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Copyright Industrial Automation Networks Inc. - 2013

How Good Are Your Numbers?

Ian Verhappen

Director, Industrial AutomationNetworks Inc.

About the Presenter – Ian Verhappen

• P.Eng. ISA Fellow, ISA CAP

• Industrial Automation Networks Inc

– Field level networks (buses & wireless) and process analyserengineering consulting firm

• MTL (2006 – 2009)

– Responsible for all digital communications products– Responsible for all digital communications products

• 20 years in the oil sands /mining industry with SyncrudeCanada Ltd.

• Past Vice-President ISA Standards & Practices Dept. Vice-President Strategic Planning Dept.– Past Director ISA Analysis and ISA Communications Divisions

• IEC TC65, SC65B, SC65E Chair for Canada

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The Problem

Too much data No information

Where do we want to be?

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Getting from Problem to Solution

Real Time EquipmentHealth DataHealth Data

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MicroprocessorsMicroprocessors

MobileInfo

Devices

Static InfoAppliances

1.4billion*

1.0billion*

Mobile ITAppliances,Telephony &Terminal DevicesWill BecomeIntegrate IntoSystems ThatInclude Signals &Data FromSensors, Machines

Mobile Phones,Smart Phones,Notebooks MobileTerminals Tablets,Media Players

Desktop PCsServers/StorageRouters/Switches/GatewaysPrinters/ImagingGame/Media Equipment & Players

Intelligent Device Hierarchy - 2010

Source: Harbor Research, Inc.

* 2010 IT-Centric Device Shipments ** 2010 Machine-Centric Device Enablement Potential

Appliances Sensors, Machines& Equipment

Consumer/CommercialVehicles Off-Highway VehiclesAir/Rail/Transit/MarineNavigation SystemsMobile Healthcare Devices

Building EquipmentRetail/Vending/POS/ATMsIndustrial MachineryHealthcare EquipmentPower Distribution EquipInfrastructureEquipmentControllersSensors,InstrumentsMetersMicroprocessorsMicrocontrollers

Approximately 130Million Machine-Centric DevicesExpected To BeIntegrated in 2010

20 billion To Avoid DoubleCounting, EmbeddedComponents Are A Sub-Set Of The OverallOpportunity

MobileDevices

StaticDevices

EmbeddedDevices

.25Billion**

5billion**

Game/Media Equipment & Players

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Diagnostics Examples

Generic

• Watchdog timer

• Temperature

• BIOS check on startup

Automation Specific

• Sensor failure– Thermocouple failure

– Impulse line plugging• BIOS check on startup

• Battery

• Memory

– pH probe fouled

• Communications Error– No acknowledgment from

“next” device

Ambient ConditionsAmbient Conditions

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Power Quality

• Ground loop errors

• ‘Noise’

– ElectromotiveInterfence (EMI)Interfence (EMI)

• Cable spacing

– Radio FrequencyInterference (RFI)

• Low voltage orCurrent

– Too long cables

Temperature

• Maximumtemperature ≈60 oC

– Heating effect ofelectronicselectronics

• Minimumtemperature (- 50oC)

– Cold start-up

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Humidity

• Condensation

– Plugged vents &drains in enclosure

– Improperly poured– Improperly pouredseals

• Instrument Air

– Ambient temperaturechanges

Status InformationStatus Information

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Maintenance Alerts

• Valves

– Cycles, distancetravelled, air supplypressurepressure

• Estimate ofremaining time tofailure

– Schedule repairappropriately

Control Loops

• Status signal

– Good, bad,uncertain,maintenancemaintenance

• Only control offgood / validinformation

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Electronic Device DescriptionLanguage (EDDL)

• Basis for smart devices in process industryHART

HARTCommunicationsFoundation

IEC 61804-3IEC 61804-4

FDI work beginswith IEC

19

90

19

93

Foundation

19

96

FoundationFieldbus

20

00

Profibus

20

04

20

11

20

14

FDI Specification& Products

Data IntegrationData Integration

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StandardsStandards

ISA-95.00.03 4-Layer Model

Business Planning &Logistics

Plant Production, Scheduling,Operational Management, etc.

