ISA108 – Intelligent Device Management · (MRO) Procurement System Enterprise Asset Maintenance...

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ISA108 – Intelligent

Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

ISA 2013 Oil Sands Conference

March 12-13, 2013 Fort McMurray Alberta

ISA108 – IntelligentDevice Management

Ian Verhappen,Industrial Automation Networks Inc.

Managing Director ISA108

What Is Asset Management?

• Activities that provide for Sustainable Managed Risk overthe Life Cycle of an Asset

• Some Asset Management Activities are Mandated byGovernment Regulation

• All Types of Enterprises have Requirements



– Financial

– Transportation

– Power Generation

– Mining and Manufacturing (M&M)

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Asset Management Goals

• Reduce Unmanaged Risk– Improve Health, Safety, Environmental, and Operability

Performance

– Manage Complexity

– Reduce Impact of Failures

• Achieve Sustainability



• Achieve Sustainability– Assure Adequate Human, Financial, and Infrastructure

Resources

– Lower Maintenance Cost

– Improve Return On Investment

• Simultaneously

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



– 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)

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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



– Allows Maintenance on Devices that Actually Need Work, OnlyWhen They Need Work

– Can Give Detailed Information on Problems Before a Field Visit

– Can Significantly Reduce (or eliminate) the Need for PeriodicTesting

– Can Reduce Impact on Operations by Advance Warning ofFailure

– A Significant but Underutilized Opportunity

– Biggest Incentives on Control Valves

Recognition of System Deviations“Before Problems Occur”



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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



• NAMUR– NE129 Plant Asset Management

• These Standards Do Cover Manual Inspect and TestMethods

• None of these cover use of Automated Diagnostics orwould apply to Intelligent Device Management

NAMUR NE 129: The Asset Health Triangle

StrategicAsset

Management

EquipmentStandardization

RAM

Life CycleAnalysis

VendorReliability

RCM

Craft Stage 3

Stage 4

Reliability Engineering

Stage 5

Operational Excellence



CraftFlexibility

OPM

Maintenance /Operations Integration

ExternalBenchmarking

Asset Strategies/ SRCM

FailureAnalysis

Asset Integrity

Craft SkillsEnhancement

EquipmentHistory

Condition BasedMaintenance

ManagingSystem

CMMS /Metrics

PreventativeMaintenance

Planning &Scheduling

TurnaroundManagement

Work Identification/ Prioritization

Work ExecutionReview

Stage 3

Organizational Excellence

Stage 2

Proactive Maintenance

Stage 1

Planned Maintenance

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PAM System Information ArchitectureSupply ChainManagement

Supply ChainManagement

Enterprise ResourcePlanning (ERP) System

E-commerceMaintenance

Repair &Operations

(MRO)Procurement

System

EnterpriseAsset

Maintenance(EAM)

SystemCMMS

Plant AssetManagement

(PAM)System

PlantAutomation

System(PAS)

Process Control &Process Management

Maintenance Work &Parts Management

Asset AdvisoryManagement

MaintenanceAdvisories

Purchaseorder

OrderTrackingWork Histories

Process Advisories

Process Events& Data



SystemCMMS

ControlParameters Control

Data

Asset Collaboration /Tolerances

Transducer Config.Monitoring Set-upInspection Routes

Asset UsageData

Asset MonitoringVariablesAsset Calibration /Tolerance Data

Control DeviceMonitoring

Portable DeviceMonitoring

Survey On-Line Monitors

ProtectionOn-Line Monitors

TransientOn-Line Monitors

SampleMonitoring

Smartvalves& FieldDevices

PLC /DCS

Vib

rati

on

Pro

cess

Oil

Th

erm

al

Ele

ctr

ical

Sh

aft

Dis

pla

ce

men

t

Ca

sin

gV

ibra

tio

n

Pro

cess

Ele

ctr

ical

Sh

aft

Dis

pla

cem

en

t

Sh

aft

Po

sit

ion

Casin

gvib

rati

on

Pro

cess

Sh

aft

Dis

pla

cem

en

t

Ca

sin

gvib

rati

on

Pro

cess

Oil

Part

icle

Oil

Ch

em

ica

l

Oil

Pro

pert

iesOperation

FieldReport

SmartMachines &Transducers

Plant Measurements / Inspections

IDM vs. PAM

Plant Asset Management System

Machinery HealthManagement

ProcessingEquipment

Management

Intelligent DeviceManagement

• Pumps • Heat • Transmitter



• Pumps• Compressors• Motors

• HeatExchanger

• Fin FanCooler

• Transmitter• Analyzer• Valve• Drive• Gas

Chromatograph

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IDM Scope

PrimaryElement / Transmitter

Final



Element /Sensor /

Transducer

• Thermocouple• RTD• Orifice plate

Transmitter/ Analyzer

Controller Positioner Actuator ControlElement

• Temperature• Pressure• Gas

chromatograph

• DCS• PLC• RTU• Logic

Solver

• Pneumatic• Electric

• Valve• Pump

• Positioner• PST

gadget• VSD

Able to diagnose...Able to diagnose...

