Industry new

Electromagnetic flowmeters enable seamless integration of equipment with digital plants

Many factories have installed a large number of smart devices that provide hundreds of parameter information to operators, technicians, inspectors, engineers or plant managers, only when these useful process and instrument data are available. Passing it to the right person, its value can be truly reflected.

The efficiency of the plant will be greatly enhanced by the ability to provide operational and maintenance personnel with actionable and useful information in a timely manner. Effective integration of engineering, configuration, maintenance, and operational displays into the operation and maintenance workstations of the CNC center allows workers to easily access on-site intelligence to improve plant performance.

Enhanced Electronic Device Description Language (EDDL) is a key technology for seamless integration of devices and plant structures, making the use of smart devices easier than ever.

stumbling block

The factory hopes to make full use of the diagnostic information of smart devices, but it has been difficult for people to achieve this goal for various reasons.

In fact, all smart devices can use the built-in self-diagnosis function to continuously monitor their status, while digital automation and asset management systems can continuously monitor these self-diagnosis information, but the old system can not do this, it can not Get diagnostic information for the device.

This is due to the fact that in some systems I/O cards use proprietary device communication protocols, while in others systems device communication is not implemented at all. Although the devices in the factory are generally communicated through the HART communication protocol, the proprietary system still cannot obtain the intelligent information of the device, and thus the diagnostic information is stranded in the device.

Many modern control systems support open communication protocols such as HART and Foundation buses, and use device management software to obtain executable diagnostic information.

In addition, if the diagnostic information is only displayed on the maintenance station, it cannot be communicated to the maintenance personnel in time, because the general maintenance staff is at the scene rather than the computer, in which case the operator needs to return to the console. Open detailed device diagnostics and see device alarms.

The third type of information is stranded in that the device or device management software is not convenient enough to operate.

Integrated device management

In order to achieve effective equipment management, the control system must be able to commission, drive and maintain all equipment.

This feature should be integrated into the control system and workstation.

connection

In order to be interoperable with the plant's field instruments, the control system needs to be equipped with HART

I/O cards or Foundation fieldbus interface cards enable communication between the device and the intelligent device management software, which is available in most modern control structures.

If the factory's control system is old-fashioned and does not support the HART protocol, the only way to do this is to connect a HART multiplexer next to the DCS I/O card, communicate with the device and pass the information to the smart device management. In the software.

Fortunately, there is now an easier way to connect the diagnostic information of a smart device to the device management software of a traditional DCS system. Connect the WirelessHART wireless adapter to an existing HART wired device for wireless intelligence such as setup and diagnostics.

With this wireless approach, adapters installed on existing devices can establish a wireless mesh network that delivers digital data to the WirelessHART wireless gateway, which is much simpler than previous wired HART multiplexer solutions. It completely rids the shackles of the traditional DCS proprietary device protocol.

Once the WirelessHART network structure is established, the factory can add WirelessHART pressure, level, flow, temperature, valve position feedback, pH and vibration transmitters to the network.

integrated

If the equipment fails and the operation is not normal, it will eventually affect the process. The degree of impact may be several minutes or several hours. The diagnostic function of the device can notify the operator to take effective measures to prevent the failure before the process is affected.

According to the equipment's fault prediction, the operator can adjust the circuit to manual or send someone to manually operate the valve. When the process is protected, they notify the maintenance personnel to repair the equipment. For the operator to use the device diagnostic information in this case, the process of obtaining information is simple and easy.

In order to prevent equipment failure, the operator will receive a forecast first, so that he can have enough time to analyze the equipment in detail through the equipment management software. At the operator station, you can directly open the detailed diagnostic information of the device with a double-click of the mouse. Double-clicking the mouse again can also obtain executable processing suggestions. It is now more time-consuming to search for this information than before. Equipment diagnostic information must be prioritized according to the importance of the equipment to the process and the severity of the fault. Only important alarms affecting the process are sent to the operator, which prevents the operator from receiving too much irrelevant information. . The operator station is best used to view device diagnostic information only, not to modify device settings or configurations.

All equipment forecasts, including relatively non-emergency, forecasts for failures that have not occurred, are available from the maintenance workstation. The state-based maintenance function should be performed by the designated workstation or integrated into the engineering station. The operator can open the device management software directly from the operator station. EDDL integrates device diagnostic information into the operator station, and EDDL is an integral part of HART, FOUNDATION fieldbus, Profibus and WirelessHART. Thanks to EDDL, device integration eliminates the need for software drivers, but only through compressed text files. This solution is very reliable and can be built into the control system itself. Other device integration solutions are not suitable for integration on the operator station.