Level 4 4 – Establishing the basic plant schedule –production, material use, delivery, andshipping. Determining inventory levels.

Time frame: Months, weeks, days

Manufacturing OperationsManagement

Dispatching Production, DetailedProduction Scheduling, Reliability

Assurance

Level 3 3 – Work flow / recipe control to produce thedesired end products. Maintainingrecords and optimizing the productionprocess

Time frame: Hours, Minutes, SecondsAssurance

Time frame: Hours, Minutes, Seconds

2 – Monitoring, supervisory control andautomated control of the productionprocess.

Time frame: Hours, Minutes, Seconds, subseconds

Level 2

1 – Sensing the production process,manipulating the production process

Level 1

0 – The actual production processLevel 0

BatchControl

Continuous

ControlDiscreteControl

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ISO 18435 Application DomainIntegration Diagram

A4.2 – Inter-enterprise activities: Supply ChainPlanning, Logistics Strategy

A3.1 – Operations Planning& Scheduling

A3.2 – CapabilityAssessment & Order

Fulfillment

A3.3 – MaintenancePlanning & Scheduling

A2.1 – Supervisory Control A2.2 – Asset Prognostics andA2.3 – Maintenance

Level R4Enterprise/Site

Level R3Area

Level R2

A4.1 – Intra-enterprise activities: BusinessPlanning, Orders & Production and

Maintenance

Assets(Equipment/Facilities, Serialized

components / Sensors / Transducers / Software /Documents)Resources (Material /Personnel)

A2.1 – Supervisory Control& Human Machine

Interface

A2.2 – Asset Prognostics andHealth, Quality, Safety &

Environment Management

A2.3 – MaintenanceExecution & Tracking

A1.3 – AssetConfiguration, Calibration

& Repair / Replace

A1.2 – Asset ConditionMonitoring & Sample / Test /

Diagnostic & Quality Monitoring

A1.1 – Control, I/O DataAcquisition, Data Historian,Asset Utilization & Displays

A0.1 – Resource Identification and Location A0.2 – Asset Identification and Location

Level R2Work Center

Level R1Work Unit

Level R1Asset

Intelligent Device Management Interactions

CMMS

Intelligent Devices

Work Orders

DCS Host

CMMS

Plant AssetManagement System

EventHistorian

Alarm ManagementSystem

ConfigurationDatabase Reporting &

Analysis

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Data FlowData Flow

Alarm Management Lifecycle• ANSI/ISA-18.2-2009

• Includes practices for newfacilities and existingplants

• Includes practices to solvethe common alarm

Philosophy

Rationalization

Identification

Detailed Design

Managementof Change

D

C

A J

B I

Philosophy

Rationalization

Identification

Detailed Design

Managementof Change

D

C

A J

B I

the common alarmproblems

• Builds on the work of ASMand EEMUA

• Documents what isrequired andrecommended , but nothow to do it.

ASM = Abnormal Situation Management Consortium

EEMUA = Engineering Equipment and Materials Users’ Association

Monitoring &Assessment

AuditDetailed Design

Implementation

Maintenance

Operation

E

G

HF

Monitoring &Assessment

AuditDetailed Design

Implementation

Maintenance

Operation

E

G

HF

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Industrial Ethernet Application Protocols

Protocol SponsoringOrganizations

TargetApplications

TransportLayer

ApplicationLayer

EtherNet/IP ODVA, Control-NetInternational, RockwellAutomation, Omron,

Any discreteor hybridmanufacturing

TCP and UDP Control andInformation Protocol(CIP)

FoundationFieldbus-HSE

Fieldbus Foundation Process control UDP Fieldbus FunctionBlocks

IDA-Modbus IDA Group, Schneider, Discrete TCP IDA Object modelIDA-Modbus IDA Group, Schneider,Jetter, Sick, Kuka,Phoenix Contact

Discretemanufacturingespecially motioncontrol

TCP IDA Object model

(Modbus/TCP)

PROFInet Profibus International ComplexMachinery

UDP, TCPplusproprietary

DCOM, PROFI-netObject Model

Source: ARC Advisory Group 2003

eXtensible Markup Language (XML)

• Language used totransfer betweenbusiness systems

– Used by ISA95– Used by ISA95(B2MML)

