Increasing Instrument Calibration Interval Though Online Monitoring Technologies

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Increasing Instrument Calibration Interval Though
On-line Monitoring Technologies

• BNFLs Experiences With The Use Of FieldBus

Presented by Thomas S Nobes, Senior CEI
Engineer, British Nuclear Group, Warrington, UK,
WA3 6AS, tom.s.nobes_at_britishnucleargroup.com
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All Fieldbuses look the same (in the sales
literature!)
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FieldBuses do the same thing, like cars ?
CAN
M-Bus
SDS
Arc-Net
FIP
Foundation FieldBus
BRAIN
SwiftNet
ProfiBus DP
InterBus
ProfiBus PA
P_NET
ProfiBus FMS
ASI
SafetyBus
InterBus S
ControlNet
WorldFIP
LONWorks
Seriplex
DeviceNet
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But they are not all the same
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FieldBus Foundation backed by the Main
Playerswho provide 92 of the world
instruments source RAND Corporation
Fuji
FISHER-ROSEMOUNTTM
HONEYWELL
M
KROHNE
Magnetrol
smar
Foxboro
FIRST IN FieldBus
EH
EndressHauser
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What's a typical existing plant example ?
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What does Foundation FieldBus look like ?
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Whats right about FieldBus Foundation ?
It's very flexible

• Most wiring is not dedicated.
• Few items that serve no useful purpose
  (junction boxes, tray, trunking, marshalling
  panels, Klippon terminals, etc).
• One instrument several measurement points.
• Easy to add new functions (like square-root for
  flowmeter, PID) because they are Function Blocks.
• Easier to add instruments.
• Easy to modify ranges, zero, damping, because
  there Function Blocks.
• Commissioning helps (i.e. manuals inside
  instruments)
• Lots of diagnostic data (pipe is full of air,
  turbulence, etc ?).

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The Filter Test Rig is multi-vendor, with system
integration by Yokogawa
Yokogawa
Flowserve
Endress Hauser
National Instruments
SMAR/Solartron
ABB
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Segment detail
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Segment layout
FCS
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2
3
1
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Change is firmware and documented
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Filter Test Rig
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Radiation Hardness Test Rig
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Centum CS1000 Fieldbus Network mapping
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PRM Screenshot 1
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PRM Screenshot 2
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PRM Screenshot 3
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PRM Screenshot 4
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PRM Screenshot 5
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Maintenance Effort on dP and Pressure Instruments
dP flow
dP level
FieldBus diagnostics would eliminate the yellow
and reduce the blue maintenance.
Pressure
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Different Types of Device Maintenance

• Reactive maintenanceAfter the device has failed
  unexpectedly. Its already too late !
• Preventive maintenanceThe device is serviced at
  a chosen interval (scheduled), whether needed or
  not. Risk of it not working after the service !
• Unnecessary maintenanceThe device is actually
  healthy, but malfunctioning is suspected, while
  e.g. the process might cause unexpected
  behaviour, it must be the instrument.
• Predictive maintenanceThe maintenance schedule
  is optimised on the basis of failure rate and
  drift statistics. This does not stop it still
  being Reactive.
• Proactive maintenanceThe device built-in
  diagnostics (leading indicators) alerts for
  maintenance.

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Performance of the device/Lifecycle
Asset Performance
Wear
Optimal
Proactive based maint. will shorten repair time
Predictive Maint.
Normal
Loop, Process Diagnostics
Quality, Accuracy info.
Preventive Maint.
Out of Spec
Proactive Maint.
Proactive Maint.
Proactive Maint.
Proactive Maint.
Broken
Reactive Maint.
Out of Service
Start-up
Useful life
Predictive RCM (Reliability Centred Maintenance)
Proactive DBM (Diagnostic Based Maintenance)
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Traditional dP flow installation
3. Primary Element Venturi, Orifice Plate and
Flange Union creates dP, (see BNF.EG.0053-9)
2. Impulse Lines Connects primary element and
transmitter through the use of instrument tubing
(see BNF.EG.0014)
1. Remote Mounted dP Transmitter Mounted to
facilitate access for maintenance requirements,
such as recalibration to correct for drift and
SMART replacement or repair of unreliable dP
transmitters (see BNF.EG.0036)
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Better installed performance
Measurement of Mass Flow in Gas Steam Modern
SMART dP Txs address all three sources of flow
error
Source 1 Transmitter
Installed performance of transmitter over whole
flow range (slide 5) SolutiondP technology
designed to maximize performance in real-world
conditions, i.e. compensation and diagnostics
Source 2 PT Variation
Pressure Temperature variation in Gasses
Steam Solution Multivariable (MV) technology
with embedded flow-software calculates density
and mass flow in real time
Source 3 Primary Element
Flow Coefficients not constant Solution
Embedded flow software re-calculates ALL flow
coefficients in real time
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Source 1Installed performance v Reference
(sales) Accuracy
Reference Accuracy
Ambient Temperature
Long-term Stability
Over Pressure
Line Pressure Span Zero
Reference Accuracy -in manufacturers Lab
Installed - in our plant
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Advanced diagnostics technologies
Two Temperature Sensors
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Advanced diagnostics technologies

• Impulse Line Clogging Diagnostics

• Main causes of plugging
• Fluid conditions (increase in viscosity)
• Pipe heating trouble
• Drop of ambient temperature

• Signs of pipe line plugging
• Change of fluctuation of process pressure by
  plugging
• Imbalance of fluctuation between differential
  pressure (dP) signal and static
• pressure (SP) signal

• SMARTs can detect both of Differential Pressure
  and Static Pressure.
• Comparing the fluctuation of two signals, we
  identify plugged side (H/L) of Impulse Pipe Line.
  

