ISA-108 Intelligent Device Management Ian Verhappen – Yokogawa Canada Herman Storey – Herman Storey Consulting LLC Standards Certification Education & Training Publishing Conferences & Exhibits IEC Plenary 2012 September 26, 2012 Orlando, FL What Is Asset Management? • Activities that provide for Sustainable Managed Risk over the Life Cycle of an Asset • Some Asset Management Activities are Mandated by Government Regulation • All Types of Enterprises have Requirements – – – – Financial Transportation Power Generation Mining and Manufacturing (M&M) IEC Plenary 2012 September 26, 2012 Orlando, FL Asset Management Goals • Reduce Unmanaged Risk – Improve Health, Safety, Environmental, and Operability Performance – Manage Complexity – Reduce Impact of Failures • Achieve Sustainability – Assure Adequate Human, Financial, and Infrastructure Resources – Lower Maintenance Cost – Improve Return On Investment • Simultaneously IEC Plenary 2012 September 26, 2012 Orlando, FL 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 – 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) IEC Plenary 2012 September 26, 2012 Orlando, FL 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 When They Need Work – Can Give Detailed Information on Problems Before a Field Visit – Can Significantly Reduce (or eliminate) the Need for Periodic Testing – Can Reduce Impact on Operations by Advance Warning of Failure – A Significant but Underutilized Opportunity – Biggest Incentives on Control Valves IEC Plenary 2012 September 26, 2012 Orlando, FL Recognition of System Deviations “Before Problems Occur” IEC Plenary 2012 September 26, 2012 Orlando, FL 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 – NE129 Plant Asset Management • These Standards Do Cover Manual Inspect and Test Methods • None of these cover use of Automated Diagnostics or would apply to Intelligent Device Management IEC Plenary 2012 September 26, 2012 Orlando, FL NAMUR NE 129: The Asset Health Triangle IEC Plenary 2012 September 26, 2012 Orlando, FL PAM System Information Architecture Enterprise Resource Planning (ERP) System Supply Chain Management Asset Advisory Management Process Control & Process Management Plant Automation System (PAS) Maintenance Work & Parts Management Process Events & Data Enterprise Asset Maintenance (EAM) System CMMS Maintenance Advisories Plant Asset Management (PAM) System Process Advisories Asset Collaboration / Tolerances Transducer Config. Control Monitoring Set-up Inspection Routes Data Control Parameters Supply Chain Management Work Histories Asset Monitoring Variables Asset Calibration / Tolerance Data E-commerce Maintenance Repair & Operations (MRO) Procurement System Purchase order Order Tracking Asset Usage Data Plant Measurements / Inspections IEC Plenary 2012 September 26, 2012 Orlando, FL Oil Properties Oil Chemical Sample Monitoring Oil Particle Process Casing vibration Transient On-Line Monitors Shaft Displacement Process Casing vibration Shaft Position Protection On-Line Monitors Shaft Displacement Electrical Process Casing Vibration PLC / DCS Survey OnLine Monitors Shaft Displacement Smart valves & Field Devices Thermal Electrical Transducers Oil Smart Machines & Process Operation Field Report Portable Device Monitoring Vibration Control Device Monitoring Smart Pressure Transmitters are the Norm Installed Base Smart, Microprocessor Based Conventional or Pneumatic Source: ARC Advisory Group IEC Plenary 2012 September 26, 2012 Orlando, FL Intelligent Device Management • Intelligent Devices Are Pervasive, but Are Not Being Used Properly – Most Diagnostics are not Prioritized or Utilized • Considered Approach to Intelligent Device Management is Required – Technology and Products are Widely Available – Work Processes and Best Practices are the Key – A New ISA Standards Effort is Needed IEC Plenary 2012 September 26, 2012 Orlando, FL New ISA Intelligent Device Management Standard • • • • Content Proposals: Models and Terminology Implementation Guidelines Work Processes – Diagnostics Based Maintenance – Configuration Management – Auditing IEC Plenary 2012 September 26, 2012 Orlando, FL Work Process Life Cycle • FED – Criticality Ranking – Vendor Qualification & Templating • Design / FAT – Work Process Selections and Design – Initial System Configuration (Build Tools) – Training • Install, Commission, Loop Check – Device and System Integration – Initial Use of Diagnostics • Pre-Startup Safety Review • Routine Maintenance • Turnaround Management IEC Plenary 2012 September 26, 2012 Orlando, FL 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 by Application Criticality – Criticality Ranking should be established in FED – Alert Priority Depends on Impact Severity – Not Likelihood – Send Alerts to Operator and well as Maintenance Only if Operator Action is Required – Log All Alerts regardless of Priority – Different from process alarm management • Needs Definition Before Configuration Activities IEC Plenary 2012 