December, 2014

L’automazione al servizio della manutenzione Oscar Viganò – Alphacon , Massimiliano Veronesi – Yokogawa

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Process Control System Maintenance Automation

A combination of hardware, software and services used to assess the heal of plant assets by monitoring asset condition periodically or in real-time to identify potential problems before they affect the process or lead to a catastrophic failure.

Plant Measurements & Historian Information

PCSMA

Maintenance Operations

Information Flow

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Approach

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Approach

Minimum plant downtime, maximum asset utilization

Reduce blind spots Monitor plant-wide asset conditions

Preempt bottlenecks Optimize operation and maintenance

Avoid surprises Predict asset conditions and avoid downtime

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Solutions

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Device status viewing

Audit Trail

Tuning, Adjustment & Calibration

Maintenance Information Management

Maintenance Alarm

Diagnostics

Platforms for Maintenance & Diagnosis

Online Maintenance Core

Predictive Diagnostics Core

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Typical System Architecture of PCSMA

Ethernet

Control Network

Temperature Transmitter

Wireless Gateway

Pressure Transmitter

ENG HIS SENG

OPC Server

SQL Server

PIMS Client

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Requirement for LNG projects

Transfer process data between Exaquantum systems, for example sea based:

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How does it Work?

Two simple functions

– Extract process data from the Publisher’s Exaquantum system

– Store process data into the Consumer’s Exaquantum system

Exaquantum RDS Publisher Exaquantum RDS Consumer

Exaquantum

Historian

Exaquantum

Historian

OPC HDA TCP/IP Network

Connection OPC HDA

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OPC Servers

DCS OWS and Controllers

VNet

Ethernet

Ethernet

SQL Servers

SQL Servers

Environmental parameters under control

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User Interface – Publisher (Settings)

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Remote communication with on-shore terminal

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Beneficial Concepts and Features of PCSMA

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Beneficial Concepts of PCSMA

1. Minimize Risks & Cost (lead-time) for commissioning & start-up work

Centralized Plug & Play remote device connection check

Centralized remote setting of field device parameters

Quick online diagnosis

Standardized approach for multi-vendor devices

2. Minimize the risk of unnecessary site trips By monitoring device healthiness thru diagnostics

3. Minimize scheduled maintenance downtime Optimize maintenance work by advanced device diagnostics

4. Generate collaboration between Operation and Maintenance

Maintenance work to assure Reliability, but not repair work after breakdown.

Shift maintenance paradigm from event-driven to scheduled work

Maintenance to contribute better operation availability.

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1. Real time Plant Asset Management Environment – Cyclic device patrol of device health condition check – Maintenance alarm to maintenance personnel – User-friendly device configuration tools （EDDL and FDT/DTM base)

2. Full integration with DCS and SIS – Device alarm message equalization – Time synchronization – Device diagnosis alarm to be shown on the DCS HMI

3. Wide Openness

– Remote alarm & event monitoring, analysis and reporting

– Integration: Host diagnostics server interface of both field devices and machinery units

– Open interface: CommDTM/DeviceDTM are available

Safer plant operation – PST Scheduler to extend the available time of SIL3 safety loop without

process shutdown

Features of PCSMA

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Main Functions of PCSMA

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Main Functions and Features of PRM

1. Device Management

– Device Master Information

– Historical Messages

2. Device Configuration

– DTM Works

3. Alarm Notification

– Device Status Icons

– Device Diagnostics Monitor

4. Historical and Maintenance Records

– Historical Messages

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1. Device Management - Device Master Information

Device Navigator

Window

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3. Alarm Notification - Device Diagnosis (DeviceViewer function)

* DeviceViewer can be shown in both DCS HMI and PRM Client if integrated.

Normal

Abnormal

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3. Alarm Notification – Maintenance Alarm

(Blue) GE System 1 Status -Device to be investigated

(Orange) GE System 1 Status –

Device Non Critical

Icon Detail

(Green) Healthy by Device Patrol

(Red) Maintenance alarming

by Device patrol

(Yellow) Maintenance Warning

By Device patrol

(Gray) Communication failure

(White) Status not yet confirmed

(Background

Gray)

Alarm Off

Un-confirmed alarm

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4. Historical and Maintenance Records – Historical Messages

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Maintenance Related Functions

Schedule – Records maintenance schedule

Memo – Records maintenance memorandum

Parts – Records necessary parts for devices

Doc – Records necessary documents for maintenance such

as instruction manual

Tool – Setup the necessary tools for maintenance

Plug-in – Setup to ranch necessary tools for devices configuration

Cal. Data – Records calibration data for devices

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Maintenance Mark and Operation Mark Synchronization

PRM is able to electronically assign “Maintenance Mark” to each device by online. Users can assign this mark when they adjust or maintain the field devices. Once assigning it, users can give the restriction to handle with field devices management and what they has been in the status of adjustment and maintenance. When the Maintenance Mark is set on PRM, Operation Mark to prohibit the operation is automatically set on the HIS faceplate.

Operation Mark

HIS PRM

Synchronization

Maintenance Mark

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Some Real Examples

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Some Real Examples

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Some Real Examples

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Some Real Examples

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Some Real Examples

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Some Real Examples

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Some Real Examples

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Some Real Examples

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Plant Historian

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Stores

- Secure - Scheduled reports - Email reports to users - SQL Server 2005 - Multi-dim. RDB/OLAP

Provides

- KPIs Definition & Reporting - Alarm Reporting - Report Grouping - Time selection & filtering - Export to Microsoft Excel

Collects

- A&E

Alarm Reporting and Analysis (ARA)

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Alarms that remain active beyond a specified time period (i.e. 12 hours) are called Long standing Alarms, also referred as Stale Alarms

Chart and Tabular

The list of Long standing alarms

Duration for which the alarm remained stale

X-axis displays the day

Y-axis displays stacked alarm duration

Long Standing Alarms

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Top most frequent alarms are listed and ranked

Tabular and Chart

The x-axis shows time

The y-axis the alarm count

Alarm Frequency Report

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– MV and SV change count over the specified time period • changes made to MV for PID controller in MAN mode • changes made to SV for PID controller in AUT mode • Acknowledge time is also reported

Manual operation monitoring

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• Changes to Alarm Threshold Settings are captured

• The Document Map (on the left) aids navigation to other pages within the report

Alarm setting changes

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Excel Add-In

Create your

report by

simple Tags

“Drag &

Drop” into

Excel cells

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An Example Excel Report

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Some Historian Examples

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Some Historian Examples

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Next developments: Trends by web

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Summary

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Summary

Process Control Systems architectures nowadays can integrate nodes for supporting diagnosis and maintenance functions

System performance monitoring and maintenance operations can be done both by local and remote workstations – Process Trends, Process/System alarms can be viewed

by remote through redundant connected SQL servers

– Field instruments and devices status can be checked and updated even by remote

- 65 - <ISD-MASP-S11070> Copyright © Yokogawa Electric Corporation <August, 2012>

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