Almost every intelligent process measurement device has some level of in-built diagnostic capability to indicate the health of the device or integrity of the measurement.
Yet ensuring the data is captured, logged and passed to the most appropriate person for action is not necessarily straightforward. This is why Endress+Hauser has developed a solution that harnesses device intelligence and uses existing plant communication networks and platforms for data transfer. The web-based system removes the need to access information from each device individually using the display or by connecting a programmer or laptop – a process that becomes entirely impractical on plants with hundreds of assets – thus saving time and reducing the possibility of error.
There are three requirements for implementing a successful diagnostic monitoring system in modern process plants – credible and useful information, a reliable method of transporting the data and a simple to way to notify the relevant person that diagnostic data is available. The availability and quality of diagnostic data is very much down to the individual manufacturer. In order to ensure the end user is not left with too little or too much data, Endress+Hauser has fully embraced the recommendations of NAMUR NE 107, an industry-recognised standard for self-monitoring and diagnosis of field devices. Each piece of diagnostic data is now assigned to one of four defined categories and we will also give details of suggested cause and remedy to assist the operations and maintenance staff in understanding why an error occurred and how to avoid it in future.
Effective data transportation has existed for many years in the form of common industrial networks. For example, profibus DP/PA or simple HART communication networks all have the capability to transfer diagnostic data around a process plant. With correct design, implementation and maintenance, plant networks provide a stable and reliable way of making diagnostic information available.
So the remaining challenge is to ensure the data is captured, logged and appropriate action is taken. Of course the data could be handled within the process control system but this may require additional development work by the manufacturers or system integrators. Additionally, in many cases control systems are configured to simply show the status of the plant devices rather than display the detailed diagnostic data. A full Computerised Maintenance Management Systems (CMMS), which automatically translates the information, could be added but this introduces an extra layer of complexity that may not be needed.
Endress+Hauser’s solution is a web-based system for displaying, logging and notifying that is suitable for all HART and profibus devices. Supplied as a complete solution, the system will be delivered with relevant engineering services to ensure correct implementation and operation. The hardware consists of a Fieldgate SFG500 that can be connected to an existing profibus DP network. In its basic form the Fieldgate can be considered an access point between the profibus DP network and an Ethernet layer. By connecting an open device configuration tool such as FieldCare you can ensure simple and transparent communication between networks. The current status of the communications and device information can be viewed online. With the addition of the SFM500 memory module the device becomes an asset monitor, providing real-time diagnostic monitoring for all profibus and HART connected devices.
The on-board device library holds diagnostic data for many hundreds of devices from all manufacturers. Although the NE 107 diagnostic categories are predefined, both they and the diagnostic messages can be edited to be more relevant to the application. This makes for a very flexible monitoring system. Device library data can be exported for use in other asset monitor systems or printed out to form part of the system documentation. The diagnostic data status is also displayed online using the NE 107 graphics. You can also access further details about each device condition and suggested causes and remedies. The asset monitor can be configured to log diagnostic events, giving them a date and time stamp. This is particularly useful if the diagnostic condition only occurs for a very short time period, as all data is captured and can then be used for further analysis. Email notifications can also be configured and sent to the relevant person or department when diagnostic events occur.
Endress+Hauser will also provide the engineering services to ensure the asset monitor system is correctly implemented and configured. This includes full plant network test and verification and integration within your plant IT infrastructure. Once implemented, full training for onsite personnel can also be delivered.
NAMUR is an international user association of automation technology in the process industries. The NE 107 recommendation aims to regulate diagnostics information in order to improve operator efficiency and productivity reduce costs and make efficiency savings. Each piece of diagnostic data is now assigned to one of four defined categories:
For more information please email sales@uk.endress.com or call us on 0161 286 5050