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Fieldbus Foundation – A Way Forward


                                     Advance Plant
                                      Management
                                      Module in FF
                                    Controlled Process
                                        Industry
                                                       Jasbir Singh
                                                       Essar Oil Ltd
                 2008 FFIMC - Automation 2008-Mumbai
1

                                                                 © 2008 Fieldbus Foundation
ROI – Improvement

                                 Increase ROI

    Reduce Capital Cost                                    Increase Profitability


                                                                           Increase Revenue
                       Reduce conversion Costs

                                                    Increase Productivity           Reduction of losses

                                                                                          Reduced
                                                              Increased
        Reduced
                                 Reduced                                           Unscheduled Downtime
                                                                 Yield
     Project Capital
                               Feed stocks                                           & Small stoppages
                                                               Product
      Installation &
                            Energy and Utilities                                     Planned Shutdowns
                                                             Consistency
     Commissioning
                               Maintenance                                         Low Maintenance time
                                                             New product
          Cost
                                  waste                                             Optimize Maintenance
                                                          Equipment Capacity
       Warehouse
                             Abnormal Events                                             Resources,
                                                           Equip. Efficiency
       Inventory /
                            Low grade product                                       Minimum Spare parts
         Spares
                                Penalties                                                Inventory,
      Product mix/
                                                                                    Reliable Maintenance
       Feed stock
                                                                                           history
                                     2008 FFIMC - Automation 2008-Mumbai
2

                                                                                          © 2008 Fieldbus Foundation
PM Plan for time base proactive maint.

                                            PROBEBLITY OF
         Asset Wear Pattern:                   FAILURE
                                                                                   AGE

  DESCRIPTION         GRAPHICAL REPRESENTATION                  Type of                  EXAMPLES
                                                                 Asset
                                                                Maint.
                                                                            Failure of control Valves moving
A. Traditional view                                              Time
                                                                            parts, Mechanical drive items
                                                                 Base
                                                                            (gear box, chain)
                                                                Wear
                                                                            Electro-mechanical items,
B. Bath Tub Curve                                               & Tear
                                                                            Electronic components (positioners)
                                                                            give rise to infant failure at the left
                                                                            side of curve, while mechanical
                                                                            component give late life failure,
                                                                            (Internal failure of control Valves)

                                                                             Control Valves (external affects)
C. Slow Aging

                                                                Random       Hydraulic & compressed air
D. Best New
                                                                 Wear        System

                                                                              Rolling element bearing
E. Constant Random
     Failure
                                                                             Electronic Instruments
F. Worst New
                                                                             (transmitters, Sensors, Cards,
                                                                             FF accessories, Switching Hub,
                                                                             Operator /Touch Screen
                                  2008 FFIMC - Automation 2008-Mumbai
  3

                                                                                                   © 2008 Fieldbus Foundation
Maintenance Practices



    Process devices start deteriorating and wear out from the
      minute it’s placed in service. Types of maintenance:
    Run to failure – No maintenance till device fail
    Preventative maintenance – Based on schedule given by
      equipment vendor or past history
    Predictive maintenance – Based on future prediction of
      condition of devices




                          2008 FFIMC - Automation 2008-Mumbai
4

                                                                © 2008 Fieldbus Foundation
Maintenance Practices


           Run to failure

    “If it’s not broke, why to fix it?”
    “It’s been in operation for years…”
    “Do not touch it will give more problem”
    “We’ve never had a problem”
    “It was already calibrated at the factory”
    “No budget this year”
    “No schedule given by vendor for maintenance this year”
    “Process running and outage not possible”
    “We do everything by ourselves, if broke we can repair”


                         2008 FFIMC - Automation 2008-Mumbai
5

                                                               © 2008 Fieldbus Foundation
Maintenance Practices


     Preventive Maintenance

    “Strip down all Devices & Control valves for maintenance
    during annual Turn around?”
    “Workshop to be equipped to calibrate and maintenance of
    all instruments & valves”
    “Spare parts to be procured based on experience”
    “Large Resources to be arranged to complete the job”
    “Long turn around time to finish all jobs”
    “Manual data entry for history of problem & maintenance”
    “High budget”
    “Large inventory of unused spare parts”

                        2008 FFIMC - Automation 2008-Mumbai
6

                                                              © 2008 Fieldbus Foundation
Maintenance Practices


      Predictive Maintenance

    “Condition Monitoring by On Line instruments on machine &
    OFF line tools (NDT tools) by schedule checking”
    “Gather information from intelligent devices”
    “Use of Hand held tool for monitoring health of equipments
    & devices”
    “Human intelligence for analysis of data”
    “Prediction based on Various tools”
    “Not very accurate probability: Accuracy of plan based on
    judgment”
    “Some maintenance missed out due to result in uncertainty
    of failure”
                         2008 FFIMC - Automation 2008-Mumbai
7

