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Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
Callibratie onderhoud en communicatie interfaces
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Callibratie onderhoud en communicatie interfaces

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Net zoals de meeste toestellen zijn ook drukmetingen onderhevig aan externe en interne factoren waardoor ze in de loop van hun levensjaren meetfouten, afwijkingen, en onnauwkeurigheden gaan vertonen. …

Net zoals de meeste toestellen zijn ook drukmetingen onderhevig aan externe en interne factoren waardoor ze in de loop van hun levensjaren meetfouten, afwijkingen, en onnauwkeurigheden gaan vertonen. Hierdoor is het nodig om de toestand van de meettoestellen te beoordelen en te calibreren of eventueel te vernieuwen.
We dienen er eveneens over te waken dat de meettoestellen regelmatig een onderhoudsbeurt ondergaan om steeds de best mogelijke meetprestaties te leveren. Die elementen worden belicht in deze zitting.

Sprekers:
Jan Heynen (ENDRESS+HAUSER SA/NV)
Jeroen Wynants (ENDRESS+HAUSER SA/NV)

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  • 1. 22/06/2012 Advantages of digital communication Unlocking the potenitial of diagnostic information Slide 1 Jeroen Wynants
  • 2. 22/06/2012 OpEx savings maintenance Source: HPI market data 2003 Gulf publishing company Instrument & valves Mechanical equipment Process equipment Electrical equipment
  • 3. 22/06/2012 Customer survey and questionnaire Which maintenance strategy to apply?
  • 4. 22/06/2012 Typical maintenance strategies Corrective Maintenance Device is maintained when it failed > uncontrolled plant shutdowns Preventive Maintenance Device is periodically maintained to prevent failures > controlled but high maintenance intervals Condition Based Maintenance Device detects when a maintenance is necessary and notifies in advance > controlled and optimized low maintenance intervals Corrective Maintenance Preventive Maintenance Condition based Maintenance Consequenceoffailure Increasing effectiveness and efficiency Costs Availability
  • 5. 22/06/2012 Typical maintenance strategies Corrective Maintenance Device is maintained when it failed > uncontrolled plant shutdowns Preventive Maintenance Device is periodically maintained to prevent failures > controlled but high maintenance intervals Condition Based Maintenance Device detects when a maintenance is necessary and notifies in advance > controlled and optimized low maintenance intervals Source: ARC Advisory Group 020406080100 Type of maintenance 65% 30% 5% 60% of preventive maintenance activities is unnecessary!
  • 6. 22/06/2012 Condition Based Maintenance Device detects when a maintenance is necessary and notifies in advance -> controlled and optimized low maintenance intervals Condition based maintenance strategy Condition Time Failure occur Reduction of functional reserve Condition based Initialized on condition (basic diagnosis: diagnosis value 1 device Pro-Active Static analysis ‘Reference value’ • evaluation: <,>, =, hyst.,… Predictive Dynamic analysis ‘Reference trend’ • extrapolation, time, … Condition based Initialized on condition (advanced diagnosis: correlated diagnostic values) Pro-Active Static analysis ‘Reference value’ • evaluation: <, >, =, hyst., .… • Boolean logic (AND, OR, …) • Methods algorithms,… Predictive Dynamic analysis ‘Reference trend’ • evaluation: <, >, =, hyst., .… • Boolean logic (AND, OR, …) • methods, algorithms,… Condition based Initialized on condition (process diagnosis: correlated devices) Pro-Active Static analysis ‘Reference value’ • evaluation: <, >, =, hyst., .… • Boolean logic (AND, OR, …) • correlation algorithms,… Predictive Dynamic analyses ‘Reference trend’ • evaluation: <, >, =, hyst., .… • Boolean logic (AND, OR, …) • correlation, algorithms,… Value B-E-F Value B-E-F Value B-E-F Value B-E-F Value B-E-F Value B-E-F
  • 7. 22/06/2012 Service technician diagnostics in automotive industry Slide 7 Jaap Westeneng Driver Quality Manager • As detailed as possible • Includes suggestions for possible remedies • All information for safe driving • Only essential information, summary messages • As early as possible
  • 8. 22/06/2012 Maintenance technician Process operator diagnostics in process industry Slide 8 Jaap Westeneng Reliability Manager • All information for safe operation • Only essential information, summary messages • As early as possible • As detailed as possible • Includes suggestions for possible remedies
  • 9. 22/06/2012 Challenges faced by today  Difficult to get overview status of process.  Operators are bombarded with nuisance alarms.  Inconsistencies in diagnostics information from different vendors and product classes.  Different applications, terminals, interfaces with unsynchronized data.  Operators are integral part of control loops and need to take decisions in critical situations.
