FF Seminar November 2011

Asset Management and Foundation

Fieldbus

Bindert Douma; Certified FF trainer for STC

Contents

Successful Asset Management is balance between:

People

Technology Work procedures

Diagnostic contributors

Sub-elements:

People

Technology Work procedures

TRAINING

MAINTENANCE

STRATEGY

FOUNDATION

FIELDBUS

STANDARDS

TOOLS

ORGANIGRAM

STC-Brielle One of the 7 Dutch locations

Education centre of process automation

Certified FF training site

Several STC centres

STC Training Centres

9 Pilot plants

Brielle existing units

Central control room

Units are planned for the

regular programme

Brielle new building for maintenance

FF training will be given in

the new building

Additional maintenance pilot plants

are forseen.

Asset Management and FF technology

• Diagnostics with proper alerts and events is key to success?

• Standards are important?

• Proper tools are needed?

BLOCK

Function Resource Transducer

Encapsulate basic automation

functions

Link across the fieldbus

network

Explicitly scheduled

Provide deterministic control

General information of

the device

Resource related

timers

Input/Output specific

information

Calibration

Configuration

Function blocks applications

• Every FF 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; Today most diagnostic information is found

in a Transducer Block!

Transducer, Resource and Function Blocks

Transducer, Resource and Function Blocks

Quality 2 bits : Sub-status

4 bits

Limit 2 bits :

– Good(NC) - Non

Cascade

– Good(C) - Cascade

– Uncertain

– Bad

Additional details on

the status of the data

Notify of upstream

alerts

Block communication

and handshake

High Limited

Low Limited

Constant

Not Limited

All Function Block inputs/output contain status Status can be read as three separate parts. Status relates to health and quality of data.

Function Blocks; Data quality and diagnostics

In total 256 status possibilities of which several free configurable.

Status often lost in the DCS processing

Function Block status is not readily used in diagnostics

Function Blocks; Data quality and diagnostics

0 – Other

1 – Block Configuration

2 – Link Configuration

3 – Simulation

4 – Override

5 – Fault State

6 – Maintenance Needed Soon

7 – Input Failure

8 – Output Failure

9 – Memory Failure

10 – Lost Static Memory

11 – Lost NV Memory

12 – ReadBack Failure

13 – Maintenance Needed Now

14 – Power Up

15 – Out of Service

This parameter reflects the error

status associated with the hardware

or software components associated

with a block. It is a bit string, so that

multiple errors may be shown

Traditional the Block_Err was used as

diagnostic ‘trigger’

Device Diagnostic Alarm scope is Resource/Transducer Alarms.

Process Alarms are managed by existing Function Blocks alarms.

Alarm Type Relation Failure Type Block Type

Process Alarm Process / Environment Process failures

Faults in the process Function

Device Alarm

Instrument

Sensor/Actuator element failures

Faults in the sensor or actuator element

Transducer &

Resource

Electronic failures

Faults in the electronics

Configuration/servicing failures

Installation faults, fault during start-up

Process / Environment

Process induced failures

Faults due to process influence

Faults due to non-compliance with specified

operating conditions

Function Blocks; Data quality and diagnostics

Device vendors use dedicated Diagnostic Transducer Blocks

Asset management/DCS system do not always find these specific Blocks

NAMUR NE107 Standard

NAMUR NE107 standard adopted in the FF specification:

Traffic light approach is insufficient for diagnostic reporting

– Field Diagnostics has four standard device alarms:

• Failure FD_FAIL

• Off Specification FD_OFFSPEC

• Maintenance FD_MAINT

• Check Function FD_CHECK

– 32bit Block_Err now located in the RESOURCE Block

– Configuration must be definable by user

– Developer must define a default configuration, as well

– Standardizes the organizing, filtering, and reporting of

diagnostics • Not the specific diagnostic elements

– Guarantee valuable information to the user • Done with Role Based Diagnostics

Data quality and diagnostics

– Field Diagnostics provide right info to the right person

at the right time

• Role based diagnostics – ie: maintenance stuff to an asset management setup, to let them know that something needs

replacing soon

• Each bucket (failure, maint, off-spec, check) can be directed

to a different place, and can select for which conditions are

included in each bucket

• Consistent diagnostics structure, delivery

• Still part of push based diagnostic information

Data quality and diagnostics

SYSTEM I/O

FF ASi Hart DP

L1 (Vnet, UCN, HSE, wireless)

IPF

4-20

FGS

4-20

PL

AN

T S

YS

TE

MS

L2 Control Bus

Fiscal

4-20

Other

4-20

L3 Process Control Network

BU

SIN

ES

S

SY

ST

EM

S

L4 Office Network

PCAD

HIST. Appl. Servers

ERP

Bently Nev.