                                                               © 2008 Fieldbus Foundation
Maintenance Practices




                    2008 FFIMC - Automation 2008-Mumbai
8

                                                          © 2008 Fieldbus Foundation
Three- Level Diagnostics Module - “Abnormality Analysis”
          Three-                            “Abnormality Analysis”


                                                                           Level 3




                                 Level 2
                                                                                     Operations
                                                         Drift




                                                           Loop
Level 1
                µP

                                    External
                                   influence
          Electronics   Sensor
          Defective      Drift



                                               2008 FFIMC - Automation 2008-Mumbai
                  Device
   9

                                                                                        © 2008 Fieldbus Foundation
Three- Level Diagnostics Module - “Abnormality Analysis”
      Three-                            “Abnormality Analysis”

Device Checking & Maintenance:

     Maintenance based on vendor’s recommendation
  Decisions and actions based primarily on the passed
history
  Maintenance by reactions triggered by what has
happened and some corrective action has been taken
  Schedule maintenance by CMMS (Computerised
Maintenance Management System) to warranty for its
functioning till next turn around
  Information collected from log book and some time
device show flag of deterioration
                       2008 FFIMC - Automation 2008-Mumbai
10

                                                             © 2008 Fieldbus Foundation
Three- Level Diagnostics Module - “Abnormality Analysis”
       Three-                            “Abnormality Analysis”

Loop Testing & Maintenance:


     Mostly limited to loop checking by current / voltage
        injection from field
     Tightening of terminals
     Inspection of Junction boxes
     DCS input card, Signal conditioner calibration




                        2008 FFIMC - Automation 2008-Mumbai
11

                                                              © 2008 Fieldbus Foundation
Three- Level Diagnostics Module - “Abnormality Analysis”
     Three-                            “Abnormality Analysis”

Process Diagnosis & Corrective actions:

  No boundary between Process abnormalities and
device failure, unless checked physically
   More effective analysis with DCS process real time &
historical trends
 Monitoring long term process deviation by use of
Analytical tool like Graphs, Run Charts, Control Chart,
Cause & Effect diagram, Check Sheets, Histogram,
Gauge R & R etc.
  Use of Log books or CMMS in Text form to capture
long term historical deviation / changes
                      2008 FFIMC - Automation 2008-Mumbai
12

                                                            © 2008 Fieldbus Foundation
Maintenance Practices in Digital World




                       2008 FFIMC - Automation 2008-Mumbai
13

                                                             © 2008 Fieldbus Foundation
Maintenance Practices in Digital World




       When maintenance is to be done ?
       What kind of maintenance is needed ?
                       2008 FFIMC - Automation 2008-Mumbai
14

                                                             © 2008 Fieldbus Foundation
Four - Level Management Module - “Abnormality Analysis”
                                            “Abnormality Analysis”
                                                                                    Level 4      Enterprise 
                                                                                                  Network




                                                Level 3



                                                                                              Communication
                          Level 2

                                                                                              & Networking
                                                      Drift

                                                                             Operations
               FF Accessories
Level 1A


                                                  Loop

                              FF Sensors
Level 1
                µP
                                   External
                                  influence
                         Sensor
           Electronics
                          Drift
           Defective                          2008 FFIMC - Automation 2008-Mumbai
   15

                     Device                                                                      © 2008 Fieldbus Foundation
Maintenance Practices in Digital World
      Advance tool:
       Process knowledge captured by machine in terms of logics &
     algorithms.
       Knowing better what you are doing now by capturing real time data
     and its historical trends
       Developing model and continuously improving its algorithms
       Comparing what you are doing now against what you expected to do
     and understanding difference
       Systematic storage and graphical display representation of the
     measurement & fault
       Graphical Display the deterioration trend & alarming the operator
       Forecasting the future failure time limit before it become critical
       Allow Engineer to take decision for plant stoppage basing decisions
     more on facts and data and less on intuition
       Detecting problems before they become critical
     ON LINE ALERT        2008 FFIMC - Automation 2008-Mumbai
16

                                                                © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Sensing):


                                                        Device Health Information:

                                                        ۩ Electronic Failure
                                                        ۩ Sensor not responding
              µP
                                                        ۩ Device communication
                                                        problem
                             External
                            influence

                                                        ۩ Communication Hardware
     Electronics

                                                        component deterioration
     Defective
                   Sensor
                    Drift

                                                        ۩ Power supply failure


                            2008 FFIMC - Automation 2008-Mumbai
17

                                                                        © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Sensing):                               Device Configuration:


