ISA-108 Intelligent Device Management

1. ISA-108Intelligent Device Management Ian Verhappen – Yokogawa Canada Herman Storey – Herman Storey Consulting LLC

2. 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)

3. 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

4. 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)

5. 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

6. Recognition of System Deviations “Before Problems Occur”

7. 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

8. NAMUR NE 129: The Asset Health Triangle

9. PAM System Information Architecture Supply Chain Management Supply Chain Management Enterprise Resource Planning (ERP) System Asset Advisory Management Maintenance Work & Parts Management Process Control & Process Management Plant Asset Management (PAM) System Enterprise Asset Maintenance (EAM) System CMMS Plant Automation System (PAS) E-commerce Maintenance Repair & Operations (MRO) Procurement System Process Advisories Maintenance Advisories Purchase order Work Histories Order Tracking Process Events & Data Asset Collaboration / Tolerances Transducer Config. Monitoring Set-up Inspection Routes Control Parameters Asset Monitoring Variables Asset Calibration / Tolerance Data Asset Usage Data Control Data Plant Measurements / Inspections Operation Field Report Smart Machines & Transducers Control Device Monitoring Portable Device Monitoring Survey On-Line Monitors Protection On-Line Monitors Transient On-Line Monitors Sample Monitoring Smart valves & Field Devices PLC / DCS Vibration Process Oil Thermal Electrical Shaft Displacement Casing Vibration Process Electrical Shaft Displacement Shaft Position Casing vibration Process Shaft Displacement Casing vibration Process Oil Particle Oil Chemical Oil Properties

10. Smart Pressure Transmitters are the Norm Source: ARC Advisory Group

11. 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

12. New ISA Intelligent Device Management Standard • Content Proposals: • Models and Terminology • Implementation Guidelines • Work Processes • Diagnostics Based Maintenance • Configuration Management • Auditing

13. 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

14. 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

15. 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

16. Graphical User Interface for Maintenance Source: AG-181

17. 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

18. 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

19. 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

20. Intelligent Device Management Interactions Work Orders Intelligent Devices CMMS DCS Host Event Historian Configuration Database Reporting & Analysis Alarm Management System Plant Asset Management System

21. Integrated Data System User Interface (Configuration & Monitoring) Database Rules Engine Enterprise Asset Manager System Interface Enterprise Asset Management System Enterprise Server / Middleware B2MML SQL & ODBC XML User Interface Alert Monitor Instrument Asset Management System Device server Database(s) Tag data FDT/DTM Audit Trail Calibration Data EDDL HART FF Profibus DeviceNet Others

22. 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

23. 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)

24. What Is Exception Based Surveillance? Semi Real Time Activities Real Time Activities Planned Activities 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

25. 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

26. To Learn More: ISA108 Committee Managing Director: Ian Verhappen +1 403 258 2681 x2222 Ian.verhappen@ca.yokogawa.com • http://www.isa.org/MSTemplate.cfm?MicrositeID=1528&CommitteeID=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