Fieldbus Diagnostics

Agenda

z Introduction
z Level of Diagnostics
z Function Block Diagnostics
z Resource Block Diagnostics
z Transducer Block Diagnostics

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27-Jun-01, Slide 2
Fieldbus brings dramatic
savings in installation and
commissioning, but the
real value is seen during
plant operation...
 Elimination of ““Unneeded”
Unneeded” Trips to
the field: Transmitter Diagnostics
•• 63%
63% of
of trips
trips to
to the
the field
field can
can be
be eliminated
eliminated
50

40 35%
28%
30
20%
20
6% 6%
10 4%

0
Routine No Calibration Zero Plugged Failed
Check Problem Shift Off Lines Instrument

Source: Dow Chemical

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27-Jun-01, Slide 4
 Diagnostics Definitions

Level 3 Operations

Level 2 Loop Boiler

Turbine
Generator

Make Up Water

Pulveration

Drift
Level 1 Device
Communications
Diagnostics

µP Plugged
Impulse
Line

Electronics Sensor
Diagnostics Drift

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27-Jun-01, Slide 5
 Device Maintains Statistics For Communication
Diagnostics

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27-Jun-01, Slide 6
 Diagnostic Examples

z Transmitter generates an alert

when
‰ the sensor degenerates
‰ the device has exceeded
factory maximum field
temperature usage
• Cycle Counter
• Valve Signature
• Dynamic Error Band

z O2 Sensor creates alert when the

sensor fouls

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27-Jun-01, Slide 7
 Using Device Intelligence

The
The Device
Device
Detects
Detects Process
Process
Conditions
Conditions

Impulse
Impulse Lines
Lines Plug
Plug
1.82
1.819
1.818
PV (V)

1.817
1.816
1.815
1.814
1.813
1.812
1.811
1.810 2 4 6 8 10 12 14 16 18 20
Time (min)

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27-Jun-01, Slide 8
 Devices Provide Predictive Diagnostics

Provide Information On Life Expectancy and

Performance Degradation

Predictive Alarm
Failure

Device Performance

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27-Jun-01, Slide 9
 Diagnostics are Utilized in Fieldbus
Blocks for Measurement and Control

PV
PV is
is Marked‘Uncertain’
Marked‘Uncertain’
or
or ‘Bad’
‘Bad’ ifif Abnormal
Abnormal

and
andpropagated
propagated

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27-Jun-01, Slide 10
 Event is Time Stamped At The Source!

H1

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27-Jun-01, Slide 11
 FT-101
Conditions of FT-101 ? X Inlet 3, Cooling Tower 1
Failed Electrode Signal Fault
Recommended Action: Perform recommended sensor/wiring checks
Maintenance Sensor Calibration
Failed Conditions

Sensor Process Electronics

Communications Failure
Failed Failed
Enable

Electrode Signal Fault Maintenance

Advisory
Enable

Grounding/Wiring Fault 50/60 Hz Noise:: .003401 mV

Maintenance TOWER_1

i
Advisory

Print Close Help

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27-Jun-01, Slide 12
Process plants can be tough on field
devices!

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27-Jun-01, Slide 13
 Internal Diagnostics
z Sensor failure
z Sensor malfunction
z Sensor disconnected
z Electronic Board failure
z Bad grounding
z Operating conditions out of specifications

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27-Jun-01, Slide 14
 Process Diagnostics
z Plugged line
z Empty pipe
z Statistical Process Monitoring
z Vibration
z Valve travel integration
z Noise
z Drift
z Flame instability
z >>>>>>

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27-Jun-01, Slide 15
 Diagnostic Examples
z Transmitter generates an alert
when
‰ the sensor degenerates
‰ the device has exceeded
factory maximum field
temperature usage
• Cycle Counter
• Valve Signature
• Dynamic Error Band

z O2 Sensor creates alert when the

sensor fouls

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27-Jun-01, Slide 16
Variability Index provides additional
insight into Loop Performance
Variability Index Diagnostic
Variable

Performance Change

Variability Is Detected with

Index Variability Index
Acceptable
Value
DeltaV Inspect Identifies
Under-performing Loops

Measured Standard Deviation

VI=
Minimum Expected Standard Deviation Take Corrective Action

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27-Jun-01, Slide 17
 Plugged Impulse Line Diagnostic
1.82

1.819

1.818

1.817

Manifold 1.816

1.815

Sensing 1.814

Both Open HP Closed LP Closed Both Closed

1.813
Line 1.812

1.811

Clog 1.81
0 2 4 6 8 10 12 14 16 18 20

Flow

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27-Jun-01, Slide 18
 Statistical Process Monitoring

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27-Jun-01, Slide 19
 Proof Using SPM Prevents Plant
Damage
10.00
Statistical
PHD Data
Process 23:30 9.00

Monitoring data 8.00

23:30 coming from 7.00
3051 ADB
23:00 helped predict 6.00

catalyst problem 5.00

30 min 4.00
in advance 23:00
23:00 3.00

SPM Data 2.00

1.00

0.00
6/4 6/6 6/8 6/10 6/12

Source: ExxonMobil Baytown, Tx Refinery

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27-Jun-01, Slide 20
 Status
All connectable variables have
STATUS.
STATUS VALUE

Value: 234.5 m3/h

Status: Good, Bad or Uncertain
Sub-Status: (more status details)
Limit : High, Low, Constant or not limited
Diagnostics
Status can be used in the control
AI
AI strategy to switch a controller to
Manual when the variable goes to
a Bad status.

