Arasu Thanigai Commissioning Solutions

11 Successful Implementation & Improved Operation

Commissioning issues and solutions

Arasu ThanigaiPepperl+Fuchs Pte LtdSingapore

Fieldbus Foundation Seminar Perth – 15th May 2013


Device Commissioning

Physical layer Commissioning

Commissioning Process


Install the CablesCheck out the cable installationInstall the DevicesCheck the device installation

Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mAPhysical Parameters

Commissioning Process


4~20mAInstall the CablesCheck out the cable installationInstall the DevicesCheck the device installation

Install the DCSAssigning the I/OCalibration the SensorRangingCalibration the 4~20mASystem RangingSystem Calibration 4~20mA

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 Fieldbus4-20mA

P.S.

fieldbus

P.S.

Distance and relevant issueArtificial hours and relevant costCable connection QuantityHidden trouble points

Cable installation








4~20mA Foundation Fieldbus4-20mA

P.S.

fieldbus

P.S.

Test Report

Distance and connection QuantityTools

Checking of cable installation.














Device Commissioning


Assigning the I/OFoundation 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.





• Install the DCS• Assigning the I/O• Calibration the Sensor• N/A• N/A• N/A• N/A



No range mismatchUnit downloaded when device is replaced

Transmitter PositionerFF FF

BUSFF

CTRL

CPU

CPU

CPUDigital DigitalDigital

TransmitterRange

0-800 kPa

SystemRange

0-400 kPa

8 mAProcess200 kPa

Reading100 kPa

...alarms and tripsnot working

AIUnit

Unit

AOUnit

Unit


4~20mA

Foundation Fieldbus


Why Foundation Fieldbus

The global process industry loses $20billion, or five percent of annual production,due to unscheduled downtime and poorquality.

ARC estimates that almost 80 percent ofthese losses are preventable, with 40 percentlargely due to operator error.

Source ARC Insight June 10 2010


Common issues – Device Commissioning

Check DD file and integrate into Engineering systemCheck ITK versionCheck if HIST doneCheck 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

OPERATORINSTRUMENT 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 invalidmalfunction 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 showingintermittent faults

Interoperability testingby end user

Electro-magnetic interferenceFaulty field deviceCable 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 Independent Research


Zone1Device Coupler

IS Device Coupler

Fiel

d De

vice

s

Fiel

d De

vice

s

Fiel

d De

vice

s

Zone2Device coupler TerminatorSurge

Protect.

SurgeProtect.

Fiel

d De

vice

s FieldbusProcess

Interfaces

Complete Interface

PowerSupplies


Hazardous safety rules not followed

– Ground faults– Fieldbus and power

cables tied together


Poor cable installation


ANSI recommendation

CommunicationCables(Fieldbus)

Shielded/UnshieldedCables Carrying>60 VDC or>25 VAC but<= 400 V

Shielded/UnshieldedCables Carrying> 400 V

Any Cables at risk ofLighting

Communication

Cables

(Fieldbus)

10 cm 20 cm 50 cm

Shielded/Unshielded

Cables Carrying

>60 VDC or

>25 VAC but

<= 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 Reportx


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 atDCS Station

Rela

y co

ntac

top

tiona

l)

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 ReadoutCreates baseline report: – Snapshot of all measurements – Complete documentation

Saves pre-commissioning time significantly


Online monitoringClean layout shows boundaries– Displays measurement values – Highlights violations with color coding: – Issues diagnostic messages

Good value

Maintenance required

Out of specification


Diagnostic MenuExpert System delivers

clear text information for fast fault finding

1 Active messages2 Actionable information

with solution guideance based on expert system

3 History with timestampsWhen 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

5353 Successful Implementation & Improved Operation53

Bad wiring technique

Welding, variable frequency drives (VFD), Motors, machinery:Increase of HF noiseIncreasing number of retransmissionsCan 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

PROCESSINTERFACE

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

Technology

Arasu Thanigai Commissioning Solutions