healthy instrument relationships – are yours really listening?

2015 Honeywell Users GroupEurope, Middle East and Africa

Healthy Instrument Relationships – Are Yours Really

Listening?

Peter Overgaauw, Honeywell

Phil Millette, Honeywell

2 © 2014 Honeywell International All Rights Reserved

• Comstock Load Discovered in Gold Canyon 1859

History Lesson

Problem – Growing Piles of Blue-Gray Mud


• Smart instruments are smarter than ever‒ Diagnostic messages readily available

‒ Large amount of information about health and maintenance

• Where does the information go?‒ Are devices set up during the project and forgotten?

‒ Are device alerts and alarms sent to the journal and ignored?

‒ Is a process in place to take advantage of this wealth of

information?

• Leading companies putting this information to work… ‒ Detecting issues

‒ Taking proactive actions

‒ Preventing process and equipment problems before they

happen!

Where is your Blue-Gray “Mud”?

Are You Getting the Value? Are You Listening?


Valve_Stuck_Sensor_Arm_Damage

IP_Primary_Nozzle_Plugged

Processor_Impaired

IP_Latched

Relay_Cross_Misadjusted

Air_Line_Blocked

Relay_Jammed

Performance_Critical_Alert

Press_Fallback_Alert

Travel_Sensor_Alert

Press_ABSensor_Alert

Supply_Press_Sensor_Alert

Temp_Sensor_Alert

External_Relay_Ring_Leak

External_Relay_Ring_Leak_Alert

... Etc…

What Is All of This “Noise”?

• Device off net (disconnected)• C300 – redundancy / FTE state / soft fail state• FIM – state / CPU / Memory• Series C IO – channel status/ redundancy status / fail status• Segment health (jitter/ variance/ noise…)• Control loop – stiction / oscillation / bias / drift / hysteresis

/ deviation

Device Diagnostic Information

Other Diagnostic Information


Experion Control System

• Control functions & Alarming

• Data Source

Asset SentinelAsset Health, Condition &

Performance Management

• Interpreting & processing

diagnostic data into meaningful

faults, manage fault history

• Prioritization based on Asset

criticality; notifications

FDMDevice Management

• Device Configuration & trouble

shooting

Comprehensive Instrument / Field Device

Management: configuration, health, performance

Visual

Integration


Uniformance Asset Sentinel for Instruments

Maint. Mgt

Engineering

Reliability, Maintenance, & Process

Mgt. Reporting &

KPI’s

Dashboards / Displays / Trends

Asset Sentinel

Operator

Historian

Alerts & Data

Calc Results

Work

Requests

Real-time / Historical Data

Event Detection(Symptoms/Faults)

Analytics

• Embedded

• User Defined

• UniSim

• Other

Notifications(E-mail & Alerts)

Equipment Lib.

Templates• Attributes

• Calculations

• Rules

Asset Model

Unified real-time asset and process & asset surveillance / monitoring solution

Historian Vibration

Monitoring

Other

ApplicationsDCS / PLC Smart

Instruments

Visual

Inspections


Providing Structure – Grouping & Organization

Symptom Name Fault Name

Software_Error

Failure

Sensor_DB_Error

Probe_Missing

Electronics_Failure

Software_Compatibility_Error

Memory_Failure

Com_Failure

Temp_Critical

Off Spec

Measure_Error

Level_Measure_Failure

Volume_Measure_Failure

Config_Error

Temp_Outof_Limit

Maintenance

Volume_Measure_Warning

Measure Warning

Lost_SD_NV

Config_Warning

Data_Integrity_Error

Algorithm_Error

RB_SimAct

Function Check

AI_SimAct

PWA_SimAct

RB_OOS

AI_OOS


• Experion ERDB Synchronization‒ Import Adv Alarming or DD file definition

• Define ‘Template’ for device types ONCE‒ Organize diagnostic messages (per NAMUR 107)

‒ Time delay to minimize chatter

‒ Define ‘Severity’ of fault

‒ Define Action (OPC, Email, CMMS)