Amadas / Analysers

TDAS

Etc.

Operator

Maintenance

Engineering

Simul/Train

Asset Man.

Optimisation

….

E.g. OPC, AMS, ..

Continuous

Batch

Discrete

Production

Management

Systems

Business

Logistics

Systems

Sales,

Scheduling

Production Planning

Plant Optimisation

Quality Managemnent

Data Quality

Maintenance alerts to

maintenance station

Process alarms to

operator station

Alarm routing and Data quality

• Current strategy is mainly based on re-active and on

preventive maintenance with 4- 20 mA technology

• No maintenance advantage is being realised with HART

technology.

• Foundation Fieldbus (FF) devices with dedicated asset

management packages now provides a better basis for an

optimal maintenance strategy

Maintenance today

CCGCTL01 CCGCTL02 CCGCTL03

03-01-29-02MF2

03-01-29-01MF2

03-01-19-01MF2

03-01-17-02MF2

03-01-17-01CSS

03-01-13-02

MF2/CSS03-01-01-01

MF2

03-01-01-02MF2

03-01-03-01MF2

03-01-03-02

CSS/MF2

03-01-05-01

CSS/MF1

03-01-05-02MF2

03-01-09-01

CSS/MF2

03-01-09-02MF2

03-01-11-01

CSS/MF2

03-01-11-02CSS

03-01-13-01

MF2/CSS

01-01-01-01

CCS/RR2

01-01-01-02CSS

01-01-03-01

CSS/RR2

01-01-03-02

CSS/RR2

01-01-05-01CSS

01-01-05-02CSS

01-01-09-01CSS

01-01-17-02

CSS/RR2

01-01-19-01

CSS/RR2

01-01-19-02

CSS/RR2

01-01-21-01

CSS/RR2

01-01-21-02RR2

01-01-25-01

CSS/RR2

01-01-25-02CSS

01-01-27-01

CSS/RR2

01-01-27-02RR2

01-01-29-01RR2

01-01-29-02

CSS/RR2

02-01-01-01RR1

02-01-01-02RR1

02-01-03-01RR1

02-01-03-02NONE

02-01-05-01RR1

02-01-05-02RR1

02-01-09-01RR1

02-01-09-02RR1

02-01-23-02RR1

02-01-23-01RR1

02-01-21-02RR1

02-01-21-01NONE

02-01-19-02RR1

02-01-19-01CSS

02-01-17-02RR1

02-01-17-01RR1

02-01-25-01RR1

02-01-25-02

RR1/CSS

02-01-27-01RR1

02-01-27-02RR1

02-01-29-01RR1

02-01-11-01RR1

02-01-11-02

CSS/RR1

02-01-13-01

CSS/RR1/MF1

02-01-13-02RR1

02-01-15-01RR1

01-01-09-02CSS

01-01-11-01CSS

01-01-11-02CSS

01-01-13-01CSS

01-01-13-02CSS

01-01-31-01RR2

01-01-31-02RR2

01-01-17-01RR2

02-01-15-02NONE

02-01-29-02

RR1/CSS

03-01-27-02

MF2/CSS

03-01-27-01

MF2/CSS

03-01-21-02MF2

03-01-21-01MF2

03-01-19-02

CSS/MF2

FIELDBUS MAINTENANCE OVERVIEW

Good

FF example of maintenance graphics

Good

Maintenance graphics pop-up details

Use diagnostic data to information tools: e.g. EDDL and/or FDT/DTM

(no FDI available yet).

Device replacement procedures (training!):

- Identical device and identical version

- Identical device, but different DD/CFF

- Different device

Use commissioning procedures and develop responsibilities

per function

Maintenance procedures

After diagnostic alarms/events have been received:

The right tools at the right moment

Use the same standard diagnostic tools for HART, Profibus, and FF.

Who Input Sub-Processes Output

Responsible

Organization

or Individual

Major Work Process Sub-processes for: Provide Instrumentation Original Issue Date: Aug 10, 2010 Asset Management Executive Process Owner: Instrument Technical Discipline Network (ITDN) Latest Revision Date: Draft Rev 0

Instrument

Specialist

CSE Organization

Technician

Operations &

Maintenance

Device

Alarm Alert

Report

ITDN

Analyze Report and

Review Company

Performance

5.0

Analyze

Performance

(Unit, Area)

3.0

Execute

Daily

Proactive

Maintenance

2.0

Initiate

Proactive

Maintenance

Setup (Unit)

1.0

Unit / Area

Asset Manager

(CAM)

Plant

Leadership

DCS

Documented

Saves

History of

Failures

(SAP)

Info. for

Stds. &

Sharing

Repaired

Equipment

a

b b

a

Resources 8 9

6

Info. from

Stds. &

Sharing

Report and

Review

Performance

(Plant)

4.0

Maintenance work process flows

No

Major Work Process Tasks for: 1.0 Initiate Proactive Maintenance setup (unit) Original Issue Date:Draft Rev 1.0

Work Process Owner: Instrument Technical Discipline Network Last Revision Date: 05/15/07

WHO Input

Responsible

Organization

or Individual

Work Process Analysis Output

PlantLeadership

Unit/AreaAsset Mgr.(CapacityAssuranceManager)

InstrumentSpecialist/Asset mgr

CSE/Inspector

DCS &3RD PartyVendor

Operations /OSE

Maintenance/RCM

Project

1.1

Communication

with Stakeholders

a

1.2

Assign roles &

responsibilities

1.5 Train (use & access)

CSE/Inspector

Techs

Maintenance

Operations

Engineering and

other personnel as

required by project/

site needs.

DeviceAlarm/Alert

Report

PM WorkOrder

1.6

Establish Project

Needs in FEDa

Tools missing?(see explanation)

No

Yes

WorkProcessManual

Priorities

Funding

Project

Resources

Commu-nications plan

Hardware/Software &

Tools

Eng Guides& Config Stds

C.M.M.S(SAP)

1.7

Validation of

Device Alarm/

Alert report

1.8.2

Develop Maint PM

Tickets

b

1.4

Establish

Process,

Segment, and

Alert Priorities

(See Detail)

1.2.2 Develop

Roll out plan

1.8.1 Develop

Maintenance

Procedures /

Orders

ProjectDeliverables

LEGEND

Start or End Task Decision a Connector 1Metric /

Control Point

EmbeddedExternalWork Process

LEGEND

Start or End Task Decision a Connector 11Metric /

Control Point

EmbeddedExternalWork Process

1.3.2 Setup

Alerts & Graphics

1.3.1 Setup

Consoles

1.3.3 Setup

History

1.3.4 Setup

Reports,

Remote Access

1.3 Setup

Additional

Procedures

Needed?

YesIAM Maint

ProceduresNo

b

Agreed to project scope

to be delivered within

FED/project budget

Additional

Training

Required?

Yes

TrainingComplete

Major Work Process Tasks for:1.4 Priorities (unit) Original Issue Date:Draft Rev 1.1

Work Process Owner: Instrument Technical Discipline Network Last Revision Date: 06/06/07

WHO Input

Responsible

Organization

or Individual

Work Process Analysis Output

InstrumentSpecialist/Asset mgr

CSE/Inspector

Operations /OSE

Maintenance/RCM

DeviceCriticality andAlert Priorites

ProcessCritical

EquipmentList(s)

1.42

Establish

Process

Priorities

LEGEND

Start or End Task Decision a Connector 1Metric /

Control Point

EmbeddedExternalWork Process

LEGEND

Start or End Task Decision a Connector 11Metric /

Control Point

EmbeddedExternalWork Process

1.41

Set Generic

Hardware Alert

Priorities 1.43

Implement

application specific

alert priorities

SupportingProcesses

Eng Guides& System/

DeviceConfig Stds

SIFPRO,RCM, ESP

1.44

Capture Saves

Value

Input forSaves

DatabaseProcess

YES

Who Input Work Process Activities

Responsible

Organization

or Individual

Major Work Process Tasks for: 2.0 Execute Daily Proactive Maintenance Original Issue Date: Draft Rev 0

Work Process Owner: Instrument Technical Discipline Network (ITDN) Last Revision Date: 08/10/06

Ops

ITDN

Instrument

Specialist

CSE

Technician

Maintenance

Planner

Maintenance

Coordinator

T/A

Manager

Output

OMC

DCSDevice

Alarm/Alert

Report

PM Work

Order

LEGEND

Start or End Task Decision a Connector 1 Metric / Control Point

Embedded

External

Work Process

SAP

Condition

History*

2.8

Quick Fix?

