-
Asset Effectiveness Solutions
Delivering Operational Value with
FOUNDATION Fieldbus devices
Craig Webb
Application Consultant
The views expressed in this paper are solely those of the
author/presenter and do not reflect the views of, and
should not be attributed to Honeywell, The Fieldbus FOUNDATION
or any other organisation or individual.
-
2
Synopsis
To deliver perpetual value from FF device
diagnostics requires:
• outcome focussed diagnostic assessment
• templated device type based fault logic
• using diagnostics for:
– campaign maintenance requirements assessment
– device type life cycle management
– critical equipment condition assessment
• planning
-
3
• satisfactory behaviour can be confirmed without the need to
venture into the field
• questionable device behaviour can be identified before
functionality is lost
• life-cycle performance can be monitored
• infrequent condition related events can be dealt with
consistently
Value Expectation
-
4
Minimally Manned Sites
-
5
High Reliability
• FF devices are highly reliable
– 0.5 failures per million operating hours typical
= one failure every 250 accumulated operating years
= one failure every 2.5 years per 100 devices
• process plants seldom over instrumented
– no device redundancy
– provide optimised control and production efficiency
• faults affect production
• avoiding impact requires fault recognition and
response with appropriate urgency
-
6
High Dependability
• AS IEC 60300 defines dependability as:
– the collective term used to describe the availability
performance and its influencing factors: reliability
performance, maintainability performance and
maintenance support performance
• high reliability doesn’t equal high dependability
without timely maintenance.
• timely maintenance
demands accurate
condition
monitoring
(IEC 60300)
-
7
Pre-Requisites to Value
• define outcomes and their urgency
• select devices that can deliver required data
• implement fault/symptom history capture
• train ops personnel in the tools used
-
8
Outcome Focus
• first decide what you want to find:
– what type of maintenance actions are possible
1. check device is behaving normally
2. device parameter adjustment
3. device replacement
– What sort of device problems drive these actions
• select devices that can deliver required data
• use experience and manufacturer
recommendations to structure diagnostics
relating to your required outcomes
-
9
Nature of Event
Facility Type
Manned Minimally Manned Not Normally
Manned
Severity Effect
Gas Plant FPSO Unmanned Platform
Response
BREAK
DOWN
production affected Replace device within
this shift
Replace device within
48 hours
Intervention visit to
replace device
no immediate effect on
process
Replace device within
48 hours
Replace device within
72 hours
Replace on next
available access
FAULT
device primary function
impaired
Adjust or replace
device within 72 hours
Adjust within 72 hours
or replace at next
campaign
maintenance
Adjust within 72 hours
or replace at next
campaign
maintenance
information diagnostic
not requiring immediate
response
Monitor Monitor Monitor
Response Urgency
-
10
Response Urgency
3144P FF 0103 Temperature Sensor
Performance Impact
LOGIC SYMPTOM
sensor 1 open OR
sensor 1 shorted
sensor 2 open
3144P sensor failure Serious
AND
OR sensor 2 shorted
sensor 1 open XOR
sensor 2 open
sensor 1 shorted XOR
XOR sensor 2 shorted
sensor 1 beyond operating limits
3144P sensor fault Significant
OR
sensor 2 beyond operating limits
sensor 1 out of operating range 3144P sensor alert Tolerable
OR
sensor 2 out of operating range
sensor 1 degraded 3144P sensor warning Minor OR
sensor 2 degraded
-
11
Diagnostic Detail Varies
-
12
Beyond the Device
• diagnostics assessing external factors
Valve Leakage in Closed Position Fault
FVP_TRANSDUCER.FINAL_POSITION_VALUE.VALUE less than 1.1 AND
FLOWSENSORTAG.PV greater than 0
DVC6000 Valve Actuator Fault
valve stuck low or arm damage
Bit 10 of ValveTag.transducer.PD_DETAIL1_ACTIVE' is on AND
travel deviation Bit 0 of ' ValveTag.transducer.TRAVEL_ACTIVE'
is on
valve stuck high or arm damage
Bit 11 of ' ValveTag.transducer.PD_DETAIL1_ACTIVE' is on
OR
AND
travel deviation Bit 0 of ' ValveTag.transducer.TRAVEL_ACTIVE'
is on
• diagnostics + off-device indications
-
13
Beyond the Device
-
14
Beyond the Device
-
15
Summary
• deliver outcome focussed diagnostic assessment
• use device type based fault logic for maximum
applicability
• consider device diagnostics for critical equipment
condition assessment
• utilise diagnostic indications remotely for
campaign maintenance and life cycle
management
• plan your requirements and select devices that
can accommodate your needs
-
16
Thank You
