09 Simplified commissioning 5.22 Mb

Transcription

Commissioning Simplified
ARASU THANGAI – PEPPERL+FUCHS
Fieldbus Infrastructure
Commissioning Benefits
• Commissioning - Device integration
• Commissioning - Physical layer
• Commissioning - Device integration
Device Integration
Continuous Productivity Improvements
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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
Fieldbus Maintenance Made Easy:
Device Commissioning Wizard
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
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
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
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
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•
0
7
Configuration
Parameterization
Commissioning
Controller
Diagnosis
Maintenance
Calibration
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Process variables
Time synchronization
Status
Field Devices
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•
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
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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!
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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 - 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
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
Advanced Commissioning for physical layer
A portable tool for commissioning, monitoring, and troubleshooting.
Versions to suit your every need
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
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
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
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
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%
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
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
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?