2.6 MOC

Required?

Work

Request

(SAP)

2.1 Assign

Daily PM

Work Order

2.2 Obtain

PM W.O.

and device

Alarm/Alert

report

2.3 Select

Next Priority

Item (from

A/A list and

A/A Report)

2.7 Enter

notification in SAP

and complete

documentation

2.10 Get Written Work

Permit, Repair &

Document on PM Work

Order in SAP

(Document status in Log)

NO

YES

b

Repaired

Equipment

b

NO

MOC

Request

2.11 Daily PM

W.O. Complete?

NO

2.12 Complete

Documentation

& Closeout PM

Work Order

* NOTE: An Excel Spreadsheet that records status (condition history) of all actions taken by Alarm/Alert will be maintained in Log until the Site has

implemented Level 5 SAP

b

3

a

YES 2.4

Emergency?

2.x

E-ticket &

communicate

priority to OMC

for appropriate

action

(Technician

documents status in

Log)

NO

YES

a

c

c

Who Input Work Process Activities

Responsible

Organization

or Individual

Major Work Process Tasks for: 3.0 Analyze Performance (Unit/Area) Original Issue Date: Draft Rev 0

Work Process Owner: Instrument Technical Discipline Network Last Revision Date: 08/10/06

ITDN

Instrument

Specialist

CSE

SGS

Output

Plant

Leadership

Unit/Area

Asset Mgr.

(CAM)

Weekly/Monthly

PIM

History Rpt (SAP)

LEGEND

Start or End Task Decision a Connector 1 Metric /

Control Point

Embedded

External

Work Process

Document

ed Saves

History of

Failures (SAP)

Work

Assignment

Info for

Stds &

Sharing

3.1 Verify

appropriate

actions are

being taken

to diagnostic

info

(Unit/Area)

3.2 Identify

repeat/pattern of device

failures/abnormal

conditions

3.5

Incorporate

Value Info for

Saves

(Unit/Area)

3.7 Review Report of

Saves, Failures & Rec.

for Improving Reliability

(Area) and take

appropriate action

c

Vendor

Technician

3.3

Determine

Cause

(conduct

RCA)

3.4 Initiate

appropriate

corrective action

Monthly/Quarterly

b

DCS

Device

Alarm/Alert

Report

(Summary)

3.6 Develop

Report

(Unit/Area)

Action

Assignee

c

1

2 4 5

7 89

b

b

Who Input Work Process Activities

Responsible

Organization

or Individual

Major Work Process Tasks for: 4.0 Report and Review Performance (Plant) Original Issue Date: Draft Rev 0

Work Process Owner: Instrument Technical Discipline Network Last Revision Date: 08/10/06

ITDN

Instrument

Specialist

CSE

SGS

Output

Plant

Leadership

Unit/Area

Asset Mgr.

(CAM)

Weekly/Monthly

PIM

History Rpt (SAP)

LEGEND

Start or End Task Decision a Connector 1 Metric /

Control Point

Embedded

External

Work Process

Document

ed Saves

History of

Failures (SAP)

Work

Assignment

Info for Stds &

Sharing

Vendor

Technician

4.1 Analyze Plant

Performance &

Develop Report

(Plant)

Monthly/Quarterly Quarterly/Annually

DCS

Device

Alarm/Alert

Report

(Summary)

Action

Assignee

4.2 Review

Report of

Saves,

Failures & Rec.

for Improving

Reliability

(Plant) and

take

appropriate

action

Document

ed Saves

Maintenance work process flows

Develop local detailed

workflows

Summary

• Foundation Fieldbus is a most powerful technology for

diagnostics and for hence Instrument Asset Management

• No maintenance advantage is being realised without

proper balance between people (training) and

workprocedures (use of standards and tools)