Net zoals de meeste toestellen zijn ook drukmetingen onderhevig aan externe en interne factoren waardoor ze in de loop van hun levensjaren meetfouten, afwijkingen, en onnauwkeurigheden gaan vertonen. Hierdoor is het nodig om de toestand van de meettoestellen te beoordelen en te calibreren of eventueel te vernieuwen. We dienen er eveneens over te waken dat de meettoestellen regelmatig een onderhoudsbeurt ondergaan om steeds de best mogelijke meetprestaties te leveren. Die elementen worden belicht in deze zitting. Sprekers: Jan Heynen (ENDRESS+HAUSER SA/NV) Jeroen Wynants (ENDRESS+HAUSER SA/NV)

1. 22/06/2012
Advantages of digital communication
Unlocking the potenitial of diagnostic information
Slide 1
Jeroen Wynants

2. 22/06/2012
OpEx savings maintenance
Source: HPI market data 2003 Gulf publishing company
Instrument & valves
Mechanical equipment
Process equipment
Electrical equipment

3. 22/06/2012
Customer survey and questionnaire
Which maintenance strategy to apply?

4. 22/06/2012
Typical maintenance strategies
Corrective Maintenance
Device is maintained when it failed
> uncontrolled plant shutdowns
Preventive Maintenance
Device is periodically maintained to prevent failures
> controlled but high maintenance intervals
Condition Based Maintenance
Device detects when a maintenance is necessary
and notifies in advance
> controlled and optimized low maintenance intervals
Corrective
Maintenance
Preventive
Maintenance
Condition
based
Maintenance
Consequenceoffailure
Increasing effectiveness and efficiency
Costs
Availability

5. 22/06/2012
Typical maintenance strategies
Corrective Maintenance
Device is maintained when it failed
> uncontrolled plant shutdowns
Preventive Maintenance
Device is periodically maintained to prevent failures
> controlled but high maintenance intervals
Condition Based Maintenance
Device detects when a maintenance is necessary
and notifies in advance
> controlled and optimized low maintenance intervals
Source: ARC Advisory Group
020406080100
Type of maintenance
65%
30%
5%
60% of preventive maintenance activities is unnecessary!

6. 22/06/2012
Condition Based Maintenance
Device detects when a maintenance is necessary
and notifies in advance
-> controlled and optimized low maintenance intervals
Condition based maintenance strategy
Condition
Time
Failure occur
Reduction of
functional
reserve
Condition based
Initialized on condition
(basic diagnosis: diagnosis value 1 device
Pro-Active
Static analysis
‘Reference value’
• evaluation: <,>, =, hyst.,…
Predictive
Dynamic analysis
‘Reference trend’
• extrapolation, time, …
Condition based
Initialized on condition
(advanced diagnosis: correlated diagnostic values)
Pro-Active
Static analysis
‘Reference value’
• evaluation: <, >, =, hyst., .…
• Boolean logic (AND, OR, …)
• Methods algorithms,…
Predictive
Dynamic analysis
‘Reference trend’
• evaluation: <, >, =, hyst., .…
• Boolean logic (AND, OR, …)
• methods, algorithms,…
Condition based
Initialized on condition
(process diagnosis: correlated devices)
Pro-Active
Static analysis
‘Reference value’
• evaluation: <, >, =, hyst., .…
• Boolean logic (AND, OR, …)
• correlation algorithms,…
Predictive
Dynamic analyses
‘Reference trend’
• evaluation: <, >, =, hyst., .…
• Boolean logic (AND, OR, …)
• correlation, algorithms,…
Value
B-E-F
Value
B-E-F
Value
B-E-F
Value
B-E-F
Value
B-E-F
Value
B-E-F

7. 22/06/2012
Service technician
diagnostics in automotive industry
Slide 7
Jaap Westeneng
Driver
Quality Manager
• As detailed as possible
• Includes suggestions for possible
remedies
• All information for safe driving
• Only essential information,
summary messages
• As early as possible

8. 22/06/2012
Maintenance technician Process operator
diagnostics in process industry
Slide 8
Jaap Westeneng
Reliability Manager
• All information for safe operation
• Only essential information,
summary messages
• As early as possible
• As detailed as possible
• Includes suggestions for possible
remedies

9. 22/06/2012
Challenges faced by today
 Difficult to get overview status of process.
 Operators are bombarded with nuisance alarms.
 Inconsistencies in diagnostics information from different
vendors and product classes.
 Different applications, terminals, interfaces with
unsynchronized data.
 Operators are integral part of control loops and need to take
decisions in critical situations.

