Transparency of diagnostics - Are you human? Process Day 2009 Cerabar S/Deltabar S Pressure Transmitter E 113: Measurement Fault in the pressure/temperature measuring The sensor does

Profibus process dayTransparency of diagnostics

Profibus Process Day 2009

Agenda

Intelligent instruments

…what does a “modern” device give us?

Diagnostic availability

…interpreting diagnostic information

Levels of diagnostics

Faceplates

Condition monitoring

Demonstration

Intelligent devices

Slide 3


What is an intelligent device?

• PressureCerabar MCerabar SDeltabar S

• LevelLevelflex MMicropilot MMulticapLiquiphant M

• AnalyticalLiquiline MMycom S

• FlowPromag 50/53Promass 83Prowirl 72/73t-mass 65

• Temperaturei-temp


Intelligent devices - a wealth of information available

Configuration informationCalibration informationCondition MonitoringDiagnosticsAdvanced diagnostics

Level TemperaturePressure

Process variables


Multi-variable meters

Diagnostic availability…from intelligent devices

Slide 7


Types of Maintenance

Corrective Maintenancea device is maintained when it fails-> uncontrolled plant shutdowns

Preventive Maintenancea device is periodically maintained to prevent failures

-> controlled, but high maintenance costs

Predictive Maintenancea device indicates when maintenance is necessary

and informs in advance of a failure-> controlled and optimised low maintenance costs


Relative costs of maintenance

0

10

20

30

40

50

60

70

corrective preventive predictive

%

65 %

5 %

... of which 60% are unnecessary!

30 %

Source:ARC Advisory Group

Predictive Preventive Corrective


Available device diagnostic data

Quantity

Process Device Process Control System

Signal evaluatio

n

measured value 1

Measured values: process variables (level, flow, density, pH etc

E+H error codes: device specific alarms and warnings (E641, E700 etc)

Generic errors: common device errors (configuration error, maintenance required etc)

Diagnosic variables: quality of measurement (excitation current, signal to noise ratio, sensor impedance)

E+H error codes

Generic errors

Diagnosicvariables

ProcessControlSystemSensor

Diagnostic data

measured value 2

measured value 3

Status Byte


Vibrating limit switch

• Detection of either corrosion or build-up of the fork

• A piezo crystal drive causes the fork to vibratewhilst the frequency shift is monitored

• A lower frequency is an indication of build-up, ahigher frequency is an indication of corrosion


Electromagnetic flowmeter

• Detection of corrosion or build-up on the electrodes

• Test voltage applied to both electrodes, the voltage is monitored for decay

• Any difference between electrode voltage decay indicates a fault.


Cerabar S/Deltabar S Pressure Transmitter

E 113: Measurement Fault in the pressure/temperature measuring

The sensor does not convert the pressure and temperature value correctly.

Connection "pressure signal" (pin 6) on the plug is interrupted. Check connection.

Sensor electronic defective. Replace sensor.

E 120: Sensor underpressurePressure too low. Increase pressure until message disappears.

Sensor electronic: Insert cable. Connection interrupted. Check cable connection.

Sensor defective: Replace sensor.

W 620: Current out of rangeMeasured value outside of lower/upper range value. Maybe the pressure is too high or too low.

The calibration values for "set 4mA" and "set 20mA" are incorrect. Please correct them.


Cerabar S/Deltabar S Pressure Transmitter

E 102: Electronic instrument errorerror with the maximum counter function

To resolve the problem, carry out a reset (Code 5140) and recalibrate the instrument.

E 115: Sensor overpressurePressure too high. Decrease pressure until message disappears.

Sensor electronic: Insert cable. Connection interrupted. Check cable connection.

Sensor defective: Replace sensor.

E 610: Calibration errorsame pressure value for "Lower Range Value" and "Upper Range Value“

Please check the calibration


Levelflex M guided wave radar level transmitter

E 650: Signal/noise ratio too low or no echo is received

E 221: HF module failure on channel 1Try reset and check the system for EMC. Improve as necessary.

If the alarm is still present after reset and improvement of EMC, replace electronics.

E 241: Broken probe on channel 1Maybe the value for the probe length is too short. Please check the probe length in 033.

Check the probe itself, if the probe is broken change the probe, or change to a non contact system.

W 611: Less than 2 linearisation points for channel 1Please enter additional value pairs.

W 651: The level is in the safety distanceRisk of overspill.

The warning disappears when the level leaves the safety distance.


iTemp temperature transmitter

E 70: Drift alarmThe drift limit is exceeded.

A possible reason is corrosion of the sensor or the cable.

Please start maintenance activities

Please check the sensor.

E 16: A/D convertor defectivePlease replace the device.

E 81: Measuring range undershootMeasuring range poss. set too small

W 17: Temperature limit exceededThe electronics are possibly damaged due to exceeding the ambient temperature range.

Please return the electronics to manufacturer for check.


