Chapter 9 PDF

Fieldbus Diagnostics
Agenda
Introduction
Level of Diagnostics
Function Block Diagnostics
Resource Block Diagnostics
Transducer Block Diagnostics
[File Name or Event]

Emerson Confidential
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 Trips to

the field: Transmitter Diagnostics
63% of trips to the field can be eliminated
50
40
35%
28%
30
20%
20
6%
10
6%
4%
0
Routine
Check
No
Calibration
Problem
Shift
Source: Dow Chemical

27-Jun-01, Slide 4
Zero
Off
Plugged
Failed
Lines Instrument
Diagnostics Definitions
Level 3
Level 2
Loop
Operations
Boiler
Turbine
Generator
Make Up Water
Pulveration
Drift
Level 1
Device
Communications
Diagnostics
Electronics
Diagnostics

27-Jun-01, Slide 5
Plugged
Impulse
Line
Sensor
Drift
Device Maintains Statistics For Communication

Diagnostics

27-Jun-01, Slide 6
Diagnostic Examples
Transmitter generates an alert

when
the sensor degenerates
the device has exceeded

factory maximum field
temperature usage
Cycle Counter
Valve Signature
Dynamic Error Band

27-Jun-01, Slide 7
O2 Sensor creates alert when the

sensor fouls
Using Device Intelligence

The Device
Detects Process
Conditions
Impulse Lines Plug

PV (V)
1.82
1.819
1.818
1.817
1.816
1.815
1.814
1.813
1.812
1.811
1.810

27-Jun-01, Slide 8
10
12
Time (min)
14
16
18
20
Devices Provide Predictive Diagnostics

Provide Information On Life Expectancy and
Performance Degradation
Predictive Alarm
Failure
Device Performance

27-Jun-01, Slide 9
Diagnostics are Utilized in Fieldbus

Blocks for Measurement and Control
PV is MarkedUncertain
or Bad if Abnormal
and propagated

27-Jun-01, Slide 10
Event is Time Stamped At The Source!
H1

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

Enable
Maintenance
Grounding/Wiring Fault
50/60 Hz Noise::
.003401 mV
i
Advisory
Print

27-Jun-01, Slide 12
Close
Help
TOWER_1
Process plants can be tough on field

devices!

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

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

27-Jun-01, Slide 15
Diagnostic Examples
Transmitter generates an alert

when
the sensor degenerates
the device has exceeded

factory maximum field
temperature usage
Cycle Counter
Valve Signature
Dynamic Error Band

27-Jun-01, Slide 16
O2 Sensor creates alert when the

sensor fouls
Variability Index provides additional

insight into Loop Performance
Variability Index Diagnostic
Variable
Performance Change
Variability
Index
Is Detected with
Variability Index
Acceptable
Value
DeltaV Inspect Identifies

Under-performing Loops
VI=
Measured Standard Deviation

Minimum Expected Standard Deviation

27-Jun-01, Slide 17
Take Corrective Action
Plugged Impulse Line Diagnostic

1.82
1.819
1.818
1.817
Manifold
P V (V)
1.816
Sensing
Line
1.815
1.814
Both Open
1.813
HP Closed
LP Closed
Both Closed
1.812
1.811
Clog
Flow

27-Jun-01, Slide 18
1.81
0
10
12
Time (min)
14
16
18
20
Statistical Process Monitoring

27-Jun-01, Slide 19
Proof Using SPM Prevents Plant

Damage
10.00
Statistical
Process
Monitoring data
coming from
3051 ADB
helped predict
catalyst problem
30 min
in advance
PHD Data
23:30
23:00
9.00
23:30
8.00
7.00
6.00
5.00
4.00
23:00
23:00
3.00
SPM Data
2.00
1.00
0.00
6/4
6/6
6/8
Source: ExxonMobil Baytown, Tx Refinery

27-Jun-01, Slide 20
6/10
6/12
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
AI

27-Jun-01, Slide 21
Status can be used in the control

strategy to switch a controller to
Manual when the variable goes to
a Bad status.
Status

27-Jun-01, Slide 22
Diagnostics are Utilized in Fieldbus

Blocks for Measurement and Control
PV is MarkedUncertain
or Bad if Abnormal
and propagated

27-Jun-01, Slide 23
Event is Time Stamped At The Source!
Classic I/O
Other Buses
Other Buses
H1

27-Jun-01, Slide 24
Plantweb alerts
Sensor
Failure
Maintenance
Soon
Installation
Problems
Sensor
Failure
Maintenance
Soon
Installation
Problems
Sensor
Failure
Installation
Problems
Sensor
Failure
Maintenance
Soon
Maintenance
Soon
Failed

