healthy instrument relationships – are yours really listening?

Healthy Instrument Relationships – Are Yours Really Listening? John Yingst, Product Manager Bart Winters, Product Line Manager

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


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 monitoring solution

Historian Vibration Monitoring

Other Applications

DCS / 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


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


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-TPS TPN Server

ES-TPS TPS 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

Experion Server

FDM Server

MUX Monitoring Gateway PC

Profibus Gateway Module

MUX

Remote PC with RCI

Remote PC with RCI

Experion Flex Station with FDM Client

Sentinel Web Client

FDM Client

One Wireless Adaptor

Series C I/O AI/AO Series C Universal I/O

Instrument Sentinel Server

Instrument Sentinel Shadow Server

Inst. Engr Desktop Sentinel Web

Client

Enterprise Apps CMMS, E-Mail…

Firewall


Where It All Fits

Field Devices (Smart & Traditional)

Field Device Manager Device Configuration Management

Trouble shooting Maintenance (e.g., Methods)

DCS & Safety System

Asset Sentinel Device Health Management

Fault Modeling Reporting

Device Alarms (OPC A&E)

Device Status (OPC DA)

Visual Integration

Device Access (Remote

Communications)


Value Proposition


Reducing Unplanned Capacity Loss

Rare Frequent

High

Cos

t Im

pact

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


QUESTIONS?

healthy instrument relationships – are yours really listening?

Technology

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error temp

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failure temp