Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam
Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam
Optimale proces betrouwbaarheid en beschikbaarheid door Heartbeat verificatie op flowmetingen bij Albemarle Amsterdam
Door het toepassen van Heartbeat Technology is de volgende stap in het
kader van beschikbaarheid en voorspellend onderhoud gemaakt bij
Albemarle in Amsterdam.
Ingebouwde diagnostiek, verificatie en bewakingsfuncties leggen de basis
om processen betrouwbaarder en veiliger te laten verlopen en dragen ook
bij aan een efficiënter kalibratie proces.
What is Heartbeat Technology?
Heartbeat Technology – The pulse of your measurement
Permanent process and device diagnostics, simple testing without removal
and clear trend monitoring.
Calibration, Proof Testing and Verification
Calibration• Accuracy• Traceability• ISO 17025
Proof testing• Functional Safety• Reliability • IEC61508/61511
Verification• Diagnostics• Reliability• Confirmation
• Overlap topics• Periodical repetition• Standard as fundament
Heartbeat Technology
Diagnostics Verification Monitoring
Permanent process and device diagnostics
Documented verification without process interruption
Information for predictive maintenance
Increased plant availability …
… safe processes … reduced verification effort… optimization of processes and
maintenance
Heartbeat Technology – Diagnostics, Verification and Monitoring
Heartbeat Technology for different measuring principles
Flow Level Temperature Analysis
Heartbeat Technology - Monitoring
• The provision of instrument and process data facilitates trend recognition for predictive maintenance.
• The combination of instrument and process parameter facilitates the analysis for targeted process optimization.
Benefit:• Information for predictive maintenance• Increased plant availability• Optimization of process and maintenance strategy
Heartbeat Technology
Monitoring
Information for predictive maintenance
Increased plant availability …
… optimization of processes and maintenance
Heartbeat Technology – Monitoring
The Heartbeat Sensor Integrity (HBSI) Parameterdetermines beyond any doubt the health status of the measuring tube.
▪ For corrosion or abrasion detection▪ Detection in the context of Heartbeat verification
▪ Process-independent detection of changes to the measuring tube from 0.01mm
Heartbeat Technology
Monitoring
Information for predictive maintenance
Increased plant availability …
… optimization of processes and maintenance
Heartbeat Technology – Monitoring
Water Sand 6% Sand 3% Sand 6% Water
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0.2%
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0 50 100 150 200 250
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Sen
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Promass I
Heartbeat Technology
Monitoring
Information for predictive maintenance
Increased plant availability …
… optimization of processes and maintenance
Heartbeat Technology – Monitoring
Corrosion / abrasion Sedimentation Bubbles Cavitation
Heartbeat Technology
Monitoring
Information for predictive maintenance
Increased plant availability …
… optimization of processes and maintenance
Demonstration Heartbeat Verification Report
Before Heartbeat Technology implementation
▪ According to Albemarle work instruction flow measurement needs to be calibrated each year.
▪ For each calibration the installation needs to be prepared by maintenance engineer for secure dismantling of the flow measurement.
▪ After calibration it often happens that flow measurement is not working properly (modified configuration, poor electrical connections,…)
▪ In practice it is an exception for a flow measurement to be out of tolerance.▪ Calibration report cannot be automatically uploaded to Asset Information
Management system (W@M).
Flow Calibration Unit @ Albemarle
Albemarle Catalysts Company B.V.
The main activity of the site is productionand research of Catalysts for the petrochemical industry. These Catalysts are used for the production of high quality fuels such as gas, petrol, diesel and kerosene from crude oil.
On the Amsterdam site, three plants are in operation.
▪ FCC plant, producing Fluid Cracking Catalysts (since 1953)
▪ HPC plant, producing Hydro Processing Catalysts (since 1956)
▪ Multi-Purpose plant, producing Isomerization, Methyl Chloride, Methyl Amine, Melamine and Oxychlorination Catalysts
Goals @ Albemarle Catalysts
Albemarle Catalysts
CalibrationOptimization of calibration intervals.
Manageable scheduled maintenanceReducing capital and operating expenditure on assetsby optimizing workflows and business processes.
Integrated device informationProvide device - and life cycle information in Centralized Maintenance Management System. (SAP-PM)
Availability of critical devicesPlants need to work more efficiently and have to improve their availability. (OEE)
Safety Process Hazard Analyses. (SIL. ATEX)
Challenges @ Albemarle Catalysts
▪ How to exploit the power of smart devices and smart technology in your maintenance processes?
▪ Which relevant information is available from a smart device for process control, operations and maintenance?
▪ How to get access to smart devices and their diagnostics? (wired- and/or wireless infrastructure, smart pass-through components,…)
▪ How to monitor the health status of smart devices and smart networks and transferthis to a (condition based) maintenance strategy?
▪ How to measure, secure and display availability and reliability in order to support the (condition based) maintenance strategy? (It is too much engineering effort to read and interpret each and every manufacturer specific status/diagnostic data in Process Automation System for each device!)
