Arasu Thanigai Commissioning Solutions

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Arasu Thanigai Commissioning Solutions

  1. 1. 11 Successful Implementation & Improved OperationCommissioning issues andsolutionsArasu ThanigaiPepperl+Fuchs Pte LtdSingaporeFieldbus Foundation SeminarPerth – 15th May 2013
  2. 2. 22 Successful Implementation & Improved OperationDevice CommissioningPhysical layer CommissioningCommissioning Process
  3. 3. 33 Successful Implementation & Improved OperationInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installationInstall the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAPhysical ParametersCommissioning Process
  4. 4. 44 Successful Implementation & Improved Operation4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installationInstall the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAFoundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mACommissioning Process Comparison.
  5. 5. 55 Successful Implementation & Improved Operation4~20mA Foundation Fieldbus4-20mAP.S.fieldbusP.S.Distance and relevant issueArtificial hours and relevant costCable connection QuantityHidden trouble pointsCable installation
  6. 6. 66 Successful Implementation & Improved Operation4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installationInstall the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAFoundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mACommissioning Process Comparison.
  7. 7. 77 Successful Implementation & Improved Operation4~20mA Foundation Fieldbus4-20mAP.S.fieldbusP.S.TestReportDistance and connection QuantityToolsChecking of cable installation.
  8. 8. 88 Successful Implementation & Improved Operation4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installationInstall the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAFoundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mACommissioning Process Comparison.
  9. 9. 99 Successful Implementation & Improved Operation4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installationInstall the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAFoundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation• Install the DCS• Assigning the I/O• Calibration the Sensor• Ranging• Calibration the 4~20mA• System Ranging• System Calibration 4~20mACommissioning Process Comparison.
  10. 10. 1010 Successful Implementation & Improved OperationDevice Commissioning
  11. 11. 1111 Successful Implementation & Improved OperationAssigning the I/OFoundation fieldbus devices are recognized by threemechanisms: a traditional node address for communication, ahuman readable device tag corresponding to the project P&Idiagram, and a unique identifier allowing the system toautomatically resolve any tag or address conflicts.The system automatically assigns the address to all devices,avoiding human errors such as address duplication associatedwith manually managed protocols, and saving time.Therefore technicians work based on tag and need not beconcerned with address.Thanks to the unique identifier, multiple devices can beconnected and commissioned at the same time.It is plug-n-play.
  12. 12. 1212 Successful Implementation & Improved Operation4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installationInstall the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAFoundation Fieldbus• Install the Cables• Check out the cable installation• Install the Devices• Check the device installation• Install the DCS• Assigning the I/O• Calibration the Sensor• N/A• N/A• N/A• N/ACommissioning Process Comparison.
  13. 13. 1313 Successful Implementation & Improved OperationNo range mismatchUnit downloaded when device is replacedTransmitter PositionerFF FFBUSFFCTRLCPUCPUCPUDigital DigitalDigitalTransmitterRange0-800 kPaSystemRange0-400 kPa8 mAProcess200 kPaReading100 kPa...alarms and tripsnot workingAIUnitUnitAOUnitUnitCommissioning Process Comparison.4~20mAFoundation Fieldbus
  14. 14. 1414 Successful Implementation & Improved OperationWhy Foundation FieldbusThe global process industry loses $20billion, or five percent of annual production,due to unscheduled downtime and poorquality.ARC estimates that almost 80 percent ofthese losses are preventable, with 40 percentlargely due to operator error.Source ARC Insight June 10 2010
  15. 15. 1515 Successful Implementation & Improved OperationCommon issues – Device CommissioningCheck DD file and integrate into EngineeringsystemCheck ITK versionCheck if HIST doneCheck if the device listed at www.fieldbus.org
  16. 16. 1616 Successful Implementation & Improved OperationHow to Check
  17. 17. 1717 Successful Implementation & Improved OperationCollaboration with NAMURUsing the power of FOUNDATION Fieldbus, andconsidering NAMUR requirements, the new standarddiagnostic profile aim to:– Standardize the integration of diagnostic information– Guarantee valuable information to the user
  18. 18. 1818 Successful Implementation & Improved OperationDiagnosis results must be reliableDiagnosis results must always be viewed inthe context of the application.Internal diagnosis must be categorized into 4standard “status signals”Configuration must be free, as reactions willdepend on the users requirementsDetailed information can be read out by thedevice specialistNAMUR NE107: Self-Monitoring and Diagnosisof Field Devices
  19. 19. 1919 Successful Implementation & Improved OperationNamur - Diagnostic categoriesMaintenance Required The output from the device isvalid but the wear reserve is nearly exhausted or functionwill be restricted due to operational conditionsOut of Specification Measurement uncertainty, oroutput position deviation, is greater than expected due todeviations in ambient or process conditions.Function Check Output invalid due to ongoing work on the deviceFailure Output is invalid due to a malfunction in the field device
  20. 20. 2020 Successful Implementation & Improved OperationDistribution of informationMaintenanceRequiredOut ofSpecificationFunctionCheckFailureOutput is validMeasurement isuncertainOngoing work on thedevice, output invalidWear reserve isexhausteddue to deviations inambient conditions.Output is invalid malfunction in the fielddeviceOPERATORINSTRUMENTTECH
  21. 21. 2121 Successful Implementation & Improved OperationMapping to FF Quality Status & Block Error bitsMaintenanceRequiredOut ofSpecificationFunctionCheckFailureOutput is validMeasurement isuncertainOngoing work on thedevice, output invalidWear reserve isexhausteddue to deviations inambient conditions.Output is invalidmalfunction in the fielddeviceINSTRUMENT TECHGOODUNCERTAINOUT OF SERVICEBADNEEDS MAINT SOONNEEDS MAINT SOONNEEDS MAINT NOWQUALITY STATUS BLOCK ERROROPERATOR
  22. 22. 2222 Successful Implementation & Improved OperationCommissioning IssuesPhysical Layer commissioning.