                                                      ۩ FF Basic-to-LM device wizard
                                                            “Safe” way to enable/disable
                                                          Backup LAS
                                                            Provides wizard to step
                                                          through sequence
                                                            Insures BLAS will
                                                          work when needed




                          2008 FFIMC - Automation 2008-Mumbai
18

                                                                          © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Sensing):
                                                      Device Replacement:

                                                      ۩ Device Replacement by
                                                      Operator
                                                      ۩ Replacement from Operator
                                                      Station or Engineering Station
                                                      ۩ Auto replacement
                                                      ۩ Upgrading devices on-line




                          2008 FFIMC - Automation 2008-Mumbai
19

                                                                          © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level Performance (Sensing):


                 Advance Prediction:
                  Predictive Alarm


                                                             Failure




                              Time


                       2008 FFIMC - Automation 2008-Mumbai
20

                                                                       © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Final Element):

Device Health Information:
         REASONS                                       FAILURE TYPE

   External /           Valve corrosion, Gland packing degradation
 Environmental Effect   (leakage of toxic, expansive fluid), lubricating
                        oil attrition
   Internal Effect /    Stem deformation , Stem linkage damage,
 Improper Process       Spring failure, Stem & plug scuffing, Actuator
 control                air leakage, air insufficient, Air loss, Positioner
                        failure, Positioner linkage loose or improper
                        setting, Seat ring damage, Plug damage, High
                        Packing torque, Change in friction etc.

                        2008 FFIMC - Automation 2008-Mumbai
21

                                                                      © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Final Element):

Device Health Information:
                           Air Loss                               Linkage loose
                                               Hunting

                           Packing            Stick - slip        Positioner fail




     Accurate analysis (No Human error)
     Information available at Control room (Problem Description)
     Stroke repetition
     Hysteresis data, Input output deviation
     Valve signature
     Overshoot / Undershoot stem travel
                            2008 FFIMC - Automation 2008-Mumbai
22

                                                                                    © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Final Element):

Asset Measurement & Solutions:

         REASONS                                ANALYSIS & ACTIONS

   External /             Mostly Physical Inspection & decision, Some
 Environmental Effect   information from software (steam / high temp
                        fluid leakage from gland)
   Internal Effect /     Captured at AMS module & Maintenance
 Improper Process       Planning through online prediction.
 control                 Deterioration type is indicated
                         Available operating time can be predicted
                         Exact spare parts can be planned
                         Correction, corrective and preventive action
                        can be planned
                        2008 FFIMC - Automation 2008-Mumbai
23

                                                                     © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Final Element):

Asset Measurement & Solutions:




   Reduce the unnecessary overhauling / maintenance of control
 valves by analyzing the degradation indexes which is
 determined based on the long term gathered data
   Valve passing in close & overshoot condition - Valve lapping
 or trim replacement
   Positioner calibration, Replacement needed
   Surrounding temperature information


                           2008 FFIMC - Automation 2008-Mumbai
24

                                                                 © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Device Level (Final Element):

Asset Measurement & Solutions:




Effectiveness for diagnostic
      Detecting inner valve failure
       – Wearing of seat ring
       – Sticking the foreign object
      Detecting the failure by vibration
       – Moving from proper mounting position of positioner by vibration.


                           2008 FFIMC - Automation 2008-Mumbai
25

                                                                 © 2008 Fieldbus Foundation
Maintenance Practices in Digital World
                                                 Issue with FF:
Plant level Communication:                       Common issue in Electrical wiring
                                                (loose wire strands, water ingress, faulty
                                                devices, EMC, etc..)
                                                 Bus topology connects multiple devices
                                                       Serial communications signal
       Advance diagnosis
           module                                      One fault can affect several devices
                                                 Available tools are for conventional
                                                technology
                                                       Tools lacks ability to visualize
                                                    Fieldbus related signals
                                                       Locating the problem is difficult
                                                    and time consuming many devices in
                                                    one loop; interoperability)
                                                    Field Bus installation
                                                       Tools to commission, Supervise &
                                                    trouble shoot (signal distortion)
                           2008 FFIMC - Automation 2008-Mumbai
26

                                                                          © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

                                                     Measurement & Solutions:
Plant level Communication:
                                                 ۩ Segment Voltage, Current
                                                 ۩ Segment & device Noise
                                                 ۩ Segment & Device Signal
       Advance diagnosis
                                                 level
           module
                                                 ۩ Device Termination
                                                 ۩ Segment / Shield earth fault
                                                 ۩ Device communication
                                                 ۩ Earth fault information
                                                 ۩ Cable degradation
                                                 ۩ Device configuration
                                                 ۩ Device remote access
                                                 ۩ Signal quality & strength
                           2008 FFIMC - Automation 2008-Mumbai
27