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Fault detection Pressure transmitter

• Impulse line clogging detection
  Local/Proactive/Device
• Uses on-board EXPERT system

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What is Asset Management in Plant Automation?

• Asset management in plant automation is a means
  to realise higher plant availability and improved
  operating efficiency, reducing Total Life Cycle
  Cost.

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Asset Management Tools Position
Office Domain
AutoCAD
ERP (SAP)
Asset Management SystemYokogawa PRM,etc.
Interfaces
Control Domain
Maintenance ManagementSystem (MOVEX)
Process Control System
Plant Equipment/Devices
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Diagnostic Potential with FF Devices
Remarks Fully digital, hence no drift and
(re-)ranging. Sufficient power for running
diagnostics in the instrument most processing
done at the instrument. FF protocol fast gt200
messages/sec. Diagnostics still require too much
mouse-clicks for results ongoing development
work on application packages to convert data into
knoledge. Asset Management Systems (like PRM)
become good platforms for diagnostics.
Host
FF comm. PVs status
AMS
Data provider of processed diagnostic data
capable of alerting for needed maintenance
Asset Management System receives processed
diagnostic information and alerts
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Diagnostics Coverage in FF systems
Level 4 early development
Level 3 selectively available
Level 1 and 2 readily available
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Development of Asset Management
Deveopment direction Devices

• Pressure transmitters
• Plugged impulse lines
• Loss of fill fluid in wet leg
• Valve/positioners
• Signature, leak detection,friction, wear,
  sticking
• In-line flow devices
• U/S, vortex, coriolis
• Temperature Transmitters
• T/C impedance
• Rtd resistance hi/lo
• Analysis .

Priority based on field experience
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Development of Asset Management Systems
Development direction Systems

• Alarm/Alert handling
• Routing to Operations or/and Maintenance
• Traffic light presentation
• Enhanced diagnostics for FF communications
• Translate diagnostics data into maintenance
  information
• Info on possible cause
• Suggestion for repair
• Consequences on accuracy, useful time
• Integration with ERP (SAP)
• Proactive maintenance tools

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Example of Smart Valve positioner
Remarks Interfacing positioners with Asset
Management Systems are restricted in
interoperability DVC5000 with Valvelink (AMS)
and Yokogawa YVP with ValveNavi (PRM) i.e.
single vendor approach for best results with
advanced diagnostics. Work ongoing to broaden
interoperability with e.g. Metso valve/postioners
and ValveCare package with PRM but not within
British Nuclear Group.
Smart Valve Features

• Configuration
• Remote calibration
• Actual valve position
• Diagnostics
• Valve travel alerts
• Packing leakage
• Signature
• Step response
• Maintenance history

• Valve/positioner combinations under test
• Flowserve
• Yokogawa YVP

Positioners are data servers
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FF Valve Signature (Shell test site results)
Up going signal
Down going signal
Recalibration required
Non-linear response
Friction due to deposits
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Future Asset Management for Instrument System

• Strategic direction DevicesVendors should
  provide FF devices with
• Ability to discriminate between process and
  device related problems
• Use MVC as second source of information
• Loop diagnostics, process diagnostics
• Device performance information during its
  lifecycle
• Build-in leading indicators for early warning,
  to enable proactive maintenance mode
• Provide a quality/inaccuracy indication of
  reading
• Certification for safety systems

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Future Asset Management for Device System

• Strategic direction SystemsVendors should
  provide systems with
• Smart interpretation of all diagnostics data to
  provide the operator with real
  maintenance information
• Advise on most likely cause of a problem.
• Advise for repair action and consequence
• Use MVC or soft sensor as second source to make
  a patch
• Provide a quality/inaccuracy indication on this
  patch
• Provide info how long the patch will last
• Open system approach of diagnostic packages with
  ERP
• Advanced diagnostics integrated in safety
  systems
• Provide a quality/inaccuracy indication of
  reading

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Future Asset Management for Device System

• Strategic response to the new developments
• Recognise the required changes in maintenance
  own organisation
• Training to implement new capabilities
• Own interpretation of diagnostics data before
  going to ISC
• Plan the maintenance more efficiently
• Work on the devices requiring real attention
  Bad Actor Manager
• Increase diagnostic coverage for safety systems
• Reduce test intervals

• Benefits
• Reduced maintenance effort/cost
• Improved process availability

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Summary

• Foundation Fieldbus and open-system-architectures
  is the best diagnostics platform to achieve
  optimised asset management.
• Advanced/process diagnostics in FF devices is
  vendor- selectively available products are
  improving rapidly.
• Ongoing Shell test programme focuses on
  diagnostics for process interface and valve
  positioners.
• Best results with diagnostics and asset
  management tools are currently achieved with a
  single vendor approach.
• Own maintenance organisation needs to be trained
  to exploit new asset management tools