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27-Jun-01, Slide 21
 Status

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27-Jun-01, Slide 22
Diagnostics are Utilized in Fieldbus
Blocks for Measurement and Control

PV
PV is
is Marked‘Uncertain’
Marked‘Uncertain’
or
or ‘Bad’
‘Bad’ ifif Abnormal
Abnormal

and
andpropagated
propagated

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27-Jun-01, Slide 23
 Event is Time Stamped At The Source!

Classic I/O Other Buses

Other Buses
H1

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27-Jun-01, Slide 24
 Plantweb alerts
Sensor Maintenance Sensor Sensor
Failure Soon Failure Failure Installation
Installation Installation Problems
Problems Problems
Maintenance Installation nce
Soon n a
Sensor Problems Maintenance inte
Failure Soon sor Ma Soon
Sen lure
In
s Fai
M Pr tall n
ai
nt
o b a ti
a ll atio s
lem on t
So ena s
Maintenance Se Ins oblem
on nc Soon Fa nso Pr
e ilu r
re

Failed Maintenance Advisory

Route to appropriate plant organization

Recommended Action
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27-Jun-01, Slide 25
 FT-101
Conditions of FT-101 ? X Inlet 3, Cooling Tower 1
Failed Electrode Signal Fault
Recommended Action: Perform recommended sensor/wiring checks
Maintenance Sensor Calibration
Failed Conditions

Sensor Process Electronics

Communications Failure
Failed Failed
Enable

Electrode Signal Fault Maintenance

Advisory
Enable

Grounding/Wiring Fault 50/60 Hz Noise:: .003401 mV

Maintenance TOWER_1

i
Advisory

Print Close Help

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27-Jun-01, Slide 26
 Operation
„ Devices are identified by Tag
„ Variables are identified by:
TAG.Desired Parameter
FT FIC FCV
102A 102A 102A

FIC102A.OUT

No need to remember the Transmitters Hardware Address .

FT102A, not CTL01C03A01

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27-Jun-01, Slide 27
 Transducer, Resource and Function Blocks
z Every Field device has to have a Resource Block and
one or more Transducer blocks.
z Function Blocks are desirable, but not mandatory.
z Resource Block contains information about the device
resources: hardware and software.
z Transducer blocks control access to Input and Output
interfaces such as sensors, switches, actuators etc.
z Transducer decouples the process interface from the
Function Blocks. They can run as fast as they can.
z Transducer blocks also allow calibration and access to
diagnostics.

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27-Jun-01, Slide 28
 Resource Block
z Hardware and Software resources.
z When Mode is Out of Service, all other blocks will
be Out of Service.
z Allow Device resetting, including resetting with
Default values.
z All Emerson devices have a common Resource
Block, with very small variations.

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27-Jun-01, Slide 29
 Pressure Resource Block - Identification

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27-Jun-01, Slide 30
 Pressure Resource Block - Process

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27-Jun-01, Slide 31
 Pressure Resource Block - Alarms

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27-Jun-01, Slide 32
 Pressure Resource Block - Hardware

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27-Jun-01, Slide 33
 Pressure Resource Block - Options

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27-Jun-01, Slide 34
 Pressure Resource Block – Suppressed
Alarms

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27-Jun-01, Slide 35
 Transducer Blocks
z Transducer blocks provide the interface to
sensors, switches, actuators, etc.
z Transducer blocks also allow access to
calibration and I/O diagnostics.
z If the Transducer Block is in Out of Service
Mode, the Function Blocks will have
measurement value with Bad Status.
z Transducer communicates the values to the I/O
Function Blocks via Channels.

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27-Jun-01, Slide 36
 Transducer
Free Running Schedule

Transducer
Channel 1 Ch. 1 AI 1

Sensor 1
Channel 2 Ch. 2 AI 2
Sensor 2

Sensor 3
Channel 3 Ch. 3 AI 3

calc Channel 4 Ch. 4 AI 4

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27-Jun-01, Slide 37
 Important to remember
z AI or AO block has to have the Channel
configured accordingly. Channel = 0, no
measurement or actuation.
z AI or AO block XD_SCALE parameter has to
have the same valid Engineering Unit. Pressure
measurement should be inH2O@68F, mbar,
psi,etc. Temperature should be deg. C, not C.
z Transducer should be in Auto.

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27-Jun-01, Slide 38
 Pressure Transducer - Process

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27-Jun-01, Slide 39
 Pressure Transducer - Sensor

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27-Jun-01, Slide 40
 Pressure Transducer - PV

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27-Jun-01, Slide 41
 Pressure Transducer --SV
SV

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27-Jun-01, Slide 42
 Pressure Transducer - Materials

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27-Jun-01, Slide 43
 Pressure Transducer - LCD

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27-Jun-01, Slide 44
 Pressure Transducer - LCD

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27-Jun-01, Slide 45
 Pressure Transducer – Advanced
Diagnostic Block

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27-Jun-01, Slide 46
 Pressure Transducer – Advanced
Diagnostic Block

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27-Jun-01, Slide 47
 Pressure Transducer - Status

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27-Jun-01, Slide 48
 Pressure Transducer - Status

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27-Jun-01, Slide 49
 Pressure Transducer - Status

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27-Jun-01, Slide 50
 Pressure Transducer - Status

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27-Jun-01, Slide 51