09 Simplified commissioning 5.22 Mb
Transcription
09 Simplified commissioning 5.22 Mb
Commissioning Simplified ARASU THANGAI – PEPPERL+FUCHS Fieldbus Infrastructure Commissioning Benefits • Commissioning - Device integration • Commissioning - Physical layer Commissioning Benefits • Commissioning - Device integration Device Integration Continuous Productivity Improvements • • • • Integrated system environment Freedom of choice Information availability Fieldbus solutions to meet all plant requirements Plug and produce Device Integration Easier - Real Number Engineering Unit Range mismatch No range mismatch Unit downloaded when device is replaced Transmitter Range 0-800 kPa Process 200 kPa Range Range Transmitter CPU D/A FF Digital 8 mA System Range 0-400 kPa Range exceed (more than100%) Reading 100 kPa ...alarms and trips not working Digital BUS AI FF A/D CTRL AO CPU 4-20 mA D/A 4-20 mA Digital Positioner A/D FF CPU Digital FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Lower Cost & Faster Plug-n-Play •Devices are auto-recognized •Devices are auto-addressed •Devices identify themselves Traditional: 2 hours / device for 2 technicians (Calibration) Only FF has automatic addressing Foundation fieldbus: 25 minutes / device for 1 technician (Remote) Attach device Verify 4-20 mA signal » five points Verify link to control strategy Check device parameters with handheld Attach device Drag-and-drop commissioning wizard Compare configuration faster on computer FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Fieldbus Maintenance Made Easy: Device Commissioning Wizard FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Fieldbus Maintenance Made Easy: Protective Decommission Removing device in an orderly fashion “Safely remove hardware” Temporary removal To remove for calibration etc. with intention to put back into same place soon after Permanent removal To remove for replacement etc. Control-in-the-field does not mean just “simple” PID FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Easier FF Device Commissioning and Replacement Commission or replace device without touching the software System automatically logs process in background Automatic configuration reconciliation with device database Automatic configuration download View details in historian and log FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Faster Project Startup Express and Batch Download Reduced commissioning time •Initiate multiple downloads at the same time •Runs unattended •At pre-commissioning need not run as a background communication to real-time control FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Intelligent Devices via Fieldbus is a Must Process Industries worldwide require fieldbus based systems because of cost reduction Reduction of wiring and cabinet costs Less system and instrumentation hardware Reduced commissioning time Intelligent devices enable Asset Optimization Increase of maintenance effectiveness Improves process availability Enhances productivity Aventis says: Fieldbus technology saves costs and enables innovative applications. Future plant will be equipped with fieldbus Device Management Incorporating intelligent devices via fieldbus integration streamlines work processes, improves process and product quality, maximizes plant availability integrates fieldbus seamlessly Exploiting new levels of field device information Making device resident information available to the right people at the right time Device Management lowers costs over life cycle in design, implementation, operation and maintenance Expectations on Fieldbus Technology Optimization Engineering Operations • • 0 7 Configuration Parameterization Commissioning Controller Diagnosis Maintenance Calibration • • Process variables Time synchronization Status Field Devices • • Operation Display Alarm signals • Industry proven and reliable High system availability through redundancy concepts Intrinsically safe solutions Seamlessly integrated into control system Access to device internal data Openness for all device manufacturers Easy to use Fieldbus and Field Device Configuration • • • Integrated fieldbus management tools and comprehensive Device Libraries for – Configuration of function block applications – Device parameterization with graphical user interfaces – Online and offline configuration All devices accessible from a central workplace Early plausibility checks ensure proper and fast configuration Fieldbus and Change History Process Event & Alarm History Calibration Changes Maintenance Event & Work Order History Operator Changes Configuration Changes Audit List Intelligent Devices Enable Asset Optimization BAD! Oops! OK! • • • • Scheduled monitoring of asset health status Smart condition reporting Notification of key personnel independent of their location Generation of fault reports and submission to CMMS Device Management 800xA System Device Management HART Fieldbus Builder PROFIBUS/HART Basic HART DTM / HART DTM Builder OPC Server HART HART Device Library HART Multiplexer Connect Device Management FOUNDATION Fieldbus Object Types Fieldbus Builder FOUNDATION Fieldbus OPC Server FOUNDATION Fieldbus FOUNDATION Fieldbus Device Library Commissioning Benefits • Commissioning - Physical layer Physical Layer Commissioning Guidelines • IEC 61158-2 – Physical Layer standard • AG 181 (Rev-3.2.1) – System Engineering Guidelines User Benefit : Design guidelines FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand The physical layer – alive and well? Proper termination Water ingress Ground faults Loose wiring Faulty devices The physical layer – alive and well? Proper termination Water ingress Ground faults Loose wiring Faulty devices Unstable communication Short circuits Bulk power failure … Typical locations and Fieldbus issues Advanced Commissioning for physical layer Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Advanced Commissioning for physical layer A portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Commissioning Tools expectations User interface in the control room: Display of values Warnings with actionable information Color coding for easy recognition Value-add: Automated commissioning procedures and documentation Live segment monitoring with alarms Expert troubleshooting tools Embedded expert-knowledge FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Commissioning Tools Expectaions Plan and purchase Install and commission Cash Flow Commission Operate and maintain Monitor Troubleshoot ■ Longer plant uptime ■ Know before you act ■ Actionable information in clear text ■ Verify against original design ■ Automated checkout procedures ■ Design Verification tools: design of the physical layer FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Commissioning in the past Always on the critical path Manual, step-by-step procedure Labor intensive Requires » Screw driver » Check sheet » Pencil » Multimeter » Oscilloscope Test Report D D D D Connect one device at a time Disconnect after testing FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Commissioning now 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 Test Report D D D D Commissioning Wizard D D D D FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Cable Type A Type B Cable structure Twisted wire pair, shielded One or more twisted wire pairs, complete shielding Conductor cross-section (nominal) 0,8 mm² (AWG 18) 0,32 mm² (AWG 22) Loop resistor (direct current) 44 Ω/km 112 Ω/km Wave resistance at 31.25kHz (direct current) 100 Ω ± 20% 100 Ω ± 30% Wave attenuation at 39kHz 3 dB/km 5dB/km Capacitive asymmetry 2 nF/km 2nF/km Group runtime distortion (7.9 … 39 kHZ) 1.7 µs 1.7us Covering level of the shield 90 % 10% Max. extent of the network for non IS applications 1900 m 1200 m Max. extent of the network for IS applications (e.g using FISCO power supplies) Suitability check for existing cable Failure margin check Communications check Device coupler short-circuit check Surge Protector health check Water Ingress 38 Water Ingress in Junction Box 39 Water Ingress in Junction Box 40 Water Ingress information at DCS level Commissioning based on Standards Simple to use Eliminates manual test procedures Ensures compliance with AG181 and IEC 61158-2 Creates baseline report: » Snapshot of all measurements » Complete documentation Recommends warning and alarm limits for the ADM Stores limits in non-volatile memory Reduces pre-commissioning time by up to estimted 80% FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Commissioning saves time and money A few mouse clicks conduct automatic testing Reports on the actual installation with all devices connected Automatic setting of warning and alarm limits Online monitoring Advanced Commissioning tools increases the number of detectable faults Monitors continuous operation Notifies when deviations occur Enables proactive plant up keep Keeps the plant up and running The Advanced Commissioning Tools helps to: Monitor the health condition of the physical layer Detect changing conditions Report limit violations with time stamps Alert operators before the segment fails FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Online monitoring – Continuous health check – Inline with NAMUR Commissioning Tools increase the number of detectable faults Displays measurement values Issues warnings and alarms Highlights violations with color coding: Good value Maintenance required Out of specification FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand Fault Finding is Easier •Commissioning Tools delivers actionable information to minimize the time spent for fault finding 1 Active messages 2 Actionable information with solution guideance based on expert knowledge 3 History with timestamps When the failure… … occured … disappeared Export function for external analysis and storage Troubleshooting is easier •Advanced Diagnostics Tools provide expert tools for fast fault finding Simplifies testing Captures intermittent problems Pinpoints the issue Guides to potential solutions Is accessible from remote for consultation with fieldbus experts. Loose wire Bad cable impedance Simplified commissiong leads CAPEX and OPEX savings Rapid commissioning: Accelarates loop check Longer operation: Warns before failure Faster troubleshooting: Assists with actionable information Conclusion- Device Foundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof. Fieldbus devices transmit measurements are unaltered. For most Fieldbus transmitters there is no need to set a range. Avoids Rang mismatch, the reading for controls and alarms in the system will be correct. Therefore, traditional five point loop test can be replaced by a simple plausibility check thus speeding up project completion Fieldbus devices have no error due to analog signal calibration (4-20 mA) differences between transmitter output and DCS input, saving time on recalibration Conclusion- Device Foundation Fieldbus address assignment is automatic and error free. Some systems have wizards to guide the technician, even commission the devices without using software, thus demystifying Fieldbus commissioning The configuration for all Fieldbus devices is maintained in a database and can be downloaded remotely in a single click saving time as compared to checking devices one by one, parameter by parameter, with a handheld field communicator and maintaining documentation separately. Conclusion – Physical Layer 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 inhouse procedures to ensure reliable operation QUESTIONS?