  23. 23. 2323 Successful Implementation & Improved OperationAG 181
  24. 24. 2424 Successful Implementation & Improved OperationTypical problemsImproperly closed housingLoose wireInternally modifiedError log showingintermittent faultsInteroperability testingby end userElectro-magnetic interferenceFaulty field deviceCable degradationWrong termination
  25. 25. 2525 Successful Implementation & Improved OperationNeed for diagnostics• Field study by installation and commissioningEngineers around the world shows that morethan 80% of the plant disturbances come fromthe physical layer level be it conventional4-20mA applications or Fieldbus applications.• Unless the engineers sufficiently trained forFieldbus applications the most commonmistakes are made at the physical layer levelsuch as wiring faults, wrong termination etc.
  26. 26. 2626 Successful Implementation & Improved OperationAsset/Resource SystemInfluencers• Maintenance Cost Reduction Drives End Users• 40% of Mfg. Cost is Maintenance• 50% of Maintenance Is Corrective– 10 times More Costly Than Preventative Maintenance• Preventative Maintenance is Done 25% of Time– 5 Times More costly Than Predictive Maintenance• 60% of Preventative Maintenance is Unnecessary• What has been largely missing up to now is timely,relevant, and accurate informationFrom ARC IndependentResearch
  27. 27. 2727 Successful Implementation & Improved OperationZone1Device CouplerIS Device CouplerFieldDevicesFieldDevicesFieldDevicesZone2Device couplerTerminatorSurgeProtect.SurgeProtect.FieldDevicesFieldbusProcessInterfacesComplete InterfacePowerSupplies
  28. 28. 2828 Successful Implementation & Improved OperationHazardous safety rules not followed– Ground faults– Fieldbus and powercables tied together
  29. 29. 2929 Successful Implementation & Improved OperationPoor cable installation
  30. 30. 3030 Successful Implementation & Improved OperationANSI recommendationCommunicationCables(Fieldbus)Shielded/UnshieldedCables Carrying>60 VDC or>25 VAC but<= 400 VShielded/UnshieldedCables Carrying> 400 VAny Cables atrisk ofLightingCommunicationCables(Fieldbus)10 cm 20 cm 50 cmShielded/UnshieldedCables Carrying>60 VDC or>25 VACbut<= 400 V10 cm 10 cm 50 cmShielded/UnshieldedCables Carrying> 400 V20 cm 10 cm 50 cmAny Cables atrisk of Lighting 50 cm 50 cm 50 cm
  31. 31. 3131 Successful Implementation & Improved OperationPoor cable installations– Cable gland not tight– Seal missing
  32. 32. 3232 Successful Implementation & Improved OperationAnd corrosion as a consequence– Water ingress or worse:– Aggressive media
  33. 33. 3333 Successful Implementation & Improved OperationPoor Device Instalation
  34. 34. 3434 Successful Implementation & Improved OperationPoor maintenance
  35. 35. 3535 Successful Implementation & Improved OperationTypical locations and Fieldbus issues
  36. 36. 3636 Successful Implementation & Improved Operation– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires• Screw driver• Check sheet• Pencil• Multimeter• Battery Powered Oscilloscope– Connect one device at a time– Disconnect after testingTest ReportCommissioning in the Past.
