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3/15/2013
1
ISA108 – Intelligent
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
ISA108 – IntelligentDevice Management
Ian Verhappen,Industrial Automation Networks Inc.
Managing Director ISA108
What Is Asset Management?
• Activities that provide for Sustainable Managed Risk overthe Life Cycle of an Asset
• Some Asset Management Activities are Mandated byGovernment Regulation
• All Types of Enterprises have Requirements
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Financial
– Transportation
– Power Generation
– Mining and Manufacturing (M&M)
3/15/2013
2
Asset Management Goals
• Reduce Unmanaged Risk– Improve Health, Safety, Environmental, and Operability
Performance
– Manage Complexity
– Reduce Impact of Failures
• Achieve Sustainability
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
• Achieve Sustainability– Assure Adequate Human, Financial, and Infrastructure
Resources
– Lower Maintenance Cost
– Improve Return On Investment
• Simultaneously
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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– 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)
3/15/2013
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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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Allows Maintenance on Devices that Actually Need Work, OnlyWhen They Need Work
– Can Give Detailed Information on Problems Before a Field Visit
– Can Significantly Reduce (or eliminate) the Need for PeriodicTesting
– Can Reduce Impact on Operations by Advance Warning ofFailure
– A Significant but Underutilized Opportunity
– Biggest Incentives on Control Valves
Recognition of System Deviations“Before Problems Occur”
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
3/15/2013
4
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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
• NAMUR– NE129 Plant Asset Management
• These Standards Do Cover Manual Inspect and TestMethods
• None of these cover use of Automated Diagnostics orwould apply to Intelligent Device Management
NAMUR NE 129: The Asset Health Triangle
StrategicAsset
Management
EquipmentStandardization
RAM
Life CycleAnalysis
VendorReliability
RCM
Craft Stage 3
Stage 4
Reliability Engineering
Stage 5
Operational Excellence
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
CraftFlexibility
OPM
Maintenance /Operations Integration
ExternalBenchmarking
Asset Strategies/ SRCM
FailureAnalysis
Asset Integrity
Craft SkillsEnhancement
EquipmentHistory
Condition BasedMaintenance
ManagingSystem
CMMS /Metrics
PreventativeMaintenance
Planning &Scheduling
TurnaroundManagement
Work Identification/ Prioritization
Work ExecutionReview
Stage 3
Organizational Excellence
Stage 2
Proactive Maintenance
Stage 1
Planned Maintenance
3/15/2013
5
PAM System Information ArchitectureSupply ChainManagement
Supply ChainManagement
Enterprise ResourcePlanning (ERP) System
E-commerceMaintenance
Repair &Operations
(MRO)Procurement
System
EnterpriseAsset
Maintenance(EAM)
SystemCMMS
Plant AssetManagement
(PAM)System
PlantAutomation
System(PAS)
Process Control &Process Management
Maintenance Work &Parts Management
Asset AdvisoryManagement
MaintenanceAdvisories
Purchaseorder
OrderTrackingWork Histories
Process Advisories
Process Events& Data
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
SystemCMMS
ControlParameters Control
Data
Asset Collaboration /Tolerances
Transducer Config.Monitoring Set-upInspection Routes
Asset UsageData
Asset MonitoringVariablesAsset Calibration /Tolerance Data
Control DeviceMonitoring
Portable DeviceMonitoring
Survey On-Line Monitors
ProtectionOn-Line Monitors
TransientOn-Line Monitors
SampleMonitoring
Smartvalves& FieldDevices
PLC /DCS
Vib
rati
on
Pro
cess
Oil
Th
erm
al
Ele
ctr
ical
Sh
aft
Dis
pla
ce
men
t
Ca
sin
gV
ibra
tio
n
Pro
cess
Ele
ctr
ical
Sh
aft
Dis
pla
cem
en
t
Sh
aft
Po
sit
ion
Casin
gvib
rati
on
Pro
cess
Sh
aft
Dis
pla
cem
en
t
Ca
sin
gvib
rati
on
Pro
cess
Oil
Part
icle
Oil
Ch
em
ica
l
Oil
Pro
pert
iesOperation
FieldReport
SmartMachines &Transducers
Plant Measurements / Inspections
IDM vs. PAM
Plant Asset Management System
Machinery HealthManagement
ProcessingEquipment
Management
Intelligent DeviceManagement
• Pumps • Heat • Transmitter
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
• Pumps• Compressors• Motors
• HeatExchanger
• Fin FanCooler
• Transmitter• Analyzer• Valve• Drive• Gas
Chromatograph
3/15/2013
6
IDM Scope
PrimaryElement / Transmitter
Final
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
Element /Sensor /
Transducer
• Thermocouple• RTD• Orifice plate
Transmitter/ Analyzer
Controller Positioner Actuator ControlElement
• Temperature• Pressure• Gas
chromatograph
• DCS• PLC• RTU• Logic
Solver
• Pneumatic• Electric
• Valve• Pump
• Positioner• PST
gadget• VSD
Able to diagnose...Able to diagnose...