                                                                     © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Plant level Communication:
                                                      Predictive maintenance:
                                                 ۩ Supervision & Diagnosis
                                                 ۩ Measurement, alarming &
       Advance diagnosis
                                                 trending
           module
                                                 ۩ Online and real time data
                                                 from DCS / HMI
                                                 ۩ Digital Oscilloscope function
                                                 ۩ Signal (Segment voltage,
                                                 current), Actual Noise level
                                                 ۩ Proper termination, Isolation
                                                 to ground and polarity

                           2008 FFIMC - Automation 2008-Mumbai
28

                                                                       © 2008 Fieldbus Foundation
Maintenance Practices in Digital World
                               Predictive maintenance:
Plant level Communication:




     Advance diagnosis
         module




                         2008 FFIMC - Automation 2008-Mumbai
29

                                                               © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Plant level Communication:             Measurement & Online Solutions:
                                        ۩ Identify kind of failure &
                                        guided actions
                                           Grounding, Software, hardware
                                           & wiring problem
                                           ۩ Highlight Problem with help
                                           ۩User configure warning &
                                           Alarm alerts before segment
                                           fails
                                           ۩ Can be used as a
                                           Commissioning tool
                                           ۩ Digital Oscilloscope function
                                           (Lost telegram)
                                           ۩ Log of each event at DCS / HMI
                       2008 FFIMC - Automation 2008-Mumbai
30

                                                                   © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Loop Level:


                                                     1. Availability
                                                     2. Controllability
                Drift
                         AMS




                        2008 FFIMC - Automation 2008-Mumbai
31

                                                                   © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Loop Level:                                   1. Availability
                                                Vendor’s Solutions
                                                 Distinguish between process
                                               and loop problem
                                                 Number of loops in manual
                                               mode
                Drift
                         AMS                     Specific loop taken in
                                               manual how many times a day
                                                 Total % of time in manual
                                               mode in 24 Hrs.
                                                 Trend graph for manual &
                                               auto Vrs. Time

                        2008 FFIMC - Automation 2008-Mumbai
32

                                                                 © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Loop Level:
                                                2. Controllability
                                                   Vendor’s Solutions
                                                  Loop performance within
                                                defined bandwidth
                                                  Total % of time operation
                Drift
                                                remain in Excellent zone
                           AMS
                                                   Loop to Loop comparison
                                                  Alarm management
                                                  Guided actions during plant
                                                emergency



                        2008 FFIMC - Automation 2008-Mumbai
33

                                                                 © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

                                        Vendor’s Solutions (Controllability)
Loop Level Diagnosis:




                        2008 FFIMC - Automation 2008-Mumbai
34

                                                                © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Process Level Diagnosis:
                                               Vendor’s Solutions

                                             Impulse line chocking
                                             pH sensor deteriorated
                                             Coating on probe of magnetic pickup
                                             Shedder bar not vibrating due to
                                          internal or external reasons
                                             High temperature around the devices
                                             Controllability problem due to
                                          process fluctuation
                                             Inappropriate step taken by
                                          Operator (SP not followed)



                       2008 FFIMC - Automation 2008-Mumbai
35

                                                                    © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

Communication & Networking:
                                                                                           Asset
                                                                                           Management
                                                                                         ETHERNET


                                        HIS              HIS           HIS                              EWS
       Proprietary BUS

                                                                                                          HART




                                                                           PROCESS FIELD BUS




                                     Mod Bus

                                                                           OmROn
                    Control Net




       AB PLC            Device
                                                        Optic
                         Net R I/O
                                                        Fibre                                  TCP IP



                     Local start / stop
                     Panel with indication

                                                                Touch panel
                                               2008 FFIMC - Automation 2008-Mumbai
36

                                                                                                                 © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

    Communication & Networking: Communication Peripheral
                                Device Health:
                                                                             Provision for current & Future
                                                                           Demands of the Industry like
                    Enterprise 
                                              Secure Access 
                     Network
                                                                           wireless integration, Security against
                                              to Enterprise Network
                   Redundant Link
                                                                           Hacking & Spy worm etc.
                                                                              Network Traffic Control
                    Dual Homing
                                                                              Integration of several industrial
                                           HiPER Ring
                                                                           networking standards
                                                                              Cabling, Software Management,
Camera                                        Secure Access 
                                              to Plant Floor
   Video 
                                                                           System Integration, Installation and
                             Wireless 
   Surveillance 
                             Transmitter
                                                                           Maintenance.
                                                                              Configuration of secure and
                                                                           reliable Networks in highly
                                                                           sophisticated Industrial environment
                                                   2008 FFIMC - Automation 2008-Mumbai
         37

