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Understanding the value that intelligent devices and digital diagnostics brings to the world of process automation
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1Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Digital Doesn’t Mean Intelligent:Realizing the Potential of
Intelligent Field Device Management
2Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Outline
• It’s a Digital World, but what does that really mean?
• The prize is significant, but we are not using digital instrumentation to its full potential
• How can we realize this potential? What are the obstacles?
3Automation 2013 Mumbai
© 2013 Fieldbus Foundation
About Me
• 18 Years with ARC Advisory Group as a Process Automation Market Analyst
• 3 Years with Fieldbus Foundation as Global Marketing Manager
• Focus on DCS, Instrumentation, Field Networks, Process Safety
4Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Fieldbus Foundation
• Dedicated to Stewardship and Advancement of FOUNDATION Fieldbus Digital Protocol & Automation Infrastructure
• Over 350 Member Companies
• Strong Regional and Local Marketing Committees and End User Councils
5Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Process Automation: How the Digital Age Crept up on Us
• Digital Devices are Everywhere
• The Rise of Cyber Physical Systems
• Why we Cling to Analog Thinking in a Digital World
6Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Quick Definitions
• Intelligent Field Device: Microprocessor-based field device or control valve/actuator/positioner that also utilizes a bidirectional digital communication protocol to provide information to plant systems.
• Field Communication Protocols for Process Automation: FOUNDATION fieldbus, HART, Profibus PA.
• Intelligent Device Management: Turning the diagnostic data from intelligent field devices into useful information, which is available to applications and end users as it is required, when it is required.
7Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Intelligent Devices are now the Norm, not the Exception
Source: ARC Advisory Group
Global Installed Base of All Field Devices by Smart vs. Conventional: 2011
8Automation 2013 Mumbai
© 2013 Fieldbus Foundation
New Market for Wireless is Expanding the Reach of Intelligent Devices
Source: ARC Advisory Group
9Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Fieldbus Market is Growing Well into Double Digits
Source: ARC Advisory Group
• Market for FOUNDATION fieldbus products (excluding EPC and system integrator services) exceed $1 billion in 2012.
• The installed base of FOUNDATION fieldbus systems and devices is over $6 billion
• Celebrating 20 years in 2014!Market for Digital Fieldbus Products and Services
(Source: ARC Advisory Group)
10Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Rise of Cyber Physical Systems: Everything is Connected
Mainframe computing (60s – 70s)
Large computers to execute big data processing applications
Desktop computing & Internet (80s – 90s)
One computer at every desk to do business/personal activities
Ubiquitous computing (00s)
Numerous computing devices in every place/person
Millions for desktops vs. billions for embedded processors
Cyber Physical Systems (10s)
Source: Introduction to. Cyber Physical Systems. Yuping Dong. Sep. 21, 2009
11Automation 2013 Mumbai
© 2013 Fieldbus Foundation
What are Cyber Physical Systems?
• Cyber Physical System is a system featuring a tight combination of, and coordination between, the system’s computational and physical elements.
• CPS uses computations and communication deeply embedded in and interacting with physical processes to add new capabilities to physical system.
• Convergence of computation,
communication, and control
Source: Introduction to. Cyber Physical Systems. Yuping Dong. Sep. 21, 2009
CPS
Sensors
Equipment
People
Safety
Software
Control
12Automation 2013 Mumbai
© 2013 Fieldbus Foundation
What CPS Means for Process Automation
• Process field devices are becoming computers unto themselves
• The old hierarchy of workstations, controllers, networks, field devices, and final control elements is collapsing
• CPS means that process
automation systems will be increasingly connected to other systems in the plant and enterprise
• CPAS – Collaborative Process Automation Systems – are the result
Source: ARC Advisory Group
13Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Are your Intelligent Devices Underachievers?
• Despite their large installed base, not many
companies are actually using the diagnostic
information from their intelligent devices to
improve their operating performance
• Plant Asset Management workstations
collecting dust
• Users complain they aren‘t getting the
benefits, but why is this?