With EDDL, the debug and maintenance interface displayed on the engineering station has a similar look and feel and is very simple to operate. For example, it is convenient to set up the device on a console with system data. Therefore, it takes only one engineering station to manage system data and set up and edit fieldbus devices.

The maintenance personnel workstation is preferably separated from the operator's console, and the maintenance workstation alone performs device diagnostics and settings other than the operational functions.

The system can be flexibly used for integrated or separate device diagnostics, but the designated maintenance station does not replace the debug and maintenance functions built into the control system.

Only the control system operating program and the smart device management software are integrated, the servers are separate, and for security reasons, the maintenance workstation requires a separate server and strict management of access. This will prevent the entire control system from being affected by changes in the network without proper control and management of the change program.

simplify

Another important benefit of EDDL is that the display of the device is uniform. Device manufacturers have created EDDL files for their devices that describe how the system displays their devices. These include menu structures, graphical displays for advanced diagnostics and comprehensive setup functions, step-by-step instructions for complex tasks such as simplified calibration, and help information and graphics. Because manufacturers know best about their own products, it is most appropriate for them to make these documents.

Since the content and structure of the display is controlled by the device manufacturer rather than the system vendor, the interoperability of the device can be achieved, and the system can control the look and feel of the display. For example, the equipment manufacturer defines the vibration signal of the mechanical device status transmitter to be graphically displayed, the X axis represents the frequency, the Y axis represents the speed, and the system can define a toolbar that matches the graphic, including enlarging an area in the graphic. This way all device graphics will be displayed in the same way.

Regardless of which manufacturer the locator is from, which communication protocol is used, the valve stroke map is displayed in the same way; the echo curve of the radar level gauge is the same; the toolbox for all trend graphs is the same; therefore It is the same for the technician to operate any device.

This consistency is not achieved by device drivers, which makes the use of EDDL easier than ever. All equipment problems can be reflected in the same way, clear and clear. Use device diagnostic information

A simple temperature transmitter can detect sensor failure or wire breakage, which allows the operator to obtain valuable minutes or even hours to take effective action before the process is affected. More advanced temperature transmitters can also detect sensor drift by comparing two sensors, or by monitoring the resistance of the thermocouple to determine whether its performance is attenuated. Based on this information, the technician can advance several days or weeks. Schedule maintenance to minimize the impact on the process.

Control valves have many moving mechanical parts that are prone to wear or leakage. The valve positioner calculates the number of valve stem returns and the total stroke. These data provide a good indication of the strength of the valve operation and are more accurate than the calculated date when estimating the wear of the stem packing.

Alarms can be set in the positioner. For example, the manufacturer of the valve or actuator recommends that the number of return trips should reach 1 million. The moving parts should be replaced. Therefore, when the number of return trips calculated by the positioner reaches this value, an alarm will be issued to the maintenance personnel. .

These valve diagnostics allow technicians to place time on valves that require attention, avoiding unnecessary valve disassembly and maintenance.

Electromagnetic flowmeters can detect ground faults, for example, flow pipe grounding fails due to corrosion. This problem can be solved in a timely manner, rather than waiting until the measurement accuracy drops negatively on the process to find the problem. Mechanical condition transmitters can identify motor pump imbalances and other problems that can be used to detect critical pump failures and schedule maintenance schedules before they fail.

The pH analyzer provides detailed diagnostic information to continuously measure the impedance of the glass and reference electrodes, and thus the sensor's failure or performance degradation, such as contact blockage or electrode fill fluid dryness, can also be detected by glass electrode fragmentation. The pH reading is incorrect for timely replacement, ensuring that the process is unaffected and always in compliance.

The pressure transmitter can detect sensor failures such as corrosion of the sealing diaphragm. More advanced pressure transmitters can also use statistical process monitoring (SPM) to detect process and installation problems, such as anomalies such as clogging of the impulse line, air bubbles, compressor or pump failure, etc., instead of Wait until the fault occurs before processing.

Implementation and management

Most factories today rely on traditional DD technology to manage smart devices. If you upgrade to the new enhanced EDDL to replace the original driver software technology, the use of smart devices will become more convenient.

EDDL meets NAMURNE

All the requirements of 105, such as when using the new operating system version, can make the user's investment worthwhile; the installation of the EDDL file is very simple, saving the time to join the new device or upgrade the new device version, without the authorization of the device The key, and the interoperability testing of the device has been done in advance by an independent third party. In addition, EDDL is a single technology for use in smart device management software, DCS and handheld field devices.

The diagnostic information of the smart device is integrated into the operator console through the EDDL-based smart device management software, and the device fault prediction is sent to the relevant personnel before the process is affected. Once information is integrated, the use of device diagnostic information will naturally become part of the day-to-day work, which is critical to predicting the successful implementation of a maintenance program.

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