                                                                                                  © 2008 Fieldbus Foundation
Maintenance Practices in Digital World

                                                                     Measurement & Solutions:
    Communication & Networking:

                                                                                  Communication Peripheral device
                                                                             Health Deterioration indication &
                    Enterprise 
                                              Secure Access 
                     Network                                                 replacement
                                              to Enterprise Network
                   Redundant Link
                                                                                 Bus cable termination
                                                                                  Replacement of Cable on Physical
                    Dual Homing
                                                                             health information
                                           HiPER Ring
                                                                                  Bus cable rerouting if interference
                                                                             is noticed
Camera                                        Secure Access 
                                              to Plant Floor
   Video 
                                                                                  Redundancy alert of Device Active
                             Wireless 
   Surveillance 
                             Transmitter
                                                                             / failure
                                                                                  Updating the Anti virus, Firewall
                                                                             software
                                                                                 High temperature alarm in &
                                                                             around the devices
                                                    2008 FFIMC - Automation 2008-Mumbai
         38

                                                                                                 © 2008 Fieldbus Foundation
New Concept:
           March towards


           Maintenance
               to
           Management
                2008 FFIMC - Automation 2008-Mumbai
39

                                                      © 2008 Fieldbus Foundation
Field Bus Foundation: A Way Forward>>>>




               Thank You
                  2008 FFIMC - Automation 2008-Mumbai
40

                                                        © 2008 Fieldbus Foundation

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Ff Presdentation User Conference Mumbai Automation 2008