• “An estimated 85% of all installed HART
devices are not being accessed to deliver
device diagnostics information with only the
Process Variable data communicated via the
4-20mA analog signal.” – HCF Web Site
Stranded Diagnostics
14Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Why We Cling to Analog Thinking in a Digital World
• Entrenched work processes: Our
fundamental maintenance processes
have not changed much since the
1950s.
• The installed base: According to ARC,
the installed base of process
automation systems reaching the end
of their useful life is $65 billion. Most
of these are 20 years old or older.
• The workforce: Many workers are
entrenched in existing work processes
and analog technology
15Automation 2013 Mumbai
© 2013 Fieldbus Foundation
India is Way Ahead
• Largest Fieldbus installation in the
world is at Jamnagar Refinery
• Over 30K Fieldbus Devices,
Thousands of Segments, with
Capacity Set to Double!
• Device Diagnostics Used Heavily!
• As close to Flawless Project
Execution as you can Get!
• A Global Effort in Project
Management
16Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Prize, and How to Get There
• The Economic Impact of Intelligent Devices
• Why You Need a Strategy for Intelligent Device Management
• Understanding Diagnostics
• The Importance of Work Processes and Ownership
17Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Impact of Automation is Often Overlooked
18Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Intelligent Device Management is Risk Management!
19Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Economic Impact of Fieldbus Devices
10-15 percent 20-40 Percent 20-40 Percent
“Saves”Reduced
Unplanned Shutdowns
20Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Economic Impact of Fieldbus Devices
21Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Economic Payback Of Intelligent Device Management
• Source: ARC Advisory Group
-60 -40 -20 0 20 40
Unplanned Breakdowns
Inventory Costs
Downtime
Defects
Equipment Life
Workforce Efficiency
Equipment Productivity
% Improvement vsTraditional Maintenance
-60 -40 -20 0 20 40
Unplanned Breakdowns
Inventory Costs
Downtime
Defects
Equipment Life
Workforce Efficiency
Equipment Productivity
% Improvement vsTraditional Maintenance
22Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Almost 2/3 of Maintenance Labor is Unnecessary
23Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Let’s Change the Mix of Maintenance in Our Plants
24Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Reducing Preventive Maintenance Hours
With device management
software
• Source: Emerson Process Management
25Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Why You Need a Strategy for Intelligent Device Management
A Broad Mix of Applications can Benefit from Intelligent Device Data
26Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Get Started Early!
A Broad Mix of Applications can Benefit from Intelligent Device Data
27Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Understanding Diagnostics
• Diagnostics can be a valuable tool that can help save you time and money and avoid unplanned shutdowns.
• Diagnostic data can be vague and require a lot of digging to get to the root cause.
• Diagnostic data can also provide you with avalanche of useless information that can grind your process to a halt.
• Not all technologies handle diagnostic information the same way.
• Trick is to get only the right information, at the right time, to the right people.
28Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Current State of Non Digital Diagnostics: Or the Idiot Light
• Doesn’t tell you what’s wrong
• No predictive guidance
• Is it a process problem or device problem?
• Sensor problem? Electronics problem? Who knows?
29Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Distinctions should be made between Instrument and Process Diagnostics
Sensorincluding process connection and sensor
electronic
Instrument Electronic
Configuratione.g. Linearization
ProcessProcess/
Environment
Information
Root Group
Information
Root Group
Instrument
Process/Environment
Sensor
Electronics
Configuration
Process
30Automation 2013 Mumbai
© 2013 Fieldbus Foundation
A Mechanism for Data Quality Helps
31Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Utilizing Diagnostic Data from Multiple Devices Together
• Certain diagnostic anomalies expressed in multiple field devices can indicate an anomaly or impending abnormal situation in the process.
32Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Diagnostics Storm
Sample Diagnostic Parameters of a
FOUNDATION Fieldbus Flowmeter
33Automation 2013 Mumbai
© 2013 Fieldbus Foundation
NAMUR NE 107
Definition of NE 107 Status
Signals
34Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Grouping Diagnostic Conditions
35Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Diagnostic Mapping Workflow
36Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Importance of Work Processes and Ownership
Yes
No
No
No
No
Yes
Yes
Yes
Major Work Process Tasks for: 2.0 Execute Daily Proactive Maintenance (Unit)
Work Process Owner: Instrument Technical Discipline Network (ITDN)
WHO Input
Responsible Organization or Individual
Work Process Analysis Output
Instrument Specialist
CSE/Inspector
Maintenance Planner
Maintenance Coordinator /
Team Leader
Technician
Ops
T/A Manager
OMC
MOC Request
T/A Work List Item (CMMS)
2.1 Assign Daily PM Work Order
b2.5.1Emergency
Priority?
Device Alarm/Alert
Report
2.9 Order Parts/Service and re-plan
d
PM Work Order
LEGEND
Start or End Task Decision a Connector 1 Metric / Control Point
EmbeddedExternalWork Process
LEGEND
Start or End Task Decision a Connector 11 Metric / Control Point
EmbeddedExternalWork Process
2.6.2Enter notification in
CMMS(Documents status in Log)
Work Request (CMMS)
b
Repaired Equipment
2.3Select Next Priority Item
(from A/A List and A/A Report)
2.4 Secure Work
Permit
2.5.2
Determine Urgency, Enter notification into
CMMS (e-Ticket) and communicate priority to OMC for appropriate Action.(Technician documents
status in log)
CMMS Condition History*
c
DCS
2.6.1 MOC or Mitigation Required?
2.7.1 Parts/ Service
Available?
2.7.2Repair and Enter
Notification to capture history
(Documents status in Log)
2.10.1 Daily PM
Complete?
2.8 Enter Notification in
CMMS(Documents status in Log)
c
c
2.10.2Update
Maintenance Coordinator / Team Leader and Closeout
PM Work Order
d
b
a
a
NOTE: An Excel Spreadsheet that records status of all actions taken by Alarm/Alert will be maintained in Log until the Site has implemented Level 5 CMMS
Original Issue Date: Aug 10, 2006Last Revision:
Revision Date: Dec 31, 2011Rev 1.3
b
3
2.2Obtain Daily PM & A/A report
37Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Removing Obstacles to IDM
• The Integration Dilemma
• The Importance of Adopting Open Standards
• Train, Train, Train
38Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Integration Dilemma
• Historically there have been multiple integration technologies for intelligent field devices
• EDDL, FDT/DTM, OPC, etc.
• FDI is a current industry effort that will unify device integration technologies and make things easier for users and suppliers
39Automation 2013 Mumbai
© 2013 Fieldbus Foundation
One Device Driver: the FDI Package
Device Package
EDDFDI encoded file format
UIP(optional)
Attach-ments
Electronic Device Description Language
(EDDL)
Windows Presentation Foundation
(WPF)
Device Definition (Def) Business logic (BL) User Interface (UID
Programmed User Interface
Device Applications
Manuals Certificates Protocol specific
Files (GSD(ML), etc.)
40Automation 2013 Mumbai
© 2013 Fieldbus Foundation
The Importance of Adopting Open Standards
• OPEN standards are continuously subject to scrutiny, review and improvement
• OPEN standards and specifications are publicly available can be purchased by anyone
• OPEN standards have better security
• OPEN standards can adapt to new technologies and market dynamics
• OPEN standards make it easier to test and register devices and host systems
41Automation 2013 Mumbai
© 2013 Fieldbus Foundation
There is a lot to Learn, and Good Training is Essential
Many sources of training are available in the marketplace
Very few are audited and certified to ensure that they adhere to a set of standards
You will need more than a two day course or online video
We are serious about training! Eight certified centers with one in India soon to come.
42Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Conclusions
• Adopt an Intelligent Device Management Philosophy
• Take an intelligent approach to managing diagnostics
• Start early
• Appoint a champion to manage the IDM processes
• Get the right work processes & train your people
• You can be successful! The Prize is significant!
43Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Thank You