– Mimosa

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CybersecurityCybersecurity

Open Systems

Risks

• Easier to ‘attack’– Same vulnerabilities as

office environment

Rewards

• Lower cost

• Increased supportavailableavailable

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Regulations

• NERC

– North AmericanElectric ReliabilityCouncilCouncil

• ISA99/IEC 62443

– Cybersecuritystandards

• DHS

– Useful links and tools

Defence in Depth - Zones and Conduits

Copyright © ISA

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ProactiveMaintenanceMaintenance

Asset ManagementAsset Management

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Standalone systems

• Most commonlyused

– Stranded data

Instrument Management Systems

• Real time datacollection fromsmart devices

• Heuristics to aid in• Heuristics to aid ininterpretation,generate workorders

• “Island” of expertise

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System Information ArchitectureSupply ChainManagement

Supply ChainManagement

Enterprise ResourcePlanning (ERP) System

E-commerceMaintenance

Repair &Operations

(MRO)

EnterpriseAsset

Maintenance (EAM)System

Plant AssetManagement

(PAM)System

PlantAutomation

System

Process Control &Process Management

Maintenance Work &Parts Management

Asset AdvisoryManagement

MaintenanceAdvisories

PurchaseorderProcess Advisories

(MRO)Procurement

System

SystemCMMS

SystemSystem(PAS)

ControlParameters Control

Data

Asset Collaboration /Tolerances

Transducer Config.Monitoring Set-upInspection Routes

Asset UsageData

Asset MonitoringVariablesAsset Calibration /Tolerance Data

Control DeviceMonitoring

Portable DeviceMonitoring

Survey On-Line Monitors

ProtectionOn-LineMonitors

TransientOn-Line Monitors

SampleMonitoring

Smartvalves& FieldDevices

PLC /DCS

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SmartMachines &Transducers

Plant Measurements / Inspections

OrderTrackingWork HistoriesProcess Events

& Data

Data MiningData Mining

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Data Capture

• What to capture and where

• Experience is retiring

– Fewer ‘experts’ available

Inferential Data

• Information frompatterns in datareceived

– Identify anomaly not– Identify anomaly notmeasured directly

• Bad sensor

• Vessel fouling

• Loop tuning

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Trends Tell All

• Need forMaintenance isbased on changesover timeover time

Work PracticesWork Practices

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Culture Change

• Knowledge = Power

– Difficult to release

• Big Brother

– Watching /spying– Watching /spying

• Fewer ‘Smarter’workers

Getting Help

• Outsource

– Remote assistance• ‘Dial in’

• Send formatted files• Send formatted files

• Training

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NAMUR NE 129: The Asset HealthTriangle

StrategicAsset

Management

EquipmentStandardization

RAM

Life CycleAnalysis

VendorReliability

RCM

Stage 4

Reliability Engineering

Stage 5

Operational Excellence

CraftFlexibility

OPM

Maintenance /Operations Integration

ExternalBenchmarking

Asset Strategies/ SRCM

FailureAnalysis

Asset Integrity

Craft SkillsEnhancement

EquipmentHistory

Condition BasedMaintenance

ManagingSystem

CMMS /Metrics

PreventativeMaintenance

Planning &Scheduling

TurnaroundManagement

Work Identification/ Prioritization

Work ExecutionReview

Stage 3

Organizational Excellence

Stage 2

Proactive Maintenance

Stage 1

Planned Maintenance

There is Incentive to Change.

Are you ready to invest in the future?

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Useful Reference Documents

“Foundation Fieldbus” 4th EditionIan Verhappen & Augusto PerieraPaper:http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm&ProductID=11959E-pub:http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm&ProductID=12461Mobi:Mobi:http://www.isa.org/Template.cfm?Section=Find_Books1&template=/Ecommerce/ProductDisplay.cfm&ProductID=12451

Questions & Contact Information

Ian VerhappenIndustrial Automation Networks Inc.53 Inverness Lane SE53 Inverness Lane SECalgary, AlbertaCanada T2Z 2Y3+1 403 829 1077iverhappen@industrialautomationnetworks.comhttp://www.industrialautomationnetworks.com