  • 1. Fieldbus Foundation – A Way Forward Advance Plant Management Module in FF Controlled Process Industry Jasbir Singh Essar Oil Ltd 2008 FFIMC - Automation 2008-Mumbai 1 © 2008 Fieldbus Foundation
  • 2. ROI – Improvement Increase ROI Reduce Capital Cost Increase Profitability Increase Revenue Reduce conversion Costs Increase Productivity Reduction of losses Reduced Increased Reduced Reduced Unscheduled Downtime Yield Project Capital Feed stocks & Small stoppages Product Installation & Energy and Utilities Planned Shutdowns Consistency Commissioning Maintenance Low Maintenance time New product Cost waste Optimize Maintenance Equipment Capacity Warehouse Abnormal Events Resources, Equip. Efficiency Inventory / Low grade product Minimum Spare parts Spares Penalties Inventory, Product mix/ Reliable Maintenance Feed stock history 2008 FFIMC - Automation 2008-Mumbai 2 © 2008 Fieldbus Foundation
  • 3. PM Plan for time base proactive maint. PROBEBLITY OF Asset Wear Pattern: FAILURE AGE DESCRIPTION GRAPHICAL REPRESENTATION Type of EXAMPLES Asset Maint. Failure of control Valves moving A. Traditional view Time parts, Mechanical drive items Base (gear box, chain) Wear Electro-mechanical items, B. Bath Tub Curve & Tear Electronic components (positioners) give rise to infant failure at the left side of curve, while mechanical component give late life failure, (Internal failure of control Valves) Control Valves (external affects) C. Slow Aging Random Hydraulic & compressed air D. Best New Wear System Rolling element bearing E. Constant Random Failure Electronic Instruments F. Worst New (transmitters, Sensors, Cards, FF accessories, Switching Hub, Operator /Touch Screen 2008 FFIMC - Automation 2008-Mumbai 3 © 2008 Fieldbus Foundation
  • 4. Maintenance Practices Process devices start deteriorating and wear out from the minute it’s placed in service. Types of maintenance: Run to failure – No maintenance till device fail Preventative maintenance – Based on schedule given by equipment vendor or past history Predictive maintenance – Based on future prediction of condition of devices 2008 FFIMC - Automation 2008-Mumbai 4 © 2008 Fieldbus Foundation
  • 5. Maintenance Practices Run to failure “If it’s not broke, why to fix it?” “It’s been in operation for years…” “Do not touch it will give more problem” “We’ve never had a problem” “It was already calibrated at the factory” “No budget this year” “No schedule given by vendor for maintenance this year” “Process running and outage not possible” “We do everything by ourselves, if broke we can repair” 2008 FFIMC - Automation 2008-Mumbai 5 © 2008 Fieldbus Foundation
  • 6. Maintenance Practices Preventive Maintenance “Strip down all Devices & Control valves for maintenance during annual Turn around?” “Workshop to be equipped to calibrate and maintenance of all instruments & valves” “Spare parts to be procured based on experience” “Large Resources to be arranged to complete the job” “Long turn around time to finish all jobs” “Manual data entry for history of problem & maintenance” “High budget” “Large inventory of unused spare parts” 2008 FFIMC - Automation 2008-Mumbai 6 © 2008 Fieldbus Foundation
  • 7. Maintenance Practices Predictive Maintenance “Condition Monitoring by On Line instruments on machine & OFF line tools (NDT tools) by schedule checking” “Gather information from intelligent devices” “Use of Hand held tool for monitoring health of equipments & devices” “Human intelligence for analysis of data” “Prediction based on Various tools” “Not very accurate probability: Accuracy of plan based on judgment” “Some maintenance missed out due to result in uncertainty of failure” 2008 FFIMC - Automation 2008-Mumbai 7 © 2008 Fieldbus Foundation
  • 8. Maintenance Practices 2008 FFIMC - Automation 2008-Mumbai 8 © 2008 Fieldbus Foundation
  • 9. Three- Level Diagnostics Module - “Abnormality Analysis” Three- “Abnormality Analysis” Level 3 Level 2 Operations Drift Loop Level 1 µP External influence Electronics Sensor Defective Drift 2008 FFIMC - Automation 2008-Mumbai Device 9 © 2008 Fieldbus Foundation
  • 10. Three- Level Diagnostics Module - “Abnormality Analysis” Three- “Abnormality Analysis” Device Checking & Maintenance: Maintenance based on vendor’s recommendation Decisions and actions based primarily on the passed history Maintenance by reactions triggered by what has happened and some corrective action has been taken Schedule maintenance by CMMS (Computerised Maintenance Management System) to warranty for its functioning till next turn around Information collected from log book and some time device show flag of deterioration 2008 FFIMC - Automation 2008-Mumbai 10 © 2008 Fieldbus Foundation
  • 11. Three- Level Diagnostics Module - “Abnormality Analysis” Three- “Abnormality Analysis” Loop Testing & Maintenance: Mostly limited to loop checking by current / voltage injection from field Tightening of terminals Inspection of Junction boxes DCS input card, Signal conditioner calibration 2008 FFIMC - Automation 2008-Mumbai 11 © 2008 Fieldbus Foundation
  • 12. Three- Level Diagnostics Module - “Abnormality Analysis” Three- “Abnormality Analysis” Process Diagnosis & Corrective actions: No boundary between Process abnormalities and device failure, unless checked physically More effective analysis with DCS process real time & historical trends Monitoring long term process deviation by use of Analytical tool like Graphs, Run Charts, Control Chart, Cause & Effect diagram, Check Sheets, Histogram, Gauge R & R etc. Use of Log books or CMMS in Text form to capture long term historical deviation / changes 2008 FFIMC - Automation 2008-Mumbai 12 © 2008 Fieldbus Foundation