September 26, 2012 Orlando, FL Intelligent Device Management • Proper Use of Diagnostics Depends on a Graphical User Interface – Would you give an Operator an Explorer Tree? – Requirement: Navigate from Overview to Detail in 3 Mouse Clicks – 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 More Information & Examples IEC Plenary 2012 September 26, 2012 Orlando, FL Graphical User Interface for Maintenance FIELDBUS MAINTENANCE OVERVIEW CCGCTL01 CCGCTL02 CCGCTL03 01-01-01-01 CCS/RR2 01-01-17-02 CSS/RR2 02-01-01-01 RR1 02-01-17-01 RR1 03-01-01-01 MF2 03-01-13-02 MF2/CSS 01-01-01-02 CSS 01-01-19-01 CSS/RR2 02-01-01-02 RR1 02-01-17-02 RR1 03-01-01-02 MF2 03-01-17-01 CSS 01-01-03-01 CSS/RR2 01-01-19-02 CSS/RR2 02-01-03-01 RR1 02-01-19-01 CSS 03-01-03-01 MF2 03-01-17-02 MF2 01-01-03-02 CSS/RR2 01-01-21-01 CSS/RR2 02-01-03-02 NONE 02-01-19-02 RR1 03-01-03-02 CSS/MF2 03-01-19-01 MF2 01-01-05-01 CSS 01-01-21-02 RR2 02-01-05-01 RR1 02-01-21-01 NONE 03-01-05-01 CSS/MF1 03-01-19-02 CSS/MF2 01-01-05-02 CSS 01-01-25-01 CSS/RR2 02-01-05-02 RR1 02-01-21-02 RR1 03-01-05-02 MF2 03-01-21-01 MF2 01-01-09-01 CSS 01-01-25-02 CSS 02-01-09-01 RR1 02-01-23-01 RR1 03-01-09-01 CSS/MF2 03-01-21-02 MF2 01-01-09-02 CSS 01-01-27-01 CSS/RR2 02-01-09-02 RR1 02-01-23-02 RR1 03-01-09-02 MF2 03-01-27-01 MF2/CSS 01-01-11-01 CSS 01-01-27-02 RR2 02-01-11-01 RR1 02-01-25-01 RR1 03-01-11-01 CSS/MF2 03-01-27-02 MF2/CSS 01-01-11-02 CSS 01-01-29-01 RR2 02-01-11-02 CSS/RR1 02-01-25-02 RR1/CSS 03-01-11-02 CSS 03-01-29-01 MF2 01-01-13-01 CSS 01-01-29-02 CSS/RR2 02-01-13-01 CSS/RR1/MF1 02-01-27-01 RR1 03-01-13-01 MF2/CSS 03-01-29-02 MF2 01-01-13-02 CSS 01-01-31-01 RR2 02-01-13-02 RR1 02-01-27-02 RR1 01-01-17-01 RR2 01-01-31-02 RR2 02-01-15-01 RR1 02-01-29-01 RR1 02-01-15-02 NONE 02-01-29-02 RR1/CSS Source: AG-181 IEC Plenary 2012 September 26, 2012 Orlando, FL Good 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 – 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 Requires Extra Engineering IEC Plenary 2012 September 26, 2012 Orlando, FL 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 Devices – 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 IEC Plenary 2012 September 26, 2012 Orlando, FL Required Intelligent Device Management Tools • Maintenance History • Resource Planning, Tracking, Accounting – Example: SAP • Design Calculation, Drawing, Documentation – Example: SPI (Intools) • Host Systems – Integrated Host (Example: DCS) – Visitor or Bench Host (Handheld or Laptop) – Provide Configuration Management, Troubleshooting, and Human Interface IEC Plenary 2012 September 26, 2012 Orlando, FL Intelligent Device Management Interactions Work Orders Intelligent Devices CMMS Event Historian Configuration Database DCS Host Plant Asset Management System IEC Plenary 2012 September 26, 2012 Orlando, FL Alarm Management System Reporting & Analysis Integrated Data System User Interface (Configuration & Monitoring) Enterprise Server / Middleware Database SQL & ODBC Rules Engine Enterprise Asset Manager System Interface B2MML Enterprise Asset Management System XML User Interface Instrument Asset Management System IEC Plenary 2012 September 26, 2012 Orlando, FL Database(s) Audit Trail Tag data Calibration Data Device server Alert Monitor EDDL HART FF FDT/DTM Profibus DeviceNet Others Intelligent Device Management Tools • Tools, Hosts, and Devices Need: – Remote Access – Multiple Simultaneous Access – Cyber Security – Role Based Security – Required for Hosts and Devices – A Standardized Security Model Would be Nice IEC Plenary 2012 September 26, 2012 Orlando, FL 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 Template Process Required for Default Settings History and Change Tracking are Needed • Field Experience – Use of Visitor Hosts (Handhelds) – Configuration Management (or Configuration Drift) IEC Plenary 2012 September 26, 2012 Orlando, FL What Is Exception Based Surveillance? Seconds Minutes Hours Real Time Activities Operation Days Weeks Months Years Life of Asset Semi Real Time Activities Diagnostics & Surveillance Planned Activities Planned Maintenance and Design Improvements Exception based Surveillance provides for Reactive Response in Semi Real Time to Diagnostic Alerts filling a Gap between Operation and Traditional Planned Activities and makes use of Diagnostic Capabilities of Field Devices IEC Plenary 2012 September 26, 2012 Orlando, FL 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 – Management Ownership • Standards Will Help – Get Engaged IEC Plenary 2012 September 26, 2012 Orlando, FL To Learn More: ISA108 Committee • http://www.isa.org/MSTemplat e.cfm?MicrositeID=1528&Com mitteeID=7281 Ellen Fussell Policastro, Standards Administrator International Society of Automation PO Box 12277, 67 Alexander Drive Research Triangle Park, NC 27709 +1 (919) 990-9227 efussell@isa.org IEC Plenary 2012 September 26, 2012 Orlando, FL Managing Director: Ian Verhappen +1 403 258 2681 x2222 Ian.verhappen@ca.yokogawa.com