IDM in Context of Purdue Model



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Smart Pressure Transmitters are the Norm

Installed Base

Smart, MicroprocessorBased



Source: ARC Advisory Group

Conventional orPneumatic

Intelligent Device Management

• Intelligent Devices Are Pervasive, but Are Not BeingUsed Properly– Most Diagnostics are not Prioritized or Utilized

• Considered Approach to Intelligent Device Managementis Required– Technology and Products are Widely Available



– Technology and Products are Widely Available

– Work Processes and Best Practices are the Key

– A New ISA Standards Effort is Needed

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New ISA Intelligent DeviceManagement Standard

• Content Proposals:

• Models and Terminology

• Implementation Guidelines

• Work Processes– Diagnostics Based Maintenance



– Diagnostics Based Maintenance

– Configuration Management

– Auditing

Work Process Life Cycle

• FED

– Criticality Ranking

– Vendor Qualification &Templating

• Design / FAT

– Work Process Selections andDesign

• Pre-Startup Safety Review

• Routine Maintenance

• Turnaround Management



Design

– Initial System Configuration(Build Tools)

– Training

• Install, Commission, LoopCheck

– Device and System Integration

– Initial Use of Diagnostics

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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 byApplication Criticality– Criticality Ranking should be established in FED



– Criticality Ranking should be established in FED

– Alert Priority Depends on Impact Severity – Not Likelihood

– Send Alerts to Operator and well as Maintenance Only ifOperator Action is Required

– Log All Alerts regardless of Priority

– Different from process alarm management

• Needs Definition Before Configuration Activities

Intelligent Device Management

• Proper Use of Diagnostics Depends on a Graphical UserInterface– Would you give an Operator an Explorer Tree?

– Requirement: Navigate from Overview to Detail in 3 MouseClicks

– Cover all System Devices, Nodes, Networks, & Modules



– 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 MoreInformation & Examples

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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



– 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 RequiresExtra Engineering

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



– Foundation Fieldbus Provides more Complete Information for allDevices – 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

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Required Intelligent DeviceManagement 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, andHuman Interface

Intelligent Device ManagementInteractions

CMMS

Intelligent Devices

Work Orders



DCS Host

Plant AssetManagement System

EventHistorian

Alarm ManagementSystem

ConfigurationDatabase Reporting

& Analysis

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Integrated Data System

Database

RulesEngine

EnterpriseAsset

ManagerSystem

Interface

User Interface (Configuration & Monitoring)

EnterpriseAsset

ManagementSystem

B2MML

XMLSQL &ODBC

EnterpriseServer /

Middleware



Device server

FDT/DTMEDDL

HART FF Profibus DeviceNet Others

AlertMonitor

Database(s) Tagdata

AuditTrail

CalibrationData

InstrumentAsset

ManagementSystem

User Interface

XMLODBC

Intelligent Device Management Tools

• Tools, Hosts, and Devices Need:– Remote Access

– Multiple Simultaneous Access

– Cyber Security

– Role Based Security

– Required for Hosts and Devices



– Required for Hosts and Devices

– A Standardized Security Model Would be Nice

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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



– 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)

Real TimeActivities

Semi RealTime

Activities

What Is Exception Based Surveillance?

Seconds Minutes Hours Days Weeks Months Years Life of Asset

PlannedActivities



ActivitiesActivities

OperationDiagnostics &Surveillance

PlannedMaintenanceand Design

Improvements

Activities

Exception based Surveillance provides for Reactive Response in Semi RealTime to Diagnostic Alerts filling a Gap between Operation and TraditionalPlanned Activities and makes use of Diagnostic Capabilities of Field Devices

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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



– Culture Change for Maintenance

– Management Ownership

• Standards Will Help– Get Engaged

To Learn More:

ISA108 Committeehttp://www.isa.org/MSTemplate.cfm?MicrositeID=1528&CommitteeID=7281

Managing Director:

Ian Verhappen+1 403 829 [email protected]



Charlie Robinson

International Society of Automation

PO Box 12277, 67 Alexander Drive

Research Triangle Park, NC 27709

+1 (919) 990-9213

[email protected]

Co-Chair:Herman [email protected]

ISA108 – Intelligent Device Management · (MRO) Procurement System Enterprise Asset Maintenance...

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