The Foundation for a Solid (Infra)Structure
Industrial Ethernet (LAN)
HART
PROFIBUS DP
Smart Connectivity Concept @ Albemarle
PROFIBUS PA
No passthrough for edge device
Device Configuration Management
Bypass for PROFIBUS and HART signal
Passthrough for HART
signal
Asset Information
Management
Building Blocks & Smart Connectivity
▪ Smart Devices(HART and PROFIBUS communication)
SMART instrument – The source of the DATA
4-20 mA
Analog process value
Digital communication protocols(HART)
AI TOT
DI DO
Multiple digital process variables
Device diagnosticsEmbedded webserver
Embedded Device Driver
Embedded device verification
Embedded OPC UA server
Monitoring + Optimization
SMART instrument – The source of the DATA
88,6 kg/h
Digital process value
Digital communication protocols(HART, Modbus, PROFIBUS, PROFINET, EtherNet/IP,…)
AI TOT
DI DO
Multiple digital process variables
Device diagnosticsEmbedded webserver
Embedded Device Driver
Embedded device verification
Embedded OPC UA server
Monitoring + Optimization
Building Blocks & Smart Connectivity
▪ Smart Devices(HART and PROFIBUS communication)
▪ Smart Connectivity Components(Siemens ET200M, AIH + AOH)
Smart Connectivity Components
▪ Siemens IM153-2 ET 200M / Link• SM 331 8 Channel AI HART• SM 332 8 Channel AO HART
Smart Connectivity Components
▪ Siemens IM153-2 ET 200M / Link• SM 331 8 Channel AI HART
HART variables cannot enabled/assigned because of
fixed PLC addresses.
Building Blocks & Smart Connectivity
▪ Smart Devices(HART and PROFIBUS communication)
▪ Smart Connectivity Components(Siemens ET200M, AIH + AOH)
▪ Smart Plant Access Points(Fieldgate SFG500 + Asset Monitor)
Smart Plant Access Points
▪ Endress+Hauser Fieldgate SFG500 PROFIBUS Gateway• SFM500 Asset Monitor
Continuous Asset Health Monitoring!
Building Blocks & Smart Connectivity
▪ Smart Devices(HART and PROFIBUS communication)
▪ Smart Connectivity Components(Siemens ET200M, AIH + AOH)
▪ Smart Plant Access Points(Fieldgate SFG500 + Asset Monitor)
▪ Centralized Device Configuration Management(FieldCare SFE500)
Building Blocks & Smart Connectivity
▪ Smart Devices(HART and PROFIBUS communication)
▪ Smart Connectivity Components(Siemens ET200M, AIH + AOH)
▪ Smart Plant Access Points(Fieldgate SFG500 + Asset Monitor)
▪ Centralized Device Configuration Management(FieldCare SFE500)
▪ Centralized Asset Information Management(W@M Portal XD88CP + W@M Enterprise SWAM10B)
Wireless Heartbeat verification (iPad connected to WLAN access point of Promass 300)
Automatic upload of Heartbeat verification report
After Heartbeat Technology implementation
▪ With Heartbeat verification calibration interval has been reduced from once every year to once every five years.
▪ Verification report can be easily uploaded to W@M Asset Information Management.
NoteUpload performance of Heartbeat verification report is poor due to HART communication – if possible consider Fieldbus or Industrial Ethernet communication.
▪ Increased availability due to continuous Asset Health Monitoring.▪ Significant time savings in preparation and securing the installation by a
maintenance engineer for a calibration.
Next steps
▪ Heartbeat integration is NOT a feature which you enable or disable. It is should be part of customers work process.
At Albemarle Heartbeat is embraced and is specified for new flow assets, BUT it is also a new work process which need to be documented (SOP, WI) and must be lived by the users.>> Having SOP and WI examples available will speed up the implementation process.
▪ Heartbeat integration (e.g. monitoring) requires sound preparation by several disciplines; maintenance –, system- and process engineer. >> Pass/Fail notification for operator
11/16/2018
IIoT Out of the Box
SAP and Endress+Hauser work on joint IIoT solutions
“Two innovative companies have come together here to realize the end-to-end OT/IT integration from field instrument all the way to business processes,” said Hala Zeine, SAP’s President of Digital Supply Chain and Manufacturing.
“When it comes to digitalization, successful companies will be those able to tie their systems directly to business processes, thus reliably and fully opening up or circumventing the classic automation pyramid,” explained Matthias Altendorf, CEO of the Endress+Hauser Group. “We and SAP share a common vision of implementing this strategy to the benefit of our customers.”
Slide 36 Jaap Westeneng
01/09/2019INTERNAL
Current Maintenance Process
Plant Shutdown
Multiple On-Site Service
Lack of historical diagnostic
information
Missing inventory
information
Inaccessible data
Locked Data & Data Silos
Limited Decision-Making
Insights
Incomplete End-to-End
View
Customers’ Key Challenges:
01/09/2019INTERNAL
Predictive Analytics
Static data Online Data
Stock
Devices, Spare Parts
Plant Maintenanc
e
Maintenance
The Digitalized End-to-End Maintenance Process
01
1 1
10
1
1 1
1
01
1 1
11
1
10
1
1
Asset Intelligence Network
Digital Twin
Increased efficiency and
safety
Control System
01/09/2019INTERNAL
ESTIMATED MAINTENANCE DATE
HEALTH SCORE
10% 15.11.2018
Predictive Analytics for E+H Devices
Developed for SAP Cloud Platform
Information
Jaap WestenengApplication Consultant Solutions
Endress+Hauser B.V.Nikkelstraat 61411 AJ Naarden
[email protected] 035-6958717M 06-53729616
Plant Asset Management solutionsIndustrial Communication Technologies