  • 13. Maintenance Practices in Digital World 2008 FFIMC - Automation 2008-Mumbai 13 © 2008 Fieldbus Foundation
  • 14. Maintenance Practices in Digital World When maintenance is to be done ? What kind of maintenance is needed ? 2008 FFIMC - Automation 2008-Mumbai 14 © 2008 Fieldbus Foundation
  • 15. Four - Level Management Module - “Abnormality Analysis” “Abnormality Analysis” Level 4 Enterprise  Network Level 3 Communication Level 2 & Networking Drift Operations FF Accessories Level 1A Loop FF Sensors Level 1 µP External influence Sensor Electronics Drift Defective 2008 FFIMC - Automation 2008-Mumbai 15 Device © 2008 Fieldbus Foundation
  • 16. Maintenance Practices in Digital World Advance tool: Process knowledge captured by machine in terms of logics & algorithms. Knowing better what you are doing now by capturing real time data and its historical trends Developing model and continuously improving its algorithms Comparing what you are doing now against what you expected to do and understanding difference Systematic storage and graphical display representation of the measurement & fault Graphical Display the deterioration trend & alarming the operator Forecasting the future failure time limit before it become critical Allow Engineer to take decision for plant stoppage basing decisions more on facts and data and less on intuition Detecting problems before they become critical ON LINE ALERT 2008 FFIMC - Automation 2008-Mumbai 16 © 2008 Fieldbus Foundation
  • 17. Maintenance Practices in Digital World Device Level (Sensing): Device Health Information: ۩ Electronic Failure ۩ Sensor not responding µP ۩ Device communication problem External influence ۩ Communication Hardware Electronics component deterioration Defective Sensor Drift ۩ Power supply failure 2008 FFIMC - Automation 2008-Mumbai 17 © 2008 Fieldbus Foundation
  • 18. Maintenance Practices in Digital World Device Level (Sensing): Device Configuration: ۩ FF Basic-to-LM device wizard “Safe” way to enable/disable Backup LAS Provides wizard to step through sequence Insures BLAS will work when needed 2008 FFIMC - Automation 2008-Mumbai 18 © 2008 Fieldbus Foundation
  • 19. Maintenance Practices in Digital World Device Level (Sensing): Device Replacement: ۩ Device Replacement by Operator ۩ Replacement from Operator Station or Engineering Station ۩ Auto replacement ۩ Upgrading devices on-line 2008 FFIMC - Automation 2008-Mumbai 19 © 2008 Fieldbus Foundation
  • 20. Maintenance Practices in Digital World Device Level Performance (Sensing): Advance Prediction: Predictive Alarm Failure Time 2008 FFIMC - Automation 2008-Mumbai 20 © 2008 Fieldbus Foundation
  • 21. Maintenance Practices in Digital World Device Level (Final Element): Device Health Information: REASONS FAILURE TYPE External / Valve corrosion, Gland packing degradation Environmental Effect (leakage of toxic, expansive fluid), lubricating oil attrition Internal Effect / Stem deformation , Stem linkage damage, Improper Process Spring failure, Stem & plug scuffing, Actuator control air leakage, air insufficient, Air loss, Positioner failure, Positioner linkage loose or improper setting, Seat ring damage, Plug damage, High Packing torque, Change in friction etc. 2008 FFIMC - Automation 2008-Mumbai 21 © 2008 Fieldbus Foundation
  • 22. Maintenance Practices in Digital World Device Level (Final Element): Device Health Information: Air Loss Linkage loose Hunting Packing Stick - slip Positioner fail Accurate analysis (No Human error) Information available at Control room (Problem Description) Stroke repetition Hysteresis data, Input output deviation Valve signature Overshoot / Undershoot stem travel 2008 FFIMC - Automation 2008-Mumbai 22 © 2008 Fieldbus Foundation
  • 23. Maintenance Practices in Digital World Device Level (Final Element): Asset Measurement & Solutions: REASONS ANALYSIS & ACTIONS External / Mostly Physical Inspection & decision, Some Environmental Effect information from software (steam / high temp fluid leakage from gland) Internal Effect / Captured at AMS module & Maintenance Improper Process Planning through online prediction. control Deterioration type is indicated Available operating time can be predicted Exact spare parts can be planned Correction, corrective and preventive action can be planned 2008 FFIMC - Automation 2008-Mumbai 23 © 2008 Fieldbus Foundation
  • 24. Maintenance Practices in Digital World Device Level (Final Element): Asset Measurement & Solutions: Reduce the unnecessary overhauling / maintenance of control valves by analyzing the degradation indexes which is determined based on the long term gathered data Valve passing in close & overshoot condition - Valve lapping or trim replacement Positioner calibration, Replacement needed Surrounding temperature information 2008 FFIMC - Automation 2008-Mumbai 24 © 2008 Fieldbus Foundation
  • 25. Maintenance Practices in Digital World Device Level (Final Element): Asset Measurement & Solutions: Effectiveness for diagnostic Detecting inner valve failure – Wearing of seat ring – Sticking the foreign object Detecting the failure by vibration – Moving from proper mounting position of positioner by vibration. 2008 FFIMC - Automation 2008-Mumbai 25 © 2008 Fieldbus Foundation
