Intelligence Device Management - ISA

Report
ISA-108
Intelligent Device
Management
Ian Verhappen – Yokogawa Canada
Herman Storey – Herman Storey
Consulting LLC
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
IEC Plenary 2012
September 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 2012
September 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 2012
September 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 2012
September 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 2012
September 26, 2012
Orlando, FL
Recognition of System Deviations
“Before Problems Occur”
IEC Plenary 2012
September 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 2012
September 26, 2012
Orlando, FL
NAMUR NE 129: The Asset Health Triangle
IEC Plenary 2012
September 26, 2012
Orlando, FL
PAM System Information Architecture
Enterprise Resource
Planning (ERP) System
Supply Chain
Management
Asset Advisory
Management
Process Control &
Process Management
Plant
Automation
System
(PAS)
Maintenance Work &
Parts Management
Process Events
& Data
Enterprise
Asset
Maintenance
(EAM)
System
CMMS
Maintenance
Advisories
Plant Asset
Management
(PAM)
System
Process Advisories
Asset Collaboration /
Tolerances
Transducer Config.
Control Monitoring Set-up
Inspection Routes
Data
Control
Parameters
Supply Chain
Management
Work Histories
Asset Monitoring
Variables
Asset Calibration /
Tolerance Data
E-commerce
Maintenance
Repair &
Operations
(MRO)
Procurement
System
Purchase
order
Order
Tracking
Asset Usage
Data
Plant Measurements / Inspections
IEC Plenary 2012
September 26, 2012
Orlando, FL
Oil
Properties
Oil
Chemical
Sample
Monitoring
Oil Particle
Process
Casing
vibration
Transient
On-Line Monitors
Shaft
Displacement
Process
Casing
vibration
Shaft Position
Protection
On-Line Monitors
Shaft
Displacement
Electrical
Process
Casing
Vibration
PLC /
DCS
Survey OnLine Monitors
Shaft
Displacement
Smart
valves
& Field
Devices
Thermal
Electrical
Transducers
Oil
Smart
Machines &
Process
Operation
Field
Report
Portable Device
Monitoring
Vibration
Control Device
Monitoring
Smart Pressure Transmitters are the Norm
Installed Base
Smart, Microprocessor
Based
Conventional or
Pneumatic
Source: ARC Advisory Group
IEC Plenary 2012
September 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 2012
September 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 2012
September 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 2012
September 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 2012
September 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 2012
September 26, 2012
Orlando, FL
Graphical User Interface for Maintenance
FIELDBUS MAINTENANCE OVERVIEW
CCGCTL01
CCGCTL02
CCGCTL03
01-01-01-01
CCS/RR2
01-01-17-02
CSS/RR2
02-01-01-01
RR1
02-01-17-01
RR1
03-01-01-01
MF2
03-01-13-02
MF2/CSS
01-01-01-02
CSS
01-01-19-01
CSS/RR2
02-01-01-02
RR1
02-01-17-02
RR1
03-01-01-02
MF2
03-01-17-01
CSS
01-01-03-01
CSS/RR2
01-01-19-02
CSS/RR2
02-01-03-01
RR1
02-01-19-01
CSS
03-01-03-01
MF2
03-01-17-02
MF2
01-01-03-02
CSS/RR2
01-01-21-01
CSS/RR2
02-01-03-02
NONE
02-01-19-02
RR1
03-01-03-02
CSS/MF2
03-01-19-01
MF2
01-01-05-01
CSS
01-01-21-02
RR2
02-01-05-01
RR1
02-01-21-01
NONE
03-01-05-01
CSS/MF1
03-01-19-02
CSS/MF2
01-01-05-02
CSS
01-01-25-01
CSS/RR2
02-01-05-02
RR1
02-01-21-02
RR1
03-01-05-02
MF2
03-01-21-01
MF2
01-01-09-01
CSS
01-01-25-02
CSS
02-01-09-01
RR1
02-01-23-01
RR1
03-01-09-01
CSS/MF2
03-01-21-02
MF2
01-01-09-02
CSS
01-01-27-01
CSS/RR2
02-01-09-02
RR1
02-01-23-02
RR1
03-01-09-02
MF2
03-01-27-01
MF2/CSS
01-01-11-01
CSS
01-01-27-02
RR2
02-01-11-01
RR1
02-01-25-01
RR1
03-01-11-01
CSS/MF2
03-01-27-02
MF2/CSS
01-01-11-02
CSS
01-01-29-01
RR2
02-01-11-02
CSS/RR1
02-01-25-02
RR1/CSS
03-01-11-02
CSS
03-01-29-01
MF2
01-01-13-01
CSS
01-01-29-02
CSS/RR2
02-01-13-01
CSS/RR1/MF1
02-01-27-01
RR1
03-01-13-01
MF2/CSS
03-01-29-02
MF2
01-01-13-02
CSS
01-01-31-01
RR2
02-01-13-02
RR1
02-01-27-02
RR1
01-01-17-01
RR2
01-01-31-02
RR2
02-01-15-01
RR1
02-01-29-01
RR1
02-01-15-02
NONE
02-01-29-02
RR1/CSS
Source: AG-181
IEC Plenary 2012
September 26, 2012
Orlando, FL
Good
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 2012
September 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 2012
September 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 2012
September 26, 2012
Orlando, FL
Intelligent Device Management
Interactions
Work Orders
Intelligent Devices
CMMS
Event
Historian
Configuration
Database
DCS Host
Plant Asset
Management System
IEC Plenary 2012
September 26, 2012
Orlando, FL
Alarm Management
System
Reporting
& Analysis
Integrated Data System
User Interface (Configuration & Monitoring)
Enterprise
Server /
Middleware
Database
SQL &
ODBC
Rules
Engine
Enterprise
Asset
Manager
System
Interface
B2MML
Enterprise
Asset
Management
System
XML
User Interface
Instrument
Asset
Management
System
IEC Plenary 2012
September 26, 2012
Orlando, FL
Database(s)
Audit
Trail
Tag
data
Calibration
Data
Device server
Alert
Monitor
EDDL
HART FF
FDT/DTM
Profibus DeviceNet Others
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 2012
September 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 2012
September 26, 2012
Orlando, FL
What Is Exception Based Surveillance?
Seconds Minutes Hours
Real Time
Activities
Operation
Days Weeks Months Years Life of Asset
Semi Real
Time
Activities
Diagnostics &
Surveillance
Planned
Activities
Planned
Maintenance
and Design
Improvements
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 2012
September 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 2012
September 26, 2012
Orlando, FL
To Learn More:
ISA108 Committee
• http://www.isa.org/MSTemplat
e.cfm?MicrositeID=1528&Com
mitteeID=7281
Ellen Fussell Policastro,
Standards Administrator
International Society of Automation
PO Box 12277, 67 Alexander Drive
Research Triangle Park, NC 27709
+1 (919) 990-9227
[email protected]
IEC Plenary 2012
September 26, 2012
Orlando, FL
Managing Director:
Ian Verhappen
+1 403 258 2681 x2222
[email protected]

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