27-Jun-01, Slide 25
Maintenance
Advisory
Route to appropriate plant organization

Recommended Action
Troubleshooting guide
Installation
Problems
Conditions of FT-101
Recommended Action: Perform recommended sensor/wiring checks
FT-101
Inlet 3, Cooling Tower 1
Failed
Maintenance
Sensor Calibration
Failed Conditions
Sensor
Failed
Process
Electronics
Communications Failure
Failed
Maintenance
Advisory
Enable

Enable
Maintenance
Grounding/Wiring Fault
50/60 Hz Noise::
.003401 mV
i
Advisory
Print

27-Jun-01, Slide 26
Close
Help
TOWER_1
Operation
Devices are identified by Tag
Variables are identified by:
TAG.Desired Parameter
FT
102A
FIC
102A
FCV
102A
FIC102A.OUT
No need to remember the Transmitters Hardware Address .
FT102A, not CTL01C03A01

27-Jun-01, Slide 27
Transducer, Resource and Function Blocks
Every Field device has to have a Resource Block and

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

27-Jun-01, Slide 28
Resource Block
Hardware and Software resources.
When Mode is Out of Service, all other blocks will

be Out of Service.
Allow Device resetting, including resetting with

Default values.
All Emerson devices have a common Resource

Block, with very small variations.

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

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

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

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

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

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

Alarms

27-Jun-01, Slide 35
Transducer Blocks
Transducer blocks provide the interface to

sensors, switches, actuators, etc.
Transducer blocks also allow access to

calibration and I/O diagnostics.
If the Transducer Block is in Out of Service

Mode, the Function Blocks will have
measurement value with Bad Status.
Transducer communicates the values to the I/O

Function Blocks via Channels.

27-Jun-01, Slide 36
Transducer
Free Running
Schedule
Transducer
Sensor 1
Channel 1
Ch. 1
AI 1
Channel 2
Ch. 2
AI 2
Channel 3
Ch. 3
AI 3
Channel 4
Ch. 4
AI 4
Sensor 2
Sensor 3
calc
27-Jun-01, Slide 37
Important to remember
AI or AO block has to have the Channel

configured accordingly. Channel = 0, no
measurement or actuation.
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.
Transducer should be in Auto.

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

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

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

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

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

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

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

27-Jun-01, Slide 45
Pressure Transducer Advanced

Diagnostic Block

27-Jun-01, Slide 46
Pressure Transducer Advanced

Diagnostic Block

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

27-Jun-01, Slide 48

27-Jun-01, Slide 49

27-Jun-01, Slide 50

27-Jun-01, Slide 51

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Fieldbus Diagnostics

Function Block Diagnostics

Resource Block Diagnostics

Transducer Block Diagnostics

[File Name or Event]

Fieldbus brings dramatic

Elimination of Unneeded Trips to

Source: Dow Chemical

[File Name or Event]

Device Maintains Statistics For Communication

[File Name or Event]

Transmitter generates an alert

the sensor degenerates

the device has exceeded

[File Name or Event]

O2 Sensor creates alert when the

Using Device Intelligence

Impulse Lines Plug

[File Name or Event]

Devices Provide Predictive Diagnostics

[File Name or Event]

Diagnostics are Utilized in Fieldbus

[File Name or Event]

Event is Time Stamped At The Source!

[File Name or Event]

Recommended Action: Perform recommended sensor/wiring checks

Electrode Signal Fault

Electrode Signal Fault

[File Name or Event]

Process plants can be tough on field

[File Name or Event]

Electronic Board failure

Operating conditions out of specifications

[File Name or Event]

[File Name or Event]

Transmitter generates an alert

the sensor degenerates

the device has exceeded

[File Name or Event]

O2 Sensor creates alert when the

Variability Index provides additional

DeltaV Inspect Identifies

Measured Standard Deviation

[File Name or Event]

Take Corrective Action

Plugged Impulse Line Diagnostic

[File Name or Event]

Statistical Process Monitoring

[File Name or Event]

Proof Using SPM Prevents Plant

Source: ExxonMobil Baytown, Tx Refinery

Value: 234.5 m3/h

[File Name or Event]

Status can be used in the control

[File Name or Event]

Diagnostics are Utilized in Fieldbus

[File Name or Event]

Event is Time Stamped At The Source!

[File Name or Event]

[File Name or Event]

Route to appropriate plant organization

Recommended Action: Perform recommended sensor/wiring checks