IEC Plenary 2012 September 26, 2012 Orlando, FL Standards Certification Education & Training...
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Transcript of IEC Plenary 2012 September 26, 2012 Orlando, FL Standards Certification Education & Training...
IEC Plenary 2012September 26, 2012 Orlando, FL
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
ISA-108Intelligent Device ManagementIan Verhappen – Yokogawa Canada
Herman Storey – Herman Storey Consulting LLC
IEC Plenary 2012September 26, 2012 Orlando, FL
What Is Asset Management?
• Activities that provide for Sustainable Managed Risk over the Life Cycle of an Asset
• Some Asset Management Activities are Mandated by Government Regulation
• All Types of Enterprises have Requirements– Financial– Transportation– Power Generation– Mining and Manufacturing (M&M)
IEC Plenary 2012September 26, 2012 Orlando, FL
Asset Management Goals
• Reduce Unmanaged Risk– Improve Health, Safety, Environmental, and Operability
Performance– Manage Complexity– Reduce Impact of Failures
• Achieve Sustainability– Assure Adequate Human, Financial, and Infrastructure
Resources– Lower Maintenance Cost– Improve Return On Investment
• Simultaneously
IEC Plenary 2012September 26, 2012 Orlando, FL
Maintenance Work Processes
• Work Processes are the Key to Success• Traditional Processes
– Run to Failure– Preventive (Scheduled) Maintenance– Predictive Maintenance
– Schedule Based on Risk and Failure History– May Include Bad Actor / Root Cause Analysis
• Condition Based Maintenance– Based on Real Time Diagnostic Data– Multivariable Model Based (Equipment / Process)– Intelligent Device Based (Instruments / Valves)
IEC Plenary 2012September 26, 2012 Orlando, FL
Maintenance Work Processes
• Traditional Processes– Waste Effort on Poorly Defined Problems (“Broke”)– Maintenance is Often Deferred for Non-Critical Devices– Scheduled Inspection and Testing is Wasteful But Necessary
• Intelligent Device Management– Allows Maintenance on Devices that Actually Need Work, Only
When They Need Work– Can Give Detailed Information on Problems Before a Field Visit– Can Significantly Reduce (or eliminate) the Need for Periodic
Testing– Can Reduce Impact on Operations by Advance Warning of
Failure– A Significant but Underutilized Opportunity– Biggest Incentives on Control Valves
IEC Plenary 2012September 26, 2012 Orlando, FL
Recognition of System Deviations “Before Problems Occur”
IEC Plenary 2012September 26, 2012 Orlando, FL
Standards for Traditional Asset Management
• ISO 55000– Part 1 Overview (Principles and Terminology)– Part 2 Requirements (Includes Mandatory Compliance Metrics)– Part 3 Guidelines for Application– ASTM is US TAG, No Involvement of Automation Professionals
• NAMUR– NE129 Plant Asset Management
• These Standards Do Cover Manual Inspect and Test Methods
• None of these cover use of Automated Diagnostics or would apply to Intelligent Device Management
IEC Plenary 2012September 26, 2012 Orlando, FL
NAMUR NE 129: The Asset Health Triangle
IEC Plenary 2012September 26, 2012 Orlando, FL
PAM System Information ArchitectureSupply Chain Management
Supply Chain Management
Enterprise Resource Planning (ERP) System
E-commerce Maintenance
Repair & Operations
(MRO) Procurement
System
Enterprise Asset
Maintenance (EAM)
System CMMS
Plant Asset Management
(PAM) System
Plant Automation
System (PAS)
Process Control &Process Management
Maintenance Work &Parts Management
Asset AdvisoryManagement
ControlParameters Control
Data
Asset Collaboration /Tolerances
Transducer Config.Monitoring Set-upInspection Routes
Asset UsageData
Asset MonitoringVariablesAsset Calibration / Tolerance Data
Control Device Monitoring
Portable Device Monitoring
Survey On-Line Monitors
ProtectionOn-Line Monitors
TransientOn-Line Monitors
Sample Monitoring
Smart valves & Field Devices
PLC / DCS
Vib
rati
on
Pro
cess
Oil
Th
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Ele
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cal
Sh
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Dis
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cem
ent
Cas
ing
Vib
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on
Pro
cess
Ele
ctri
cal
Sh
aft
Dis
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ce
me
nt
Sh
aft
Po
siti
on
Cas
ing
vi