10. 22/06/2012
Status today
 Large part of the production and quality losses are
primarily result of operator error which can be prevented by
ensuring that the right information is available to the right
person at the right time.
Global process industry loses $ 20 billion, or 5 % of annual
production, due to unscheduled downtime and poor quality.
ARC estimates that almost 80 % of these losses are preventable and
40 % are primarily the result of operator error.

11. 22/06/2012
Purpose of diagnostics
 Analyze status information (i.e. from field devices)
 With the objective of detecting causes for potential
malfunction.
Diagnostics form the basis to remove malfunctions
Value of diagnostics:
 Minimizes ad-hoc maintenance
 Enables proactive maintenance
 Minimizes unwanted plant shutdowns
 Enables event triggered inspections
 Forms the basis for Plant Asset Management
 Reduces costs

12. 22/06/2012
NAMUR NE107
Standardisation of diagnostics
Slide 12
Jeroen Wynants

13. 22/06/2012
NAMUR
NormenArbeitsgemeinschaft für Meß- Und Regeltechnik in der chemischen Industrie
NAMUR is an international association of users of automation in
process industries.
• Membership of NAMUR is open only to companies of the process
industries, provided that these companies are
• Manufacturers of chemical or pharmaceutical products, or
• Users of process plants which bear responsibility for operating these
plants, or
• Providers of services to chemical/pharmaceutical manufacturers
with or without plant operating responsibility;
• Also eligible for membership are organizations with a technical or
scientific purpose, e.g. scientific bodies, associations, universities
etc.
Slide 13
Jeroen Wynants

14. 22/06/2012
NAMUR
 NAMUR promotes the interests of the process industry in the
field of automation
127 member companies
Slide 14
Jeroen Wynants

15. 22/06/2012
NAMUR
• NAMUR promotes the interests of the process industry in the
field of automation, including
• Instrumentation with sensors and actuators
• Batch control, advanced process control, plant and process
monitoring,
• DCS, MES and Logistic systems
• Communication between process control equipment
• Process management, plant asset management and
• Electrical engineering
• Covering the whole plant life cycle from engineering,
procurement, installation, operation, and maintenance right
through to decommissioning,
Slide 15
Jeroen Wynants

16. 22/06/2012
NAMUR Publications
• The results of the work carried out by NAMUR are published:
• In NAMUR recommendations (NE) and worksheets
• In presentations at the Annual General Meeting
• In publications which appear in technical journals
(e.g. atp, at, C&A, ChemManager, CIT, etz, GIT,process , P & A,
Messtech & Automation, SPS-Magazin, tm )
• In speeches made at workshops and conferences organized by
cooperating partners
(ARC, DECHEMA, GMA, GVC, ISA, WIB)
Slide 16
Jeroen Wynants

17. 22/06/2012
NAMUR Recommendations
Slide 17
Jeroen Wynants
Current ranges for signal levels of digital transmitters
NE 43 (1988): Standardization of the Signal Level for Failure
Information
• Discrimination between process and failure information
• P based devices
NE 107 (2005): Self-Monitoring and diagnostics of Field Devices
Diagnostics
• Analyze status information (i.e. from field devices)
• With the objective of detecting causes for potential malfunction.
Diagnostics form the basis to remove malfunctions.

