Arasu Thanigai Commissioning Solutions

11 Successful Implementation & Improved Operation
Commissioning issues and
solutions
Arasu Thanigai
Pepperl+Fuchs Pte Ltd
Singapore
Fieldbus Foundation Seminar
Perth – 15th May 2013

Device Commissioning
Physical layer Commissioning
Commissioning Process

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 4~20mA
Physical Parameters
Commissioning Process

4~20mA
Install the Cables
Install the Devices
Install the DCS
Assigning the I/O
Ranging
System Ranging
Foundation 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 4~20mA
Commissioning Process Comparison.

4~20mA Foundation Fieldbus
4-20mA
P.S.
fieldbus
P.S.
Distance and relevant issue
Artificial hours and relevant cost
Cable connection Quantity
Hidden trouble points
Cable installation

4~20mA
Install the Cables
Install the Devices
Install the DCS
Assigning the I/O
Ranging
System Ranging
Foundation Fieldbus
• Install the DCS
• Ranging
• System Ranging

4~20mA Foundation Fieldbus
4-20mA
P.S.
fieldbus
P.S.
Test
Report
Distance and connection Quantity
Tools
Checking of cable installation.

4~20mA
Install the Cables
Install the Devices
Install the DCS
Assigning the I/O
Ranging
System Ranging
Foundation Fieldbus
• Install the DCS
• Ranging
• System Ranging

Device Commissioning

Assigning the I/O
Foundation fieldbus devices are recognized by three
mechanisms: a traditional node address for communication, a
human readable device tag corresponding to the project P&I
diagram, and a unique identifier allowing the system to
automatically resolve any tag or address conflicts.
The system automatically assigns the address to all devices,
avoiding human errors such as address duplication associated
with manually managed protocols, and saving time.
Therefore technicians work based on tag and need not be
concerned with address.
Thanks to the unique identifier, multiple devices can be
connected and commissioned at the same time.
It is plug-'n'-play.

4~20mA
Install the Cables
Install the Devices
Install the DCS
Assigning the I/O
Ranging
System Ranging
Foundation Fieldbus
• Install the DCS
• N/A
• N/A
• N/A
• N/A

No range mismatch
Unit downloaded when device is replaced
Transmitter Positioner
FF FF
BUS
FF
CTRL
CPU
CPU
CPU
Digital Digital
Digital
Transmitter
Range
0-800 kPa
System
Range
0-400 kPa
8 mAProcess
200 kPa
Reading
100 kPa
...alarms and trips
not working
AI
Unit
Unit
AO
Unit
Unit
4~20mA
Foundation Fieldbus

Why Foundation Fieldbus
The global process industry loses $20
billion, or five percent of annual production,
due to unscheduled downtime and poor
quality.
ARC estimates that almost 80 percent of
these losses are preventable, with 40 percent
largely due to operator error.
Source ARC Insight June 10 2010

Common issues – Device Commissioning
Check DD file and integrate into Engineering
system
Check ITK version
Check if HIST done
Check if the device listed at www.fieldbus.org

How to Check

Collaboration with NAMUR
Using the power of FOUNDATION Fieldbus, and
considering NAMUR requirements, the new standard
diagnostic profile aim to:
– Standardize the integration of diagnostic information
– Guarantee valuable information to the user

Diagnosis results must be reliable
Diagnosis results must always be viewed in
the context of the application.
Internal diagnosis must be categorized into 4
standard “status signals”
Configuration must be free, as reactions will
depend on the user's requirements
Detailed information can be read out by the
device specialist
NAMUR NE107: Self-Monitoring and Diagnosis
of Field Devices

Namur - Diagnostic categories
Maintenance Required The output from the device is
valid but the wear reserve is nearly exhausted or function
will be restricted due to operational conditions
Out of Specification Measurement uncertainty, or
output position deviation, is greater than expected due to
deviations in ambient or process conditions.
Function Check Output invalid due to ongoing work on the device
Failure Output is invalid due to a malfunction in the field device

Distribution of information
Maintenance
Required
Out of
Specification
Function
Check
Failure
Output is valid
Measurement is
uncertain
Ongoing work on the
device, output invalid
Wear reserve is
exhausted
due to deviations in
ambient conditions.
Output is invalid malfunction in the field
device
OPERATOR
INSTRUMENT
TECH

Mapping to FF Quality Status & Block Error bits
Maintenance
Required
Out of
Specification
Function
Check
Failure
Output is valid
Measurement is
uncertain
Ongoing work on the
device, output invalid
Wear reserve is
exhausted
due to deviations in
ambient conditions.
Output is invalid
malfunction in the field
device
INSTRUMENT TECH
GOOD
UNCERTAIN
OUT OF SERVICE
BAD
NEEDS MAINT SOON
NEEDS MAINT SOON
NEEDS MAINT NOW
QUALITY STATUS BLOCK ERROR
OPERATOR

Commissioning Issues
Physical Layer commissioning.

AG 181

Typical problems
Improperly closed housing
Loose wire
Internally modified
Error log showing
intermittent faults
Interoperability testing
by end user
Electro-magnetic interference
Faulty field device
Cable degradationWrong termination

Need for diagnostics
• Field study by installation and commissioning
Engineers around the world shows that more
than 80% of the plant disturbances come from
the physical layer level be it conventional
4-20mA applications or Fieldbus applications.
• Unless the engineers sufficiently trained for
Fieldbus applications the most common
mistakes are made at the physical layer level
such as wiring faults, wrong termination etc.

