Bus Integration and Calibration Record Retrieval

Matt MacConnell Air Products, Global Engineering Analyzer Systems Technology Manager Allentown, Pennsylvania

IFPAC 2014 January 23, 2014

Presentation by

Three Global Businesses

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Merchant

Tonnage Gases, Equipment and Energy

Electronics and Performance Materials

Air Products supply modes Stability and profitable growth

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Onsite/Pipeline

15-20 year contracts

Limited volume risk

Energy pass through

Package Gases & Specialty Materials

Short-term contracts

Differentiated positions

Liquid Bulk

3-5 year contracts

Cost recovery

Equipment & Services

Sale of equipment

PO based

8% 41% 30% 21%

Industry leading onsite exposure

Talk Outline •Strategic view of digital, bus type integration of analyzer systems and challenges – cost, risk, organizational

•Tactical implementation approaches using Profibus DP

•Maintenance Aspects –

-Automated Calibration Record and Retrieval and Benefits and TCP/IP Tools

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• Improving Process Measurement

• Life Cycle Positioning

-Digital communication technology is next generation

• Builds on Core Skills and Network Technology

-Profibus DP bus native to Siemens DCS

-Normal function chart programming

-Utilize existing network infrastructure (Aspen Tech)

• Capital and Operation Cost Reduction

-Eliminate signal wiring costs and I/O Hardware, reduce design cost

-Faster Commissioning, simplified physical system

-Eliminate analyzers via wider measurement range

Strategic Basis for Digital Integration using Bus Technology (in lieu of analog)

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Architecture – Profibus DP and PA

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Hardware Configuration “one view”

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Profibus DP – Digital platform we use

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Network Diagnostics

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Address 16

• The Profi Trace diagnostic Tool •Powered termination Assembly at one end •Voltage and waveform variation observed •Baseline diagnostic tool

Functional Features of Platform

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• Process Control Skill Sets Required – Core competency

• Remote Calibration of Analyzers via • Calibration permissives - valve feedback, PSL’s on

calibration gases and FSL on sample • Automated return to primary sample after calibration • Validation function (i.e., cal check only) • Calculate pass/fail and record as-found/as-left errors in

DCS

• Automated Calibration Record Retrieval and Reporting Using Standard DCS IT “Plumbing” • Aspen Tech CIMIO, IP21 and macro enabled Excel using

VB and SQL+ queries (similar to pay meter tool) • Calibration records easily accessible via Intranet (from

instrument shop, manager’s offices, OSC, etc.)

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Digital System Benefits

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• Analyzer Elimination via enhanced rangeability

• Eliminate Analog and Discrete IO Hardware modules

• Additional Process Information free

• Eliminate Analog Range Change Logic and Assoc. Risks

• Improved measurement precision

• Electronic calibration records – Use CPU not Humans to calculate errors and log results

• Improved safety and reduced maintenance cost via remote/automated calibration

• Remote maintenance via TCP/IP

• Higher Density, reduced design cost via turn key supply

• Plug and Play, faster project execution and commissioning

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Siemens Standard Function Block for Byte to Real Conversions

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•Four Bytes in, Real Number out

•Teledyne analytical method

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ABB Method - Input Double Word (ID)

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More Signals Available in Digital Mode

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Servomex Method

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14 analyzers plus sample systems – single Profibus DP connection (800 terminations eliminated)

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Higher Density installation Possible

Architecture of Teledyne Valve BoxTM Profibus Integration

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115VAC

24VDC

RS232

Profibus DP

Analyzer Valve Box

Profibus DP multi-drop to each VB, RS232 between analyzer and VB. No signal wiring required.

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ABB Profibus DP/PA Combination Module

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Use Profibus Map to set up parameters To be communicated to control system

CPU and fiber OLM

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Communication Runs > 300 ft typically require fiber optic cable and media converters

Project Costs/Savings with Fieldbus Solutions

© 2010 Fieldbus Foundation

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Profibus Integration – A Strategic Technology for Capital and Operating Cost Reductions

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• Analyzers are clustered thus enabling bundling in signal bus.

• Digital data more process and analog range constraints and logic are eliminated (liberation !!)

Process Visibility – trace and percent analyzer sensor measurement range overlap

• Trace and % Purity O2 analyzers both cover full 0-100% range

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Trace range 0-10/100ppm

Purity range 95-100%

Digital values cover full range

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Small Differential between ppm and % range sensors

– only possible in Digital Mode

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SAP Work Order Enterprise Summary

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Analyzer work orders are the enterprise most frequent, automation of calibration records adds value

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Traditional Practice – Paper Logs Opportunity – Electronic Data

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1960’s Technology

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Automated Excel – Data mines cal records from Process Historian

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Analyzers Drift and Require Routine Maintenance – An Opportunity for Bus Automation

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•Automated Calibration saves operating cost and improves measurement performance •Bus technology enables better control system integration and automated documentation

Remote Cal with Automated Calibration Records Add Value By…

• Minimize Travel – Less need to be in front of analyzer

• Less Technician Paperwork – focus on higher value work, PC automation via IP21, Excel

• Remote Operating Center Ready – unconventional savings

• Operating Efficiency –More accurate analyzers via optimized cal intervals

• Auditing Analyzer Performance – Easily flag problem units

• Safety – Easier review of safety related systems

• Maintenance and Procurement – performance driven management

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ABB Analyzer Remote HMI via TCP/IP

IFPAC-2012

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Download Spectra for Remote Troubleshooting and Support

Remote data exchange benefits both User and Supplier

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Web Browser Based Multiple Location Analyzer Access

Network to multiple analyzers and facilities for remote troubleshooting

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Technicians Happy to Have Digital Remote Communications

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Fresh after commissioning a remote HMI for multiple analyzers at the world’s largest CO2 capture installation at our H2 complex in Texas