  • 26. Maintenance Practices in Digital World Issue with FF: Plant level Communication: Common issue in Electrical wiring (loose wire strands, water ingress, faulty devices, EMC, etc..) Bus topology connects multiple devices Serial communications signal Advance diagnosis module One fault can affect several devices Available tools are for conventional technology Tools lacks ability to visualize Fieldbus related signals Locating the problem is difficult and time consuming many devices in one loop; interoperability) Field Bus installation Tools to commission, Supervise & trouble shoot (signal distortion) 2008 FFIMC - Automation 2008-Mumbai 26 © 2008 Fieldbus Foundation
  • 27. Maintenance Practices in Digital World Measurement & Solutions: Plant level Communication: ۩ Segment Voltage, Current ۩ Segment & device Noise ۩ Segment & Device Signal Advance diagnosis level module ۩ Device Termination ۩ Segment / Shield earth fault ۩ Device communication ۩ Earth fault information ۩ Cable degradation ۩ Device configuration ۩ Device remote access ۩ Signal quality & strength 2008 FFIMC - Automation 2008-Mumbai 27 © 2008 Fieldbus Foundation
  • 28. Maintenance Practices in Digital World Plant level Communication: Predictive maintenance: ۩ Supervision & Diagnosis ۩ Measurement, alarming & Advance diagnosis trending module ۩ Online and real time data from DCS / HMI ۩ Digital Oscilloscope function ۩ Signal (Segment voltage, current), Actual Noise level ۩ Proper termination, Isolation to ground and polarity 2008 FFIMC - Automation 2008-Mumbai 28 © 2008 Fieldbus Foundation
  • 29. Maintenance Practices in Digital World Predictive maintenance: Plant level Communication: Advance diagnosis module 2008 FFIMC - Automation 2008-Mumbai 29 © 2008 Fieldbus Foundation
  • 30. Maintenance Practices in Digital World Plant level Communication: Measurement & Online Solutions: ۩ Identify kind of failure & guided actions Grounding, Software, hardware & wiring problem ۩ Highlight Problem with help ۩User configure warning & Alarm alerts before segment fails ۩ Can be used as a Commissioning tool ۩ Digital Oscilloscope function (Lost telegram) ۩ Log of each event at DCS / HMI 2008 FFIMC - Automation 2008-Mumbai 30 © 2008 Fieldbus Foundation
  • 31. Maintenance Practices in Digital World Loop Level: 1. Availability 2. Controllability Drift AMS 2008 FFIMC - Automation 2008-Mumbai 31 © 2008 Fieldbus Foundation
  • 32. Maintenance Practices in Digital World Loop Level: 1. Availability Vendor’s Solutions Distinguish between process and loop problem Number of loops in manual mode Drift AMS Specific loop taken in manual how many times a day Total % of time in manual mode in 24 Hrs. Trend graph for manual & auto Vrs. Time 2008 FFIMC - Automation 2008-Mumbai 32 © 2008 Fieldbus Foundation
  • 33. Maintenance Practices in Digital World Loop Level: 2. Controllability Vendor’s Solutions Loop performance within defined bandwidth Total % of time operation Drift remain in Excellent zone AMS Loop to Loop comparison Alarm management Guided actions during plant emergency 2008 FFIMC - Automation 2008-Mumbai 33 © 2008 Fieldbus Foundation
  • 34. Maintenance Practices in Digital World Vendor’s Solutions (Controllability) Loop Level Diagnosis: 2008 FFIMC - Automation 2008-Mumbai 34 © 2008 Fieldbus Foundation
  • 35. Maintenance Practices in Digital World Process Level Diagnosis: Vendor’s Solutions Impulse line chocking pH sensor deteriorated Coating on probe of magnetic pickup Shedder bar not vibrating due to internal or external reasons High temperature around the devices Controllability problem due to process fluctuation Inappropriate step taken by Operator (SP not followed) 2008 FFIMC - Automation 2008-Mumbai 35 © 2008 Fieldbus Foundation
  • 36. Maintenance Practices in Digital World Communication & Networking: Asset Management ETHERNET HIS HIS HIS EWS Proprietary BUS HART PROCESS FIELD BUS Mod Bus OmROn Control Net AB PLC Device Optic Net R I/O Fibre TCP IP Local start / stop Panel with indication Touch panel 2008 FFIMC - Automation 2008-Mumbai 36 © 2008 Fieldbus Foundation
  • 37. Maintenance Practices in Digital World Communication & Networking: Communication Peripheral Device Health: Provision for current & Future Demands of the Industry like Enterprise  Secure Access  Network wireless integration, Security against to Enterprise Network Redundant Link Hacking & Spy worm etc. Network Traffic Control Dual Homing Integration of several industrial HiPER Ring networking standards Cabling, Software Management, Camera Secure Access  to Plant Floor Video  System Integration, Installation and Wireless  Surveillance  Transmitter Maintenance. Configuration of secure and reliable Networks in highly sophisticated Industrial environment 2008 FFIMC - Automation 2008-Mumbai 37 © 2008 Fieldbus Foundation
  • 38. Maintenance Practices in Digital World Measurement & Solutions: Communication & Networking: Communication Peripheral device Health Deterioration indication & Enterprise  Secure Access  Network replacement to Enterprise Network Redundant Link Bus cable termination Replacement of Cable on Physical Dual Homing health information HiPER Ring Bus cable rerouting if interference is noticed Camera Secure Access  to Plant Floor Video  Redundancy alert of Device Active Wireless  Surveillance  Transmitter / failure Updating the Anti virus, Firewall software High temperature alarm in & around the devices 2008 FFIMC - Automation 2008-Mumbai 38 © 2008 Fieldbus Foundation
  • 39. New Concept: March towards Maintenance to Management 2008 FFIMC - Automation 2008-Mumbai 39 © 2008 Fieldbus Foundation
  • 40. Field Bus Foundation: A Way Forward>>>> Thank You 2008 FFIMC - Automation 2008-Mumbai 40 © 2008 Fieldbus Foundation