  • 10. 22/06/2012 Status today  Large part of the production and quality losses are primarily result of operator error which can be prevented by ensuring that the right information is available to the right person at the right time. Global process industry loses $ 20 billion, or 5 % of annual production, due to unscheduled downtime and poor quality. ARC estimates that almost 80 % of these losses are preventable and 40 % are primarily the result of operator error.
  • 11. 22/06/2012 Purpose of diagnostics  Analyze status information (i.e. from field devices)  With the objective of detecting causes for potential malfunction. Diagnostics form the basis to remove malfunctions Value of diagnostics:  Minimizes ad-hoc maintenance  Enables proactive maintenance  Minimizes unwanted plant shutdowns  Enables event triggered inspections  Forms the basis for Plant Asset Management  Reduces costs
  • 12. 22/06/2012 NAMUR NE107 Standardisation of diagnostics Slide 12 Jeroen Wynants
  • 13. 22/06/2012 NAMUR NormenArbeitsgemeinschaft für Meß- Und Regeltechnik in der chemischen Industrie NAMUR is an international association of users of automation in process industries. • Membership of NAMUR is open only to companies of the process industries, provided that these companies are • Manufacturers of chemical or pharmaceutical products, or • Users of process plants which bear responsibility for operating these plants, or • Providers of services to chemical/pharmaceutical manufacturers with or without plant operating responsibility; • Also eligible for membership are organizations with a technical or scientific purpose, e.g. scientific bodies, associations, universities etc. Slide 13 Jeroen Wynants
  • 14. 22/06/2012 NAMUR  NAMUR promotes the interests of the process industry in the field of automation 127 member companies Slide 14 Jeroen Wynants
  • 15. 22/06/2012 NAMUR • NAMUR promotes the interests of the process industry in the field of automation, including • Instrumentation with sensors and actuators • Batch control, advanced process control, plant and process monitoring, • DCS, MES and Logistic systems • Communication between process control equipment • Process management, plant asset management and • Electrical engineering • Covering the whole plant life cycle from engineering, procurement, installation, operation, and maintenance right through to decommissioning, Slide 15 Jeroen Wynants
  • 16. 22/06/2012 NAMUR Publications • The results of the work carried out by NAMUR are published: • In NAMUR recommendations (NE) and worksheets • In presentations at the Annual General Meeting • In publications which appear in technical journals (e.g. atp, at, C&A, ChemManager, CIT, etz, GIT,process , P & A, Messtech & Automation, SPS-Magazin, tm ) • In speeches made at workshops and conferences organized by cooperating partners (ARC, DECHEMA, GMA, GVC, ISA, WIB) Slide 16 Jeroen Wynants
  • 17. 22/06/2012 NAMUR Recommendations Slide 17 Jeroen Wynants Current ranges for signal levels of digital transmitters NE 43 (1988): Standardization of the Signal Level for Failure Information • Discrimination between process and failure information • P based devices NE 107 (2005): Self-Monitoring and diagnostics of Field Devices Diagnostics • Analyze status information (i.e. from field devices) • With the objective of detecting causes for potential malfunction. Diagnostics form the basis to remove malfunctions.