Promass 83 Coriolis Mass Flowmeter

Two phase or slug flowTubes not oscillating

High viscosity liquid or gas in liguid alarmOcsillation amplifier limit

Informs you if either the drive or pick up coils failSensor failure alarm

Informs you when either the process or the sensor temperature limits have been exceededSensor temperature alarms

Warning in case of any current, frequency, measurand or test output has been left in simulation modeSimulation errors

Annunciates any batch errors such as time limit, under/over batchingBatch errors

Checks validity of all analogue and frequency outputsOutput configuration errors

Annunciates various programming or configuration errors such as instrumment in simulation, incorrect zero adjustment, measuring range error, etcProgramming errors

Annunciates various electronic component failures such as amplifier failure, DAT failure, software incompatibilityVarious electronic failures

ExplanationError


Promass 83 Coriolis Mass Flowmeter

Used in advanced diagnostics to detect poor measuring conditions, e.g. air or hi/lo viscosity

Tube damping (resistance offered by the product to tube oscillation)

Used for process diagnosticsExcitation frequency

Used for process diagnosticsExcitation current

Mass, volume, density, temperature, Process values

Annunciates when variables such as process measurements or sensor conditions deviates from definable limitsAdvanced diagnostics errors

Flow too high for this sensorFlow limit

Gas in liquid alarmFluid inhomogeneous

Two phase or slug flowExcitation current limit

Empty pipe on liquid applicationsor below density threshholdEmpty pipe detection

Cavitation or high gas velocityNoise limit

ExplanationError


Prosonic M Ultrasonic Level Transmitter

Used for sensor failure diagnosticsSensor overtemperature

Warning of potential overspillLevel in safety distance

No usable echo in the measuring rangeNo usable echo

Device left in simulation modeSimulation on

Programming errors such as incorrect linearisation tableProgramming errors

Annunciates temperature sensor failureTemperature sensor failure

Annunciates ultrasonic unit failureSensor failure

Configuration download errorsDownload error

Annunciates an electronics failure or EMC effectsElectronics failure

ExplanationError


Promag 53 Electromagnetic flowmeter

Difference in voltage decay times used to detect presence of build up on electrodesElectrode voltages

Used for sensor failure diagnosticsCoil current

Volume flowProcess values

Empty pipe or invalid adjustment of empty pipe detectionEmpty pipe detection

Sensor coil wiring, moisure or power board failureCoil tolerance error

Warning in case of any current, frequency, measurand or test output has been left in simulation modeSimulation errors

Annunciates ant batch errors such as time limit, under/over batchingBatch errors

Checks validity of all analogue and frequency outputsOutput configuration errors

Annunciates various programming or configuration errors such as instrumment in simulation, incorrect zero adjustment, measuring range error, etcProgramming errors

Annunciates various electronic component failures such as amplifier failure, DAT failure, software incompatibilityVarious electronic failures

ExplanationError


Types of error and meanings

XW153. Electronic module failure. Carry out reset or replace complete transmitter.alarm89

W103. Instrument initialising - please wait 10 seconds until complete.warning88

XW621. Transmitter in simulation mode. Set back into operating mode.warning87

W601. Linearisation curve has an incorrect value entered. Correct table and put back into service.warning86

W512. Mapping in progress - wait approx 30 secondswarning84

W511. No factory map available. Record new map.alarm83

W681. Current output is out of range. Bring level back into normal range. Check configuration.warning82

XW271. Electronic module failure. Carry out reset or replace complete transmitter.alarm78

XW651. Level in Safety distance. Reduce the level and check configuration parameter.warning77

XW641. Lost echo. Possible causes include turbulent surface, foam on surface or build up on sensor. Improve process conditions and check calibration parameters or vessel influences.

warning76

A270. Custody switch error. Ensure custody switch is in the correct position.warning75

XA651. Level in Safety distance. Reduce the level and check configuration parameter.warning74

A671. Linearisation table not available. Activate entered linearisation table.alarm73

XA641. Lost echo. Possible causes include turbulent surface, foam on surface or build up on sensor. Also check calibration parameters or vessel influences.

warning72

A116. Error encountered during configuration download. Start download again or reset the transmitter.alarm71

A106. Configuration downloading to transmitter. Please wait until completed.warning70

XA272. Electronic module failure. Carry out reset or replace complete transmitter.alarm69


XA231. Defective HF module or electronics. Replace HF module, electronics or complete transmitter.alarm67


SelectedDescriptionStatusDiag-Bit

Failure

Maintenance

Operational

Levels of diagnostics…and visibility

Slide 22


Levels of diagnostics

Level 1Device status byte

Level 2Faceplates

Level 3Condition monitoring

Level 1 Level 2 Level 3

Device Status monitoring

+ diagnosis data, showing diagnosis text

+ device configuration & asset management by FieldCare

GoodBadUncertain


SCADA faceplates showing all sensor information

Extended Diagnostics

Diagnostics

Extended Information

Primary Information

Measurement Quality

Global Templates provide the following features


FieldCare Condition Monitoring

EthernetEthernet

Condition Monitoring allows the condition of measuring devices to be visualised using a networked Internet browser. Exceptions are notified via email.

OK Warning Alarm not monitored comms error


Condition Monitoring – engineering a solution

Noise limit

Excitation current limit

Empty pipe detection

Tubes not oscillating

Temperature sensor failure

Sensor failure

Amplifier failure

Sensor DAT failure

Description

S

S

S

F

F

F

F

F

Status

703/704

701

700

587

381/382/ 383

385/386

388/389/ 390

31

Error Code

Cavitation near meter

Air or solids in measuring tubes

Measuring tubes only partially filled

Text generated within condition monitoring module


Diagnostics available from all levels

Ethernet

Profibus DP

Profibus PA

CMMS

E-mail

Web reportsDevice diagnostics

Device configuration

Network diagnostics

FDT frame

application

SCADA

Faceplate

Profibus process day…demonstration

Documents

Transparency of diagnostics - Are you human? Process Day 2009 Cerabar S/Deltabar S Pressure Transmitter E 113: Measurement Fault in the pressure/temperature measuring The sensor does