18. 22/06/2012
NAMUR Recommendation NE107
Plant Asset Management - Evolution of diagnostics
NE107 Self-Monitoring and diagnostics of Field Devices
 diagnostics results must be reliable, bad diagnostic is worse
than none at all.
 The diagnostics results must always be viewed in the context of
the application.
 Each diagnostic information must be mapped to one of the four
categories (FMCS)
 The configuration of the mapping between the diagnostic and
the category should be free but predefined.
 The plant operator to see only the status signals.
 Detailed information can be read out by the device specialist.Slide 18
Jeroen Wynants

19. 22/06/2012
NAMUR Categories (FMCS)
 Failure – F
 The device provides a non-valid output signal due to some
malfunction at the device level.
 Maintenance required – M
 Although the device is still able to provide a valid output signal,
the device is about to loose some of its functionality or capability
due to some external operation conditions. The maintenance can
be needed short-term or mid-term.
 Check function – C
 The device is temporary non-valid due to some activities,
maintenance activities on the device
 Off-specification – S
 The Device operates out of the specified measurement range
Slide 19
Jeroen Wynants

20. 22/06/2012
NAMUR recommendations
Maintenance required
Out of specification
Check function
Failure
Diagnostics active
Diagnostics passive
Diagnostic symbols (NE 107)
Slide 20
Jeroen Wynants

21. 22/06/2012
Detailed Device Diagnostics
e.g. Process Automation, Asset Management, Data Acquisition
HART / PROFIBUS / FOUNDATION Fieldbus
Detailed Diagnostic Events
Slide 21
Jeroen Wynants

22. 22/06/2012
e.g. Process Automation, Asset Management, Data Acquisition
HART / PROFIBUS / FOUNDATION Fieldbus
Maintenance
Required Failure
Functional
Check
Out of
Specification
Condensed Status and Diagnostics
Plant Asset Management - Evolution of diagnostics
Slide 22
Jeroen Wynants

23. 22/06/2012
NAMUR recommendations
Instrument diagnostics
e.g. SIL certified devices
(IEC 61508/61511)
Application diagnostics (NE 107)
e.g. Coriolis mass flow meter
Gas bubbles in the liquid, fouling, clogging, erosion, corrosion,
faulty mounting, external vibrations, pulsating flow, incomplete
filling
Application diagnostics are defined for flow -, level -, pressure -,
temperature measurements and control valves
Plant Asset Management - Evolution of diagnostics
Slide 23
Jeroen Wynants

24. 22/06/2012
Connect diagnostic to
one status signal
NAMUR recommendations
On / off switch
diagnostics
Example: mass flowmeter
Coriolis mass flow meter
Gas bubbles in the liquid
Fouling, clogging
Erosion, corrosion
Faulty mounting
Asymmetry of measuring tubes
(dual tube only)
External vibrations
Pulsating flow
Incomplete filling
Application diagnostics (NE 107)
Plant Asset Management - Evolution of diagnostics
Slide 24
Jeroen Wynants

25. 22/06/2012
Communication protocols
Slide 25
Jeroen Wynants

26. 24/10/2012
Products Solutions Services
HART
Technology
Slide 26
Jeroen Wynants

27. 22/06/2012
History
HART: Highway Addressable Remote Transducer
 1986 Developed by Rosemount
 1989 HART communication protocol made an open standard
 1993 Standards developed and supported enabled by HART
Communication Foundation in Austin, Texas, U.S.A
http://www.hartcomm.org
 2007 HART added to IEC-61158 International Standard for Fieldbus
 2008 HART 7 (Wireless) Specifications finalized.
 Most instruments in field today HART 5.
 HART 6 and later require prescribed testing to registration.

28. 22/06/2012
HART facts
 Digital Frequency Shift Keying (FSK) based on the
Bell 202 telephone communication standard
 Transmission speed 1.2 kbit/s >> 1 transaction = 500
ms
 Binary 0 = 2200 Hz, Binary 1 = 1200 Hz
 Simple twisted pair 4-20mA wiring
 Analog channel for fastest possible data transfer of
control signal (main process value)
 Digital channel >> HART based transmission of device
parameters and diagnostic data to and from field
devices
 Frequency modulated signal on the 4-20 mA
current signal modulated
 Serial data transmission

29. 22/06/2012
HART news and highlights
 Field-proven standard used by over 32 million devices around
the world
 Most instruments in field today HART 5 or HART 6
 More and more HART 7 devices are available but at the
moment mostly for WirelessHART communication
 Currently the HCF is working on a NE107 integration for the
HART specification >> improved diagnostics