  • 18. 22/06/2012 NAMUR Recommendation NE107 Plant Asset Management - Evolution of diagnostics NE107 Self-Monitoring and diagnostics of Field Devices  diagnostics results must be reliable, bad diagnostic is worse than none at all.  The diagnostics results must always be viewed in the context of the application.  Each diagnostic information must be mapped to one of the four categories (FMCS)  The configuration of the mapping between the diagnostic and the category should be free but predefined.  The plant operator to see only the status signals.  Detailed information can be read out by the device specialist.Slide 18 Jeroen Wynants
  • 19. 22/06/2012 NAMUR Categories (FMCS)  Failure – F  The device provides a non-valid output signal due to some malfunction at the device level.  Maintenance required – M  Although the device is still able to provide a valid output signal, the device is about to loose some of its functionality or capability due to some external operation conditions. The maintenance can be needed short-term or mid-term.  Check function – C  The device is temporary non-valid due to some activities, maintenance activities on the device  Off-specification – S  The Device operates out of the specified measurement range Slide 19 Jeroen Wynants
  • 20. 22/06/2012 NAMUR recommendations Maintenance required Out of specification Check function Failure Diagnostics active Diagnostics passive Diagnostic symbols (NE 107) Slide 20 Jeroen Wynants
  • 21. 22/06/2012 Detailed Device Diagnostics e.g. Process Automation, Asset Management, Data Acquisition HART / PROFIBUS / FOUNDATION Fieldbus Detailed Diagnostic Events Slide 21 Jeroen Wynants
  • 22. 22/06/2012 e.g. Process Automation, Asset Management, Data Acquisition HART / PROFIBUS / FOUNDATION Fieldbus Maintenance Required Failure Functional Check Out of Specification Condensed Status and Diagnostics Plant Asset Management - Evolution of diagnostics Slide 22 Jeroen Wynants
  • 23. 22/06/2012 NAMUR recommendations Instrument diagnostics e.g. SIL certified devices (IEC 61508/61511) Application diagnostics (NE 107) e.g. Coriolis mass flow meter Gas bubbles in the liquid, fouling, clogging, erosion, corrosion, faulty mounting, external vibrations, pulsating flow, incomplete filling Application diagnostics are defined for flow -, level -, pressure -, temperature measurements and control valves Plant Asset Management - Evolution of diagnostics Slide 23 Jeroen Wynants
  • 24. 22/06/2012 Connect diagnostic to one status signal NAMUR recommendations On / off switch diagnostics Example: mass flowmeter Coriolis mass flow meter Gas bubbles in the liquid Fouling, clogging Erosion, corrosion Faulty mounting Asymmetry of measuring tubes (dual tube only) External vibrations Pulsating flow Incomplete filling Application diagnostics (NE 107) Plant Asset Management - Evolution of diagnostics Slide 24 Jeroen Wynants
  • 25. 22/06/2012 Communication protocols Slide 25 Jeroen Wynants
  • 26. 24/10/2012 Products Solutions Services HART Technology Slide 26 Jeroen Wynants
  • 27. 22/06/2012 History HART: Highway Addressable Remote Transducer  1986 Developed by Rosemount  1989 HART communication protocol made an open standard  1993 Standards developed and supported enabled by HART Communication Foundation in Austin, Texas, U.S.A http://www.hartcomm.org  2007 HART added to IEC-61158 International Standard for Fieldbus  2008 HART 7 (Wireless) Specifications finalized.  Most instruments in field today HART 5.  HART 6 and later require prescribed testing to registration.
  • 28. 22/06/2012 HART facts  Digital Frequency Shift Keying (FSK) based on the Bell 202 telephone communication standard  Transmission speed 1.2 kbit/s >> 1 transaction = 500 ms  Binary 0 = 2200 Hz, Binary 1 = 1200 Hz  Simple twisted pair 4-20mA wiring  Analog channel for fastest possible data transfer of control signal (main process value)  Digital channel >> HART based transmission of device parameters and diagnostic data to and from field devices  Frequency modulated signal on the 4-20 mA current signal modulated  Serial data transmission
  • 29. 22/06/2012 HART news and highlights  Field-proven standard used by over 32 million devices around the world  Most instruments in field today HART 5 or HART 6  More and more HART 7 devices are available but at the moment mostly for WirelessHART communication  Currently the HCF is working on a NE107 integration for the HART specification >> improved diagnostics
  • 30. 22/06/2012 Diagnostics  Acyclic access to diagnostics  Commands for transmitting diagnostics data  Command 0 (Read Unique Identifier): Universal Command, supported by every HART device. Response Code (2nd Byte): Field Device Malfunction + More Status available  Command 48 (Read Additional Transmitter Status): Common Practice Command, containing the device status Additional generic device status information  Command 231: Manufacturer Specific Command (Endress+Hauser) for transmission of diagnostics data Transmission of failure number and NE107- Category (MFCS)
  • 31. 22/06/2012 HART topology overview Controller Point to Point Multidrop Remote I/O Multiplexer WirelessHART
  • 32. 24/10/2012 Products Solutions Services PROFIBUS Technology Slide 32 Jeroen Wynants
  • 33. 22/06/2012 History PROFIBUS: PROcess FIeldBUS  1989 Standards developed and supported enabled by PROFIBUS Nutzer Organisation (PNO) http://www.profibus.com  1995 Founding of PROFIBUS International  1996 PROFIBUS PA (Process Automation)  2000 Standard field devices for process automation, Profile 3.0  2004 PROFIsafe, Condensed status and I&M functions, Profile 3.01  2008 Device integration, fast parameter transmission, Profile 3.02  Most instruments in field today have Profile 3.0 as a minimum
  • 34. 22/06/2012 PROFIBUS facts  Two technologies:  DP (Decentralized Periphery) Transmission speed DP: up to 12Mbit/s  PA (Process Automation) Transmission speed PA: fixed 31.25kbit/s)  Simple twisted pair + Shield  DP: only communication, cable length up to 1200m  PA: power and communication, cable length up to 1900m non- ex, up to 1000m
  • 35. 22/06/2012 PROFIBUS news and highlights  Successful fieldbus with more than 40 million devices installed (6.8 million in process industries)  Latest version PA Profile 3.02 introduces the NAMUR NE107:  Mapping of diagnosis information on standardized and accepted diagnostic categories (Condensed Status & Diagnosis Messages)
  • 36. 22/06/2012 Diagnostics  Continuous transmission of device status (STATUS)  Event-triggered transmission of device status (diagnostics)  Slot index for transmitting diagnostics data Diagnostic data … Calculation of Status Byte Calculation of extended diagnostics data 1 2 3 Slot 0 1 2 3 25 5 … Index 0 255… diagnostics diagnosticsE XTENSION Physical Block …… PROFIBUS diagnostics Status (cyclic data exchange) Diagnostic Parameter: 4 + 1 Byte (Quality code)
  • 37. 22/06/2012 PROFIBUS topology overview PLC/DCS Commissioning tool PROFIBUS DP T T T Remote I/O T PROFIBUS PA
  • 38. 24/10/2012 Products Solutions Services FOUNDATION fieldbus Technology Slide 38 Jeroen Wynants
  • 39. 22/06/2012 Fieldbus Foundation  1994 Standards developed and supported enabled by Fieldbus Foundation http://www.fieldbus.org  1996 FOUNDATION Fieldbus H1  1998 Registration of first H1 fieldbus products  1999 High Speed Ethernet (HSE)  2001 Registration of first HSE linking devices  2005 Safety Instrumented Functions (SIF)  2006 Diagnostic Profiles Specification according to NE107 FF History
  • 40. 22/06/2012 FF facts Two technologies:  HSE (High Speed Ethernet)  H1 (Process Automation) Transmission speed H1: fixed 31.25kbit/s)  Simple twisted pair + Shield  H1: power and communication, cable length up to 1900m non-ex, up to 1000m ex
  • 41. 22/06/2012 FF news and highlights  FF912 introduces the NAMUR NE107:  Mapping of diagnosis information on standardized and accepted diagnostic categories (Condensed Status & Diagnosis Messages)
  • 42. 22/06/2012  Continuous transmission of device status (STATUS)  Automatically and used for control (Status Propagation)  Event-triggered transmission of device status (diagnostics)  Device diagnostic can be reflected in different parts of a FOUNDATION Fieldbus device  Device specific diagnostic parameter e.g. Transducer Block parameter  Transducer Error  Block error  Alarms Diagnostics
  • 43. 22/06/2012 FF topology overview PLC/DCS Commissioning tool T T FF H1

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