Realizing the Potential of Intelligent Device Management

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Automation 2013 Mumbai
© 2013 Fieldbus Foundation
Digital Doesn‟t Mean Intelligent:
Realizing the Potential of
Intelligent Field Device Management

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• 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?

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• 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

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• 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

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• Digital Devices are
Everywhere
• The Rise of Cyber
Physical Systems
• Why we Cling to Analog
Thinking in a Digital
World

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• 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.

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Source: ARC Advisory Group
Global Installed Base of All Field Devices by Smart vs.
Conventional: 2011

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• 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)

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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

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• 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

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• 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

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• 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

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• 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

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• 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

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• The Economic Impact of Intelligent Devices
• Why You Need a Strategy for Intelligent Device
Management
• Understanding Diagnostics
• The Importance of Work Processes and Ownership

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10-15 percent 20-40 Percent 20-40 Percent
“Saves”
Reduced
Unplanned
Shutdowns

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• Source: ARC Advisory Group
- 6 0 - 4 0 - 2 0 0 2 0 4 0
U npla nned Brea kdow ns
Inventory Costs
D ow ntim e
D efects
Equipm ent Life
W orkforce Efficiency
Equipm ent Productivity
% Im provem ent vs Tra ditiona l M a intena nce
- 6 0 - 4 0 - 2 0 0 2 0 4 0
U npla nned Brea kdow ns
Inventory Costs
D ow ntim e
D efects
Equipm ent Life
W orkforce Efficiency
Equipm ent Productivity
% Im provem ent vs Tra ditiona l M a intena nce

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With device
management
software
• Source: Emerson Process Management

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A Broad Mix of Applications can Benefit from Intelligent Device Data

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A Broad Mix of Applications can Benefit from Intelligent Device Data

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• 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.

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• Doesn‟t tell you what‟s
wrong
• No predictive guidance
• Is it a process problem
or device problem?
• Sensor problem?
Electronics problem?
Who knows?

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Sensor
includingprocessconnectionandsensor
electronic
Instrument Electronic
Configuration
e.g.Linearization
Process
Process/
Environment
Information
Root Group
Information
Root Group
Instrument
Process/
Environment
Sensor
Electronics
Configuration
Process

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• Certain diagnostic anomalies expressed in multiple field devices can
indicate an anomaly or impending abnormal situation in the process.

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Sample Diagnostic Parameters of a
FOUNDATION Fieldbus Flowmeter

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Definition of NE 107 Status
Signals

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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
b2.5.1
Emergency
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
Embedded
External
Work Process
LEGEND
Start or End Task Decision a Connector 11 Metric /
Control Point
Embedded
External
Work Process
2.6.2
Enter notification in
CMMS
(Documents status in Log)
Work
Request
(CMMS)
b
Repaired
Equipment
2.3
Select 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?
2.7.2
Repair and Enter
Notification to
capture history
2.10.1
Daily PM
Complete?
2.8
Enter Notification in
CMMS
c
c
2.10.2
Update
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, 2006
Last Revision:
Revision Date: Dec 31, 2011
Rev 1.3
b
3
2.2
Obtain Daily PM & A/A
report

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• The Integration Dilemma
• The Importance of Adopting Open
Standards
• Train, Train, Train

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• 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

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Device Package
EDD
FDI 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.)

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• 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

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 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.

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• 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!

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