‒ Corrective Action

• Instances ‘Auto Created’ ‒ Define Criticality - (instrument on compressor vs back-up pump) to calculate priority

Listening To Your Devices

Experion Control Builder

Asset Mgr Fault

Diagnostic Criticality

Failure 6-Critical

Out of Specification 5-Serious

Maintenance Required 4-Important

Function Check 2-Minor

Information 1-None


1

2

Configuring HART Devices


Instrument Asset Synchronisation – ERBD, EMDB


Synchronized ERDB in Asset Sentinel


Automatic Tag Mapping (by sync)


Fault Model Imported (by sync)


Fault Model Continued…


View of data sources

EPKS OPC AE Data source definition automatically created by

Sync for the target System

EPKS OPC DA Data Source definition created by configuring

engineer


Health Context


Attribute Mapping


Taking Action

• Real-time Dashboard

• Drill-down

• Fault Summary

• Fault Help

• Work-flow‒ Close-out

• Info Links‒ FDM Client

‒ Info displays (graphics)

‒ Data sheets

• Notifications‒ E-mail

‒ OPC

‒ CMMS (SAP/Maximo)


Reporting

• Reporting – KPI’s

‒ Standard Reports

‒ Custom reports


Fault History view

Since the asset model CAN contain manufacturer and model as well as serial number, performance reports and failure history of certain product models can be accumulated over time, providing valuable basis for sourcing decisions;Cumulative service time, MTBF, MTTR also are cumulated automatically, based on context state of an asset.


FDM Basics

FDM simplifies smart instrument management

Configuration, Diagnostics and Maintenance

Supports configuration, diagnostics and

management tasks

Displays device health status to help

maintenance personnel find problems

Handles a large database of devices from

the entire plant (up to 16K)

Saves effort by auto-building database

from live connected devices

Uses open standard DDs/EDDLs and DTMs to create templates for

devices

Allows easy download from FDM to devices or upload from devices to

save valuable configurations

Works with Experion, non-Experion, Wireless, RTU, TPS, and Safety

networks

Simplifying Smart Instrument Maintenance


• Maintenance‒ Performing routine maintenance (especially valves)

‒ Checking device status (alarms) and troubleshooting

‒ Device database upload (history) for archive/reference

‒ Device replacement and needed setup/reconfiguration

• Engineers ‒ Configuring and setup of devices during FAT

‒ Device commissioning during startup

‒ Assisting maintenance with troubleshooting

‒ Assisting operations with problem solving

• Operators ‒ Device diagnostics/status checks

‒ Device information reference for running the process

Typical FDM Use Cases

Always The Right Tool!


• “Teach” instruments to tell you the right information!

‒ Set alerts and alarms properly

‒ Correctly set ranges, options, etc.

‒ Compare configurations against known's

• “Check up” on instruments to make sure they

are doing their jobs!

‒ View status of instruments

‒ Check performance criteria

‒ Prevent surprise failures with proper care

• Better organize instrument information

‒ Plant Area View (PAV) for viewing status

‒ History records of all your instruments

• “Remedial Training” through “tune ups”

‒ Run valve diagnostics

‒ Perform instrument calibrations

What You Can Do With FDM

Are You Training Your Instruments?


• Experion compatibility‒ R430, R410, R400, and R311

• Foundation Fieldbus DD/EDDL Support‒ Complements previously introduced DTM support

• OneWireless/ISA100 Wireless Support‒ Through Honeywell’s Wireless Device Manager

• New RTU2020 Support‒ Geographically distributed wellhead monitoring and pipeline solutions

• EDDL Enhancements‒ Visualization and layout improvements

• Plant Area View‒ Provides organization of smart device asset health for easy monitoring

‒ Originally released in FDM R430 Patch

• Virtualization Support‒ All FDM components tested with VMWare and are fully supported

