Optimale proces betrouwbaarheid en beschikbaarheid door ... · Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam

Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam

Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam

Door het toepassen van Heartbeat Technology is de volgende stap in het

kader van beschikbaarheid en voorspellend onderhoud gemaakt bij

Albemarle in Amsterdam.

Ingebouwde diagnostiek, verificatie en bewakingsfuncties leggen de basis

om processen betrouwbaarder en veiliger te laten verlopen en dragen ook

bij aan een efficiënter kalibratie proces.

What is Heartbeat Technology?

Heartbeat Technology – The pulse of your measurement

Permanent process and device diagnostics, simple testing without removal

and clear trend monitoring.

Calibration, Proof Testing and Verification

Calibration• Accuracy• Traceability• ISO 17025

Proof testing• Functional Safety• Reliability • IEC61508/61511

Verification• Diagnostics• Reliability• Confirmation

• Overlap topics• Periodical repetition• Standard as fundament

Heartbeat Technology

Diagnostics Verification Monitoring

Permanent process and device diagnostics

Documented verification without process interruption

Information for predictive maintenance

Increased plant availability …

… safe processes … reduced verification effort… optimization of processes and

maintenance

Heartbeat Technology – Diagnostics, Verification and Monitoring

Heartbeat Technology for different measuring principles

Flow Level Temperature Analysis

Heartbeat Technology - Monitoring

• The provision of instrument and process data facilitates trend recognition for predictive maintenance.

• The combination of instrument and process parameter facilitates the analysis for targeted process optimization.

Benefit:• Information for predictive maintenance• Increased plant availability• Optimization of process and maintenance strategy


Monitoring



… optimization of processes and maintenance

Heartbeat Technology – Monitoring

The Heartbeat Sensor Integrity (HBSI) Parameterdetermines beyond any doubt the health status of the measuring tube.

▪ For corrosion or abrasion detection▪ Detection in the context of Heartbeat verification

▪ Process-independent detection of changes to the measuring tube from 0.01mm


Monitoring





Water Sand 6% Sand 3% Sand 6% Water

0.0%

0.1%

0.2%

0.3%

0 50 100 150 200 250

Hea

rtb

eat

Sen

sor

Inte

gri

ty (

HB

SI)

t 300

Promass I


Monitoring





Corrosion / abrasion Sedimentation Bubbles Cavitation


Monitoring




Demonstration Heartbeat Verification Report

Before Heartbeat Technology implementation

▪ According to Albemarle work instruction flow measurement needs to be calibrated each year.

▪ For each calibration the installation needs to be prepared by maintenance engineer for secure dismantling of the flow measurement.

▪ After calibration it often happens that flow measurement is not working properly (modified configuration, poor electrical connections,…)

▪ In practice it is an exception for a flow measurement to be out of tolerance.▪ Calibration report cannot be automatically uploaded to Asset Information

Management system (W@M).

Flow Calibration Unit @ Albemarle

Albemarle Catalysts Company B.V.

The main activity of the site is productionand research of Catalysts for the petrochemical industry. These Catalysts are used for the production of high quality fuels such as gas, petrol, diesel and kerosene from crude oil.

On the Amsterdam site, three plants are in operation.

▪ FCC plant, producing Fluid Cracking Catalysts (since 1953)

▪ HPC plant, producing Hydro Processing Catalysts (since 1956)

▪ Multi-Purpose plant, producing Isomerization, Methyl Chloride, Methyl Amine, Melamine and Oxychlorination Catalysts

Goals @ Albemarle Catalysts

Albemarle Catalysts

CalibrationOptimization of calibration intervals.

Manageable scheduled maintenanceReducing capital and operating expenditure on assetsby optimizing workflows and business processes.

Integrated device informationProvide device - and life cycle information in Centralized Maintenance Management System. (SAP-PM)

Availability of critical devicesPlants need to work more efficiently and have to improve their availability. (OEE)

Safety Process Hazard Analyses. (SIL. ATEX)

Challenges @ Albemarle Catalysts

▪ How to exploit the power of smart devices and smart technology in your maintenance processes?

▪ Which relevant information is available from a smart device for process control, operations and maintenance?

▪ How to get access to smart devices and their diagnostics? (wired- and/or wireless infrastructure, smart pass-through components,…)

▪ How to monitor the health status of smart devices and smart networks and transferthis to a (condition based) maintenance strategy?

▪ How to measure, secure and display availability and reliability in order to support the (condition based) maintenance strategy? (It is too much engineering effort to read and interpret each and every manufacturer specific status/diagnostic data in Process Automation System for each device!)

