Fieldbus Tutorial Part 9 - Fieldbus Diagnostics

4,108 views

Published on

Fieldbus Tutorial Part 9 – Fieldbus Diagnostics: Introduction, Level of Diagnostics, Function Block Diagnostics, Resource Block Diagnostics, Transducer Block Diagnostics

Published in: Technology, Business
1 Comment
9 Likes
Statistics
Notes
No Downloads
Views
Total views
4,108
On SlideShare
0
From Embeds
0
Number of Embeds
3
Actions
Shares
0
Downloads
1,401
Comments
1
Likes
9
Embeds 0
No embeds

No notes for slide

Fieldbus Tutorial Part 9 - Fieldbus Diagnostics

  1. 1. Fieldbus Diagnostics
  2. 2. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 2  Introduction  Level of Diagnostics  Function Block Diagnostics  Resource Block Diagnostics  Transducer Block Diagnostics Agenda
  3. 3. Fieldbus brings dramatic savings in installation and commissioning, but the real value is seen during plant operation...
  4. 4. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 4 Routine Check No Problem Failed Instrument Plugged Lines Zero Off Calibration Shift 35% 28% 20% 6% 6% 4% Source: Dow Chemical • 63% of trips to the field can be eliminated 0 10 20 30 40 50 Elimination of “Unneeded” Trips to the field: Transmitter Diagnostics
  5. 5. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Level 3 Operations Make Up Water Turbine Generator Boiler Pulveration Level 2 Drift Loop Level 1 µP Device Plugged Impulse Line Electronics Diagnostics Sensor Drift Communications Diagnostics Diagnostics Definitions
  6. 6. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 6 Device Maintains Statistics For Communication Diagnostics
  7. 7. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 7 Diagnostic Examples  Transmitter generates an alert when  the sensor degenerates  the device has exceeded factory maximum field temperature usage • Cycle Counter • Valve Signature • Dynamic Error Band  O2 Sensor creates alert when the sensor fouls
  8. 8. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 8 Using Device Intelligence The Device Detects Process Conditions Impulse Lines Plug 0 2 4 6 8 10 12 14 16 18 201.81 1.811 1.812 1.813 1.814 1.815 1.816 1.817 1.818 1.819 1.82 Time (min) PV(V)
  9. 9. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 9 Devices Provide Predictive Diagnostics Provide Information On Life Expectancy and Performance Degradation Device Performance Failure Predictive Alarm
  10. 10. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 10 Diagnostics are Utilized in Fieldbus Blocks for Measurement and Control PV is Marked„Uncertain‟ or „Bad‟ if Abnormal and propagated
  11. 11. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 11 H1 Event is Time Stamped At The Source!
  12. 12. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 12 Failed Electrode Signal Fault Communications Failure Failed Maintenance Advisory Maintenance Sensor Calibration FT-101 Inlet 3, Cooling Tower 1 TOWER_1 Conditions of FT-101 Sensor Failed Perform recommended sensor/wiring checksRecommended Action: Failed Conditions Advisory Process HelpClosePrint ? Electrode Signal Fault Grounding/Wiring Fault mV50/60 Hz Noise:: Enable Enable .003401 i Electronics Maintenance X
  13. 13. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 13 Process plants can be tough on field devices!
  14. 14. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 14 Internal Diagnostics  Sensor failure  Sensor malfunction  Sensor disconnected  Electronic Board failure  Bad grounding  Operating conditions out of specifications
  15. 15. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 15 Process Diagnostics  Plugged line  Empty pipe  Statistical Process Monitoring  Vibration  Valve travel integration  Noise  Drift  Flame instability  >>>>>>
  16. 16. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 16 Diagnostic Examples  Transmitter generates an alert when  the sensor degenerates  the device has exceeded factory maximum field temperature usage • Cycle Counter • Valve Signature • Dynamic Error Band  O2 Sensor creates alert when the sensor fouls
  17. 17. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 17 Variability Index provides additional insight into Loop Performance Variable Variability Index Acceptable Value VI= Measured Standard Deviation Minimum Expected Standard Deviation Is Detected with Variability Index DeltaV Inspect Identifies Under-performing Loops Take Corrective Action Performance Change Variability Index Diagnostic
  18. 18. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 18 Plugged Impulse Line Diagnostic Manifold Sensing Line Flow Clog 0 2 4 6 8 10 12 14 16 18 20 1.81 1.811 1.812 1.813 1.814 1.815 1.816 1.817 1.818 1.819 1.82 Time (min) PV(V) Both Open HP Closed LP Closed Both Closed
  19. 19. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 19 Statistical Process Monitoring
  20. 20. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 20 Proof Using SPM Prevents Plant Damage SPM Data 6/4 6/6 6/8 6/10 6/12 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 23:30 23:00 PHD Data 23:30 23:00 Statistical Process Monitoring data coming from 3051 ADB helped predict catalyst problem 30 min in advance 23:00 Source: ExxonMobil Baytown, Tx Refinery
  21. 21. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 21 Status AI Value: 234.5 m3/h Status: Good, Bad or Uncertain Sub-Status: (more status details) Limit : High, Low, Constant or not limited Status can be used in the control strategy to switch a controller to Manual when the variable goes to a Bad status. All connectable variables have STATUS. STATUS VALUE Diagnostics