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Pro
cess
Sh
aft
Dis
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ent
Ca
sin
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vib
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on
Pro
cess
Oil
Par
ticl
e
Oil
Ch
em
ical
Oil
P
rop
erti
es
Operation Field
Report
Smart Machines & Transducers
Plant Measurements / Inspections
Maintenance Advisories
Purchase order
Order TrackingWork Histories
Process Advisories
Process Events & Data
IEC Plenary 2012September 26, 2012 Orlando, FL
Smart Pressure Transmitters are the Norm
Source: ARC Advisory Group
Installed Base
Smart, Microprocessor Based
Conventional or Pneumatic
IEC Plenary 2012September 26, 2012 Orlando, FL
Intelligent Device Management
• Intelligent Devices Are Pervasive, but Are Not Being Used Properly– Most Diagnostics are not Prioritized or Utilized
• Considered Approach to Intelligent Device Management is Required– Technology and Products are Widely Available– Work Processes and Best Practices are the Key– A New ISA Standards Effort is Needed
IEC Plenary 2012September 26, 2012 Orlando, FL
New ISA Intelligent Device Management Standard
• Content Proposals:• Models and Terminology• Implementation Guidelines• Work Processes
– Diagnostics Based Maintenance– Configuration Management– Auditing
IEC Plenary 2012September 26, 2012 Orlando, FL
Work Process Life Cycle
• FED– Criticality Ranking– Vendor Qualification & Templating
• Design / FAT– Work Process Selections and Design– Initial System Configuration (Build Tools)– Training
• Install, Commission, Loop Check– Device and System Integration– Initial Use of Diagnostics
• Pre-Startup Safety Review• Routine Maintenance• Turnaround Management
IEC Plenary 2012September 26, 2012 Orlando, FL
Intelligence Device Management
• Most Diagnostics Go Directly to a Black Hole– Diagnostics May Need to go to Engineering, Maintenance,
and/or Operations
• Use and Priority of Diagnostics are Determined by Application Criticality– Criticality Ranking should be established in FED– Alert Priority Depends on Impact Severity – Not Likelihood– Send Alerts to Operator and well as Maintenance Only if
Operator Action is Required– Log All Alerts regardless of Priority– Different from process alarm management
• Needs Definition Before Configuration Activities
IEC Plenary 2012September 26, 2012 Orlando, FL
Intelligent Device Management
• Proper Use of Diagnostics Depends on a Graphical User Interface – Would you give an Operator an Explorer Tree?– Requirement: Navigate from Overview to Detail in 3 Mouse
Clicks– Cover all System Devices, Nodes, Networks, & Modules
• Free Format Diagnostic Reports are Necessary– Individual Alerts are Not Generally Useful and are Often
Repetitive– Reports can Summarize and Clarify Large Amounts of Raw Data
• See Fieldbus Foundation User Guide (AG-181) for More Information & Examples
IEC Plenary 2012September 26, 2012 Orlando, FL
Graphical User Interface for Maintenance
CCGCTL01 CCGCTL02 CCGCTL03
03-01-29-02MF2
03-01-29-01MF2
03-01-19-01MF2
03-01-17-02MF2
03-01-17-01CSS
03-01-13-02MF2/CSS
03-01-01-01MF2
03-01-01-02MF2
03-01-03-01MF2
03-01-03-02CSS/MF2
03-01-05-01CSS/MF1
03-01-05-02MF2
03-01-09-01CSS/MF2
03-01-09-02MF2
03-01-11-01CSS/MF2
03-01-11-02CSS
03-01-13-01MF2/CSS
01-01-01-01CCS/RR2
01-01-01-02CSS
01-01-03-01CSS/RR2
01-01-03-02CSS/RR2
01-01-05-01CSS
01-01-05-02CSS
01-01-09-01CSS
01-01-17-02CSS/RR2
01-01-19-01CSS/RR2
01-01-19-02CSS/RR2
01-01-21-01CSS/RR2
01-01-21-02RR2
01-01-25-01CSS/RR2
01-01-25-02CSS
01-01-27-01CSS/RR2
01-01-27-02RR2
01-01-29-01RR2
01-01-29-02CSS/RR2
02-01-01-01RR1
02-01-01-02RR1
02-01-03-01RR1
02-01-03-02NONE
02-01-05-01RR1
02-01-05-02RR1
02-01-09-01RR1
02-01-09-02RR1
02-01-23-02RR1
02-01-23-01RR1
02-01-21-02RR1
02-01-21-01NONE
02-01-19-02RR1
02-01-19-01CSS
02-01-17-02RR1
02-01-17-01RR1
02-01-25-01RR1
02-01-25-02RR1/CSS
02-01-27-01RR1
02-01-27-02RR1
02-01-29-01RR1
02-01-11-01RR1
02-01-11-02CSS/RR1
02-01-13-01CSS/RR1/MF1
02-01-13-02RR1
02-01-15-01RR1
01-01-09-02CSS
01-01-11-01CSS
01-01-11-02CSS
01-01-13-01CSS
01-01-13-02CSS
01-01-31-01RR2
01-01-31-02RR2
01-01-17-01RR2
02-01-15-02NONE
02-01-29-02RR1/CSS
03-01-27-02MF2/CSS
03-01-27-01MF2/CSS
03-01-21-02MF2
03-01-21-01MF2
03-01-19-02CSS/MF2
FIELDBUS MAINTENANCE OVERVIEW
Good
Source: AG-181
IEC Plenary 2012September 26, 2012 Orlando, FL