30. 22/06/2012
Diagnostics
 Acyclic access to diagnostics
 Commands for transmitting diagnostics data
 Command 0 (Read Unique Identifier): Universal Command,
supported by every HART device.
Response Code (2nd Byte): Field Device Malfunction + More Status
available
 Command 48 (Read Additional Transmitter Status): Common
Practice Command, containing the device status
Additional generic device status information
 Command 231: Manufacturer Specific Command
(Endress+Hauser) for transmission of diagnostics data
Transmission of failure number and NE107- Category (MFCS)

31. 22/06/2012
HART topology overview
Controller
Point
to
Point
Multidrop
Remote I/O
Multiplexer
WirelessHART

32. 24/10/2012
Products Solutions Services
PROFIBUS
Technology
Slide 32
Jeroen Wynants

33. 22/06/2012
History
PROFIBUS: PROcess FIeldBUS
 1989 Standards developed and supported enabled by PROFIBUS Nutzer
Organisation (PNO)
http://www.profibus.com
 1995 Founding of PROFIBUS International
 1996 PROFIBUS PA (Process Automation)
 2000 Standard field devices for process automation, Profile 3.0
 2004 PROFIsafe, Condensed status and I&M functions, Profile 3.01
 2008 Device integration, fast parameter transmission, Profile 3.02
 Most instruments in field today have Profile 3.0 as a minimum

34. 22/06/2012
PROFIBUS facts
 Two technologies:
 DP (Decentralized Periphery)
Transmission speed DP: up to 12Mbit/s
 PA (Process Automation)
Transmission speed PA: fixed 31.25kbit/s)
 Simple twisted pair + Shield
 DP: only communication, cable length up to 1200m
 PA: power and communication, cable length up to 1900m non-
ex, up to 1000m

35. 22/06/2012
PROFIBUS news and highlights
 Successful fieldbus with more than 40 million devices
installed (6.8 million in process industries)
 Latest version PA Profile 3.02 introduces the NAMUR NE107:
 Mapping of diagnosis information on standardized and
accepted diagnostic categories (Condensed Status & Diagnosis
Messages)

36. 22/06/2012
Diagnostics
 Continuous transmission of device status (STATUS)
 Event-triggered transmission of device status (diagnostics)
 Slot index for transmitting diagnostics data
Diagnostic
data
…
Calculation
of Status Byte
Calculation
of extended
diagnostics data
1
2
3
Slot
0
1 2 3 25
5
…
Index
0
255…
diagnostics
diagnosticsE
XTENSION
Physical Block
……
PROFIBUS diagnostics
Status (cyclic data exchange)
Diagnostic Parameter:
4 + 1 Byte (Quality code)

37. 22/06/2012
PROFIBUS topology overview
PLC/DCS
Commissioning tool
PROFIBUS DP
T T
T
Remote I/O
T
PROFIBUS PA

38. 24/10/2012
Products Solutions Services
FOUNDATION fieldbus
Technology
Slide 38
Jeroen Wynants

39. 22/06/2012
Fieldbus Foundation
 1994 Standards developed and supported enabled by Fieldbus
Foundation
http://www.fieldbus.org
 1996 FOUNDATION Fieldbus H1
 1998 Registration of first H1 fieldbus products
 1999 High Speed Ethernet (HSE)
 2001 Registration of first HSE linking devices
 2005 Safety Instrumented Functions (SIF)
 2006 Diagnostic Profiles Specification according to NE107
FF History

40. 22/06/2012
FF facts
Two technologies:
 HSE (High Speed Ethernet)
 H1 (Process Automation)
Transmission speed H1: fixed 31.25kbit/s)
 Simple twisted pair + Shield
 H1: power and communication, cable length up to
1900m non-ex, up to 1000m ex

41. 22/06/2012
FF news and highlights
 FF912 introduces the NAMUR NE107:
 Mapping of diagnosis information on standardized and
accepted diagnostic categories (Condensed Status & Diagnosis
Messages)

42. 22/06/2012
 Continuous transmission of device status (STATUS)
 Automatically and used for control (Status Propagation)
 Event-triggered transmission of device status (diagnostics)
 Device diagnostic can be reflected in different parts of a
FOUNDATION Fieldbus device
 Device specific diagnostic parameter
e.g. Transducer Block parameter
 Transducer Error
 Block error
 Alarms
Diagnostics

43. 22/06/2012
FF topology overview
PLC/DCS Commissioning tool
T T
FF H1