  22. 22. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 22 Status
  23. 23. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 23 Diagnostics are Utilized in Fieldbus Blocks for Measurement and Control PV is Marked„Uncertain‟ or „Bad‟ if Abnormal and propagated
  24. 24. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 24 Classic I/O H1 Other Buses Other Buses Event is Time Stamped At The Source!
  25. 25. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 25 Plantweb alerts Sensor Failure Maintenance Soon Maintenance Soon Maintenance Soon Maintenance Soon Sensor FailureInstallation Problems Installation Problems Sensor Failure Installation Problems Installation Problems Sensor Failure Failed Maintenance Advisory Route to appropriate plant organization Recommended Action Troubleshooting guide
  26. 26. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 26 Failed Electrode Signal Fault Communications Failure Failed Maintenance Advisory Maintenance Sensor Calibration FT-101 Inlet 3, Cooling Tower 1 TOWER_1 Conditions of FT-101 Sensor Failed Perform recommended sensor/wiring checksRecommended Action: Failed Conditions Advisory Process HelpClosePrint ? Electrode Signal Fault Grounding/Wiring Fault mV50/60 Hz Noise:: Enable Enable .003401 i Electronics Maintenance X
  27. 27. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 27 Operation  Devices are identified by Tag  Variables are identified by: TAG.Desired Parameter No need to remember the Transmitters Hardware Address . FT102A, not CTL01C03A01 FT 102A FIC 102A FCV 102A FIC102A.OUT
  28. 28. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 28 Transducer, Resource and Function Blocks  Every Field device has to have a Resource Block and one or more Transducer blocks.  Function Blocks are desirable, but not mandatory.  Resource Block contains information about the device resources: hardware and software.  Transducer blocks control access to Input and Output interfaces such as sensors, switches, actuators etc.  Transducer decouples the process interface from the Function Blocks. They can run as fast as they can.  Transducer blocks also allow calibration and access to diagnostics.
  29. 29. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 29 Resource Block  Hardware and Software resources.  When Mode is Out of Service, all other blocks will be Out of Service.  Allow Device resetting, including resetting with Default values.  All Emerson devices have a common Resource Block, with very small variations.
  30. 30. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 30 Pressure Resource Block - Identification
  31. 31. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 31 Pressure Resource Block - Process
  32. 32. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 32 Pressure Resource Block - Alarms
  33. 33. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 33 Pressure Resource Block - Hardware
  34. 34. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 34 Pressure Resource Block - Options
  35. 35. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 35 Pressure Resource Block – Suppressed Alarms
  36. 36. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 36 Transducer Blocks  Transducer blocks provide the interface to sensors, switches, actuators, etc.  Transducer blocks also allow access to calibration and I/O diagnostics.  If the Transducer Block is in Out of Service Mode, the Function Blocks will have measurement value with Bad Status.  Transducer communicates the values to the I/O Function Blocks via Channels.
  37. 37. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 37 Transducer Sensor 1 Sensor 2 Sensor 3 AI 1Channel 1 Ch. 1 AI 2Channel 2 Ch. 2 AI 3Channel 3 Ch. 3 AI 4Channel 4 Ch. 4calc Transducer ScheduleFree Running
  38. 38. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 38 Important to remember  AI or AO block has to have the Channel configured accordingly. Channel = 0, no measurement or actuation.  AI or AO block XD_SCALE parameter has to have the same valid Engineering Unit. Pressure measurement should be inH2O@68F, mbar, psi,etc. Temperature should be deg. C, not C.  Transducer should be in Auto.
  39. 39. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 39 Pressure Transducer - Process
  40. 40. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 40 Pressure Transducer - Sensor
  41. 41. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 41 Pressure Transducer - PV
  42. 42. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 42 Pressure Transducer -SV
  43. 43. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 43 Pressure Transducer - Materials
  44. 44. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 44 Pressure Transducer - LCD
  45. 45. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 45 Pressure Transducer - LCD
  46. 46. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 46 Pressure Transducer – Advanced Diagnostic Block
  47. 47. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 47 Pressure Transducer – Advanced Diagnostic Block
  48. 48. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 48 Pressure Transducer - Status
  49. 49. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 49 Pressure Transducer - Status
  50. 50. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 50 Pressure Transducer - Status
  51. 51. [File Name or Event] Emerson Confidential 27-Jun-01, Slide 51 Pressure Transducer - Status

×