FDM R440 New Capabilities Summary

Focus On Expanded Protocol Support


ESV-TPSTPN Server

ES-TPSTPS DocTool

HPMs

NIMs

UC

N

LCN

• Experion compatibility‒ R431, R430, R410, and R400

• Partial Valve Stroke Test (PVST) Planner‒ New optional feature to automatically

validate emergency shutdown devices

• TPS DE Protocol Device Integration‒ Support for DE Protocol devices

connected to HPMs (TPS Networks)

• Other Enhancements‒ EDDL enhancements

‒ FDT enhancements

‒ Support for 40-character

Experion tags

‒ Support for 32-character

MUX Monitoring tags

FDM R450 New Capabilities Summary

Expanding The Role Of FDM


FDM Supported Protocols

• HART devices via Experion and Safety Manager

HART I/O

• HART devices via non-Experion-connected

HART multiplexers and modems

• Profibus networks and PA or DP devices using

Profibus Communication and Device Type

Managers (DTMs)

• Profibus Gateway (same capabilities)

• HART devices connected to Profibus networks

via HART-over-Profibus gateway devices

• Foundation Fieldbus devices via Experion-

connected Fieldbus I/O

• OneWireless and ISA100 Wireless

• HART IP (RTU2020, WDM, WirelessHART GW)

• DE Protocol devices (TPS-connected)

Supporting Open Standards


Sentinel/FDM Architecture

PMIO AI/AO

Series-A (1756) AI/AO Series-A FIM

Series C FIM

Wireless Devices

IP

Wireless Device

Manager

Universal Safety I/O

Universal Safety Logic Solver

Safety

Manager

ExperionServer

FDM Server

MUX MonitoringGateway PC

Profibus

Gateway

Module

MUX

Remote PCwith RCI

Remote PCwith RCI

Experion Flex Station

with FDM ClientSentinel Web

Client

FDM Client

One Wireless Adaptor

Series C I/O AI/AO

Series C Universal I/O

InstrumentSentinelServer

InstrumentSentinelShadowServer

Inst. Engr Desktop

Sentinel Web

Client

Enterprise Apps

CMMS, E-Mail…

Firewall


Where It All Fits

Field Devices(Smart & Traditional)

Field Device ManagerDevice Configuration Management

Trouble shooting

Maintenance (e.g., Methods)

DCS & Safety

System

Device Alarms(OPC A&E)

Device Status(OPC DA)

Visual

Integration

Device Access(Remote

Communications)

Link to multi-sensor fault models,

Equipment Fault models, real-time

SIL and LOPA, test history

capture, URL links etc

Asset SentinelDevice Health Management

Fault Modeling, Fault History

Reporting


Value Proposition


Reducing Unplanned Capacity Loss

Rare Frequent

High

Co

st

Imp

ac

t

Low

Frequency

Process Deviations

Unit Shutdown

Degraded Efficiency

Non-Critical Eq. Failure

Critical Eq. Failure

Reduced

Capacity Loss

Original Capacity

Loss

Mitigation

Strategies

Leading Cause


• Combined solution of Configuration Management and

Health Management equals Integrated Instrument

Asset Management!

• Important to take full advantage of the investment in

your smart instruments!

• Find the “Blue-Grey Mud” and listen to your devices!!

So, What Are the Messages?

https://www.google.com/url?q=http://www.shutterstock.com/pic-39795229/stock-vector-cartoon-series-success.html&sa=U&ei=lqyEU4P6KOyn0wWt7YC4Dg&ved=0CEQQ9QEwCw&usg=AFQjCNG6fnDUOrIEbtMAhaPSVpcgpJUKQg

https://www.google.com/url?q=http://www.shutterstock.com/pic-39795229/stock-vector-cartoon-series-success.html&sa=U&ei=lqyEU4P6KOyn0wWt7YC4Dg&ved=0CEQQ9QEwCw&usg=AFQjCNG6fnDUOrIEbtMAhaPSVpcgpJUKQg


QUESTIONS?

healthy instrument relationships – are yours really listening?

Technology