L automazione al servizio della manutenzione Oscar Viganò Alphacon, Massimiliano Veronesi Yokogawa December, 2014
Process Control System Maintenance Automation A combination of hardware, software and services used to assess the heal of plant assets by monitoring asset condition periodically or in real-time to identify potential problems before they affect the process or lead to a catastrophic failure. Maintenance Information Flow Operations PCSMA - 4 - Plant Measurements & Historian Information
Approach - 8 -
Approach Minimum plant downtime, maximum asset utilization Reduce blind spots Monitor plant-wide asset conditions Avoid surprises Predict asset conditions and avoid downtime Preempt bottlenecks Optimize operation and maintenance - 9 -
Solutions - 11 -
Platforms for Maintenance & Diagnosis Online Maintenance Core Predictive Diagnostics Core Device status viewing Maintenance Information Management Diagnostics Maintenance Alarm Audit Trail Tuning, Adjustment & Calibration - 12 -
Typical System Architecture of PCSMA PIMS Client SQL Server SENG ENG HIS OPC Server Ethernet Control Network Wireless Gateway - 15 - Temperature Transmitter Pressure Transmitter
Requirement for LNG projects Transfer process data between Exaquantum systems, for example sea based: - 16 -
How does it Work? Two simple functions Extract process data from the Publisher s Exaquantum system Store process data into the Consumer s Exaquantum system OPC HDA TCP/IP Network Connection OPC HDA Exaquantum Historian Exaquantum Historian Exaquantum RDS Publisher Exaquantum RDS Consumer - 17 -
Environmental parameters under control SQL Servers OPC Servers Ethernet SQL Servers Ethernet VNet DCS OWS and Controllers - 19 -
User Interface Publisher (Settings) - 20 -
Remote communication with on-shore terminal - 22 -
Beneficial Concepts and Features of PCSMA - 23 -
Beneficial Concepts of PCSMA 1. Minimize Risks & Cost (lead-time) for commissioning & start-up work Centralized Plug & Play remote device connection check Centralized remote setting of field device parameters Quick online diagnosis Standardized approach for multi-vendor devices 2. Minimize the risk of unnecessary site trips By monitoring device healthiness thru diagnostics 3. Minimize scheduled maintenance downtime Optimize maintenance work by advanced device diagnostics 4. Generate collaboration between Operation and Maintenance Maintenance work to assure Reliability, but not repair work after breakdown. Shift maintenance paradigm from event-driven to scheduled work Maintenance to contribute better operation availability. - 24 -
Features of PCSMA 1. Real time Plant Asset Management Environment Cyclic device patrol of device health condition check Maintenance alarm to maintenance personnel User-friendly device configuration tools (EDDL and FDT/DTM base) 2. Full integration with DCS and SIS Device alarm message equalization Time synchronization Device diagnosis alarm to be shown on the DCS HMI 3. Wide Openness Remote alarm & event monitoring, analysis and reporting Integration: Host diagnostics server interface of both field devices and machinery units Open interface: CommDTM/DeviceDTM are available Safer plant operation PST Scheduler to extend the available time of SIL3 safety loop without process shutdown - 25 -
Main Functions of PCSMA - 26 -
Main Functions and Features of PRM 1. Device Management Device Master Information Historical Messages 2. Device Configuration DTM Works 3. Alarm Notification Device Status Icons Device Diagnostics Monitor 4. Historical and Maintenance Records Historical Messages - 27 -
1. Device Management - Device Master Information Device Navigator Window - 28 -
3. Alarm Notification - Device Diagnosis (DeviceViewer function) Normal Abnormal * DeviceViewer can be shown in both DCS HMI and PRM Client if integrated. - 29 -
3. Alarm Notification Maintenance Alarm Icon Detail (Green) (Red) (Yellow) Healthy by Device Patrol Maintenance alarming by Device patrol Maintenance Warning By Device patrol (Gray) (White) (Background Gray) Communication failure Status not yet confirmed Alarm Off Un-confirmed alarm (Blue) (Orange) GE System 1 Status -Device to be investigated GE System 1 Status Device Non Critical - 31 -
4. Historical and Maintenance Records Historical Messages - 32 -
Maintenance Related Functions Schedule Records maintenance schedule Memo Records maintenance memorandum Parts Records necessary parts for devices Doc Records necessary documents for maintenance such as instruction manual Tool Setup the necessary tools for maintenance Plug-in Setup to ranch necessary tools for devices configuration Cal. Data Records calibration data for devices - 33 -
Maintenance Mark and Operation Mark Synchronization PRM is able to electronically assign Maintenance Mark to each device by online. Users can assign this mark when they adjust or maintain the field devices. Once assigning it, users can give the restriction to handle with field devices management and what they has been in the status of adjustment and maintenance. When the Maintenance Mark is set on PRM, Operation Mark to prohibit the operation is automatically set on the HIS faceplate. HIS PRM Maintenance Mark Synchronization Operation Mark - 34 -
Some Real Examples - 35 -
Some Real Examples - 36 -
Some Real Examples - 37 -
Some Real Examples - 38 -
Some Real Examples - 39 -
Some Real Examples - 40 -
Some Real Examples - 41 -
Some Real Examples - 42 -
Plant Historian - 43 -
Alarm Reporting and Analysis (ARA) Collects - A&E Stores - Secure - Scheduled reports - Email reports to users - SQL Server 2005 - Multi-dim. RDB/OLAP Provides - KPIs Definition & Reporting - Alarm Reporting - Report Grouping - Time selection & filtering - Export to Microsoft Excel - 44 -
Long Standing Alarms Alarms that remain active beyond a specified time period (i.e. 12 hours) are called Long standing Alarms, also referred as Stale Alarms Chart and Tabular The list of Long standing alarms Duration for which the alarm remained stale X-axis displays the day Y-axis displays stacked alarm duration - 45 -
Alarm Frequency Report Top most frequent alarms are listed and ranked Tabular and Chart The x-axis shows time The y-axis the alarm count - 46 -
Manual operation monitoring MV and SV change count over the specified time period changes made to MV for PID controller in MAN mode changes made to SV for PID controller in AUT mode Acknowledge time is also reported - 47 -
Alarm setting changes Changes to Alarm Threshold Settings are captured The Document Map (on the left) aids navigation to other pages within the report - 48 -
Excel Add-In Create your report by simple Tags Drag & Drop into Excel cells - 49 -
An Example Excel Report - 50 -
Some Historian Examples - 51 -
Some Historian Examples - 52 -
Next developments: Trends by web - 53 -
Summary - 62 -
Summary Process Control Systems architectures nowadays can integrate nodes for supporting diagnosis and maintenance functions System performance monitoring and maintenance operations can be done both by local and remote workstations Process Trends, Process/System alarms can be viewed by remote through redundant connected SQL servers Field instruments and devices status can be checked and updated even by remote - 63 -
Thanks you for your attention <ISD-MASP-S11070> Copyright Yokogawa Electric Corporation <August, 2012> - 65 -