Asset/Resource System
Influencers
• 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 information
From ARC IndependentResearch

Zone1
Device Coupler
IS Device Coupler
FieldDevices
FieldDevices
FieldDevices
Zone2
Device coupler
Terminator
Surge
Protect.
Surge
Protect.
FieldDevices
Fieldbus
Process
Interfaces
Complete Interface
Power
Supplies

Hazardous safety rules not followed
– Ground faults
– Fieldbus and power
cables tied together

Poor cable installation

ANSI recommendation
Communication
Cables
(Fieldbus)
Shielded/Unshielded
Cables Carrying
>60 VDC or
>25 VAC but
<= 400 V
Shielded/Unshielded
Cables Carrying
> 400 V
Any Cables at
risk of
Lighting
Communication
Cables
(Fieldbus)
10 cm 20 cm 50 cm
Shielded/Unshielded
Cables Carrying
>60 VDC or
>25 VACbut
<= 400 V
10 cm 10 cm 50 cm
Shielded/Unshielded
Cables Carrying
> 400 V
20 cm 10 cm 50 cm
Any Cables at
risk of Lighting 50 cm 50 cm 50 cm

Poor cable installations
– Cable gland not tight
– Seal missing

And corrosion as a consequence
– Water ingress or worse:
– Aggressive media

Poor Device Instalation

Poor maintenance

Typical locations and Fieldbus issues

– 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 testing
Test Report
Commissioning in the Past.

A portable tool for commissioning, monitoring,
troubleshooting and printout.
Portable Commissioning Tools

Online Commissioning Tools

What parameters to look for
– External power supply
– Fieldbus Output Power
– Fieldbus Segment current
– Grounding and shielding
– Communicaiton quality ( jitter) of segment and
devices
– Signal amplitude
– Noise at segment and deivces
– FF Signal Waveform of the semgent
– Terminators
– Surge protection
– Water / Moisutre

Simple 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 Wizard
Test
Report
x

One Plant Asset Management
– Includes fieldbus now as asset
– Customary look and feel
– Reduces required training
– Reduces potential for errors
Open Architecture Integration:
– AMS Suite
– PRM
– FieldCare
– FieldMate
– PACTware
– OPC Interface
– Experion
– Many More
Commissioning now via DCS

Commissioning done from control room
Spurs
Field Instruments
Power Supply
Advanced Diagnostic Module
Device coupler
Trunk
Surge Protector
Terminator
Host

Just an Example - ADM via DCS Asset
Management
Diagnostics at
DCS Station
Relaycontact
optional)
RS485
Industrial Switch
Ethernet
or
FF H1
Address switches

Just an Example - Commissioning via
DCS Asset management
PRM Alarm window view
PRM Network view
Segment-specific status of the physical layer
ADM status view with PRM TAG
FF-Segment
FF-Host

Commissioning Wizard
With Expert System Support
– Takes snapshot
– Identifies wiring errors
– Ensures compliance with
AG181 and IEC 61158-2
– Recommends limits for ADM
messages
– Stores limits in non-volatile memory
Automatic Tag Readout
Creates baseline report:
– Snapshot of all measurements
– Complete documentation
Saves pre-commissioning time
significantly

Online monitoring
Clean layout shows boundaries
– Displays measurement values
– Highlights violations with color coding:
– Issues diagnostic messages
Good value
Maintenance required
Out of specification

Diagnostic Menu
Expert System delivers
clear text information for
fast fault finding
1 Active messages
2 Actionable information
with solution guideance
based on expert system
3 History with timestamps
When the failure…
… occured
… disappeared
– Export function for
external analysis and
storage
11
222
33

Built-in fieldbus oscilloscope Feature
ADM provides expert tools
for fast fault finding
– For diagnosing complex scenarios
– For the fieldbus expert
– With fieldbus specific triggers
– Captures up to 10 shots in a row

Wiring issues

53
Bad wiring technique
Welding, variable frequency drives (VFD),
Motors, machinery:
Increase of HF noise
Increasing number of retransmissions
Can be a combination of both

Practical Example – Line frequency coupled
In this example the frequency of noise was
approx. 150Hz
7 ms

Not a good device location
FF Device Moved away from
Drive

Loose wiring issues
“Make” Disturbance
"Break" disturbance
Vibration
frequency
FF signal
Failed telegram
Telegram

Does Surge Protection works?
FIELDBUS
TERMINATOR
SEGMENT
PROTECTORS
HOST
FIELDBARRIERS
PROCESS
INTERFACE
POWER
SUPPLY
CONVENTIONAL
FIELD DEVICES
FIELDBUS
DEVICES
JUNCTION
BOX
But Practically this setup is not
possible due to cost reasons.
Protection at both trunk ends is
more feasible
During commissioning or
normal operation, surge
protection devices can be
check if it works

Conclusion
– Advanced Diagnostics tools for for physical layer
reduced physical layer commissiong time and
provided online monitoring and reporting system that
saves 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 device
commissioning crew to check network operation, spotting any problems
early
– Many contractors and Technicians are trained and are skilled in Fieldbus
installation and commissioning, and have the test equipment and in-
house procedures to ensure reliable operation

Arasu Thanigai Commissioning Solutions

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