  37. 37. 3737 Successful Implementation & Improved OperationA portable tool for commissioning, monitoring,troubleshooting and printout.Portable Commissioning Tools
  38. 38. 3838 Successful Implementation & Improved OperationOnline Commissioning Tools
  39. 39. 3939 Successful Implementation & Improved OperationOnline Commissioning Tools
  40. 40. 4040 Successful Implementation & Improved OperationOnline Commissioning Tools
  41. 41. 4141 Successful Implementation & Improved OperationOnline Commissioning Tools
  42. 42. 4242 Successful Implementation & Improved OperationWhat parameters to look for– External power supply– Fieldbus Output Power– Fieldbus Segment current– Grounding and shielding– Communicaiton quality ( jitter) of segment anddevices– Signal amplitude– Noise at segment and deivces– FF Signal Waveform of the semgent– Terminators– Surge protection– Water / Moisutre
  43. 43. 4343 Successful Implementation & Improved OperationSimple Commissioning Steps with ADM– Verify address setting– Wire up devices in the right location– Check shielding– Activate communication– Use automated work procedures• Testing• Documentation– All devices at once– Wiring remains undisturbed! Commissioning WizardTestReportx
  44. 44. 4444 Successful Implementation & Improved OperationOne Plant Asset Management– Includes fieldbus now as asset– Customary look and feel– Reduces required training– Reduces potential for errorsOpen Architecture Integration:– AMS Suite– PRM– FieldCare– FieldMate– PACTware– OPC Interface– Experion– Many MoreCommissioning now via DCS
  45. 45. 4545 Successful Implementation & Improved OperationCommissioning done from control roomSpursField InstrumentsPower SupplyAdvanced Diagnostic ModuleDevice couplerTrunkSurge ProtectorTerminatorHost
  46. 46. 4646 Successful Implementation & Improved OperationJust an Example - ADM via DCS AssetManagementDiagnostics atDCS StationRelaycontactoptional)RS485Industrial SwitchEthernetorFF H1Address switches
  47. 47. 4747 Successful Implementation & Improved OperationJust an Example - Commissioning viaDCS Asset managementPRM Alarm window viewPRM Network viewSegment-specific status of the physical layerADM status view with PRM TAGFF-SegmentFF-Host
  48. 48. 4848 Successful Implementation & Improved OperationCommissioning WizardWith Expert System Support– Takes snapshot– Identifies wiring errors– Ensures compliance withAG181 and IEC 61158-2– Recommends limits for ADMmessages– Stores limits in non-volatile memoryAutomatic Tag ReadoutCreates baseline report:– Snapshot of all measurements– Complete documentationSaves pre-commissioning timesignificantly
  49. 49. 4949 Successful Implementation & Improved OperationOnline monitoringClean layout shows boundaries– Displays measurement values– Highlights violations with color coding:– Issues diagnostic messagesGood valueMaintenance requiredOut of specification
  50. 50. 5050 Successful Implementation & Improved OperationDiagnostic MenuExpert System deliversclear text information forfast fault finding1 Active messages2 Actionable informationwith solution guideancebased on expert system3 History with timestampsWhen the failure…… occured… disappeared– Export function forexternal analysis andstorage1122233
  51. 51. 5151 Successful Implementation & Improved OperationBuilt-in fieldbus oscilloscope FeatureADM provides expert toolsfor fast fault finding– For diagnosing complex scenarios– For the fieldbus expert– With fieldbus specific triggers– Captures up to 10 shots in a row
  52. 52. 5252 Successful Implementation & Improved OperationWiring issues
  53. 53. 5353 Successful Implementation & Improved Operation53Bad wiring techniqueWelding, variable frequency drives (VFD),Motors, machinery:Increase of HF noiseIncreasing number of retransmissionsCan be a combination of both
  54. 54. 5454 Successful Implementation & Improved OperationPractical Example – Line frequency coupledIn this example the frequency of noise wasapprox. 150Hz7 ms
  55. 55. 5555 Successful Implementation & Improved OperationNot a good device locationFF Device Moved away fromDrive
  56. 56. 5656 Successful Implementation & Improved OperationLoose wiring issues“Make” Disturbance"Break" disturbanceVibrationfrequencyFF signalFailed telegramTelegram
  57. 57. 5757 Successful Implementation & Improved OperationDoes Surge Protection works?FIELDBUSTERMINATORSEGMENTPROTECTORSHOSTFIELDBARRIERSPROCESSINTERFACEPOWERSUPPLYCONVENTIONALFIELD DEVICESFIELDBUSDEVICESJUNCTIONBOXBut Practically this setup is notpossible due to cost reasons.Protection at both trunk ends ismore feasibleDuring commissioning ornormal operation, surgeprotection devices can becheck if it works
  58. 58. 5858 Successful Implementation & Improved OperationConclusion– Advanced Diagnostics tools for for physical layerreduced physical layer commissiong time andprovided online monitoring and reporting system thatsaves CAPEX and OPEX– Most problems at early bus installations were due to poor installation.However, simple, user-friendly, Fieldbus testers are now available,allowing the installation crew to easily check the wiring, and the devicecommissioning crew to check network operation, spotting any problemsearly– Many contractors and Technicians are trained and are skilled in Fieldbusinstallation and commissioning, and have the test equipment and in-house procedures to ensure reliable operation

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