Automated Use of Diagnostics
• Diagnostics Must Flag Data Quality– Data Quality (PV Status) Must Propagate to All Applications and
Graphics in Host Systems for Automated Failure Handling
• Data Quality Should Include:– Active Alerts (Follow NAMUR NE107)
– Good, Bad, Advisory, Bubba is Working on it– Full Support by Fieldbus Foundation Devices and Hosts
– Configuration Mismatch with Host– Excess Communication Errors– All Device and Loop Blocks in Normal Mode
• Utilization of Data Quality in Control Schemes Requires Extra Engineering
IEC Plenary 2012September 26, 2012 Orlando, FL
Automated Use of Diagnostics
• Data Quality (Fieldbus Foundation vs. HART)– HART Devices Support Good and Bad Status for Analog Inputs
(Measurements) Through NAMUR NE 43– NAMUR NE 43 Does Not Work for Analog Outputs (Valves)– Additional HART Information is Available by Polling Devices– Foundation Fieldbus Provides more Complete Information for all
Devices – Much Faster
• Diagnostic Performance (Fieldbus Foundation vs. HART)– Polling Requirement and Speed– Multiple Simultaneous Polling Groups (Modems) for HART
– 64 Maximum Recommended Devices per Group– Utilize Data Cache in HART Modems
IEC Plenary 2012September 26, 2012 Orlando, FL
Required Intelligent Device Management Tools
• Maintenance History• Resource Planning, Tracking, Accounting
– Example: SAP
• Design Calculation, Drawing, Documentation– Example: SPI (Intools)
• Host Systems– Integrated Host (Example: DCS)– Visitor or Bench Host (Handheld or Laptop)– Provide Configuration Management, Troubleshooting, and
Human Interface
IEC Plenary 2012September 26, 2012 Orlando, FL
Intelligent Device Management Interactions
DCS Host
CMMS
Plant Asset Management System
Event Historian
Alarm Management System
Intelligent Devices
Configuration Database
Work Orders
Reporting & Analysis
IEC Plenary 2012September 26, 2012 Orlando, FL
Integrated Data System
Device server
FDT/DTMEDDL
HART FF Profibus DeviceNet Others
AlertMonitor
Database(s)Tag data
Audit Trail
Calibration Data
Instrument Asset
Management System
User Interface
DatabaseRules
Engine
Enterprise Asset
Manager System
Interface
User Interface (Configuration & Monitoring)
Enterprise Asset
Management System
B2MML
XMLSQL & ODBC
Enterprise Server /
Middleware
IEC Plenary 2012September 26, 2012 Orlando, FL
Intelligent Device Management Tools
• Tools, Hosts, and Devices Need:– Remote Access– Multiple Simultaneous Access– Cyber Security
– Role Based Security– Required for Hosts and Devices– A Standardized Security Model Would be Nice
IEC Plenary 2012September 26, 2012 Orlando, FL
Configuration Data Management
• Each Tool has a Database– Each Tool is Designed to Use its Data as Master– The Actual Data Master Changes During the Lifecycle
• Tools, Devices, and Systems Must Manage Data– Import, Export, and Reformat are Needed for Exchange– Data Comparison and Reconciliation is Necessary– Template Process Required for Default Settings– History and Change Tracking are Needed
• Field Experience– Use of Visitor Hosts (Handhelds)– Configuration Management (or Configuration Drift)
IEC Plenary 2012September 26, 2012 Orlando, FL
What Is Exception Based Surveillance?
Seconds Minutes Hours Days Weeks Months Years Life of Asset
Operation Diagnostics & Surveillance
Planned Maintenance and Design
Improvements
Real Time Activities
Semi Real Time
Activities
Planned Activities
Exception based Surveillance provides for Reactive Response in Semi Real Time to Diagnostic Alerts filling a Gap between Operation and Traditional Planned Activities and makes use of Diagnostic Capabilities of Field Devices
IEC Plenary 2012September 26, 2012 Orlando, FL
Conclusion
• Large Incentives for Intelligent Device Management– Most Efficient System for Maintenance– Reduced Impact of Failures
• Barriers are Significant– Changes in Engineering Practices– Culture Change for Maintenance– Management Ownership
• Standards Will Help– Get Engaged
IEC Plenary 2012September 26, 2012 Orlando, FL
To Learn More:
ISA108 Committee• http://www.isa.org/
MSTemplate.cfm?MicrositeID=1528&CommitteeID=7281
Ellen Fussell Policastro, Standards AdministratorInternational Society of Automation
PO Box 12277, 67 Alexander Drive
Research Triangle Park, NC 27709
+1 (919) 990-9227
Managing Director:
Ian Verhappen
+1 403 258 2681 [email protected]