IDM in Context of Purdue Model
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
3/15/2013
7
Smart Pressure Transmitters are the Norm
Installed Base
Smart, MicroprocessorBased
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
Source: ARC Advisory Group
Conventional orPneumatic
Intelligent Device Management
• Intelligent Devices Are Pervasive, but Are Not BeingUsed Properly– Most Diagnostics are not Prioritized or Utilized
• Considered Approach to Intelligent Device Managementis Required– Technology and Products are Widely Available
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Technology and Products are Widely Available
– Work Processes and Best Practices are the Key
– A New ISA Standards Effort is Needed
3/15/2013
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New ISA Intelligent DeviceManagement Standard
• Content Proposals:
• Models and Terminology
• Implementation Guidelines
• Work Processes– Diagnostics Based Maintenance
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Diagnostics Based Maintenance
– Configuration Management
– Auditing
Work Process Life Cycle
• FED
– Criticality Ranking
– Vendor Qualification &Templating
• Design / FAT
– Work Process Selections andDesign
• Pre-Startup Safety Review
• Routine Maintenance
• Turnaround Management
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
Design
– Initial System Configuration(Build Tools)
– Training
• Install, Commission, LoopCheck
– Device and System Integration
– Initial Use of Diagnostics
3/15/2013
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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 byApplication Criticality– Criticality Ranking should be established in FED
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Criticality Ranking should be established in FED
– Alert Priority Depends on Impact Severity – Not Likelihood
– Send Alerts to Operator and well as Maintenance Only ifOperator Action is Required
– Log All Alerts regardless of Priority
– Different from process alarm management
• Needs Definition Before Configuration Activities
Intelligent Device Management
• Proper Use of Diagnostics Depends on a Graphical UserInterface– Would you give an Operator an Explorer Tree?
– Requirement: Navigate from Overview to Detail in 3 MouseClicks
– Cover all System Devices, Nodes, Networks, & Modules
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– 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 MoreInformation & Examples
3/15/2013
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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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– 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 RequiresExtra Engineering
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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Foundation Fieldbus Provides more Complete Information for allDevices – 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
3/15/2013
11
Required Intelligent DeviceManagement Tools
• Maintenance History
• Resource Planning, Tracking, Accounting– Example: SAP
• Design Calculation, Drawing, Documentation– Example: SPI (Intools)
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
• Host Systems– Integrated Host (Example: DCS)
– Visitor or Bench Host (Handheld or Laptop)
– Provide Configuration Management, Troubleshooting, andHuman Interface
Intelligent Device ManagementInteractions
CMMS
Intelligent Devices
Work Orders
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
DCS Host
Plant AssetManagement System
EventHistorian
Alarm ManagementSystem
ConfigurationDatabase Reporting
& Analysis
3/15/2013
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Integrated Data System
Database
RulesEngine
EnterpriseAsset
ManagerSystem
Interface
User Interface (Configuration & Monitoring)
EnterpriseAsset
ManagementSystem
B2MML
XMLSQL &ODBC
EnterpriseServer /
Middleware
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
Device server
FDT/DTMEDDL
HART FF Profibus DeviceNet Others
AlertMonitor
Database(s) Tagdata
AuditTrail
CalibrationData
InstrumentAsset
ManagementSystem
User Interface
XMLODBC
Intelligent Device Management Tools
• Tools, Hosts, and Devices Need:– Remote Access
– Multiple Simultaneous Access
– Cyber Security
– Role Based Security
– Required for Hosts and Devices
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Required for Hosts and Devices
– A Standardized Security Model Would be Nice
3/15/2013
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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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– 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)
Real TimeActivities
Semi RealTime
Activities
What Is Exception Based Surveillance?
Seconds Minutes Hours Days Weeks Months Years Life of Asset
PlannedActivities
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
ActivitiesActivities
OperationDiagnostics &Surveillance
PlannedMaintenanceand Design
Improvements
Activities
Exception based Surveillance provides for Reactive Response in Semi RealTime to Diagnostic Alerts filling a Gap between Operation and TraditionalPlanned Activities and makes use of Diagnostic Capabilities of Field Devices
3/15/2013
14
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
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
– Culture Change for Maintenance
– Management Ownership
• Standards Will Help– Get Engaged
To Learn More:
ISA108 Committeehttp://www.isa.org/MSTemplate.cfm?MicrositeID=1528&CommitteeID=7281
Managing Director:
Ian Verhappen+1 403 829 [email protected]
ISA 2013 Oil Sands Conference
March 12-13, 2013 Fort McMurray Alberta
Charlie Robinson
International Society of Automation
PO Box 12277, 67 Alexander Drive
Research Triangle Park, NC 27709
+1 (919) 990-9213
Co-Chair:Herman [email protected]