The Foundation for a Solid (Infra)Structure

Industrial Ethernet (LAN)

HART

PROFIBUS DP

Smart Connectivity Concept @ Albemarle

PROFIBUS PA

No passthrough for edge device

Device Configuration Management

Bypass for PROFIBUS and HART signal

Passthrough for HART

signal

Asset Information

Management

Building Blocks & Smart Connectivity

▪ Smart Devices(HART and PROFIBUS communication)

SMART instrument – The source of the DATA

4-20 mA

Analog process value

Digital communication protocols(HART)

AI TOT

DI DO

Multiple digital process variables

Device diagnosticsEmbedded webserver

Embedded Device Driver

Embedded device verification

Embedded OPC UA server

Monitoring + Optimization

http://engine.endress.com/irj/portal?NavigationTarget=navurl://d5d32ad1e65b34b8a6aa3b23f50c4fe5

SMART instrument – The source of the DATA

88,6 kg/h

Digital process value

Digital communication protocols(HART, Modbus, PROFIBUS, PROFINET, EtherNet/IP,…)

AI TOT

DI DO

Multiple digital process variables

Device diagnosticsEmbedded webserver

Embedded Device Driver

Embedded device verification

Embedded OPC UA server

Monitoring + Optimization

http://engine.endress.com/irj/portal?NavigationTarget=navurl://d5d32ad1e65b34b8a6aa3b23f50c4fe5



▪ Smart Connectivity Components(Siemens ET200M, AIH + AOH)

Smart Connectivity Components

▪ Siemens IM153-2 ET 200M / Link• SM 331 8 Channel AI HART• SM 332 8 Channel AO HART

Smart Connectivity Components

▪ Siemens IM153-2 ET 200M / Link• SM 331 8 Channel AI HART

HART variables cannot enabled/assigned because of

fixed PLC addresses.




▪ Smart Plant Access Points(Fieldgate SFG500 + Asset Monitor)

Smart Plant Access Points

▪ Endress+Hauser Fieldgate SFG500 PROFIBUS Gateway• SFM500 Asset Monitor

Continuous Asset Health Monitoring!





▪ Centralized Device Configuration Management(FieldCare SFE500)





▪ Centralized Device Configuration Management(FieldCare SFE500)

▪ Centralized Asset Information Management(W@M Portal XD88CP + W@M Enterprise SWAM10B)

Wireless Heartbeat verification (iPad connected to WLAN access point of Promass 300)

Automatic upload of Heartbeat verification report

After Heartbeat Technology implementation

▪ With Heartbeat verification calibration interval has been reduced from once every year to once every five years.

▪ Verification report can be easily uploaded to W@M Asset Information Management.

NoteUpload performance of Heartbeat verification report is poor due to HART communication – if possible consider Fieldbus or Industrial Ethernet communication.

▪ Increased availability due to continuous Asset Health Monitoring.▪ Significant time savings in preparation and securing the installation by a

maintenance engineer for a calibration.

Next steps

▪ Heartbeat integration is NOT a feature which you enable or disable. It is should be part of customers work process.

At Albemarle Heartbeat is embraced and is specified for new flow assets, BUT it is also a new work process which need to be documented (SOP, WI) and must be lived by the users.>> Having SOP and WI examples available will speed up the implementation process.

▪ Heartbeat integration (e.g. monitoring) requires sound preparation by several disciplines; maintenance –, system- and process engineer. >> Pass/Fail notification for operator

11/16/2018

IIoT Out of the Box

SAP and Endress+Hauser work on joint IIoT solutions

“Two innovative companies have come together here to realize the end-to-end OT/IT integration from field instrument all the way to business processes,” said Hala Zeine, SAP’s President of Digital Supply Chain and Manufacturing.

“When it comes to digitalization, successful companies will be those able to tie their systems directly to business processes, thus reliably and fully opening up or circumventing the classic automation pyramid,” explained Matthias Altendorf, CEO of the Endress+Hauser Group. “We and SAP share a common vision of implementing this strategy to the benefit of our customers.”

Slide 36 Jaap Westeneng

01/09/2019INTERNAL

Current Maintenance Process

Plant Shutdown

Multiple On-Site Service

Lack of historical diagnostic

information

Missing inventory

information

Inaccessible data

Locked Data & Data Silos

Limited Decision-Making

Insights

Incomplete End-to-End

View

Customers’ Key Challenges:

01/09/2019INTERNAL

Predictive Analytics

Static data Online Data

Stock

Devices, Spare Parts

Plant Maintenanc

e

Maintenance

The Digitalized End-to-End Maintenance Process

01

1 1

10

1

1 1

1

01

1 1

11

1

10

1

1

Asset Intelligence Network

Digital Twin

Increased efficiency and

safety

Control System

01/09/2019INTERNAL

ESTIMATED MAINTENANCE DATE

HEALTH SCORE

10% 15.11.2018

Predictive Analytics for E+H Devices

Developed for SAP Cloud Platform

Information

Jaap WestenengApplication Consultant Solutions

Endress+Hauser B.V.Nikkelstraat 61411 AJ Naarden

[email protected] 035-6958717M 06-53729616

Plant Asset Management solutionsIndustrial Communication Technologies

mailto:[email protected]

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Optimale proces betrouwbaarheid en beschikbaarheid door ... · Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam