticket) and communicate priority to OMC for appropriate Action. (Technician documents status in log) CMMS Condition History* c DCS 2.6.1 MOC or Mitigation Required? 2.7.1 Parts/ Service Available? 2.7.2 Repair and Enter Notification to capture history (Documents status in Log) 2.10.1 Daily PM Complete? 2.8 Enter Notification in CMMS (Documents status in Log) c c 2.10.2 Update Maintenance Coordinator / Team Leader and Closeout PM Work Order d b a a NOTE: An Excel Spreadsheet that records status of all actions taken by Alarm/Alert will be maintained in Log until the Site has implemented Level 5 CMMS Original Issue Date: Aug 10, 2006 Last Revision: Revision Date: Dec 31, 2011 Rev 1.3 b 3 2.2 Obtain Daily PM & A/A report
  • 37. 37 Automation 2013 Mumbai © 2013 Fieldbus Foundation • The Integration Dilemma • The Importance of Adopting Open Standards • Train, Train, Train
  • 38. 38 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Historically there have been multiple integration technologies for intelligent field devices • EDDL, FDT/DTM, OPC, etc. • FDI is a current industry effort that will unify device integration technologies and make things easier for users and suppliers
  • 39. 39 Automation 2013 Mumbai © 2013 Fieldbus Foundation Device Package EDD FDI encoded file format UIP (optional) Attach- ments Electronic Device Description Language (EDDL) Windows Presentation Foundation (WPF)  Device Definition (Def)  Business logic (BL)  User Interface (UID  Programmed User Interface  Device Applications  Manuals  Certificates  Protocol specific Files (GSD(ML), etc.)
  • 40. 40 Automation 2013 Mumbai © 2013 Fieldbus Foundation • OPEN standards are continuously subject to scrutiny, review and improvement • OPEN standards and specifications are publicly available can be purchased by anyone • OPEN standards have better security • OPEN standards can adapt to new technologies and market dynamics • OPEN standards make it easier to test and register devices and host systems
  • 41. 41 Automation 2013 Mumbai © 2013 Fieldbus Foundation  Many sources of training are available in the marketplace  Very few are audited and certified to ensure that they adhere to a set of standards  You will need more than a two day course or online video  We are serious about training! Eight certified centers with one in India soon to come.
  • 42. 42 Automation 2013 Mumbai © 2013 Fieldbus Foundation • Adopt an Intelligent Device Management Philosophy • Take an intelligent approach to managing diagnostics • Start early • Appoint a champion to manage the IDM processes • Get the right work processes & train your people • You can be successful! The Prize is significant!
  • 43. 43 Automation 2013 Mumbai © 2013 Fieldbus Foundation