Fieldbus Tutorial Part 9 - Fieldbus Diagnostics

[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

Fieldbus brings dramatic
savings in installation and
commissioning, but the
real value is seen during
plant operation...

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

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

27-Jun-01, Slide 6
Device Maintains Statistics For Communication
Diagnostics

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

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)

27-Jun-01, Slide 9
Devices Provide Predictive Diagnostics
Provide Information On Life Expectancy and
Performance Degradation
Device Performance
Failure
Predictive Alarm

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

27-Jun-01, Slide 11
H1
Event is Time Stamped At The Source!

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

27-Jun-01, Slide 13
Process plants can be tough on field
devices!

27-Jun-01, Slide 14
Internal Diagnostics
 Sensor failure
 Sensor malfunction
 Sensor disconnected
 Electronic Board failure
 Bad grounding
 Operating conditions out of specifications

27-Jun-01, Slide 15
Process Diagnostics
 Plugged line
 Empty pipe
 Statistical Process Monitoring
 Vibration
 Valve travel integration
 Noise
 Drift
 Flame instability
 >>>>>>

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

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

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

27-Jun-01, Slide 19
Statistical Process Monitoring

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

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

27-Jun-01, Slide 22
Status

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

27-Jun-01, Slide 24
Classic I/O
H1
Other Buses
Other Buses
Event is Time Stamped At The Source!

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

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-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

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.

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.

27-Jun-01, Slide 30
Pressure Resource Block - Identification

27-Jun-01, Slide 31
Pressure Resource Block - Process

27-Jun-01, Slide 32
Pressure Resource Block - Alarms

27-Jun-01, Slide 33
Pressure Resource Block - Hardware

27-Jun-01, Slide 34
Pressure Resource Block - Options

27-Jun-01, Slide 35
Pressure Resource Block – Suppressed
Alarms

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.

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

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.

Fieldbus Tutorial Part 9 - Fieldbus Diagnostics

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Fieldbus Tutorial Part 9 - Fieldbus Diagnostics